Instruction Book Part 1

1I|AN
Et&ut
\-
lnstructionBook
PartI
Section
301- 310
Bazan15
EngineType
7L23l30
MAN B&W D|ESCIA/S

lloleby Diesel
@stervei2, DK-4960 Holeby
Telephohe : + 1553 90 @ 26
: + 45 53 90 66 76
Telefax
Cables t- : oildieselmaribo
Marketing
Telex
:
Service
Telex
Telefax
Reg. No.
-q/
Edition02H
89.02
40646 hodiel dk
: &28O hodel dk
: +4553907426
:
2481
{elBY
CEII\ERAT\G SETS
ltAhl
Ett*ut
Instructionsfor Plantsbasedon EngineType23
to
Theinstructionseamthe purposeto providegeneralinformationfor operationand maintenace,
describethe designand to be usedfor referencewhen orderirq spareparts.
operation
and
Reliabilityandoperationecoromyof
theplantwilltoagreatextentdependoncorrect
propermaintenance.
Thereforeit is essentialthatthe engineroom personnelin additionto basickrowledgeof diesel
erqine machineryinstallationsis fullyacquaintedwith the contentsof the instructions.
Part ll
The instructions
consistof 2 volumesdesignatedPart | (section301 - 310) respectively
(section311 320).
Thefirstfive sections(301- 304)of the bookserveas a guideon the operationof the engine,and
with
the nextfourteensections(305- 318)contantechnicaldescriptions,
sparepartsillustrations
pertainingpartslstsas wellas overhaulingprocedures.
The engineis dividedintoa nunber of maincomponents/assemblies,
eachof whichis described
in a sectionol this book (secton305-319).Eachof these sectionsstartswith a shorttechncal
followedby overhaulingpocedures,latersparepartsillustrations
description,
andsparepartslists
areto be found.
Indescriptions
of overhaulproceduresare mentionedor illustratednotonlyspecialtoolsdatawhch
mghtbe partof our delivery,but alsocomrtclnhard toolsand machinng
tools,whichusuallyare
availableon boardships.
Theamountof tools,deliveredacrordingto contac;tfor eachspecificplantappeatsfromthe plantlistol tools.
adaP,ted
The instructionsmustnot be copiedwithoutwrittenpermissionof MANB&W DieselA/S, Holeby.
1991.04.10
HOI.W
GSENANTGSEIS
TA|
EEUl'
MANB&W Diese|A/S
1991.06.19
MB/3419
PLANT:Bazan15
ORDERNO:290076
ENGINENO:233016-017-018
ENGINETYPE:7L23t30
INSTRUCTION
BOOK
EDITION:02H
89.02
THE FOLLOWING
SPECIALINSTRUCTION
AREADDED:
309
COMBUSTION
AIR DIAGRAM,
DrawingNo.162124$6
TURBOCHARGER: NR20/R
313
No. 1605352-3
ELECTRIC
WIRINGDIAGRAMFORENGINE,Drawing
ELECTRIC
WIRINGDIAGRAMFORJETASSISTBOX:DrawingNo. 1605353-5
EL-DIAGRAM
FORRELAYBOX:DrawingNo. 1406188-1
DataSheet1991.06.19
ARRANGEMENT
PRESSOSTATES:
OF THERMO.AND
SPEEDTRANSDUCER:
Drawingno. 1611396-1
Drawingno.1350352-0E
DEUTAMEASURING
TURBOCHARGER:
CONVERTER
GOVERNOR:
03040D
Woodward
UGDialGovernor,
ShutdownSolenoid,03013N
SpeedAdjustment(Synchronizing
) Motor,03505C
314
DIAGRAMFORCOMPRESSED
AIR SYSTEM,DrawingNo.1621246-8
315
DIAGRAMFORLUBRICATING
OILSYSTEM,DrawingNo.162124|-2
COMB.LUB.OILANDF.W.COOLER:DataSheet1990.09.25
COOLER:
Alfa LavallnstructionBook.
316
DIAGRAMFORFUELOILSYSTEM,DrawingNo. 1621242-0
317
DfAGRAMFORCOOLINGWATERSYSTEM,DrawirqNo.16212M-4
319
GENERALARRANGEM
ENT,DrawingNos.1621027-6,1621028
LISTOF FLANGES,
DrawingNo.162039'l-1
320
TESTREPORTFORENGINE
ICI.EBY
CEI\CRANNCSETS
/--
Ordering of Spare Parts, EngineType L23l3O
Wheneversparepartsare ordered(or referenceis madein onespondarrceetc.)the followingdata rrust be
indicatedfor the particularengine:
1.
2.
3.
4.
5.
Ex.:
Nameof plant
EngineNo.--, builtby
lllustrationplate number(completewith ed. figures)
ItemNo.
Quantityrequired(anddescription)
Bazan14
2330013
PlateNo.
ItemNo.
Qty.
8 off
(Piston)
w
Thisdatais usedby us to ensuresupplyof the correctsparepartsfor the individualengines,eventhoughthe
sparepartsillustrationscontainedin this book may not alwaysbe in completeaccordarrce
withthe irdividual
componentsof a specificengine.
MarineGenSetspare parts
MANB&WDieselA/S
CenterSyd
Stamholmen
161,DK-2650l-tvidovre,
Copenhagen
Telephone:
+4531 492501
Telecopy :
+ 45 31 49 25 01
Cables
:
bwdiesel
Telex
:
31197bwpartdk
Reg.No. :
24?f.1
9o.34
StationaryGenSetspareparts
MANB&WDiese!A/S
HolebyGenerating
Sets
2, DK-4960
Hole$r
@stervej
Denmark
Telephone
Telecopy
Cables
Telex
Reg.No.
+4553906026
+ 45 53 907426
oildieselmaribo
hodieldk
4020
24231
HC...EY
GEIERATIIESEI!;
IY|AN
L23/30
CROSS
SECTION
VIEl.lEDFROMFRONT
19 8 8 .0 3. 0 9
cl&ult
PLATE3OOOO-O7H
= ltg
t-lfbtt
GENERA'N\G
SETS
L23/30
D E F I N I T I O NFSO RI N - L I N EE N G I N E S
1 9 8 51. 2 . 0 5
DESIGNATIO
ONF C Y L I N D E R E
SN
, GINE
S I D E SA N D
D I R E C T I OO
NF ROTATION
Flywheel
Front end
E xh a u s t side ,/ Right side
l
Control side ./ Camshaft side ,/
Left side
Left side
Anti-clockwise
Rotation
Right side
Clockwise Rotation
(Standard)
Engine viewed from Flywheel

End
tffi*e;g
EngineData
z
o
of Engine
Operation
E
fr
andGondition
o. EnginePerformance
o
Tracing
Trouble
EngineFrameand Bedplate
and MainBearings
Crankshaft
CylinderHeadand CylinderLiner
Rod
PistonandConnecting
Operating
Gearfor InletValveg
ExhaustValvesand FuelInjectionPumps
UJ
?e
Gfr
Zl-
Turbocharger
System
FuellnjectionPump
E=
Ro
FuelInjection
=z
=<
z
4,9
Camshaftand CamshaftDrive
ControlandSafetySystems
Automatics
andInstruments
F
F -
a,
d tJg
cl
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
Fueland FuelTreatment
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
SpecificPlantInformation
UAhl
Eteut
D301
DATA
Edition06H
Data1 (1)
DIESEL ENGINE.MAINDATA
The plantconsistsof 3 high-pressure

engines
turbocharged,4-stroke
of the type:3x7L73t30,
EngineNos.233016-017-018.
The mainparliculars
of the erqinesare:
.
Numberof cylinders
bore..........
Cylinder
Stroke
\-
230 mm
..
Enginespeed
Output
300 mm
720 rlmin
..
910 kW
(1240BHP)
ilOT.EBY
cgEnA'nNcsEls
Lz3/30
\--
/--At
0302
ENGINE
DATA
Edition 07H
Data 1 (l)
S T A R T I NO
GF E N G I N E
S t a r t i n g a i r p r e s s u r e ,n o r m a l
S t a r t i n g a i r p r e s s u r e ,m i n i m u m
25 - 30 bar
7 bar
E#.EEV
CENERATNGSEN
7F
Iri
,
Vt.
\e
\:
o.;
\'
$.
$'
E$l
t r l
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E&U'
L?3/30
OPERATINGDATA
0303
Edition 21H
Data I (?)
MARINE
GENSETS
Normal Value al Full load
Alarm St pont
Aulostop ol engne
kbricating Clil System

Ternp. before cooler
(o|rtletengine)
SAE 30
SAE 40
Tt 20
Tl 20
60-70'c
65-7s"C
TAH 20
TAH 20
1@'C
Temp.aftercooler
(inletengine)
SAE 30
SAE 40
Tt22
Tl22
45-60'C
so-6s"c
TAH22
fAH22
75. C
85" C
TSH 22
TSH 22
85'C
95" C
Pressureafter fitter(nleteng)
Pt 22
3-4 bar
PAL22
3 bar
PSL 22
2.5 bar
Elevatedpressurei.q. when
cenfugdl filter nsta'lted
Pt22
4-5 bar
PAL22
4 bar
PSL 22
3.5 bar
O.5-lbar
POAH21-22
1.5bar
LAL 25
level switch
LAL 28/LAH 28
lotrt/trighlevel
Pressure drop across filter
PDAH 21.22
Prelubricanqoressure
Pressure inlel turbochaoer
Pt 25
Pt 23
O.5-O.8
bar
1.1-1.3bar
l-ub. oil, evel in oase trale

Temp. main bearings
90" c
TE 29
7s-8s.c
TAH 29
9s"c
Pt 40
Pt 40
2-3 bar
(A)
PAL 40
PAL 40
1.5bar
4 bar
LAH 42
leakage
Press.nozz.oool.oit, nleteng.
Pt 50
2-3 bar
PAL 50
1.5bar
Temp.nozz.coot.oil, outleteng.
Tt s1
8G90" C
Fuel Oil System

Pressure after filter
MDO
HFO
Fuel oil leakingoit
Cooling Water System

Press.LT-cirqit,nletengne
Pt 01
1-2.5bar
PAL01
O.4bar + (B)
Press. HTcircu! intet engine
Pt 10
1-3.Obar
PAL 10
O.4bar + (B)
Temp. HT-cirol( inletengine
Tl 10
60-75. C
Temp. HTciratt ouet cyl. unts
Tt11
70-85" C
TAH 1 2
90" c
48475" C
TAH 60
TDAH60
5@"C
27t350" C
TAH 6f
5@" C
Temp.HTcirat, oudetengine
Temp. raise across cyl- unts
Max.
TSH 12
950 C
10'c
EdraustGas and Charge Alr

Et'|. gas bmp. before TC
''60
Exh. gastemp. after TC
T|61
Pr31
Ch. ar press. after cooler

Ch. air tenp. after cooler
r31
Ch. air temp. afl cooler V28E2A
rsl
Comprcssed AirSystem
Press. inlet engine
2g4'2A
Press.inbtengne
23AO
Speed Control Systcm

Crer|setsfor 6O Flz
GenSets for 50 Flz
I
|
|
100"c
2-2-Sbat
35-55" C
TAH 3 1
6s"c (c)
55-75'C
TAH 3 1
85'C
PtTo I
t2-14 bar
PAL 70
12bar
7-9 bar
PAL 70
7 bar
7&rpm
SAH81
82Orpm
SSH81
820rpm
75Orpm
SAH 8I
855 rpm
ssH81
855rpm
PrTo
I
sre o I
sreo I
S p e c i f i c p l a n t s w i l I n o t co mpr isealar m equipm entand autostopfor all par am et e r s l i ste d a b o ve .

F o r s p e c i f i c p l a n t s, s e e s e c t i o n 3 1 3 .
for remarksto someparameters,see overleaf.
89.13
=-+= ==tf
E
= Ett--==
GENERA'fl\IGSTS
IIAN
Er&ut
L23/30
DATA
OPERATING
D303
MARINEGENSETS
E d it i o n z1H
Data 2 ( 2 )
R e m a r ktso i n d i v i d u a l P a r a m e t e r s .
A . F u e l 0 j l P r e s s u r e ,H F 0 - o p e r a t i o n .
Wh e no p e r a t i ngo n H F O,th e syste mpr essur em ust be s u f f i c ' i e n t t o d e p r e s s a n y
t e n d e n c yt o g a s i f i c a t i o n o f t h e h o t f u e l .
T h e s y s t e mp r e ssu reh a s to b e a d j usted accor dingto t h e f u e l o i l p r e h e a t i n g
temperature.
B. Cooli ng !'later Pressure, Al arm Set Poi nts .
A s t h e s y s t e mp r e s s u r ei n c a s e o f p u m pf a i l u r e w i l l d e p e n do n t h e h e i g h t o f
t he e x p a n s i onta n k a b o veth e e n g i ne, the alar m set point has to be adjusted to
0,4 bar plus the static pressure.
C. C h a r g eA i r T e mp e ra tu reA, l a rmS et Point.
Fo r l C S - e n g ' i n eth
s e a l a rm se t p o i nt has to be adjusted to 700C.
8 9 .t 3
c.rE=
IFG=!t
GENERATIT\IG
SETS
L23130
D3 05
ENGINEDATA
Ed'iti on 'l5H
Data 1 (4)
CRANKSFIAFT,
ETC.
FRAME,MAINBEARINGS,
BEDPLATE,
I ndex
0 . 2 0 - 0 . 3 0m m
7 0 0b a r
300 Nm
T i g h t e n i n go f s i d e s c r e w sf o r m a i n b e a r i n gcover
T i g h t e n i n go f n u ts fo r g e a r wheel
40 Nm
o n c r a n k sh a ft, a ft.
T ' i g h t e ni n go f scre wfo r co u n ter weight
250 Nm
- 1
C l e a r a n c e ' im
n a i nb e a r i n g( n e w )
T i g h t e n i n go f n u t s f o r m a i n b e a r i n gc o v e r
- 2
-zb
- 3
- 4
I-TEASUREMENT
0F CRANKTHR0T.J
DEFLECTIoNS
BY HEANS0F 0IAL INDICAToR(AUT0LoG)
C r a n k t h r o wd e f l e c t i o n = D i f f e r e n c e i n d i a l i n d i c a t o r r e a d i n o s
in two diametrically opposite crank[hrow
positions,
i.e. two positions displaced1B0o
Vertica] deflection
= D i f f e r e n c e i n t o p - b o t t o m readings
H o r i z o n t a 'dl e f l e c t i o n = D i f f e r e n c ei n s i d e - s i d e readings
VERTICAL
ANDHORI,ZONTAL
DEFLECTIONS
OF CRANKTHROl.S
Unless otherwise stated the values refer t o c o l d e n g i n e
For newor real ignedaggregate
Aim for
Acceptab'l
e
For aggregate in service realignment

if deflections exceed
is recommended
:
+
3 / ] 0 0 flfn
s/r00mfn
8 / 1 0 0mn
VTRTICAL
DEFLECTION
OF CRANKTHROW
AT FLYI,IHEEL
U n l e s so t h e r w i s es t a t e d the v a l u e s r e f e r t o c o l d e n q i n e
R i g i d c o u o ' l i n gb e t w e e n
diesel engine and driven machne
F l e x i b l e c o u p li n g b e t w e e n
diesel engine and driven machine
For newor
real i gned
aggregate
For newor
rea'li gned
aggregate
0 to + 3/100 mm
For aggregatein
servicerealignment
recommended
if deflection measured
on
walmengine exceeds + 8/100nrn
+ 6/100 rm
Aim for
Acceptable+ 8/100mm
For aggregatein
service real ignment
recormended
if deflection exceeds +l2l100 nrn
.1986.12.19
|l Lg
F=:
- -----
Fgstt
=Eg
E
-
CENERA'I\IG SETS
lYlAhl
c&ut
L23/30
ENGINEDATA
0305
Edition l2H
Data 2 (4)
(AUTOLOG)
CHECKTNG
0F MArNBEARTNGS
AL I G NMEOF
N TMA INB E A R IN GS
T h e ' l o w e rm a i nb e a r i n gs h e l l s s h o u l d b e s o p o s ' i t i o n e dt h a t t h e y k e e pt h e m a i n
b e a r i n gj o u r n a l s o f t h e c r a n k s h a f tc e n t e r e d ' i na s t r a i g h t ( a s h o r e :h o r i z o n t a l )
l i n e . D e v i a t i o n sf r o m t h i s c e n t r e l i n e c a u s et h e c r a n k s h a f tt o b e n da n d ' i n c r e a s e th e l o a d o n so mema i n bear ings.
I f t w o a d j a ce n tma i n b e a ri n gsar e placed too low, the cr ankshaftcentr e l i ne
w i l l ' i n th i s p l a ce b e l o w e redto for m an ar c, causingthe inter mediatec r ank
t h r o w t o b e n di n su ch a v.raythat T "closes" whentur ned into bottompos i ti on
a n d " o p e n s "' i n t o p p o s i t i o n . A s t h e m a g n i t u d e
o f s u c ha x i a l l e n g h t e n i n ga n d
s h o r t e n i n gd u ri n g th e tu rn i ng of the thr ow incr easesin pr opor tionto the di ff e r e n c ei n t h e h e i g h t o f t h e b e a r i n g , i t i s m e a s u r eads a c h e c ko n t h e a l i g n m e n ta n d c o n d i t i o n o f t h e b e a r i n g .
As t h e cra n ksh a fto f me d i u m - speed
enginesar e ver y stiff, any gr eat dev i ati ons
i n t h e a l i g n m e nw
t i l l r e s u l t i n c l e a r a n c ea t t h e b o t t o ms h e l l t h e b e a r i n g s .
T h e c a useo f i n co rre ct ma i n bear ing position maybe wear of the bear ingsor
m i s a l i g n m e notf t h e e n g i n e .
EFFECT
THEDEFLECTION
MEASUREMENT
Prior to the def'lection measurement
it is necessaryto check by meansof a
f e e l e r g a u g eth a t th e cra n kshaft beds downon the lower shells of all mai n
b e a r i n g s. If cl e a ra n cei s o bser vedat the lower shell of one or mor ema'i nbear i n g s , th e ca u semu st b e fo und and the fault r ectified.
T h e d e fl e cti o n me a su re meint
s effected by placing a spr ing- loadeddial gauge
i n t h e ce n tre p u n chma rksp rovided for this pur pose;see the illustr :ation.
E..E=
- -----
TFG'
CNERANIGSETS
L23 / 3 0
ENGINEDATA
0305
Edition12H
D a t a3 ( 4 )
C H E C K I NOGF M A I NB E A R I N G(SA U T O L O G )
" Cl o s i n g " o f t h e th ro w i n to p d e a dc entr e is r egar dedas negative ( com pr essi on

o f t h e g a u g e ) .I n t h e e x a m p l ea b o v e ,t h e d e f l e c t i o n r e a d i n qi s t h e r e f o r ep o s i t iv e . A s , d u r i n g th e tu rn i n g o f th e thr ow, the gaugeand the connectingr od
wi1 l m e e t n e a r th e b o tto mp o si ti o n of the thr ow, the measur ement
for the bott om p o s i t ' i o n i s to b e re p l a ce db y the aver ageof the near bypositions on either s'ide.
position (X in fig. 7), and
T h e d i a l g a u g ei s s e t t o z e r o i n t h e n e a r - b o t t o m
d u r i n g t h e t u r n i n g t h e t h r o w ' i s s t o p p e di n t h e p o s i t i o n s h o r i z o n t a l - t o p h o r i z o n t a l - n e a r-b o tto m(P -T -S -Yi n fig. 7) for r eading of the gauge.
THEDEFLECTION
CHECKING
MTASUREMENT
Th e r e a d i n g sare e n te re d i n th e ta ble fig. 1. As "bottom" r eading is used the
mea nv a l u e o f th e tw o " n e a r-b o tto m "r eadingsX and Y, fig. 2. The total def l e c t i o n ( " 0 p e n i n g- C l o s i n g " )o f t h e t h r o w d u r i n g t h e t u r n i n g f r o m b o t t o mt o
t o p p o s i t i o n i s e n te re d i n th e ta b l e fig. 3. Thesefigur es ar e due to ver tical
m i s a l i g n m e notf t h e m a i n b e a r i n g s .S i m i l a r l y , h o r i z o n t a l m i s a l i g n m e nptr o c e d u r e s t h e f i g u r e s i n t h e t a b l e f i g . 4 . B e s i d e sm i s a l i g n m e not f t h e m a i nb e a r i n g s , t h e r e a d i n g sc a n b e ' i n f l u e n c e db y o v a l i t y o r e c c e n t r i c i t y o f t h e j o u r n a ls .
t lh e nt a k i n g d ef'l e cti o n re a d i n g so n enginesequippedwith tur ning gear , the
t u rn i n g g e a r s h o u l d a t e a ch sto p p a gebe tur ned a little backwar ds
to easeoff
t h e t a n g e n t i a l p re ssu reo n th e te e th of the tur ning wheel. Other wise, this
t a n g e n t i a l p r essu rema yfa l si fy th e r eadingsespecially for the aftm ost cr ank
throws.
I*'
GNEFIA'NNGSETS
Lz3/30
/-=?\
ENGINEDATA
0305
Edition 12H
Data4 (4)
C H E C K I NOGF M A I NB E R A I N G(SA U T O L O G )
Deflection of crankshaft
pos'it'i on
Fig. l
Fig.z
Near bottom
C a m s h a f ts i d e
Top
Rear s'ide
Near bottom (starboard)
3
3
2
B o t t o m1 ( X + Y ) -
0
?
0
1
0
-
0
2
2 4 5 - ? 3
2
2
0
0
1
10
1
0
2
D e fl e cti o n fro m
v e r t i c a l m i s a li g n m e n t
Fig. 3
Top-BottomorT-$=
Fig. 4
D e fl e cti o n fro m
h o ri zo n ta l misa l 'i gnm ent
ca msh a ftsi d e - re ar side
o r P - S =
H
T + B =
Fig. 5
C h e c ko n
g a u g er e a d i n g s
P +
C a n d D s h o u l d b e near ly the sam e.Readingsfor cyl. 4 to

be repeated.
o
C@\D'
l / 1 0 0 : ff[Il
Fis. 6
"Closingo
" f the crankthrow
is considerednegative
O e)
( c am s h.
side)
X
Fig. 7
Lookingaft. Star t in position X
Turn counterclockwi
se.
LgEY
cc^tERA.nt\csTS
L?3/30
ENGINEDATA
D306
Edition 09H
UNIT
CYLINDER
Index
mm
2?5.000- 225.046
- 1
? 2 5 . 6 0mm.
- ?
7 0 0b a r
- 4
M a x .o u t e r d i a m e t e ro f v a l v e s e a t
. . . . 7 0 t 0 . 2 mm
- 5
M a x .i n n e r d i a m e t e or f v a l v e s e a t
. . . . . 6 4 mm
- 6
M a x .h e i g h t o f s p i n d ' l ea b o v ec y l i n d e r h e a d.
. . . 8 4 . 5 mm
- 7
M i n . h e i g h t o f v a l v e h e a d ,i n l e t 8 8 1 0 0 0 - 6
5 . 0 mm
- 8
M i n . h e i g h t o f v a l v e h e a d ,e x h a u s 8
t 81001-B
5 . 0 mm
- 8
1 5 0Nm
- 9
2 2 Nm
-10
N e wc yl i n d e r l i n e r, i n si d e diameter
W o r nc y l i n d e r l i n e r s h o u l db e r e p l a c e da t
T i g h t e n i n g o f c y l i n d e r h e a dn u t s
Va l v e s e a t ri n g to b e scra ppedwhenR = 0
T ' i g h t e n i n gto rq u e , ri n g n u t for fuel valve l i n e r
T i g h t e n i n gto rq u e , scre wfo r cooling jacket
0
- 0.25
Valve seat ring, exhaust
D 306- 8
V a lv e s p i n d l e
( e x h a u s t a n d i n ' le t )
D 3 0 6 -6
D 3 0 6 -5
V a l v es e a t r i n g , i n l e t
300* 3,r
.90.28
I{Ot.EBY
GENERATTNOSETS
ENGINEDATA
D3 07
Edition 20H
D a t a1 ( 3 )
PISTON
A N DC O N N I C T I NRGO D
R = 0,5
Piston rings
0i I scraper
ri ng
W+{
R
Normal heiqhts
Rinqs and qooves
New P o s s i b l eo v e r s i z e s
Hr
45 - 5.0
Hz
4s - 5.0
Hg
Tolerances
Rings
-0,010
-0,025
-0,00
-0,025
-0,013
-0,035
Grooves
+0, l4
+0. 12
{{, l
+0,09
+o,l0
{{, 08
N o t e : A l l p i s t o n r i n g s must be changedat normal p i s t o n o v e r h a u l ,see s e c t i o n 3 0 7

H 1 = U p p e rp i s t o n
H2 =
ring, marked
with ident. No.
"top 881500-3'
M i d d ' l ep i s t o n
ring, marked
with ident. No.
"top 881501-5"
H 2 = Lower piston
H3 = Scraper
ring, marked
ri ng
with ident. No.
"top 881502-71
Vertical clearance, ne!{ rings in new or renewedring grooves.
13 - 0, l5
0.t35 - 0, l0o
093 - 0, t35
Hz
|tr
tFttE-
GENERATTNG
SETS
]YIAN
Er&ut
ENGINEDATA
03 07
Edition ?0H
D a t a2 ( 3 )
PISTON
A N DC O N N E C T I R
NO
GD
M i n i m u mr i n g g a p
Pistonrings
0 i l s c r a p e rr i n g s
-I
L- 0,,
-L
H, + Q25
_T
Test-tool
Ring groovesmust be renewedwhentest-tool can be pressedmore than 2 rrn

in t o t h e g r o o ve .
t LG,=
!Frt*.t
E EI==.:ES
E
GENERANIVGSTS
0307
ENGINEDATA
Edition 20H
D a t a3 ( 3 )
A N DC O N N E C T I R
PISTON
NO
GD
l.le'ightof
p i s t o n a n d c o n n e c t i n gr o d a s s e m b l y.
I n dex
- 1
7 5 kg
C l e a r a n c ien b i g - e n db e a r i n g
0 . 1 5 - 0 . 2 0 mm
- 2
C le a r a nceb e tw e e n
c o n n e c tni g r o d b u s ha n d p i s t o n p ' i n
0 . 15 - 0 . 2 0
- 3
T I G H T T N I NO
GF C O N N E C T I N
RG
O DS C R E W S
C o ' l o u rc o d e o n t h e
b i g - e n d t o ' i n d ic a t e
correct assembl'inq
p o si t ' i o n o f t h e
c o m p o ne n ts.
T IGH TENING
ORDER
FOR
CONNECTING
RODSCREI,S
TIGHTENINGPROCEDURE
lst step
tor que 120 Nm
2 n d s t ep
repeat torque 120 Nm
3rd step
6o0 tur ning ansle

@
tur ninq checkwith 250 Nm
4 t h s t ep
Note:
Pr i o r t o a sse mb l yl u b ri ca te thr eads and contact faces of the scr ewswit h

C o p a s l i po r s i m i l a r .
Af t e r t i g h te n i n g a sce rta i n that the bigend bear ing moveseasi' l ron the
j o u r n a l.
. 1 9 8 61. 2 . 1 9
E '!,.9
- -----
tFFE=g
CENERA'INGSETS
tY|Al
BEUT'
L23/30
ENGINEDATA
0308
VALVEGEAR
Edition l3H
D a t a1 ( 1 )
Inlet valve clearance

Ex h a ustva l ve cl e a ra n ce
(cold engine)
0.5 mm
In dex
- 1
0.9 mm
- 2
40 Nm
- 3
50 Nm.
- 4
T i g h t e n i n gT o r q u e s :
( P l a t e 3 0 8 0)1
N u t f o r b ra cke t ro cke r a rm, Item No. 0 7 9 1
(Plate 30802)
Sc r e w sfo r va l ve g e a r h o u sing, Item N o . 1 6 5 0
1 9 8 9 .I 1. 1 4 .
HOLEBY
GENERArITGSETS
L,,ao
DATA
TURB@HARGER
/=*G\
D309
Edition10H
Data1 (1)
Make: MAN
Type: NR20/R170.........7
cyl.
for EngineNo.233016.
SerialNo.1181140
forEngine
No.233017.
SerialNo.1181141
for EngineNo.233018.
SerialNo.1181142
ffer.EY
cEl\cRA'nfssEns
rtAhl
E&Ul'
L23/30
D310
ENGINEDATA
Ed'ition l0H
Data 1 (3)
F U E LI N J E C T I O N
PUMP
index
Maximum
c o m b u s t i o np r e s s u r e a t f u ' l l l o a d
1 3 0 bar
Max.difference ...
I 3 bar
- 2
M a x . d i f f e r e n c e b e t w e e nc y l i n d e r s
3 bar
- 3
A c h a n g eo f t h e h e i g h t o f t h e , t h r u s t p ' i e c e s p a c e r
r i n g o f 1 / 1 0 n r nw i l l c h a n g et h e m a x . p r e s s u r e b y . .
1 bar
^
- . +
1o turning of camshaft gear wheel changes

maximumpressure by approx
3 bar
- 5
l4
( P l a t e3 1 0 0)1
C o n n e cti o np i e ce , scre w2 8 8 5
25 - 3 0 N m
Ba r r e l, scre w0 9 '1 6.
55 - 6 5 N m
P1ug screw 037?
100 - 1 2 0 N m
Capscrew 2974 .
1 0 0N m
1 5 0N m
- 10
(Plate 30802)
M o u n t i n gfu e l p u mp ,scre w 1 927
E#.EEY
CENERATII\E SETS
Lz3/30
/-A\
ENGINEDATA
D310
F U E LI N J E C T I O P
NU M P
(ADJUSTMENT
OF THEMAXIMUM
COMBUSTION
PRESSURT)
E d i t i o n 09HI
D a t a 2 ( 3)
I f e x p e r i e n c e dt o d i f f e r f r o m t e s t b e d r e c o r d s , t h e m a x i m u m
c o m b u s t i o np r e s s u r e
can be adjusted by alteration of the fuel injection timing. For each individual
c y l i n d e r u n ' i t t h e i n i e c t i o n t i m i n g i s a l t e r e d b y a d j u s t m e n to f t h e f u e l p u m p
I ead.
I n c r e a s e o f t h e l e a d w i ' l l a d v a n c et h e f r . e l i n j e c t i o n a n d i n c r e a s e t h e m a x i m u m
combust'iop
nressure.
R e d u c t i o no f t h e l e a d w i l l d e l a y t h e f u e l i n j e c t i o n a n d r e d u c e t h e m a x ' i m u cmo m bustjon pressure.
P ri o r t o a n y a tte mp t to a d j u st th e maximum
combustionpr essur eby alter ation
o f t h e f u e l i n j e c t i o n t i m i n g , i t s h o u l db e a s c e r t a i n e dt h a t t h e f u e l i n j e c t i o n
v a l v e , t h e e n g i n ep i s t o n , t h e i n l e t a n d e x h a u s tv a l v e s , a n d t h e t u r b o c h a r g e r
wit h c h a r g ea ir co o l e r a re w o rki n gcor r ectly and the com pr ession
pr essur e
c he c k e dt o b e n o rma l .
T h e f u e l p u m pl e a d ca n b e a d j u ste d by alter ing the num berand/or thicknessof
t h e w a s h e r ss ' i t u a t e du n d e rt h e t h r u s t p i e c e i n t h e t h r u s t p i n o f t h e r " o l l e r
guide.
T h e r e l a t i o n s hi p b e tw e e nth e h e i g h t of the washerpackage,the m aximum
com bu s t io n p r e s s u r ea n d o th e r re l a va n t par am eter sis shownin the schem e.
ACTION
Total
h ei g h t
of
washer
package
RESULTS
D ista n ce
||x rl
Lead
of
fue I
pump
Injecti on
tim'ing
M aximum
combu
st i on
pr essur e
INCREASED Reduced I Increased Advanced Increased

t
Y
I
t
I
RTDUCED
I Increasedt Reduced I Delayed I Reduced I
Pra c t i c a l ' l y t h e fu e l p u mpl e a d i s expr essedby the distance "X" m easur ed
bet we e nt h e u p p ere d g eo f th e ro l l e r guide housingand the top of the thr ust
pie c e , w h e nt h e ro l l e r i s re sti n g o n.the cir culr par t of the fuel cam .
n to u l d b e ch e cked
T h e "X"- m e a s u re mesh
and cor r ected, if r equir ed, whenever
a
f u e l P u m Pt," o l l e r g u i d e , r o l l e r g u i d e h o u s i n go r c a m s h a f st e c t i o n i s r e p l a c e d .
T h ed i s t a n c e" X " m u s tb e k e p t w i t h i n t h e t o l e r a n c el i m i t s t a t e d o n t h e d a t a
s he e t .
T h e t h r u s t p i e ce i s mo u n te dto th e thr ust pin with a light pr ess fit. The
t h ru s t p i e c e i s d i smo u n te d
b y th e u se of the special extr actor and r emounted
b y g e n t l e u s e o f a h a m m ewri t h s o f t l i n i n g s .
IvlAhl
cr&ut
L23/30
0310
ENGINEDATA
Edit'ion 09H1
Data 3 (3)
F U E LI N J T C T I O PUMP
N
(ADJUSTMENT
PRESSURE
OF THE MAXIMUMCOMBUSTION
)
,,X
T h ed i s t a n c e" X " i s
measuredbetweenthe
u p p e r e d g eo f th e
r o l I e r g u 'i d eh o u si n g
and the top of the
thrust piece, when
the roller is rest'ing
on the circular part
of the fue'l cam.
-Thrust
-
piece
Washers
- Thr ust
pi n
T h et h r u s t p i e c e i s
mountedto the thrust
pin with a light press
f i t . T he th ru st p i e ce
b y th e
i s d i s mo u n te d
u s e o f th e sp e ci a l
extractor and remount e d b y g e n tl e u se o f
with
a benchhammer
soft I inings.
C lG,=
- -----
!.tt--
GENERATING SETS
TYIAhI
E&UI'
L23/30
TNGINEDATA
0311
Edition 14H
Data1 (1)
F U E LI N J E C T I O V
NA L V E
F u e l v a l v e o p e n i n gp r e s s u r eto be set to
I ndex
- 1
320 bar
( P l a t e3 1 1 0 1 )
U n i o nn u t f o r n o z z l e , ' i t e mN o . 0 5 0 9
1 0 0 - 120 Nm
1 0 0N m
C a pn u t , i t e m N o . 1 1 2 2
70 Nm
N u t s f o r f u e l v a l v e s t u d s , ' i t e mN o . 0 2 3 0
30 Nm
- 5
N u t f o r a d j u sti n g scre w , 'i te m N o . 0 9 6 5
l,=I
- ----
3-.-t
GENERAIING
SETS
L?3/30
/-A\
DATA
D312
Edition 19H
Data 1 ( r )
CAI4SHAFT
Pin gaugefor camshaft, check measurement

.
Index
- 1
182
Pi n g au g efo r cra n ksh a ft, cyl. 1 top deadcentr e,

c h e c km e a s u r e m e.n. t
... 433.3
- 2
T i g h t e n i n go f b o l ts fo r a ssemb' ly
of gear wheel and
camshaft
- 3
40
T i g h t en i n go f b o l ts o n sh a ft end for inter m ediate

wheel
250 Nm
- 4
T i g h t en i n go f b o l ts fo r a ssem blyof inter m ediate

w h e e l s. . .
4 0 Nm
- 5
F u e l c a ml e a d (se e a ctu a l value, test sheet)

Ignition order:
7 cy1
1 - 2 - 4 - 6 - 7 . - 5 - 3
LG=
tFlti;t
FTE.EEE
GENERAT\IC
SETS
}IAN
Et&ut
L23/30
ENGINEDATA
D3l3
Edition 07H
D a t a1 ( 1 )
SPEEDCONTROL
SYSTEM
Index
T h e e n g i n e i s e q u i p p e dw i th a hydr aufic Gover nor
of t{oodwardm a k e :
For GeneratingSets :
Type UGSD
F o r i n stru cti o n s, se e th e separ atel,{ oodwarmanual

d
.
A d j u s t th e o ve rsp e e dtri p to stop the engine at the following
r e v o l u ti o n n u mb e rs:
G e n e r a t i n gP l a n t s :
0 v e r s p e e dtri p
720 rpn 60 Hz:

820/82s
HOT.EBY
CEITERATf,\CSETS
L23130
ENGINEDATA
L U B R I C A T I NOGI L S Y S T E M
fvlAt
EEU'
D3t5
Edition 06H
Data1 (1)
Type 123/30
M a x .I i t e r
M a x .i m p . g a l l o n
Min. I iter
Min. imp. gallon
L i te r/cm
G al - / i n c h .
I#.EBY
GENR\'ffVG STS
D317
ENGINEDATA
Edition 01H
Data 1 (2)
FRESHWATERPUMP
F a u lt L o c a t i o n :
T h e p u mpd o e s n o t w o rk a fte r star t.

C a u s e s : P u m pd r a w si n a i r a t s u c t ' i o ns ' i d e- c h e c kp a c k i n g sa n d p i p e s f o r
ti ghtness.
P u m pn o t p r i m e d .
A 'ir ca n n o t e sca p eo n deli ver y s i de.
L e a k i n gs h a f t s e a l .
Pu m pc a p a ci ty d ro p s a fte r n o r ma'oper
l
at' ion.
C a u s e s : S u c t i o ns t r a i n e r o r s u c t i o n v a l v e c l o g g e d .
A i r l e a k a g ea t s h a f t s e a l .
F o u l e d' i m p e ' l 1 e r .
P u m pd o e s n o t g i ve ma x'i mudm
eliver y.
C a u s e s : S u c t i o nv a l v e n o t f u l l y o p e n .
D e fe cti ve se a ls.
Wornimpe'ller and v'rorn!.rearrings.
Note:
R u n n i n gtro u b l e s w i th the pum ps,apar t fr om mechanicalfaults, ar e

m o s to f t e n d u e t o l e a k s i n t h e s u c t i o n l i n e . I t i s e s s e n t i a l , t h e r e fo re , th a t a l l p a ckingsand gasketsar e in or der and that they ar e
re n e w e dw h e nn e ce ssar y.Evena t' iny hole in the suction line wi l l
re d u ceth e p u mpca p acity.
W h e no v e rh a uiln g w a te r p u mp sthe
r a d i a l c l e a r a n c e" X " s h o u l db e
checked.
0 n a n e wp u m p" X " i s 0 . 3 8 - 0 . 5 0m m .
Whenthe c'learance"X" exceeds1 mm
the impellerand/ordiffusor/housing
s h o u l db e r e p l a c e d .
tJ=15
F.t5==.9
GENERANNGSETS
D317
ENGINEDATA
E d 'tii o n 0 1 H
Data 2 (2)
OF SHAFTSEAL)
PUMP (EXCHANGE
FRESH
WATER
NOTE:
T h e s h a ft se a l i s a p re ci si o n madepr oduct.
H a n d l ew i t h c a r e .
D o n o t scra tch th e se a l fa ces.
1 . T h o ro u g h l ycl e a n th e sh aft sur face and a' ll the sur facesof the seal c av i ty .
*)lub.i.ute the
2 . W i t h t h e c e r a m i cs e a t f i t t e d ' i n t o t h e r u b b e r s e a t c u p
o u t e r d i a me te ro f th e cu p and push the seat assem blyinto the seal c av i ty .
3.
" / L u b r i c a t e t h e s h a f t a n d t h e i n s i d e d i a m e t e ro f t h e r u b b e rf r i c t i o n r i n g
o f th e ro ta ti n g se a l a ssembly.Put the r otating assem blyonto the s haft
al ong
w i t h th e ca rb o nfa ce to war dsthe cer am' icface. Slide the assem b' ly
faces
m
eet.
t h e sh a ft u n ti l th e se a ling
4.
En s u reth a t th e se a l sp ring is cor r ectly located and r efit Im peller Ke- v ,

I m p e l l e r , I m p e ' l l e rW a s h ear n d I m p e ' l l e rN u t .
x)
I f p o s s i b l e , u s e t h e l i q u i d t o b e p u m p e dL. i q u i d d e t e r g e n to r v e g e t a b l e
o i 1 m a ya l s o b e u s e d .
a \
R n th e se a l dr y - fill
C A U T ION
: E V Eru
pum pwith liquid befor e oper at i ng.
-*-
- -----
--tE
CENERA'I{G SETS
1||AN
Eteut
D 319
Datafor Torquemoment
Data
Page1 (1)
Edion 17H
L23l30
Section
305
306
Thread
Description
Mainbearingstud(in frame)
Nutfor mainbearingstud
Mainbearingsidescrew
Counterweight
on crankshaft
Vibrationsdamper
on crankshaft
Frame/ bedplate
Flywheelmounting(fittedbolt)
Gearrim on flywheel
M48
Stud
M
45x3
Nut
M
24
Screw
M
2
6
x1.5
Screw
M
2
7
Nut
M
2
4
Nut
1.5
M
1
8
x
Nut
Screw
Cylindercoverstud(in frame)
Nutfor cylindercoverstud
Coolingjacketcylindercover
Fuelvalveliner(ringnut)
Stud
Nut
Screw
Nut
307
rod(seesection307)
Connecting
308
Housingfor valvegear
Valvegear bracketrockerarm
310
Fuel-pump
distr.piece
Fuel-pump
top flange(barrel)
plugs
Fuel-pump
cavitation
Fuel-pump
mounting
311
(nozzlenut)
Fuel-valve
Fuel-valve
mounting
(capnut)
Fuel-valve
Fuel-valve
adjusting(locknut)
Highpressurepipe
M48
M45
1200
i
j
i
i
I
600
Copaslip
Copaslip
Copaslip
Copaslip
I
i
Copaslip
CopasliP
r
i
I
i
CopasliP
CopasliP
Copaslip
CopasliP
i
i
i
j
i
Copaslip
Copaslip
Copaslip
Copaslip
Copaslip
4A
40
250
40
40
I
j
I
i
Ii
Copaslip
CopasliP
Copaslip
Copaslip
CopasliP
300
I copaslip
I
22
150
M12
M12
50
40
25-30
MB
Screw
55-65
M
1
0
Screw
1
0 0- 1 2 0
M
2
0
x
1
.
5
Plug
150
M
1
6
Screw
Nut
Nut
Nut
Nut
Nut
M 2 6 x 1 . 5 1 0 0- 1 2 0
30
M16
70
100
40
MlBx1.5
Camshaftassembly
Gearwheelon crankshaft
Intermediatewheelshaft
Intermediate
wheelgear
Gearwheelon camshaft
315
GearwheelonLub.oil.pump
Nut I M12
Nut1M10x1.0
Nut1M20x1.5
Nut I M12
M 12
Screw
I
Nut I
320
Conicalselementsmounting
Uppermounting
Lowermounting
Screw
Nut
M24
M24
CopasliP
Copaslip
CopasliP
Copaslip
Copaslip
CopasliP
CopasliP
CopasliP
300
250
400
500
140
34
M60x4
312
90.28
Tightening
Torque I Pressure Lubricant
bar
Nm
I
150
200
I CoPasliP
I CopasliP
I{OIEBY
GEIERATEsETs
t||AN
Ef&w
D 319
Datafor Pressureand Tolerance
Editon18H
L23t30
Clearancein mainbearing
Clearance
in guidebearing(axial)
Maximumclearancein guidebearing(axial)
Clearance
between,mainbearingcpanOframe,
before.tightening
of bracingscre* (sidescrew)
Checkingof mainbearinglAutotogj(seepageD305)
Clearance
betweencrankshaft
andseating,ing,,ppb, and lowerpart
Maximumovalnessfor cylinderliner
Newcylinderliner,insidediameter
Cylinderlinermaximuminsidediameter
Outerdiameterof valveseat
Seatwidth(sealingsurfaceaftergrinding)
Maximumheightof spindteabovecylindrhead
Minimumheightof varvehead,inretvarveand exhaustvarve
Maximuminnerdiameter,valveguide
0.06r 0.01mm.
0.30- 0.40mm.
225.000- 225.046mm.
225.60mm.
70 t 0.2mm.
3.5t 0.2mm.
84.50mm.
5.0mm.
14.25mm.
Pistonringand pistonringgrooves(seepageD307)
Clearancein b(7-endbearing
Clearancebetweenconneoingrod bushand pstonpin
Maximumovalnessin big-erd-bore
(withoutbearingj
0.'t5- 0.20mm.
0.15- 0.20mm.
0.08mm.
Valveclearance,
inletvalve(coldengine1S_55 "C)
Valveclearance,
exhaustvalve(colJengine15 _55 .C)
Maximumclearancebetweenrockerarm and rockerarmshaft
0.40- 0.50mm.
0.90- 1.0mm.
0.30mm.
Maximumcombustion
pressureat fullload
Maximumdifference
Maximumdifference
betweencylinders
A changeof heightof thethrusfpiecespacerringof 0.r0 mm.wiil
change
the maximumpressureby
1" turningof camshaftgearwheelchangesmaximumpressure
by approx
Openingpressureof fuelvalve
Clearancebetweentoothson intermediatewheel
Clearancebetweenpick-upand gearwheel
Clearance
betweencamandpicf-up,for fef system(seepage313.15)
90.29.
0.20- 0.30mm.
0.15- 0.44mm.
0.8mm.
130bar
t3bar
3 bar
1 bar
3 bar
320bar
0.20- 0.30mm.
1 + 0.3mm.
llolcgY
GEI\ERA|\ESE.S
EngineData
z
o
of Engine
Operation
FEnginePerformanceandCondition
o
o-
Tracing
Trouble
andMainBearings
Crankshaft
CylinderHeadand GylinderLiner
Rod
PistonandConnecting
Gearfor InletValves,
Operating
ExhaustValvesand FuellnjectionPumps
]U
Turbocharger
System
PE
GG
Zj-
FuelInjectionPump
E=
R;
= <z
g
4,9
FuelInjection
Controland SafetySystems
Automatics
andInstruments
F
F -
a,
d tlg
cl
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
IvlAhl
clan^t
L?3/30
O P E R A T I OONF E N G I N E
3 0 2 . 01
STANDARD
CHECKS
Edition15H
G e n e r a l l y ,t h e o r d i n a r y o p e r a t i o no f t h e m a c h i n e r yr e q u i r e so n l y p e r i o d i c a l
c h e c k i ngo f th e o p e ra ti o n a l data of the engine - pr essur esand temper atur esa n d t h e s e d a ta sh o u l d b e re cor ded,so as to be able to obser veslowly pr og r e s s i n gc h a n g e si n t h e s e r v i c e c o n d i t i o n o f t h e e n g i n e . P r o g r a m moevde r h a u l s
m a yb e p l a n n e dto su i t th e running scheduleof the plant for exampleacc or d i n g t o t h e d i r e c t i o n s f o r " O v e r h a u Il n t e r v a l s " ' i n c l u d e di n t h i s s e c t i o n . T h e
f o l l o w i n g i n stru cti o n s a re b asedon a numberof standar dcheckswhjch sh oul d
b e m a d eb e fo re sta rti n g o n the var ious oper ations, consequently,the ind i v i d u a l p o in ts to b e ch e cke da re stated fir st.
C h e c k 1 . C h e c kt h e l u b r i c a t i n g o i l s u p p l y t o b e a r i n g sa n d p i s t o n s b y p u m ping through the systemby meani of the hadpumpof the engine
o r th e p re l u b ri ca ting pump.Makesur e that oil flows out of al l
b e a r in g s .
Check 2.
A f t e r b e i n g e m p t i e dt h e l u b r i c a t i n g o i l s u m ps h o u l db e c a r e f u l l y
cl e a n e d ,a n d i t should be checkedthat ther e ar e no pieces of m t a 1 , o r t h e l i k e , i n t h e o i l p a n , a s t h i s w o u l di n d i c a t e i r r e g u l a r i t i e s i n b e a r i n g so r g e a r k h e e l s . M e a s u r e
b e a r i n gc l e a r a n c e s
b y me a n so f a fe e l er .
Check 3.
C h e ckth e w o rki n g sur face of the cylinder liner s for micr o se i zures or abnormalwear grooves.
Check 4.
C h e ckth e a l i g n mentof the cr ankshaft as pr escr ibed( section 305 C ) .
Check 5.
C l e a na l l fi l te rs
maged.
Check 6.
Checkconnectingrod bolts, various bolts betweenframe and bedp l a te , a s w e l l s holding- downbolts for cor r ect tightness.
Check 7.
C h e ckth e o i l l e vel in engine bedplateand in tur bochar ger s .
Check 8.
Turn the engine at least two turns by meansof the turning rod,
w h i l e th e i d i ca tor valves ar e open. Checkthat water or fuel i l
d o e s n o t fl o w o u t of the indicator valves.
C h e c k 9.
L u b ri ca te th e i o i n ts of the r egulating gear . Checkthe oil lev el

i n th e g o ve rn o ra nd check, thai the r gu' latinggear moveseas i l y
a l l th ro u g hth e re gulating r ange.
and check that the filter
elementsar e not da-
C h e c k1 0. F e e l -o ve rp ro g ra mm e:
a.
M a i nb e a r i n g s ,c r a n k p i n b e a r i n g s ,g u i d e b e a r i n ga n d a l t e r n a to r b e a ri n g s.
b.
P i s t o n p i n s a n d w o r k i n gs u r f a c e . o f c y l i n d e r l i n e r s .
c.
C a msh a ftb e a rings, gear wheelsand r oller guides.
l-C
-AJ
CENERATTNCSETS
rv|Ar{
Er&ult
L23/30
OF TNGINE
OPERATION
302.02
STANDARD
CHECKS
C h e c k1 1 .
E d i t i o n1 5 H
p u m pa n d f u e l o i l
d.
Lub. oil
e.
G o v e r n o rd r i v e .
f.
T u r b o c h a r g e rb e a r i n g s .
primary pump.
C h e c kt h e g o v e r n o ra s f o 1 l o w s :
S t a r t u p t h e e n g i n e a n d r u n i t a t t h e s y n c h r o n o u sn u m b e ro f r e v o l u ti ons.
a.
S p e e dse tti n g : C h e ckbefor e cutting in the gener atoron the

sw i tch b o a rdth a t th e ser vom otoradjusts the r pm at a suitable
q u i ckn e ssa fte r a ctu ation of the synchr onizerknobon the
sw itch b o a rd .
The range from -5%+ 5% fron synchronousrpm should be tested.
b.
A d j u sti n g sp e e d : C ut in the gener atoron the switchboar dand

se t th e l o a d a t a b o ut 40%.W henthe oil temper atur ein gover nor
a n d e n g i n eh a s re a chedits nor m alvalue, ' incr easethe load ' insta n ta n e o u sl y(sta rt of lar ge pumpor com pr essorto
) about B0% .
D u ri n g th i s p ro ce d u rethe fr equencym ust not fall by m or ethan
a b o u tS %,a n d
a co n stant r pmm ust be r eachedwithin about 3 sec.
( t n s r p m , h o w e v e ri,s s l i g h t l y ' l o w e r t h a n p r e v i o u so n e d u e t o
th e sp e e dd ro o po f the gover nor ) . If the engine is oper ating in
p a r a l l e l w i t h o t h e r e n g i n e s ,e v e nd i s t r i b u t i o n o f l o a d m u s t h a ve b e e no b ta i n e dw i thin about 3 seconds.If the gover norr eacts
to o sl o w l y, ma keth e compensating
adjustm entas descr ibedin
w o o d w a rd 's
i n stru cti on book ( Compensat' ing
adjustm ent) .
N o te : It i s a ssu med
that the oper ating condition of the engine
a n d tu rb ch a rg e ri s i n or der so that the tr acing of any faults
can be confined to the governora'lone.
c.
d.
H u n ti n g : R u nth e e n ginewithout load at synchr onous

r pm. W hen
th e g o ve rn o ro i l 'i s war m ,the r egulating lever m ust not take
any major periodical movements,
and neither must there be any
va ri a ti o n u p a n d d o wnin the enginespeed. If that is the case,
the compensating
adjustmenthas to be repeatedaccording to the
Woodward
instruction book.
S p e e dd ro o p : If th e re is an unsatisfactor y distr ibution of
l o a d b e tw e e ntw o o r mor eengines, the distr ibution can be im p ro ve db y i n cre a si n gthe speeddr oop setting of the engine
w h i ch , d u ri n g l o a d i n cr ease, absor bsthe gr eater par t of this
i n cre a se (o r b y re d u cingthat of the other s) . Nor m a' llythe setti n g sh o u l d n o t b e i n cr easedbeyond70 on the dial, and satisfa cto ry p a ra 'l l e l ru n ningwill gener ally be obtainableat set.ti n g s b e tw e e n4 0 a n d 60.
al
I-Gt
GENERA'NVG
SETS
L?3/30
302.03
STANDARD
CHECKS
Edition l5H
c h e c k1 2 . ch e ckp re ssu rea n d temper atur esaccor djngto Data 303.

1.
S e a w a te te
r mper atur e:
A s ' l o w a s p o s s i b l ew i t h o u t t h e f o r m a t i o no f c o n d e n s ewda t e r i n
i n t h e c h a r g i n ga i r n e c e i v e r .
2.
E xh a u stte mp er atur e:
D e p e n d os n th e load.
N o r m a vl a l u e s i n d i c a t e d i n t e s t b e d t a b l e .
C h e c k1 3. T h e a l a rm a n d mo nitor ing systemcan be checkedas follows:

1. Alarms:
P r e s s u r es w i t c h e sw i t h t e s t v a l v e c a n b e d i r e c t l y t e s t e d .
P re ssu resw i tc heswithout a test valve can be checkedby al ter i n g . t h e s e t t i n g u n t i l a n a l a r m i s g i v e n . W h e nr e a d j u s t i n gt h e
s e t t i n g t o t h e n o r m a lv a l u e , t h e a l a r m s h o u l ds t o p .
T h e rmo sta tecan
s gener ally be tested in a similar way.
?.
S h u td o w n :
T e st th e systemas descr ibedfor alar ms.
3.
0 ve rsp e e d :
R u nth e e n g i n e without load, and incr ease the r pm by mea nsof
th e syn ch ro n izercontr ol of the gover nor , until the over s peed
t r i p _ f u n c t i o n s . T h e s e t t i n g s h o u ' l db e s y n c h r o n o ussp e e d+ 1 2
to 13%-
C h e c k, |4 . T h e g o ve rn o rmu st be able to movethe fuel pum pgear to 0- po s i ti on.

ration of
ne for normal start or stand-b
1 . C a rry o u t C h eckNo. 7.
2 . Turnon cooling water, fuel oil andstarting air to the engine.
3.
Start
If th e e n g i n e has beenout of oper ation for som elength of ti me , i t sh o u l d be tur ned at least two tur ns with the indic ator
va l ve s o p e n . under these cir cum stancesit is advisableals o to
p ri me th e l u b ricating oil systemwith the handpum p( pr el ubr i cating pump).
1 . D e p re ssth e star ting button.
2 . L e t g o o f th e button whenthe engine fir es.

3 . ca rry o u t ch e ck No. 12. ( In the case of automatizedpr an t, the
p r i n c i p a l f u n c t i o n s a r e a u t o m a t i c a l l ym o n i t o r e d ) .
Ftr=EEY
GNERATT\IG SETS
t23/30
STANDARD
CHECKS
St o p
t .
2.
3 0 20
.4
Edition 15H
T h e e n g i n ei s n o r m a l ] ys t o p p e db y s e t t i n g t h e " L o a d - L i m i t , '
k n o ba t 0 .
If !!" e n g i n e i s to r ema' instoppedfor a per iod of somelength.
c o o l i n g w a t e r , f u e l o i l a n d s t a r t i n g a i r s h o u l db e t u r n e o i t .
EE.EBY
GENERA'T{C STS
tvlAI{
ct&ut
L23/30
3020
.5
tdition 15H
OVERHAULS
E x t e n s i v er e p a i r j o b s s h o u l db e p l a n n e do n t h e b a s i s o f t h e p e r i o d i c a l o b s e r v a t i o n s o f t h e o p e r a t i n gc o n d i t i o n o f t h e e n g i n ea n d , s i m ' i ' l a r l y ,t h e e x t e n t
o f t h e w o rk ca n b e d e te i mi n edon the basis of the' infor m ationobtainedby c ar r y i n g o u t C h e c k1 , 2 , 3 , 4 , 5 a n d 6 b e f o r e s t a r t ' i n g r e p a ' i r s .
'inside of the engine shouldbe very carefully
A f t e r c a r r y i n g o u t r e p a i r s , the
c l e a n e d ,a n d , i f n e c e s s a r yo, i l p i p e s a n d d u c t s s h o u l d b e f l u s h e d t h r o u g h , a n d
t h e ' i n s'i d ei f th e cra n kca seb e w a sh e d .
B e f o r e sta rti n g th e e n g i n e for the fir st

C h e c k7 , 8 , 9 a n d 1 4 .
tim e, r epeat Check1, and car r y out
S t a r t i n g a n d r u n n i n gu p t h e e n g j n e .
1 . S e t t h e " L o a d - L i m i t "k n o bo f t h e g o v e r n o ra t 0 Z . T u r n o n c o o l i n g w a t e r a n d s t a r t ' i n ga i r , a n dc l o s e t h e i n d i c a t o r v a l v e s .
3.
R u nt h e e n g i n eo n s t a r t i n g a i r u n t i l t h e o i l p r e s s u r eg a u g es t a r t s i n d i cating an oi1 pressure.
4.
ab9v9m inimum,us i ng
R e d u ceth e sp e e d se tti ngof the gover norto slightly
"Load- L' im it"knobat about 5.
the
nd
set
knob,
co
n
trl
syn
ch
ro
n
i
ze
r
the
5.
Turnon fuel oil.
6.
S t a r t t h e e n g i n ea n d c h e c kt h a t l u b . o i l p r e s s u r e ,f u e l o i l p r e s s u r e '
a n d co o l i n g a te r p re ssur ear e nor mal ( cf. Check12) -
7.
R unth e e n g i n ew i th o u t load at about 300 r /min for 5 minutes, stop the

e n g i n ea n d fe e l o ve r a s outlined in Checkl0-
B. Sta rt th e e n g i n e , a n d run up over a per iod of som e30 minutesto s y nc hr onous rpm. Then rePeat Check10.
9.
R unu p th e e n g i n e a n d l oad it gr adually unti' l about 257/over a pe r i od of

o n e h o u r , t h e n c a r r y o u t C h e c k1 1 , 1 2 , 1 3 a n d 1 0 -
, 0 . R u nu p th e e n g i n ea n d l oad it gr adually so as to obtain 100%over a per i o d o f a b o u t l 0 h o u rs.

Pro vi d e dn e wcyl i n d e r l iner s or pistons have not beenfitted, the r unn i n g -u p p e ri o d -ma yb e r educedto about 5 hour s. l.lhile incr easingt he l oad
o f [h e 'e n g i n e , ta ke re adingsof pr essur esand temper atur es,and com par e
the values recordedwith those stated in the testbed table.
lt.
S t o p t h e e n g i n e ,r e p e a tC h e c k3 , 5 , 6 ( c o n n e c t i n rgo d b o l t s ) , 7 a n d 1 0 ,
f ol l o w i n g w h i ch th e e n gine is r eady for oper ation.
EiEEH
CNERAru{G SETS
L23 / 3 0
F U E LO I L
HEAVY
3020
.6
Editionl5H
O P E R A T I OS
NE
, R V I CA
E N DM A I N T E N A N C E
0 p e r a t i o no n h e a v yf u e l o j l w i l l i n v o l v e v a r i o u s d r a w b a c ktso t h e e n g i n ec o m p a r e dt o o p e r a t i o no n m a r i n ed j e s e l o i l / m a r i n e g a s o i l .
Th e s ed r a w b a cks
a re ca u se db y th e i nfer ior combustionpr oper ties of the fuel
o j l a s w e l l a s i t s c o n t e n to f u n w a n t e idm p u r i t i e s a n d c h e m i c a lc o m p o s i t i o n s .
Whe nk n o w i n ga b o u t th e se d ra w b a cks
and appr eciating their negative effect on
t he e n g i n e , t h is e ffe ct ca n , to a consider ableextent, be counter actedand in
man yc a s e se l i mi n a te d so th a t sa ti sfactor y oper ational r esults can be achieved
w i t h o u t a p p r e c i a b l ei n c r e a s ei n s e r v i c e a n d m a i n t e n a n c e .
Dra w b a c kwsh e no p e ra ti n g o n H e a vyF uel
O p e r a t i o no n h e a v yf u e l i n v o l v e sa r i s k o f h e a v i e r f o u l i n g o f t h e c o m b u s t i o n
s p a c e sa n d g a sw a yso f th e e n g i n e . F ur ther m or e,- Ther e' isa- r isk of heavier abr a s i v e w e a ro f c y f i n d e r s , p i s t o n s a n d p i s t o n r i n g s a s w e l l a s v a l v e s e a l s ,
ildl p t t r n pasn d fu e l va l ve n o zzl e s. Cor r osiveweai m ight occur to a gr eater or
smaller extent as cold corrosion on-a-c-cornf
oTTh'e su'lphurcontent f the fuel
o i l , a n d a s h i g h t e m p e r a t u r ceo r r o s i o no n t h e e x h a u s tv a l v e s , m a i n l y o r i g i n a t i nngg ff r o m t hhei tei xoins st ion fgv a n ai ca
diu
ndsodium
h i c h a and
v sodjumwhich have
l m
coampositions
of- w
vanadium
a c o r r o s i v e e f fe ct.
Th e e x t e n t o f th e me ch a n i cadl ra w b acks
w' ill m ainly dependon the fo1' lowing
factors:
a ) T h ec h e m i c a cl o m p o s i t i o o
nf the fuel oi'I.
b ) T h e e f f i c i e n cy o f cl e a n i n g a n d adequatepr epar ationof the fuel pr ior to
use in the engine.
c)
T h e e n g i n etyp e a n d th e a ctu a l maintenance

condition and load condition.
T h e o p e r a t i o n a lr e s u l t s o f t h e i n d i v i d u a l e n g i n et y p e w i 1 ' 1 ,a s e x p l a i n e da b o v e, d e p e n do n th e co mb i n a ti o no f fu el oil quality, fue' l oil tr eatment, and the

o p e r a t i o n a n d ma i n te n a n ce
o f th e e n gine.
O p e r a toi n
P a rt L o a dO p e r a ti o n
H i g h - e f f i c i e n t t u r b o c h a r g i n go, p t i m i z e df u e l i n j e c t i o n a n d v a l v e t i m i n g w i l l
e n s u r ec o m p l e teco mb u sti o n
o ve r th e entir e com m on
load r ange, and the tendenc y
o f e x h a u s tg a s b l o w b a cka t p a rts l o ads is minimizedas wel1. Adequatetemper at u re l e v e l i n th e co mb u sti o n
ch a mb erto ensur ecor r ect ignition and complete
c o m b u s t i o ni s o b ta i n e db y ma i n ta i n i ngconstant tem per atur eof the m ediassur ro u n. d i n gt h e c omb u sti o nch a mb e r,p ri mar ily in the cooling water systemand the
'lub
o i ' l s y s t e m,(p i sto n co o l i n g me dia) but also in the fuel injetion system
a n d t h e s y s t e mfo r te mp e ra tu reco n trol of the injection valve nozzles.
l:.b.=
FFEig
E Fr=--==
E
GENERATINC SETS
IYlAhl
L23/30
F U E LO I L
HEAVY
Er&ult
302.07
Edition 15H
As l o n g as a d e q u a teco mb u stionchambertem per atur esar e maintained,pr eh eati ng

o f t h e c h a r g e - a i rs h o u l db e a v o i d e d ,a s t h e r e s u l t i n g d e c r e a s eo f a i r d e n s i t y
will
c r e a t e b a d s o o t v a l u e s ( s m o k ee m ' i s s i o n ) .
'l o n g -te rm
In caseof
H F Oo p e ration at extr em e
low load there is a risk of contaminatioo
nf
c o m b u sti o nch a mb e r,e xh a u stpipe and tur bochar g e r d u e to a h i g h e r p ro d u ct'ionof car bondeposits.
In general we recornmend
not to run the engines
a t l o a d s b e l o w2 0 %MC Rfo r l o nger per iods than
2 0 h o u r s . D u r i n gs u c ha l o n g p e r i o d o f l o w l o a d
i n c r e a s e df o u l i n g o f t h e g a s w a y iss u n a v o i d a b l e .
H o w e v eirn o u r e xp e ri e n ceth e car bondeposits
w i l l b e b u r n t o f f a f t e r 3 - 4 h o u r so p e r a t i o na t
a l o a d e x c e e d i n g6 0 %M C R .
I f s p e c i a ' lc o n d i t i o n ss h o u l dd e m a nldo n g - t e r m
l o w l o a d o p e ra ti o n e xce e d i n gabovem entioned
c o n d i t i o n si t c o u l d b e n e c e s s a r yt o e s t a b l i s h
for adjustmentof the charspec'ial arrangements
ge air temperaturein order to reduce an extrem e f i i i n g l a g c a u s e db y a s u b s t a n t i a l l y c o o ' l e d downcombustionchamber.
Start and Stop on HFO
St a r t a n d sto p o f th e e n g i n e should take place
o n H F Oi n o rd e r to p re ve n t a ny incompatib' ility
problemsby change-overto MD0.MD0'shouldonwor k
l y b e u se d i n co n'lnoencti
g eor nw i th m aintenance
p e ri ods of engine
o n t h e en g i n eo r
s t a n d s t iI I .
Before starting on HFOthe engine must be prop e r l y p r e h e a te d ,w h i ch i n cl u des:
C o o l i n gw a te r o f 5 0 -6 0 0i s ci r culated thr ough
t h e f r a me a n d cyl i n d e r h e a dfor at least 2
hours before start.
Pan-Lod Opcration
Effect
Combustion chamber temp.
Completenessof combustion.
Fouling of engine.
Smoke emission.
Operational conditions
GenSets RPM constant.
GenSets normal load-range
605% of MCR.
Seldom lowerthan 30 % MCR.
Counter-moves
Maintain consrnt temp.:
Cooling water system.
Fuel oil systemNozzle cooling system.
lf the engine is operated for more than
20 hours at load lower rhan 20 % of
MCR: 34 hours' operation at load
exceeding 60 % MCR is necessaryto
burn the combuson chamber clean.
Start & Stop on H.F.O.

Stan
l. Circulareiacketwater of temp.
5O{Oo C at least 2 hotrs before stan
of engine.
2. Circulate heated fuel oil in engine
fuel system at least I horr betore
sun of engine.
3. Circulate heated oil in fuel noz:le
cooling system at least 15 min.
before stan of engine.
StoP
Maintain circulation in engine fuel
system at adequate temp. (above poor
pointl.
Change to M.D.O. only if engineis
stopped for onerhaul. or in connecoon
with laying-up or docking of vessel.
Pr e h e a te dfu e l o f co me ct w o rking temper atur e( dependingon the nom inalv i s c os i t y ) ' i s ci rcu l a te d th ro u g hthe fuel pumpsfor one hour befor e star t. C i r c ul at i o n o f th e p re h e a te do i l th r oughthe nozzles should take place 15 m inutesbef o r e s t art.
S t o p p i ngth e e n g i n e i s n o p roblem,but it should be ensur edthat the tem per at u r e o f fu e l p i p e s i s n o t re ducedto a level below the pour pointof the fuel ,
o t h e n i sere e sta b l i sh i n go f the cir culation m ' ightcausepr oblem s.
E 3.G,t!
r-*rg
GENERAIING
SETS
IYIAt{
L23/30
ON
FENGINE
OPERATIO
HTAVY
FUILOIL
ct&ut
302.08
Edition 15H
Room
V e n t iI a t i o n
Eng'ine
G o o dv e n t i l a t i o n o f t h e e n g i n er o o ma n d a s u i t a b ' l el o c a t i o n o f t h e f r e s h a i r
i n t a k e o n t h e d e c k ' i s a l w a y s ' i m p o r t a nS
t .e a w a t e r i nt h e i n t a k em i g h t r e s u l t ' i n
c o r r o s i v ea t t a c k s a n d i n f l u e n c e t h e o v e r h a u li n t e r v a l s o f t h e e x h a u s tv a l v e s .
T h e f r e s h a i r s u p p l y ( v e n t i l a t i o n ) t o t h e e n g i n er o o mi s t o c o r r e s p o n d
to
a p p r o x .i . 5 t i m e s t h e a i r c o n s u m p t ' ioofn t h e e n g i n e sa n d p o s s b l eb o i ' l e r si n
o p e r a t i o n .S u b - p r e s s u rien t h e e n g i n er o o mw i l ' l r e s u l t i n i n c r e a s e de x h a u s t
t e m p e r a t u r lee v e l . T h e e x h a u s ts y s t e m ,i n c l u d i n g s i l e n c e r s , i s t o b e s o e x e c u t e d t h a t t h e f l o w r e s i s t a n c eo f t h e e x h a u s tg a s i s r e d u c e da s m u c ha s p o s s i b l e .
T h e e x h a u s tb a ck-p re ssu re
me a su re after
d
the tur bochar ger sat full load should
e
n o t e x c e e d2 5 0 -3 0 0rrn w a te r g a u g e .An incr easeof the exhaustbackpr essurwill
a l s o j n v o l v e a n i n c r e a s e de x h a u s tv a l v e t e m p e r a t u r el e v e l .
Main t e n a n c ea n d Mo n 'i to ri n q
D u r i n gt h e o p e r a t i o n , s m a l l a ' l t e r a t i o n so f t h e c o n d i t i o n c o n t i n u o u s l yt a k e
p l a c e i n t h e e n g i n ea s a r e s u l t o f t h e c o m b u s t i o ni ,n c l u d i n gf o u l i n g so f t h e
a i r w a y sa n d g a s w a y sf,o r m a t i o no f d e p o s i t s , w e a r , c o r r o s ' i o ne t c . I f c o n t i n u o u s 1 y r e c o r d e d ,t h e s e a l t e r a t i o n s o f t h e c o n d i t i o n c a n g i v e v a l u a b l ei n f o r m a t i o n
a b o u t t h e o p e r a t i o n a la n d m a i n t e n a n cceo n d i t i o n o f t h e e n g i n e .C o n t i n u a lo b s e r v a t i o n s c a n c o n t r i b u t e t o f o r m i n ga p r e c i s e a n d v a 1 u a b l eb a s i s f o r e v a l u a t i o n
pr ogr afimes
for the
t o 1 a y d o w nt h e o p ti ma l o p e ra ti o n a l and m aintenance
i n d i v i d u a ' pl 1 a n t .
He recommend
to take weekly records of the most important performancedata of
t h e e n g i n ep l a n t , a s s p e c i f i e d i n t h e t a b l e , o n p l a t e 3 0 2 0 2 .A t t h e r e c o r d i n g ,
t he o b s e r v a t ' io n as re to b e co n ti n u ally compar ed
in or der to ascer tain alter at io n s a t a n e a rl y sta g e a n d b e fo re these exer t an essential influence on the
ope r a t i o no f t he p 'l a n t. A s a re fe re ncecondition for the per for m ance
data, the
t es tb e d m e a s u re me notsf th e e n g i n eor possibly the measur ements
taken dur ing
deviat h e t r i a l t r i p a t t h e d e ' l i v e r yo f t h e s h i p c a n b e u s e d . I f c o n s i d e r a b l e
t i o n s f r o m t h e n o r m a lc o n d i t i o n a r e o b s e r v e d ,i t w i l l i n t h e g r e a t m a j o r i t y o f
c ase sb e p o s s ib l e to d i a g n o seth e causeof such deviations by meansof a total
after which possible adjustments/over e v a l u a t i o n a n d a se t o f me a su re ments,
h a u l s c a n b e d e c i d e da n d p l a n n e d .
F o r e x a m p l ef,o u l i n g o f t h e a i r s i d e o f t h e a i r c o o l e r w i l l m a n i f e s ti t s e l f i n
a n i n c r e a s i n gp r e s s u r ed r o p , l o w e r c h a r g i n ga i r p r e s s u r ea n d a n i n c r e a s e d
ex h a u s tt e m p e ra tu rel e ve l (w i th co nsequentialinfluence on the over haulinter v a l s f o r t h e e x h a u s vt a l v e s ) .
, aniF o u l i n go f t h e t u r b i n e s i d e o f t h e t u r b o c h a r g ewr i l l , i n i t s f i r s t p h a s e m
f e s t i t s e l f i n i n c r e a s i n gt u r b o c h a r g erre v o l u t i o n so n a c c o u n to f i n c r e a s e dg a s
v e l o c i t y t h r o u g ht h e n a r r o w e dn o z z l e r i n g a r e a . I n t h e l o n g e r r u n , t h e c h a r g i n g
air q u a n t i t y w i 'l l d e cre a seo n a cco untof the gr eater flow r esistancethr ough
t h e n o z z l er i n g , r e s u l t i n g i n h i g h e r w a l l t e m p e r a t u r eisn t h e c o m b u s t i o n
c ha m b e r .
- r.+,= t-ti=.:t
=
E 3t==-:EF
GENERATTNGSETS
tvlAht
L23/30
O P E R A T I OONF T N G I N E
HEAVY
F U E LO I L
Et&ult
302.09
E d it i o n 1 5 H
An'increased
i n v o l v e sa c o r r e s p o n d i nign c r e a s eo f t h e
c h a r g ' i n ga i r t e m p e r a t u r e
e x h a u s t e m p e r a t u rlee v e l i n a r E t i o o f a b o u t1 : 1 . 5 , i . e . l " C h i g h e r c h a r g i n g
a i r t e m p e r a t u r cea u s e sa b o u t 1 . 5 " Ch i g h e r e x h a u s tt e m p e r a t u r e .
R e d u c t i o no f t h e c h a r g ' i n ga i r p r e s s u r er e s u l t s i n a c o r r e s p o n d i nrge d u c t i o no f
t h e c o m p r e s s i opnr e s s u r ea n d m a x . c o m b u s t i opnr e s s u r e .W h e nc h e c k i n gt h e m a x .
p r e s s u r ea d j u s t m e not f t h e e n g i n e , j t i s t h e r e f o r e t o b e e n s u r e dt h a t t h e e x j s t i n g s c a v e n g i nagi r p r e s s u r ei s c o r r e c t .
T h e i n j e c t e d a m o u not f f u e l i s e q u i v a l e n tt o t h e s u p p l i e de n e r g ya n d i s t h u s a n
e x p r e s s i o no f t h e l o a d a n d m e a np r e s s u r eo f t h e e n g i n e . T h e f u e l p u m pi n d e x c a n
d b e p ropor tional to the m eanpr essur e. Conseque ntl yi,t
t h e r e f o r e b e a ssu meto
d a t th e co n nectedvalues of the fuel pum pindex and the engi ne
c a n b e a ssu meth
r e v o l u t i o n sa r e p r o p o r t i o n a lt o t h e l o a d .
A t o p e r a t ' i o no n h e a v yf u e l , t h e s p e c i f i c f u e l o ' i l c o n s u m p t i owni l l o n t h e w h o l e
r e m a i nu n a l t e r e d ,w h e nc o n s i d e r i n gt h e d i f f e r e n c e i n c a l o r i m e t r i c c o m b u s t i o n
of the specific gravity of the fuel oil andits
v a l u e . H o w e v e rt,h e c o m b i n a t i o n
c a l o r i f i c v a l u ew i l l i n v o l v ea v o l u m e t r i ca l t e r a t i o n o f t h e c o n s u m p t i oonf
3 - 6 %.D u eto th i s, th e fu e l pumpindex should be r educedby 3- 6%at oper ati on
o n r e s i d u a l f u e l a s c o m p a r etdo m a r i n ed i e s e l o i l / m a r i n e g a s o ' i l . W h e na d i u s t i n g t h e o v e r l o a dp r o t e c t i o no f t h e e n g i n e ,r e g a r d s h o u l db e p a i d t o t h i s .
A b r a s i v ep a r t i c l e s i n t h e f u e l o i l r e s u l t i n w e a r o f f u e l p u m p sa n d f u e l v a l v e
n o z z l e s .E f f e c t i v e t r e a t m e n to f t h e f u e l o i l i n t h e p u r i f i e r c a n l i m i t t h e c o n s ill result in an int e n t o f a b r a s i v ep a r t i c l e s t o a m i n i m u ml '.l o r nf u e l p u m p w
c r e a s eo f th e i n d e x o n a cco untof an incr easedloss in the pum psdue to
1e a k a g e .
W h e ne v a l u a t i n go p e r a t i o n a lr e s u l t s , a d i s t i n c t ' i o n i s t o b e m a d eb e t w e e na l t e r a t i o n s w h i c ha f f e c t t h e w h o l ee n g i n e( a l l c y l i n d e r u n i t s ) a n d a l t e r a t i o n s
w h i c ho c c u r i n o n l y o n e o r a f e w c y l i n d e r s . D e v i a t i o n so c c u r i n gf o r a f e w c y l i n d e r s a r e a s a r u l e c a u s e db y m a l f u n c t i o n i n go f i n d i v i d u a l c o m p o n e n t sf o, r
e x a m p lea fu e l va l ve w i th a too low openingpr essur e, blockednozzle ho l es ,
w e a r , o r o t h e r d e f e c t s , a n i n ' l e t o r e x h a u s tv a l v e w i t h w r o n g l ya d j u s t e dc l e a r a n c e ,b u r n t v a l v e s e a t , e t c .
by the daily r outine m onitor ingc onT h e o p e ra ti o n a l o b se rva ti o n ssupplem ented
t r i b u t e to e n su ri n gth a t fa u lty adjustm entsand other deviations in the per for ar e obser vedin tim e to avoid oper ational di s m a n c eo f i n d i vi d u a l co mp o n ents
t u r b a n ce sa n d so th a t n o rma lr outine over haulscan be car r ied out as sc hedul ed.
I f a b n o r m aol r i n c o m p r e h e n s i bdl e v i a t i o n si n t h e o p e r a t i o na r e r e c o r d e d ,
e x p e r t a s s i s t a n c ef o r e v a l u a t i o nh e r e o f s h o u l db e o b t a i n e d .
T h r o u g hco n ti n u a 'la sse ssme nt
of the oper ation, the engine r oomstaff wil l obt a i n v a l u a b l ee x p e r i e n c ea n d r o u t i n e f o r t h e b e n e f i t o f t h e o p e r a t i o n a lr e l i a b i l i t y ' o f t h e p l a n t a n d t h e o p e r a t i o n a lr e s u l t . P r e v e n t i v em o n i t o r i n go f t h e
e n g i n em i n i m i z e st h e r i s k o f u n i n t e n t i o n a ls t o p p a g e as n d c o n t r i b u t e st o o p t i m i z i n g t h e m a i n t e n a n cceo n d i t i o n a n d r e d u c i n gt h e s p a r e p a r t s c o n s u m p t i o n .
1 9 8 80. 2. 2 1
+#-==F
GENERA'NNG SETS
lvlAN
L23/30
HEAVYFUTLOIL
Et&ut
3 0 2 .10
Edition 15H
Turbochargers
S e r v i c e e x p e r i e n c eh a s s h o w nt h a t t h e t u r b i n e s i d e i s e x p o s e dt o i n c r e a s e d f o u f i n g a t o p e r a t i o n o n h e a v yf u e l .
T h e r a t e o f f o u l i n g a n d t h e r e b y t h e ' i n f l u e n c e o n t h e o p e r a t i o no f t h e e n g i n e ' i s
g r e a t e s t f o r s m a l l t u r b o c h a r g e r sw h e r e t h e f l o w o p e n i n g sb e t w e e nt h e g u i d e
. e p o s i t se s p e c i a l l y o c c u r o n t h e
v a n e s o f t h e n o z z l e r i n g a r e r e l a t i v e l y s m a ' 1 1D
g u i d e v a n e so f t h e n o z z l e r i n g a n d o n t h e r o t o r b l a d e s . I n t h e l o n g e r r u n , f o u l i n g w i l l r e d u c e t h e e f f i c ' i e n c y o f t h e t u r b o c h a r g e ra n d t h e r e b y a l s o t h e q u a n t i t y o f a i r s u p p f i e d f o r t h e c o m b u s t i o no f t h e e n g i n e . A r e d u c e dq u a n t i t y o f
a i r w i l l r e s u ' l t ' i n h i g h e r w a l l t e m p e r " a t u r e isn t h e c o m b u s t i o ns p a c e so f t h e e n g i n e . T e s t s a n d s e r v ' i c e e x p e r i e n c eh a v e s h o w nt h a t c l e a n i n g o f t h e t u r b o c h a r g e r
d u r i n g o p e r a t ' i o no f t h e e n g i n e c a n b e e f f e c t i v e l y c a r r i e d o u t b y i n i e c t i o n o f
w a t e r i n t o t h e t u r b ' i n e . T h e w a t e r w a s h i n g s y s t e mf o r t h e t u r b i n e i s u s e d a s a
s t a n d a r df o r a l l o u r e n g i n e t y p e s a t o p e r a t i o n o n h e a v yf u e l s . 0 n t h e c o m p r e s s o r s ' i d e o f t h e t u r b o c h a r g e r ,w a t e r w a s h i n gi s u s e d a s a s t a n d a r db o t h f o r o p e r a t i o n o n m a r j n e d j e s e l o j l a n d h e a v yf u e l .
F o r t h e s m a l l e r e n g i n e s , w e g e n e r a l l y r e c o m m e ntdo c a r r y o u t t u r b i n e w a s h i n g
d a i l y . T h e n e e d f o r t h i s w ' i l l d e p e n do n t h e f u e l q u a l i t y a n d t h e o p e r a t i o n a l
c o n d i t i o n s a n d i s t h e r e f o r e t o b e s c h e d u l e df o r e a c h p l a n t .
L u b r i c a t ' in g 0 i I F i I t e r s
T h e r a t e o f I u b r i c a t i n g o i 1 c o n t a m ni a t i o n w ' iI I i n c r e a s e w ' it h h e a v y f u e l o p e r a t f lubricat i o n . I n o r d e r t o a v o i d r e d u c i n g t h e i n t e r v a l s b e t w e e nr e p l a c e m e n o
ting oil filter cartridges, sufficient and effective purification of the lubricating oif is therefore essential.
Fuel Injection Valves
A s s u m i n gt h a t t h e f u e l o i l i s e f f e c t i v e l y p u r i f i e d a n d t h a t t h e e n g i n e i s w e l l m a i n t a i n e d , t h e o p e r a t i o n a l c o n d i t i o n s f o r t h e f u e l v a ' l v e sa n d t h e o v e r h a u l i n tervals wi'll not normally be essential altered at operation on heavyfuel.
I f , f o r o n e r e a s o n o r a n o t h e r , t h e s u r f a c e t e m p e r a t u r eo f t h e f u e l v a l v e n o z z l e
i s l o w e r t h a n t h e . c o n d e n s a t i o nt e m p e r a t u r eo f s u l p h u r i c a c i d , s u l p h u r i c a c i d
c o n d e n s a t ec a n f o r m a n d c o m o s i o n t a k e p l a c e ( c o l d c o r r o s j o n ) . T h e f o r m a t i o n o f
s u l p h u r i c a c i d f u r t h e r d e p e n d so n t h e s u l p h u r c o n t e n t i n t h e f u e l o i l . N o r m a l l y
t h e ^ f u e l n o z z l e t e m p e r a t u r ew i l l b e h i g h e r t h a n t h e t e m p e r a t u r e o f a p p r o x .
1 8 0 " Ca t w h i c h c o l d c o r r o s i o n s t a r t s t o o c c u r . A t l o w l o a d w h e r e t h e f u e l n o z z l e t e m p e r a t u r ed e c r e a s e s , i t m a y a t c o n t i n u o u s o p e r a t i o n b e a d v a n t a g e o u st o r e duce the fue'l nozzle cooling to avoid corros'ion.
A b r a s i v e p a r t i c l e s i n t h e f u e l o i l i n v o l v e s a h e a v i e r h r e a ro f t h e f u e l v a l v e
needle, seat, and fuel nozzle holes. Therefore, abrasive particles are to the
w i d e s t p o s s i b l e e x t e n t t o b e r e m o v e da t t h e p u r i f i c a t ' i o n .
E#.=EF
GENERAN{GSTS
L23/30
HEAVY
F U E LO I L
]Y|AI\T
B&UI'
3 0 2 .1
tdi tion 15H
E x h a u s tV a lv e s
I n r e g a r d t o m e d i u m - s p e eedn g i n e s , t h e s e r v j c e l j f e o f t h e e x h a u s tv a l v e s a t
o p e r a t i o no n h e a v y f u e l h a s a l w a y s b e e n a s u b j e c t f o r d i s c u s s i o n . T o i l l u s t r a t e h o w t h e o v e r h a u l j n t e r v a l s o f t h e v a l v e s d e p e n d so n t h e q u a l i t y o f t h e f u e l
o i l , w e h a v e , b a s e do n s e r v i c e e x p e r i e n c e , p r e p a r e d t h e g r a p h s o n p l a t e 3 0 2 0 3 .
T h e g r a p h s s h o wv a r i a t i o n a n d s p r e a d i n g o f t h e o v e r h a u l i n t e r v a l s .
H o w e v e r ,v a r i a t i o n s o u t s i d e t h e h a t c h e d a r e a s m a y o c c u r o n a c c o u n t o f e x t r e m e l y
u n f a v o u r a b l ef u e l p r o p e r t i e s a n d d e v i a t i o n s f r o m t h e n o r m a l c o n d i t i o n s f o r o p e r a t " i o n a n d m a i n t e n a n c e .E s p e c i a l l y u n d e r u n f a v o u r a b l ec o n d i t i o n s , f u e l q u a i i t i e s w i t h a h i g h v a n a d i u ma n d s o d i u mc o n t e n t w i l l p r o m o t e b u r n i n g o f t h e v a l v e
s e a t s . C o m b i n a t i o n so f v a n a d i u ma n d s o d i u mo x i d e s w i t h a c o r r o s i v e e f f e c t w i l l
b e f o r m e dd u r i n g t h e c o m b u s t i o n it h e s e a d h e s i v e a s h e s m a y , e s p e c i a ' l l y i n t h e
c a s e o f i n c r e a s e d v a l v e t e m p e r a t u r e s ,f o r m d e p o s i t s o n t h e s e a t s . L o c a l p e e l i n g
o f f o f t h e d e p o s i t s d u r i n g o p e r a t i o n w i l l i n i t i a t e b u r n i n g - t h r o u g ho f t h e v a l v e
s e a t s . A n i n c r e a s i n g s o d i u mc o n t e n t w i l l r e d u c e t h e m e l t i n g p o i n t a n d t h e r e b y
t h e a d h e s i o nt e m p e r a t u r ef o r t h e a s h e s , w h i c h w i l l i n v o l v e a g r e a t e r r i s k o f
d e p o s i t s . T h i s c o n d i t i o n w i l ' l b e e s p e c i a l l y u n f a v o u r a b l ew h e nt h e w e i g h t r a t i o
N a ' i n c r e a s e s1 : 3 .
cond' it i onand
T h e e x h a u stva l ve te mp e ra tur edependson the actual maintenance
is kept at
t h e l o a d o f t h e e n g i n e . A t c o r r e c t m a i n t e n a n cteh e v a l v e t e m p e r a t u r e
a s a t i s f a c t o r y l o w l e v e l a t a l l l o a d s . T h e a i r s u p p l y t o t h e e n g i n e( t u r b o c h a r pr essur eadjustm entar e key par am etersi n thi s
g e r / a i r co o l e r) a n d th e ma x im um
c o n n e c toi n .
T h e u s e o f n i m o n i ce x h a u s tv a l v e s p i n d l e sa n d v a l v e s e a t r i n g s o f h i g h h a r d n e s s
p r o v ' i d e st h e b e s t p o s s i b l em a t e r i a l p r o p e r t i e s i n r e s p e c to f c o r r o s i o nr e s i s t a n c e an d se a t h a rd n e ssa t high tem per atur es.
I t ' i s i m p o r t a n tf o r t h e f u n c t i o n i n go f t h e v a l v e s t h a t t h e v a l v e s e a t s a r e
eith our instructions.
c o r r e c t l y ' i n a c c o r d a n cw
overhauled
T h e u s e o f r o t o c a pe n s u r e sa u n i f o r md i s t r i b u t i o n o f t e m p e r a t u r oe n t h e v a l v e s .
Air Inlet Valves
T h eo p e r a t i o n a lc o n d i t ' i o n so f t h e a i r i n l e t v a l v e s a r e n o t e s s e n t i a l a l t e r e d
w h e nu s i n g h e a v yf u e l .
Fuel Pumps
t i o n o f t h e f u e l o i 1 , t h e o p e r a t i o no f t h e f u e l
A s s u m i negf f e c t i v e p u r i f i c a 'ly
p u m p sw i I I n o t b e e sse n tia l
affected.
#.EEH
GENERA'NAGSETS
rY|AN
L23/30
Et&ut
O P E R A T I OONF T N G I N E
HEAVYFUELOIL
30?..12
E d it i o n l 5 H
T h e o c c u r e n c eo f j n c r e a s i n g a b r a s i v e w e a r o f p l u n g e r a n d b a r r e l c a n b e a c o n s e q u e n c eo f i n s u f f i c i e n t p u r i f i c a t i o n o f t h e f u e l o i l , e s p e c i a l l y i f u s i n g a f u e l
w h i c h c o n t a ' i n sr e s i d u e s f r o m c a t a ' l y t i c c r a c k i n g - W a t e r i n t h e f u e l o i l i n v o l v e s a n j n c r e a s e d r i s k o f c a v i t a t i o n i n c o n n e c t ' i o nw i t h p r e s s u r e i m p u l s e so c c u r i n g a t t h e c u t t i n g - o f f o f t h e f u e l p u m p .A f u e l w i t h a h i g h a s p h a l t c o n t e n t h a s
d e t e r i o r a t e d l u b r i c a t i n g p r o p e r t i e s a n d c a n i n e x t r e m ec a s e s r e s u l t i n s t i c k i n g
o f t h e f u e l p u m pp l u n g e r s .
C y li n d e r C o n d ti i o n
A t o p e r a t i o nw i t h i n t h e s p e c i f i e d f u e 1 q u a l i t y t h e c y l i n d e r c o n d i t i o n w i l l n o t
b e a l t e r e d t o a n y c o n s i d e r a b l ee x t e n t a n d t h e w e a r r a t e s f o r c y l i n d e r l i n e r s ,
p ' i s t o n s , a n d p i s t o n r i n g s w i l l n o t n o r m a l l y b e a p p r e c i a b l y c h a n g e d .H o w e v e r ,
also in this case, effective purification and correct choiseof lubricating oi1
must be ensured.
O v e r h a u lI n t e r v a l s
T h e t a b l e o n p l a t e 3 0 2 0 2 ,i n d i c a t e r e c o m m e n di en dt e r v a l s f o r o v e r h a u la n d m a i n t e n a n c eo f t h e mo st i mp o rta n tco mponents

of the engine. The over haulinter vals
a r e b a s e do n o p e r a t i o no n " n o m i n a l "f u e l q u a l i t y a t n o r m a ls e r v i c e o u t p u t . F o r
p r o p u l s i o ne n g i n e s ,n o r m a ls e r v i c e o u t p u t i s a s s u m etdo b e a p p r o x . 9 0 - 1 0 0 o
%f
MC Ra n d f o r e ng i n e sfo r g e n e ra ti n gpur poses70- 80%of M CR.
iI Tl:
-----
E+FG'
GENERANVG STS
]||AhI
E&U'
L?3/30
OPERATION
OF ENGINT
30202
EXPTCTED
OPTIMAL
OVERHAUL
INTERVALS
ANDEXPECTED
SERVICE
LIFE
F , R M AINC 'M''N E N T0SF L Z 3 l30ENGINE
' ' ERATI' NUp T0 IF 200
Drycleaning of turbine side
Editi on 09H
50
of
Wetcleaninqofturbineside__.
Waterwashingof compressorside ...................
too
25-75
Air filtercleaning: Basedon observations.

Inspectaon:Check allmounting screws,casinq screws and pipe
line connectionsfor tight fir by raipping,rerighre if necessary ........
Compressor cleaning in dismantled condion: compressor
Innercomponents,finaldiffusor,compressoru/tEel ........................
Regulating system
wthnewor
overtauled
turboctEroer
onceaft loo
6.000
Sifencer cleanng andsmantled condion: silerrcerfelt linings ..
6.000
Maor overhaul: Dismanding,cleaning, inspection, ctrec*ing and

deaning cartridge,
caruidge, ctrecking
ctrecking-bearing
bx
deara'nces, cfiecking gaps
ano dearances on reassemdv
12.000
Functioncheckof overspeedand shutdowndevices.

Check that the control rdd of each individualfuel pump can easity
go to'stod position....-.....-.....
monthly
Cylinder head
Checkingand adjustmentof valve dearance
Fuelinjectionvalve
Exhautvalve
Checkirrg,deaninq and adiustmentof ooenino oressure

2.0@
Overhaurlandregndingofspindleandalvear..............-.-.........
12.000 l-unctroncheckof rotocap
monfrly
Airinletvalve
Valre guide
Overhaulinconnectionwithexhaustvalve
overhaul ...-___....-_....-....
Measuringof insidedameternconnectionwith valve overhaul ......
12.000
r2.000
Safetv valves
Cfrxer head ruts
Qvq*.aut gnaa{ustment of opening pressure

RetQhtening2Ohoursafternew oioverhaul
12.000
Compressed ar system
Checkof compressedair systern ...................

Refillof air lubiicator : Basdon observalons.
f 2.000
Main bearirqs
to classficaonsurvey, normally afrer 24.O00

lnlqa!9n accordr'r
runnrng
hours or 4 years of service
Retighteningof main bearingcap. 200 hoursafter neworoverhaul
anoevery
RetiThteningof screws lorcounterwa'ghts.200 hoursafter newor
ovemaut and every
2.000
24.000
6.0@
6-O@
Suppoding cho<lc
arid boltconnectons
Retighteningof holdingdown bolts. 20O 1OOO

hours af ter new or
or/erhaul and every
Retighteningof bdlts betên engine lrame and base frame ........
rcr necblemounted engires. Check arti-vibration mourtings ......
6.O@
6.000
6.000
Autolog reading
Crar*shaftdeneaio and main bearing derance readirg- Stould

be..qried out n connection with reghierng of main bea-ringand
holdngdown bolts
6-O00
Retghteningandctrecking of bearing dearance. 20Ohours afler

new or o\rerhaul and every
Inspeabn h orneciion riith pbton overhaul ...........-----.--.....-.........
r2.000
Psbn
o.trerfuul, repl.acementof compression rings and scraper rings,

masunngot nrlg grooves,inspectionol bigend bearingand
rspectbn of cytinderlirBr condtbn ....--..-:...............-.-..-.....-...........
r2.0@
Cylinderliner
lnspection, measrring
tsasunng
and recofiotuofltftg
afx
reconditioning oI
of frunning surface
condition: ln corneakrn with ston overtraul
t2.0oo
Overhauland reconditioning of surface between lnerand frame

and deaning of surface in olng water space
24.000
Bg-end bearing
Fuel pump
Fuel grmp baneUplurger asse<nHy.Overhaul based on operatirnal

oosefva0ofis...
Torsiord braon
darpers
OverhaLd
Lr. ol filter cartr-
Replacernert based on obsenations of pressure drop .--............-..
Flter cadrdes
Replacementbased on obsenatbns .-.............
89.13
e sampre
oisiiJir;;i i;;;;;G"Jili;ii.
6.000
30.000
GENERA'U\IC SETS
EngineData
z
o
of Engine
Operation
E
fr
andCondition
o
Tracing
Trouble
and MainBearings
Crankshaft
Rod
PistonandConnecting
Gearfor InletValveg
Operating
lJ
?e
Tlrbocharger
System
Gfr
zts
FuelInjectionPump
=z
CamshaftandCamshaftDrive
a,g
Automatics
andInstruments
E=
R;
5i<
t-
FuelInjection
F
I r
U'
d tJg
o
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
AN
PERFORMAN
CD
EC O N D I T I O N
ENGINE
Edition 05
T o e n s u r et h e g r e a t e s t p o s s i b l e r e l i a b i l i t y o f o p e r a t i o n , t h e c o n d i t ' i o no f t h e
e n g i n e s h o u ' l db e c o n t ' i n u a l l y c h e c k e ds o t h a t p r e v e n t i v e m a ' i n t e n a n cwe o r k c a n b e
c a r r i e d o u t b e f o r e s e r i o u s b r e a k d o w n st a k e p 1 a c e .
T h e p r e v e n t i v e m e a s u r e st h a t s h o u l d b e t a k e n , a n d t h e m e a n sa v a i l a b l e f o r t h e
p u r p o s eo f c h e c k i n gt h e s e r v i c e c o n d i t i o n s , a r e a s f o l l o w s l
i.
M a k es u r e t h a t t h e a 1 a r ma n d m o n i t o r i n g s y s t e m i s i n o r d e r .
2.
W a t c ht h e o p e r a t i o n a l d a t a o f t h e e n g i n e , a n d c o m p a r et h e m w i t h t h e
testbed table.
3.
C a r r y o u t p r o g r a m m eidn s p e c t i o n s a n d o v e r h a u l s , s u p p l e m e n t e bd y r e p a i r
w o r k b a s e d o n c o n c l u s ' i o n sm a d ed u r i n g t h e c u r r e n t s u p e r v ' i s i o no f t h e
p 1 a n t ,c f . 2 .
Re i.
T h e a l a r m a n d m o n i t o r i n g s y s t e ms h o u l d b e t e s t e d a s s p e c i f i e d i n
" C h e c k1 3 " ( s e c t i o n 3 0 2 ) a t l e a s t o n c e e v e r y t h r e e m o n t h s .
Re 2.
T h e o p e r a t i n g c o n d i t i o n s s h o u l d b e c h e c k e de v e r y m o n t h , a n d a t t h e
pressure,
s a m et i m e t h e p r i n c i p a l d a t a s h o u l d b e n o t e d d o w n l M a x i m u m
c o m p r e s s i o np r e s s u r e , e x h a u s t t e m p e r a t u r e ,c h a r g i n g a i r p r e s s u r e ,
c h a r g i n g a i r t e m p e r a t u r e , f u e l p u m pi n d e x , e t c . T h e v a l u e s s h o u l d b e
c o m p a r e dw i t h t h e t e s t b e d t a b l e o f t h e e n g i n e , a n d s u c h c o m p a r i s o n s
m a yg i v e , i n t e r a l i a , t h e f o l l o w i n g i n f o r m a t i o n l
a)
pressure! Defective fuel valve, lacking compression

L o wm a x i m u m
p r e s s u r e i n t h e c y l i n d e r c o n c e r n e dd u e t o l e a k y p i s t o n r i n g s a n d
b l o w - b y , l a c k i n g c o m p r e s s i o np r e s s u r e d u e t o 1 o wc h a r g i n g a i r
pressure.
b)
pr essur e( to be m easur ed
by m eansof the m ax i m um
L o wco mp re ssi on
p r e s s u r ei n d i c a t o r w h i l e p r e s s i n gt h e f u e l p u m pr e g u l a t i n gl e v e r
i n t o 0 - p o s i t i o n ) . L e a k yp i s t o n r i n g s o r l o w c h a r g i n ga i r p r e s s u r e
o w i n gt o d e f e c t ' i v eo r d i r t y t u r b o c h a r g ear n d / o r d i r t y c h a r g i n ga i r
c o o le r .
c)
H i g h e x h a u s tt e m p e r a t u r eFl o r a s i n g l e c y l i n d e r t h e c a u s em a yb e a
l e a k y e x h a u s tv a l v e o r a d e f e c t i v e f u e l v a l v e . I f t h e e x h a u s t e m p e r a t u r e so f a l l c y l i n d e r s a r e t o o h i g h , t h e c a u s em a yb e h i g h
c h a r g i n ga i r t e m p e r a t u r (ed i r t y a i r c o o l e r ) , o r 1 o wc h a r g i n ga i r
p r e s s u r e( d i r t y t u r b o c h a r g e r ) .
d)
L o we xh a u st te mper atur eiThe cylinder does not wor k due to defec t i v e f u e l v a l v e o r s t i c k i n g f u e l p u m pp l u n g e r .
e)
quantity of cooling w ater

H 'i g hco o l i n g w ater tem per atur elReduced
t h r o u g he n g i n e , i n c r e a s e dh e a t t r a n s m i s s i o nd u e t o h i g h c o m b u s t i o n
t e m p e r a t u r e (si n c o m p l e t ec o m b u s t i o n )s, m a l l q u a n t i t y o f a i r f r o m
c h a r g i n ga i r c o o l e r , e t c . ) .
I
t,E
------
tt
Gt
GENERATING SETS
L23/30
ENGINEPERFORMANCE
AND CONDITION
303.02
E d i t i o n0 5
H o w e v e r ,t h e o b s e r v a t i o n sm a y p r o v i d e m a n ym o r e p a r t i c u l a r s
than those mention_
e d a b o v e , w h ' i c hs h o u l d o n l y b e ' r e g a r d e da i e x a m p l e s
of the application of tne
method.
Re 3'
T o f i x t h e i n t e r v a l s b e t w e e np r o g r a m m e d ' i n s p e c t i o n s
o r o v e r h a u l si s a
m a t t e r o f e x p e r i e n c ea n d . d e p e n d sv e r y m u c h n i n d i v i d u a l
load and operation incryolng, in pariicurar, the quali;y conditions of
;il";;;;
;;
p u r i t y o f t h e f u e l a n d . l u b r i c a t ' i n go i l s
used. Theintervals stated in
section 302 maybe used as a guid, but considerable
d e v i a t . i o n sm a y
o c c u r f o r t h e r e a s o n sm e n t i o n d .
It is important to take into consideration the
results from observations of the.operation.of
e n g i n w n e np t a n n i n t - i n i p e c t i o n sa n d
l
!
:
,,check
o v e r h a u t sa n d ,
s i m il a r l y ,
i m p o r t a n ti n f o r m a t i o n .
3 a n dq , , i s " l l i ; ;
iijii-ily-;;o;;;.
I n a d d i t i o n t o t h e o v e r h a u li n t e r v a l s i n d i c a t e d i n
n u t s o n t h e e n g i n es h o u l db e c h e c k e dr o r c o r r . t t i gshetcntei osns3 0 2 a l l s c r e w sa n d
n J r e t i g h t e n e d ,i f
n e c e s s a r ya, t s u i t a b l e i n t e r v a l s .
H y d r a u l i c a l l yt i g h t e n e dn u t s ( o n s t u d s f o r m a i n b e a r i n g s
a r e c h e c k e db v f i t t i n g t h e . t i g h t e n i n gt o o l t i n J r a i s i n a n d c y l i n d e r h e a d s )
t"-p"irr." to the
t i g h t e n i n g p r e s s u r ep i e s c r i b e .D u r i 9i e - r i f i p a " t
o
f
t
t e n s i o n i n gi s c h e c k e db.y .a t t e m p t i n gt r o s e n - i n en u t s h e p u m p i n gt,h e
w i t h t h e ' t o m m by a r . T h e
p u m pp r e s s u r ea t w h i c h t h e n u t c o m e sl o o s e s h o u l d
b
e
n
o
t e , i o i l o w i n g w h i c ht h e
p r e s s u r ei s i n c r e a s e dt o t h e v a l u e s t a t e d i n
t h e d a t a s e c t i o n , a n dt h e n u t i s
t i g h t e n e du p .
E#.EEY
GNERANNG SETS
I||AT\T
Et&ut
L23/30
EVALUATION
OF READINGS
REGARDING
COMBUSTION
CONDITIONS
PLATE
30301-O4H
PRESSURT
DROP
INCREASING
(limit 50%)
Air filter
Fot'led.
PRESSURE
DROP
INCREASING
(Limit 50Plo)
Air ide of
cooler fouled.
ALL CYLINDERS
&hout tcmp. incrcoring:
Air syrtem fouled
(Air fi lter-blower- coolcr).
-&hout
:yrlem fotlcd
(nozzle ring, turbine wheel)
TEMP.DIFFERENCE
TOO TARGE
Woter ftow too moll
7
AT
IEMP. OIFFERENCE
too lorge.
Air cooler fouled.
ONE CYLINDER
DECREASING CHARGEATR
PRESSURE:
Decreasing
air anountFouled turbocharger,
air filter
or charge
air cooler (air side).
&,hout temp. increoring:

Fuel volve necd overhoul.
Conprorion too low owing
to leokoge of exhout volve
or pirlon ring blow-by.
P"ort.o otd
Pa.or
ARE MEASURED
by meonr of mox. prerrure gouge.
Pao-o loo low: Leoky comburrion
chomber,
loo low.
chor9i"9
P,,,o, loo
low:
P"*o
loo low,
oir prerrure
ignirion too lorc.
lE=
- -----
-=.at
GENERA.n\TGSETS
EngineData
z
o
of Engine
Operation
E
fr
andCondition
EnginePerformance
o.
o
Tracing
Trouble
and MainBearings
Crankshaft
GylinderHeadand CylinderLiner
Rod
PistonandConnecting
Gearfor InletValves,
Operating
lJ
?
e
z-fr
Turbocharger
System
FuelInjectionPump
Zj-
E=
R;
Fuel Injection
=z
=<
GontrolandSafetySystems
Automatics
andInstruments
FE
a
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Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
L23/30
}IAl\t
CIEU'
TROUBLE
TRACING
3 0 4 . 01
FAILURETO START
Edition 07H
T h e a d j u stme n to f th e e n g i ne should not be distur bed unless absolutel y nec es s ar y . I f a n y t h i n ga b n o r m ails n o t i c e d d u r i n g t h e r u n n i n g , t h e c a u s es h o u l da t o n c e b e fo u n d a n d th e fa u l t c or r ected, as an alter ation of the adjustm ent,ev en
i f i t may remedythe defect , w'iiI sel domel im'inatei t.
Be l o wi s g i ve n a b ri e f d e scr iption of som eof the tr oubles that mayappear
d u r i n g t h e r u n n i n g ,a s w e l l a s t h e i r r e m e d y .
Failure to start
I f t h e e n g i n e d o e s n o t tu rn whenthe star ting button is depr essed,the c aus e
m a yb e t h e f o l l o w i n g :
1 . T oo l o w a i r p re ssu re .Rechar ge
the r eceiver .
3.
F a u ' l t si n e l e c t r i c a l s y s t e m .
I f t h e e n g i n e tu rn s o n co mpr essed
air but does not star t fir ing, the c aus em ay
be:
A . F a i l i n g o r i r r e g u l a r f u e l o i l s u p p l yo n a c c o u n to f :
1 . Ai r i n th e fu e l o i l system.Ventingto be effected. If the failur e to fi r e
i s l i mi te d to a fe w cyl inder s, vent the cor r espondingfuel pumpsor hi ghp r e s s u r ep i p e s . I f t h e e n g i n es t i l l f a i l s t o f i r e , e x c h a n gteh e c o r r e s p o n d in g fu e l va l ve s b y sp ar e valves befor e attem ptinga nevstar t.
2.
D efe cti ve o r cl o g g e d -upfuel valves. The valve spindle m aystick, the v a'l v e
s ea ti n g b e l e a ky, th e spr ing br okenor incom ectly tightened, or th e atom i z e r ma yb e cl o g g e d -u p which
,
manifestsitself in abnor malheating of the
f u e l o i l d e l i ve ry p i p e . Exchange
the valves in questionby spar e v al v es and
m aketh e mre a d y a g a i n as soonas possible.
3.
C l o g g e d - ufpu e l o i l f i l t e r .
4.
T he b y-p a ssva l ve i n th e fuel oil pr imar y pumpsticks in openpositi on.

D i s m a n t l ea n d p o l i s h t h e v a l v e .
?
HSiltU[
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L23/30
TROUBLE
TRACING
SMOKY
EXHAUST
5.
T h e f u e l t a n k i s e m p t yo r t h e v a l v e s i n t h e s y s t e ma r e c l o s e d .
6.
L e a k yp i p e s o r j o i n t s .
304.02
Edition07H
7. |.Iaterin the fuel oil.

8.
W o r nf u el p u mpp l u n g e rsa n d b ar r els. Exchange

the pum psby spar e pumps.
9.
T h eo v e r s p e e d
t r i p p i n g d e v i c e h a s b e e na c t u a t e d .
B . T o o l o w c o m p r e s s i oonn a c c o u n to f i
1 . C i o g g e d - utpu r b o c h a r g eirn t a k e f i l t e r .
2.
S t i c k i n g , w o r no r b r o k e np i s t o n r i n g s , o r h e a v i l y w o r nc y l i n d e r l i n e r s .
3.
L e a k yi n l e t a n d e x h a u s tv a l v e s , o r n o c l e a r a n c ei n t h e v a 1 v ea c t u a t i n g
g e a r , s o t h a t t h e v a l v e s d o n o t c ' l o s ea g a i n s t t h e i r s e a t s .
Smokyexhaust
I f t i r e e x h a u s tg a s e sc o n t a i n a b n o r m asl m o k e e, x a m i n ef i r s t f r o m w h i c hc y l i n d e r
o r c y ' l i n d e r sth e smo keco me sb y reading of the exhausttemper atur es,as poo r
c o m b u s t i oinn a c y l i n d e r w i l l i n c r e a s et h e e x h a u s tt e m p e r a t u r e .
Th e c a u s e so f smo kye xh a u stma y b el
i.
D e f e c t i v eo r c l o g g e d - ufpu e l v a l v e s .
2.
T o o l o w co mp re ssi o nT. h e fa u l t can be located by m easur ingthe com pr es s i on

pressure.
3.
0 i l i s c a r r i e d u p b e c a u s eo f w o r n , c a r b o n i z e db r o k e no r s t i c k i n g s c r a p e r
r i n g s . T h e f a u l t m a n i f e s t si t s e l f i n a n a b n o r m a l l h
y i g h l u b r i c a t i n go i l
consumption.
4.
l o a d , c a u s i n go v e r l o a d i n go f s o m ec y l i n d e r s . T h e f a u l t m a yu s u a l l y
Uneven
b e a s d e s c r i b e di n p o i n t 1 o r 2 .
5.
I n a d e q u a taei r s u p p l yo w i n gt o f o u l e d t u r b o c h a r g ear n d / o r a i r c o o l e r a n d /
or air cooler intakefilter.
I{CLEBY
GEERANNOSETS
123/30
TROUBLE
TRACING
T H EE N G I N T
L O S E SS P E E D
O RS T O P S
304.03
Edition 07H
I f t h e e n g i n eh a s l o s t s p e e da n d c a n n o tp i c k i t u p a g a i n , o r i t h a s s t o p p e d
completelyw
, i t h o u t t h e c a u s eb e i n g l a c k o f f u e l o i ' 1 , t h e e n g i n em u s tn o t b e
s t a r t e d a g a i n u n t i l i t h a s b e e ne s t a b l i s h e dt h a t n o o v e r h e a t i n gh a s o c c u r e d .
C A U T I 0 NAit s i g n s o f o v e r h e a t i n gi n t h e e n g i n e , n o c r a n k c a s ed o o r sm u s t b e
o p e n e du n t i l t h e e n g i n eh a s c o o l e dd o w nf o r a t l e a s t 1 0 m i n u t e s .T h e c a u s eo f
t h e o ve rh e a ti n gto b e re mo vedbefor e the engine is r estar ted.
A' l m o sta n y tro u b l e w i th th e fuel oil systemas well as lo$,compr essi on
m ay
c a u s et h e e n g i n et o ' l o s e s p e e d ,i f t h e t r o u b l e a f f e c t s s e v e r a l c y l i n d e r s . I f
o n l y o n e o r t w o c y l i n d e r s f a i l a n d t h e e n g i n e i s n o t s u b j e c t e dt o f u l l l o a d ,
t h e e n g i n ew i l l n o t l o s e s p e e d ,a s t h e g o v e r n o rw i l l t a k e c a r e o f i n c r e a s i n g
t h e l o a d o n t h e o t h e r c y l i n d e r s c o r r e s p o n d i n g l yI.f t h e e n g i n ei s a l r e a d y
r u n n i n ga t f u l l l o a d , t h e s e c y l i n d e r s w i l l b e o v e r l o a d e da, n d t h i s a g a i nw i ' l l
r e s u l t i n s m o k ye x h a u s ta n d h i g h e x h a u s tt e m p e r a t u r e se, t c . T h e l o a d s h o u l d
t h e r e fo re b e re d u ce du n ti l the fault has been located and r em edied.
T h e c a u s e so f a s u d d e nl o a d r e d u c t i o ni n a c y ' l i n d e r , o r i t s f a i l u r e , m a yb e i
1.
D efe ctive o r c'l o g g e d -up

fuel val ve.
2.
T h e f u e l p u m pp l u n g e rh a s s e i z e d i n t h e b a r r e l . T h e f a u l t c a n b e l o c a t e d
by trying to movethe rack of the pump.Defective fue'l pumpsare to be
exchanged
by newpumps.
3.
T o 9 1 o wc o m p r e s s i oonw i n gt o s t i c k i n g , u , o r n ,o r b r o k e np i s t o n r i n g s , l e a k y
i n l e t o r e x h a u s tv a l v e s o r n o c l e a r a n c ei n t h e v a 1 v ea c t u a t i n gg e r
I f t h e e n g i n el o s e s s p e e do r s t o p s , t h e c a u s e sm a ya ' l s ob e l
1 . C l o g g e d - uf pu e l o i l f i l t e r . T h e f a u l t w i l l m a n i f e s ti t s e l f i n a f a l l i n g
o i ' l p re ssu rea f te r th e fuel oi I f i I ter .
2.
T h e b y - p a s sv a l v e o f t h e f u e l o i l p r i m a r yp u m ps t c k s i n o p e np o s i t i o n .
3.
L e a k yf u e l o i l p i p e s o r j o i n t s .
4.
l , l a t e ri n t h e f u e l o i l .
5.
J ammere
d g u l a ti n g g e a r.
6.
governorout of order.
l,loodward
7.
E l e c t r i c a l s h u t d o w vna l v e ( m o n i t o r i n gs y s t e m )e n e r g i z e d .
I{OLEBY
GÊRANVG SETS
123 / 3 0
TRACING
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T h e c a u s e sm a y b e l
1.
A'ir in the fue'l oil system.
2.
W a t e ri n t h e f u e l o i l .
3.
o n eo r m o r e
E x c e s s i v er e s i s t a n c e i n t h e r e g u l a t ' i n g g e a r , p o s s i b l y b e c a u s e
p
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are sticking.
4.
go ve rn o ro u t o f o rd e r, not sufficiently vented, or incor r ectly

W o o d w a rd
a d j u s t e d . S e e th e Wo o d w a rd
i n str uction manual.
F a i l i n g c o o l i n gw a t e r s u p p l y
I n t h e e v e n t o f f a i l i n g c o o l i n g w a t e r s u p p l y , w h i c hc a n b e n o t i c e do n t h e p r e s r the dischar gepipe, the engineload shoul d
s u r e g a u g ea n d o n th e th e rmo me teon
b e r e d u c e du n ti l th e fa u l t h a s b e enfound and r emedied.If this cannotbe don e
q u i c k l y , s o t h a t t h e r e i s a r i s k o f o v e r h e a t i n gt h e e n g i n e , t h i s m u s tb e
be
s
s t o p p e d ,a n d an y ste a mth a t ma yb e tr apped in the cooling cham bermust
b l o w no u t c a r e f u l l y . I f t h e e n g i n eh a s b e e no v e r h e a t e di,t s h o u l db e c o o l e d
d o w ns l o w l y s o a s to a vo i d h a rmfu l effects of changesin tem per atur e.
Air i n t h e c o o l i n g w a te r syste mmaybe the r esult of leaky coo' lingwater pump
s the
s t u f f i n g b o x es. A i r cu sh i o n sma ythen be tr apped in the cooling cham berof
c y l i n d e r c o v e r sa n d t h i s c o n d i t i o n i n v o l v e s t h e r i s k o f o v e r h e a t i n ga n d c o r r o sion of the covers.
F a i l i n g l u b r i c a t i n go i l p r e s s u r e
I f t h e l u b r i c a t i n g o i l p r e s s u r ed r o p s b e l o wt h e p e r m i s s i b l el i m i t , t h e e n g i n e
m u s ta t o n c eb e s t o p p e d .T h e c a u s e so f f a i l i n g l u b r i c a t i n g o i l p r e s s u r em a yb e !
1 . C l o g g e d - u p ' l u b r i c a t i on ig' l f i l t e r .
2.
T o ol o w o i l l e v e l i n t h e s u m p .
3.
C l o g g e d - uopr l e a k y s u c t i o n p i p e .
4.
S t i c k i n g b y - p a s sv a l v e i n t h e l u b r i c a t i n g o i l p u m p ,l o o s e a d j u s t i n gs c r e w ,
o r b r o k e ns p r i n g s .
5 . L e a k yd e l i v e r y p i p e s .
6.
D e f e c t i v eme ta l i n o n e o r mo rebear ings.
7.
E x c e s s i v eb e a r i n gc l e a r a n c eo w i n gt o w e a r . I n t h a t c a s e , t h e p r e s s u r ew i l l
h a v ed r o pp e dg ra d u a l l y o ve r a per iod of som elength
8.
H e a v i l yw o r nl u b r i c a t i n go i l p u m p .
I{OLEBY.
GE\ERATIAIG STS
EngineData
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of Engine
Operation
FEnginePerformanceand Condition
o
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Tracing
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Crankshaftand Main Bearings
CylinderHeadandCylinderLiner
Pistonand ConnectingRod
Gearfor InletValveg
Operating
ExhaustValvesand FuelIniectionPumps
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FuelInjectionPump
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andInstruments
Automatics
StartingSystem
Oil System
Lubricating
Oil
of Lubricating
andTreatment
Specification
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
IrIAI{
Er&urt
L23/30
E N G I N IF R A M EB, I D P L A T TC
, R A N K S H AAFNTDM A I N B E A R I N G S
DESCR
I PTION
30s.01
Editionil
Plates 30501-30502-30503.
T h e b e d p l a t e a n d t h e f r a m e c o n s t ' i t u t e t h e m a ' i ns t r u c t u r a l m e m b e r o
s f the
e n g ' i n e .T h e b e d p l a t e i s i n w e l d e do r c a s t e d d e s ' i g n .
T h e e n g i n e f r a m e ' i s m a d eo f c a s t i r o n , a n d t u r b o c h a r g e rb r a c k e t , h o u s i n gf o r
a i r c o o l e r , a n d c h a r g ' i n ga i r r e c e i v e r a r e c a s t i n t e g i a l w ' i t h t h e f r a m e .
T h e m a j n b e a r i n g s f o r t h e u n d e r s l u n gc r a n k s h a f t a r e f i t t e d i n b o r e s i n t h e
f r a m e a n d a r e s e c u r e dw i t h b e a r i n g c a p s o f s t e e l . T h e c a p s a r e p r o v i d e d w i t h
s i d e g u i d e s a n d a r e h e l d i n p l a c e ' b y m e a n so f s t u d s w i t h h y d r a u l i c a l l y t i g h t e n e d n u t s . T h e b e a r i n g c a p s a r e f u r t h e r m o r e s e c u r e d b y m e a n so f s c r e w s i n s r t e d
h o r i z o n t a l y t h r o u g ht h e e n g i n e f r a m e .
T h em a i n a n d c r a n k p i n b e a r i n g sa r e o f t h e s h e l l - t y p e i n w h i c h t h e r u n n i n g s u r f a c e i s o f s t e e l - b a c k e dt r i m e t a l .
T h e b e a r i n g t o l e r a n c e p e r m i t s r e p l a c e m e n ot f t h e s h e l l s i n p a ' i r s w ' i t h o u ta n y
kind of scraping.
T h e c y l i n d e r l i n e r s a r e m o u n t e di n o p e n i n g s i n t h e f r a m e , t h e i r t o p f l a n g e s a r e
p r e s s e da g a ' i n s t t h e t o p o f t h e f r a m e b y t h e c y l i n d e r c o v e r s , w h ' i l e a t t h e
bottomthey are guided by the bottom flange through which they are able to exp a n d f r e e l y w h e n h e a t e d . S e a l i n g b e t w e e nw a t e r c h a m b e ra n d c r n k c a s ei s
a c h i e v e db y m e a n so f t w o s e a l i n ! r ' i n g s f i t t e d i n g r o o v e s o n t h e g u i d e s u r f a c e
of the cylinder liner.
T h e g e a r w h e e l d r i v e f o r t h e c a m s h a f ti s l o c a t e d o n t h e f l y w h e e t e n d o f t h e
e n g i n e a n d ' i s e n c l o s e db y a t w o - p i e c ee n d - s h i e ' l d .
T h e c a m s h a f ti s c a r r i e d i n s t e e l - b a c k e dt r i
m e t a l b e a r i n g sf i t t e d i n t h e f r a m e .
A l o n g t h e c a m s h a f ta n d t h e c r a n k s h a f t , t h e f r a m e h a s l a r g e o p e n i n g so n b o t h
s i d e s f o r i n s p e c t i o n o f r o 1 l e r g u i d e s , c a m s , m a ' i nb e a r j n g sa n d c r n k p i n
b e a r in g s .
T h e - o p e n i n gasr e c l o s e d b y c o v e r s , s o m eo f w h i c h a r e p r o v i d e dw i t h s a f e t y r e I i e f v a l v e s w h ' i c he q u a li z e t h e p r e s s u r e ' i f o i l m i s t s i n t h e c r a n k c a s ea r i q n i t e d , f o r i n s t a n c e i n c o n s e q u e n coef a h o t b e a r i n g .
T h e b e d p l a t em a y b e u s e d a s ' l u b r i c a t i n g o i l r e s e r v o ' i r ,a n d i n t h i s c a s e a d ' i p s t i c k w j i l b e f i t t e d . H o w e v e r t, h e o i l m a y a l s o b e d r a i n e do f f t o a s e p a r a t e
b o t t o mt a n k , i n w h i c h c a s e t h e e n g i n e h a s a " d r y s u m p ' ,
e
T h e f u e l o i l p r i m a r y p u m pi s o f t h e g e a r t y p e a n d i s d r i v e n t h r o u g h a c o u p f i n g
f r o m t h e c a m s h a f t .A l s o t h e l u b . o i l p u m pi s o f t h i s t y p e a n d ' i s r i v e n f r o m
theendofthecrankshaftt#" throughaflexiblegear
wheelconnection.
t!4r
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r g!rr-E-E
GENERANNG SETS
L23/30
E N G I N EF R A M EB, E D P L A T E
C,R A N K S H AAFNTDM A I NB E A R I N G S
305.02
I PTION
DTSCR
Edition 1i
P la t e 3 0 5 0 4
T h e c r a n k s h a f t i s s o l i d - f o r g e d a n d h a s g r o u n dm a j n a n d c r a n k p i n b e a r i n g j o u r n a l s . T o e n s u r ea s u i t a b l e b e a r i n g p r e s s u r e , t h e c r a n k s h a f t j s , ' i n t h e c a s e o f
c e r t a ' i n c y l i n d e r n u m b e r s ,p r o v i d e dw i t h c o u n t e r w e i g h t sf i t t e d b y t w o d o v e t a iI
j o i n t s a n d s e c u r e db y a s c r e w c e n t r a l l y p l a c e d .
T h e q e a r w h e e l f o r t h e c a m s h a f td r i v e i s f i t t e d
shaft, and to the forward end is fitted
to the aft end of the crank-
a flexible gear wheelconnection

ffiltffirii$..$
a n dw a t e r p u m p s .
B. Maintenance
F r a m ea n d c r a n k s h a f t d o n o t r e q u i r e m u c hm a i n t e n a n c ey, e t l u b . o i l p i p e s , b e d p l a t e a n d o i l d u c t s ' i n t h e c r a n k s h a f ts h o u l da t i n t e r v a l s b e c l e a n e do f d i r t
andoi1 sludge.
T h e s c r e w sw h i c h a t t a c h c o u n t e r w e i g h t st o t h e c r a n k s h a f t s h o u l d n o w a n d t h e n b e
c h e c k e df o r c o r r e c t t i g h t n e s s . T h e c o r r e c t t ' i g h t n e s s t o r q u e i s s t a t e d i n
D -3 0 5 - 4.
N o t e l T h e l i f e o f b e a r i n g s o f m o d e r n , h ' i q h - o u t p u te n g i n e s q r e a t l y d e p e n d so n
e n q i n ed u r i n g o v e r h a u l s .
T h e p r e s e n c eo f d u s t a n d s a n d p a r t i c l e s m a y v e r y q u i c k l y s p o i l b e a r i n q s , a s n o
f i l t e r s a r e a b l e t o r e m o v et h e q u i t e s m a ' l l p a r t i c l e s q u i c k l y e n o u g ht o p r e v e n t
il
A l w a y s m a k es u r e t o m o u n tm a ' i nb e a r i n g s c o r r e c t ' l y a f t e r o v e r h a u l s .
l , l h e nm o u n t ' i n ga n e w m a i n o r g u ' i d e b e a r i n g , m a k es u r e t h a t t h e c r a n k s h a f t b e a r s
i n a l 1 b e a r i n g s ,a n d t h a t t h e s e a r e a ' l i g n e d .
T h is ' i s c h e c k e da s d e s c r ib e d i n s e c t ' i o n C . T o o ls .
T#.EEY
CENERATIAIG SETS
L23/30
E N G I N TF R A M EB, E D P L A T E
CHICKINO
G F B E A R I N GASN DJ O U R N A L S
]YIAhl
CI&Uv
3 0 5 0. 3
Edition 01H
T h em a i na n d c r a n k p i nb e a r i n g ss h o u l db e i n s p e c t e dp e r i o d ' i c a 1 1ayc c o r d i n gt o
t h e r e q u ' i r e m e not sf t h e c l a s s j f i c a t i o n s o c i e t y ( s e e a l s o " C h e c k i n g
a n dt ' t i n t e n a n c eP r o g r a mi "n S e c t i o n3 0 2 ) . I n a d d i t i o n , s o m em a i nb e a r i n g ss o u 1 db e e x a m i n e di f f l a n k e s o f b e a r i n gm e t a ' la r e f o u n d i n t h e e n g i n eU e O p l a t eo, r i n t h e
c a s eo f i n c r e a s i n gb e a r i n gc l e a r a n c eo r f a l l i n g l u b r i a t i n go i l p r e s s u r e A
. lso
i f t h e l u b r i c a t i n g o i 1 s y s t e ms h o u l db e c o mceo t a m i n a t ew
d i t h a b r a s i v ep a r t i c 1 e s , i f t h e w a t e r c o n t e n ti n t h e o i l b e c o m eesx c e s s i v eo r i f t h e l u b r i c t i n o
o i l s u p p l yh a s f a i l e d .
A t n o r m a lw e a ro f m a i na n d c r a n k p i nb e a r i n g s ,t h e g r e y i s h - w h i t el a y e r o f w h i t e
m e t a l w i l l fi rst b e w o rn th roughat the fr ont and ieai edgesat th bot tomof
t h e l o w e r s h e l l o f m a i nb e a r i n g s ,a n d a t t h e t o p o f t h e u p p e rs h e l l o f c r a n k p i n b e a r i n g s .T h e r e b yt h e c o p p e r - c o l o u r elde a d e db r o n z ei i ' u n c o v e r e di n t w o
c r e s c e t s h a p eadr e a s , w h i c hw i l l e v e n t u a l l ym e e ta t t h e f l i d d l e o f t h e s h e l l .
t ' / h e nt h i s u n co ve re d
a re a h a s incr easedto one- four th of the bear ing surfac e,
t h e s h e l l s s h o u l dP . _ r e p l a c e dT. o a v o i d e x c e s s i v el o a d i n g o f a s i n g l e s e t o i
n e wm a i nb e a r i n gs h e l l s , t h e a d j a c e n tm a i n b e a r i n gs h e l l i s h o u l ds i m u l t a n e o u s 1 y b e c h e c k e df o r w e a ra n d r e p l a c e d ,i f r e q u i r e d . - A l w a yrse p l a c et h e s h e l l s ' i n
s e t s , a s th e u p p e ra n d l o w e r shells ar e matchedtogether . It is im por ta nt to
r u n - i n n e wb e a r i n g sa s p r e s c r i b e di n S e c t i o n3 0 2 .
] t ' i : v e r y i m p o r t a n tt o m a k es u r e t h a t t h e r e i s n o t c l e a r a n c eb e l o wa n y m a i n
b e a r i n gj o u r n a l a n d , i n a d d i t i o n , c r a n k s h a f td e f l e c t i o n r e a d i n gm u s t b t a k e n ;
s e e D a t a 0 3 0 5C K E C K IN
G MAINBEARINGS.
0F
I f h a r d p a r t i c l e s ( s a d . ,w e l d i n gb e a d s ,s l a g o r r u s t ) h a v ee n t e r e dt h e b e a r i n g s
t h e y w 1 1 s c r a t c h b o t h b e a r i n gm e t a ' la n d s t e e l j o u r n a l s a n d e v e n t u a l l yb e
c r u s h e do r fo rce d i n to th e b ear ingm etal. If this has causedtoo gr eal r oughn e s s o f th e j o u rn a l s, th e se must be r econditioned.The sur face r oghne s soi a
n e wj o u r n a l i s 8 - 1 0 m i c r o i n c h e sC L A ,e q u i v a l e n tt o 0 . ? - o . z s , R . . p | i o r t o p o l i s h i n g , t h g l u b r i c a t i n g h o l e s s h o u i db e c l o s e dw i t h g r e a s e ' t o a p r e v e ngtr i n d l i n g p a r t i c l e s f o r m e n t e r i n gt h e l u b r i c a t i n g o i 1 s y s t e m
I n o r d e r to d e te rmi n ew h e th erthe jour nal sur face is adequatelysm ooth ,a
l a r g e , e d g e dc o i n m a yb e d r a w nl o n g i t u d i n a l l y a ' l o n gt h e j o u r n a i . t n e c o i n i s
p r e s s e ds l i g h t l y a t a n a n g e l o f a p p r o x .4 5 " a g a i n s l t h e j o u r n a l s u r f a c ea n d i s
h e l d t r a n sve rseto th e d i re ction of movement.
Vibr ations felt m aybe compar ed
w i t h a be a ri n gj o u rn a l w h i ch is knownto be in or der . This m ethos use w hen
a r o u g h n e sm
s e a s u r ndge v i c e i s n o t a v a i l a b l e .
IOLEBY
GENERA'NNGSETS
l||Ahr
ct&ult
L23/30
ENGINEFRAME,BEDPLATE,CRANKSHAFT
ANDMAIN BEARINGS
305.04
C H E C K I NOGF B E A R I N GASN DJ O U R N A L S
Edition 01H
T h e b e a r i n g s u r f a c e o f t h e s h e l l s i s t o b e c l e a n e d o f a n y i m p r e g n a t e dp a r t i c l e s
a n d a n y " s t u b b l e s " o f w i p e d - o u tm e t a ' l i n t h e l u b r i c a t i n g g r o o v e s s h o u l d b e r e m o v e d ,t h e o i 1 w e d g e sb e i n g f r e s h e n e du p w i t h a b a y o n e t s c r a p e r . I f u p t o I 0 %
by coarse scratches or wiped-outmetal, the
o f t h' le c a r r y ' i n g a r e a i s d a m a g e d
s h e l s h o uI d b e r e p l a c e d.
If a bearing has run hot, both bearing she'lls should be replaced and the bear i n g j o u r n a l b e e x a m i n e df o r h e a t c r a c k s ( D y e c h e c k , m a g n a f l u x )a n d d i s t o r t i o n .
W h e n e v ebr e a r i n g s h e l l s a r e i n s p e c t e d , t h e ' i r o u t e r s u r f a c e s a n d j o i n t s s h o u l d
b e c h e c k e df o r w e a r a n d p i t t i n g , w h i c h a r e s i g n s o f s m a l l r e l a t i v e m o v e m e n t s .
The iointing surfaces and lateral guiding faces of the bearing cap are to be
examinedfor the samesymptoms.
T h e b e a r i n g c l e a r a n c e s h o u l d b e m e a s u r e da t t h e t o p , a t t h e b o t t o m , a n d 1 0 o
a b o v ea n d b e l o w j o ' i n t s a t b o t h s i d e s .
B e a r i n g sm a y o f t e n w o r k s a t i s f a c t o r i l y e v e n i f t h e j o u r n a l h a s b e e n w o r n s o m e what oval, but if newbearingsare fitted the journals must be trued up. When
tightening up main and crankpin bearings, special care must be exercisedand
t' lh e i n s t r u c t i o n s g i v e n i n t h e i n s t r u c t ' i o n b o o k ( o n d a t a s h e e t s a n d i n o v e r h a u 'ing procedures must be cl osely fol I
owed.
)
!..!,=
ltlE.t
GENERA'N\G
SETS
L23/30
ENGINE
F R A M EB, E D P L A T EC,R A N K S H AAFNTDM A I NB E A R I N G S
DISMANTLIN
OG
F M A I NA N DG U I D EB E A R I N G S
3 0 55
.1
Edition 12H
Plate 30551
1.
T a k e o f f t h e c r a n k c a s ec o v e r s a n d r e m o v et h e t w o b r a c i n g s c r e w s ( P 1 a t e
30502,Item No. 8200) securing the bearjng cap to the engine frame. It may
b e n e c e s s a r yt o l o o s e n t h e b r a c i n g s c r e w s o f t h e a d j a c e n t b e a r i n g s t o o .
2.
L o o s e nt h e n u t s f r o m t h e b e a r i n g s t u d s , u s i n g t h e h y d r a u l i c t o o l s a s d e scribed in section 319.
3.
R e m o v teh e h y d r a u f i c t o o l s , u n s c r e wt h e n u t s a c o u p l e o f t u r n s , a n d l o o s e n
t h e b e a r i n g c a p b y m e a n so f t h e l e v e r b a r s 1 9 0 6 .
4.
F'it the lifting wire 0164 to the sides of the bearing cap and lift the cap
w h i l e r e m o v i n gt h e b e a r i n g n u t s a n d f i t t i n g t h e s u p p o r t i n g t u b e s 2 1 6 3 .
5.
Lowerthe bearing cap on to the collar of the supporting tubes and remove
t h e b o t t o m s h e lI .
6.
E x e r c i s i n gc a r e , r o t a t e t h e u p p e rb e a r i n gs h e l l o u t b y m e a n so f t h e s p e c i a l
d i s m a n t l i n gt o o l 1 5 4 0( b o t h m a i n -a n d g u i d e b e a r i n g ) .
7 . L i f t i n g w i r e 0 1 6 4a r e a v a i l a b l e f o r t r a n s p o r t o f m a ' i nb e a r i n gc a p s .
b . M o u n t i no
g f m a i na n d g u i d e b e a r i n g s .
1 . T h emo u n ti n gi s a ffe cte d with the sametools, by r ever sing the abov ew or k i n g s e q u e n c eM
. a k es u r e t h a t t h e b e a r i n gs h e l l s a n d c a p sa r e p o s i t i o n e d
c o r re ctl y. T h e b ra ci n g sc r ewssecur ing the bear ing caps ar e to be ti ghtened
t o th e to rq u e i n d i ca te d in D 305- 2b.
c.
C h e c k i n tgh e m a i nb e a r i n g s( c o 1 de n g i n e ) .
1.
T h ea ' l i g n m e not f t h e m a i n b e a r i n g si s c h e c k e db y m e a n so f t h e d i a l g a u g e
( a uto l o g ) fZ t, w h i ch i s to be fitted as shown,about Smm
fr om tne ogot
t h e c r a n k w e b , a n d d i a m e t r i c a l l y o p p o s i t et h e c r a n k p i n .
2 . C h e ckb y me a n so f a fe e l er that the cr ankshaft bear s against the bottomof

t h e ma i n b e a ri n g so n b o th sides of the cr ank thr ow concer ned.
3.
S e t t h e p o i n t e r o f t h e d i a l g a u g et o " 0 " a n d t u n t h e c r a n k s h a f t n e a r l y
o n e r e v o l u t i o n , r e a d i n g t h e d i a l g a u g ee v e r y 9 0 t .
4.
T h e co n n e ct'i n g
ro d s w i l l pr event the cr ankshaft fr om being tur ned thr ough
o n e c o m p l e t er e v o l u t i o n , b u t t h e r e s u ' l t i n gd e f i c i e n c y i n i e a d i n g sw i l l i n
p r a c t i c e h a v en o s i g n i f i c a n c e .
5.
I f . t h e d i f f e r e n c e i n r e a d i n g sa p p r o c h e tsh e v a l u e s t a t e d i n D 3 0 5 - 7 ,t h e
c r a n k s h a f tm u s t b e r e - a l i g n e da s t h i s v a l u e i s t h e a b s o l u t em a x i m upme r m i s s i b l ed i f f e r e n c e i n r e a d i n g s .
g t=:
g-E!t
E tt==-:E3
E
GNERATII\G
SETS
lvlAhl
L23/30
ct&ut
3 0 5s. 2
F R A M EB, E D P L A T E
ENGINE
OPERATION
GTNERATOR
Editionl2H
I n t h e c a s e o f e n g i n e s d r i v i n g a g e n e r a t o r , t h e a l i g n m e n to f t h e g e n e r a t o r b e a r i n g w i l l i n f l u e n c e t h e r e a d i n g s o f t h e a f t m o s t c r a n k t h r o w i n t h e s a m ew a y a s
the main bearingsof the engine.
For the alignment of the generator or the separate generator bearing, the same
l i m i t v a l u e s a p p l y a s s t a t e d f o r t h e m a i n b e a r i n g so f t h e e n g i n e .
t,t
F;r+.lt
CNERATTGSETS
BEDPLATE
P L A T E3 0 5 0 1- I 1 H
frffi
.
1278
c
c
c
c
FH.EEY
GENERAN\GsETS
]v|Ahr
EIEU'
- 11HPLATE
3O 5O,I
EEDPLATE
Item No.
Q{_ 0100
_qq,!,t1.C.,1.
0'299
' 6oao 0 til\ 'tli:l
6!,:,1! .:,, :, 14: 0388
6 oln, .'r/.,!.21 1,1 0+71
6ctr ,1,,(,.rlni
q566
60CO t::/6i. t{.t"
0655
-!oca . t !/ r. n)1,
.;tt
Designation
Benavnelse
Nut
M str ik
S tu d
TaP
Gast<et
P a k nni g
C o ve r
Screw
Ga ske t
Deksel
Skr ue
P a k nni g
0 74 4
_ lcrgw
0833
0922
Cover
59r9w
Skr ue
Daksel
{ol't.
n':'" }
I 09 0
Cover
Skr ue
Deksel
, : 4 . )1
?- *.
11 8 9
Gasket
P a k nni g
6 0 o . t ' / / Q P : ' , '/
1278
B e d p 'l a te
Bundrarrne
.a 4a " ,1''.il4
136i
, Stud
L o ck w a sher
ft^..
::,1'
'i'
,1 . , .
(')'"
i,,^ x(l/0 oo ll
/,tl. tPi |
_ 60oo 0
'"1":)i t ./
l
__ {t, t.
1456
1545
1634
1723
Nut
llandle
ps-tick
D_i
Tap
Sikringsskive
Mstri k
Hndtag
Pej1estok
= E.==i=
F=rfF
GENERATTVCSETS
lvlAhl
Eeut
FRAME
PLATE30502-zOH
622J
K
b
6 3 J tt
6 12 0
ry
to
\/tt
u709
6608
679 7,
05J5
7598
2959
062-
ozt.l\
t6
05
0802-
0 9 9t
JJ9
WJ;
/
ct
d#>,;1
rev. 1988.12.20
t+,=
-
---r-
t==:lg
-
GENERATING SETS
IIAh|
cr&ut
FRAME
Item No.
6t;,t ,,,: 0007
0179
,_l!_:lr , n 0?qB
_ !_?'1
PLATE
3O5O2.zOH
Designation
Benavnelse
Gasket
Pakn
i ng
Cover
Daksel
Screw
Skrue
Stativ
Skr ue
Nut
M str ik
Fi tted b o lt
Pasbol
t
M str ik
Skr ue v
"'"'r
l!rt:4: '
0 35 7
Screw
i: 4t/ li 1 '.t
6;i t,1
0446
Fr-ame
'--lt
-, -953:
lo cc Q
,.'.
[n,'
' 1-.t
1 ,, r
0624
iu-oa'/i 0713
{r:::
' 0 r i A ' ' li 0 a o ? 6 0 8 0 2
tlui
( . . ' i , ) i t . t t ' f ; .f
0991
!crew
1247
!crew
Hous
i ng
S p rin g
ve f 1ap
_!q1
f
?
1336
1425
1514
'li"
."-:t 1792
, o r ' ^ .t ' :' i , , , , . l 8 8 1
. ^ . , a : J ; , r : t ' , .(1
1970
6f
2048
r
fa"'
'
- t
f r
f
r.,'..
f ' '
i :
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lf,?
{..':i ,l't|, ii' }'

iln. t,1!7
fil,,n )'.'t 11/i.
":a.(
lon1 : -:,^ ' .' 'l
Hus
Fjeder
Ventilklap
Afstandsr sr
0-ri ng
Skr ue
Deksel
2137
2315
Screry
Tatningsring
Skrue
2404
S e cu ri n gpiece
Si kr i ngsstykke
2593
Nut
Cover
Mstri k
Deksel
Pakn
i ng
2682
x
D i s t a n c ep i p e
0 -ri n g
Screw
Cove1
Skr ue
2771
2959
S e a l i n gr i n g
Ga ske t
3027
3116
C_a.ms_haft
bearing
S e a il n g r i n g
Cover
Tatningsring
Deksel
3205
L o c k in g p ' l a t e
S ik r i n g s p ' l a d e
3394
$c,rew
M a i nb e a r i n gs h e l l ,
u p p e r a n d I ower
M a ' i nb e a r i n gs t u d
Skr ue
3483
3 6 61
Styr eaksel
I eje
Hovedl
ejeover pande,
sver ste og neder ste
Hovedl
ejetap
r e v . 1 9 8 81. 2 . 2 0
#_==F
CNERAN\C SETS
PLATE
30 502- z OH
$Vtc )tfi. r7-:

;:2r) 61") )o+:
Item No.
Designation
Benavnelse
3750
*3849
't
G u i d eti_:
Styr est' ift
4006
6o,t-,llio,c1:
'''- 4?84
{ cA,:l::,'," .',rf
q! t ! !A,!!_y{__
-417
1t','j.-.::!,,
-Lry,':'
:.' 44:6'2
6oooctl_q_rlY1551
.\-- 64!0.oqft.oirl4640
_!
4739
d , 7 t 1i ; ( 1 i 1 . r 1 . . , 7
,j
,r ,1 ,";1,.' ,,j,
,t',...1
.l
6N -d':i,l
0li11t i ' t ' !
to,oo,
'5OnC
t:9
,111'
5Ct0 ,i i'r
, rr . .
,a.1
- ".6!j"!!.-l-:i7:-*:
4828
4917
sl74
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5352
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l 0 ) n 2 l , t n1 " , N 5 9 9 6
f ?{,' :t.:\'' 6064
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6153
n:J,.''
624?
_loQQ oqto 4t)e 633]

6420
ti4 t){i
'r}.,,:'r',' : "ti' 65.|9
-. {l'
t:t l,_ J I :t o 6608
_{\ra
*:1:
d9i;;;,''t1,; itti;, ;;;l

,il4 .
i,ti':, 1t:11'
__-.__
M a ' i nb e a r i n g c a p
Endcovel llforell
Hovedl
ejedeksel
Motri k
Styr est' ift
Skr ue
"for"
Endedakse'l
_[,]-eq"
!:]!g
0 -ri n g
C o o'il n g water ni pple
fo r i n te r m ediate
P i e ce 3 0902/1976
Union
St idr i ng
0-ri ng
K a l e v a n d s n i p ptei l
mel1emstykke
30902/1976
Forskruning
E l b o wu n i o n
Sg-ew
Cover
V i n k e fl o r s k r u n ' i n g
Skr ue
Daksel
S-ealjng,-l"l'ng
Tetningsring
Screw
lryte_qlive -qap_
Skr ue
M e1
1em 1eg
Beskyttelseshette
Nut
Mstri k
Stud.f. cylUf tel!
Tap for cyl inderdaksel

Pakn'i
ng
StyreakselI eje
Nut
9urde*_Pru
Screw
*1119---*-
'.1
l :: I ", 3'.),."
57'ls
ool
n
"
6886
7043
60acivtl |ta"...,*
G_ask_et
C a msh a ftbear ing
S tu d
Stud
S tu d
Gu i d escr ew
Ga ske t
Tap
Tap
Tap
Styr eskr ue
Pakn
i ng
Qoyer
Screw
Deksel
Sqrew
Endguard "fore"
Skr ue
"for"
Endeskarm
Skrue
rev. 1988.12.20
=.+===EsEt
= 5!===-CNERATII\IG
SfS
ltAt{
Er&ult
FRA},IE
__{olg!yn
lor}
Item No.
Designation
Benavnelse
7_221
7 3 10
S p r i n gp i n
F j e d e r s t if t
H a n dI e
Hndtag
t,Jasher
G u a r {" s i d e - a f t "
Skive
S k e r m" a g t e r s i d e "
7687
Gu a rd
Skerm
7776
Guard "s_iQq-fge.'!
S k e r m" f o r s i d e "
tB6S
Scew
Skrue
l^Jasher
Skive
- ! :: -' j),lol? 7409

i 99q
_ 6oog.41yl_?.!')i-g
6A..1!l.t4 ,lt;.!
6000tqfi.fi/:
' r ' l ' - . . " ] : . , ji
P L A T E3 0 5 0 2 - Z O H
6ooo.*VtO trtld 8111
S u p p o r tni g gqar d
E n dg u a rd t t a f t t t
t)'a) : 8200
6n l,.l' f i.'ti;"
S cre w
802?
* N o t sp ar e par ts
--Ststteskern
"agter"
Endeskerm
Skr ue
* Lever esikke som
reservedel
rev. 1988.12-?0
- --CENERANNGSTS
/-G\
ANDGUIDEBEARING
FRAME
PLATE
3 0503.1
IH
(;=::i'
461e
Ot-
2839
2928
3(B
318s
t271
333
ot{8
0237
032
t rq,
0a
2017
2tq
087l
0870
I 038
ry
,- 3152
sr
330
L zp
3907
1075
38t8
({
4la
4253
*
rq---
1t12
,(43t
4520
r e v . 1 9 8 81. 2 . 2 0
*E
5---
GENERATII\IG SETS
f||AT\I
ETRU'
PLATE
30 503.1
1H-
FRAME
ANDGUIDEBEARING
Item No.
6 00. 0!/ 10 ry,171
-6e,: i:,
'
" ' : i ' r
6o.. 1','n I ) i.!

'
_ 6 g f : : i t o lrr)1n
6cc
0t48
0237
Stud
Styr elejepande
,
over ste og neder ste
Tap
0326
Screw
Skr ue
S ik r i n g s s t y k k e
t.',tl/0 I ; ' ! ' '
S p a c er i n g
Afstandsr ng
i
/,:tl
*0693
Screw
Skr ue
1))i
0782
Nut
Motr ik
Cover
Deksel
Skr ue
qat
0870
0871
*0 9 6 0
i .
ot;0,tC'10
"z/) )r72
'
f,n1a.,",''r . lt
j'j^
tlli n;,'
loan - "''::; . l;^ ?:'
.^:,'
t'.tll
6 0)c r{/ / t o n ' /

/ ^ ^ ^
t1(/t.](J
\ t /
,t
|
' )
- 9-crqw
G u i d eb e a r i n gc a p
103 8
13 0 5
Ga ske t
1494
1583
0 i l s e p a r a t o ri n s e r t
H o u s i n gf o r o i 1
se p a ra tor
Screw
-t7r
Skr ue
I n d s a t sf . o l i e u d s k ille r
H u sf o r o l i e u d s k i l l e r
Skr ue
Pakn
i ng
1850
T h ru st washer
Tr ykskive
1949
Wa sh " "
Sk' ive
2017
2106
Screw
Skrue
G u i d ep ] n
Styr estift
fisl
2!7_3
Screw
Cover
Skrue
Daksel
?592
B la n k f
'l ange
Skr ue
0 i I tra p
2928
U!o-n
Gasket
3274
8 1i n d f l a n g e
Pakning
2839
(ctr' l'i-ti-r;t - 39e-63l 85

_ !!1,: i1, :) t')C:!:"i'
roooo,tt!n!lo
Styr elejeover pande

Pakn
i ng
Screw
Ga ske t
2651
2740
t'"
{t,t,.t.
G u i d eb e a r i n g s h e 1 1 ,
__trppgr 4{ I ower
S e c u r i n gp i e c e
- 1672
ri6i
{t''
Eenavnelse
0 4 15
*0 5 0 4
00 tl
_6ool.
Designation
0liels
For skr un
i ng
Pakn
i ng
El bow
Kna
Nut
Mstr ik
rev.,|988.12.20
!!r .i,r:
FIFE-g
GENERANNGSETS
]v|A{
C&U'
FRAMEANDGUIDEBEARING
Item No.
6U,0 tlql(
1/t'l
6ooo.ollo 0la:l6 ooo : ). o.'i;l
Designation
Benevnelse
3363
3452
Screw
Skr ue
Glrid9p j l
Styrestift
3541
Cover, upper part
D a k s e l ,o v e r p a r t
3630
60co. 0l/o o !0{" 3729
6 0 0 c , 0 q n . 0 / 6 "3 8 l B
C o v e r I ower pa!:t
Screw
D a k s e l ,u n d e r p a r t
Skr ue
Screw
Skr ue
,:!:4997
-6.Qlg.Q!4
Screw
Skr ue
Qt)0 t/i0' n/i{ 4075
Screw
6000 oqla olotl
'-
PLATE
30503-1H
I
-_
4164
S e a li n g r i n g , u p p e r
part
')i"'t l-
4 ?5 3
S e a li n g r i n g, 1o w e r
part
0/0?
4342
Nut
Skrue
Tatningsring,
over par t
Tetn'ingsring,
under par t
M str i k
6oo o . /
A i ,. t f I 0
4431
U n 'i o n
For skr uning
i/
loto -.''"/!,a.':i,/
4520
looo 'tttto. aur'/

d*lt,t. )vf,i
6aol.0l/0
9i1 pipe
* N o t sp ar e par ts
Retur olier sr
* Lever esikke som

reservedel
rev. 1988.12.20
E-
- -----
GENERATI\IG
STS
IvlAhl
B&Ult
PLATE30504- 1OH
CRANKSHAFT
f-22u
l,l3
r552
l4 I
1730
1829
s 208
2r75
0ll7
020
0395
0840
sr
(>
t__
0939
r007
I t9
r285
=
ffi==-==
CENERATT\IGSTS
llAhl
cr&ut
PLATE
30504- IOH
CRANKSHAFT
Item No.
_ 6ooool/n 0//z a 11 7
0206
6onc o 9/o o//J

*
6 o o n o t / / 0 Qi , ' 7
i:!:! 6 tt ' 'l . 0,' '.i
0395
0484
- 1 0 a . 4 : t :o11 l I 0 5 7 3
_ ::0r.ottlo01/I 0662
6ooa"c/o.o//tr 0840
0939
- .-..608 9t7)iil
{lto I' '!. t,i7# I 0 0 7
-- lott .a ti/c 0 li f 11 9 6
_ 6 t t t t ' . ) 0 , 7 : 1285
6oc x t t r ! t t - 14 6 3
_ 6 0 0 . t y / 0 . / /1552
-
l1ts ltn
1641
' ' r 730
1i.:
6rl: r1'^'
6000.{'.ia trl'l/
,dj :,.'.:j
i f)j !.:"'
6ro0.|V/o0//
1829
1918
?086
2175
6 ' J t C ' t + t 3 0 / :2
l 2 64
,100 t4 [/30
Designation
Benavnelse
C o u n te rw eight
P l u g scre w
Kontravagt
Propskrue
Krumtapaksel
C ra n ksh aft
C o u piln g par t
Koblingspar t
L o ck w a sher
Screw
C o u n te rw eight
S ik r i n g s s ikv e
Skr ue
Kontravegt
Screw
Skrue
Si kri ngsstykke
S e cu ri n gpiece
L o c k i n gp ' l a t e
S ik r i n g s pal d e
Screw
F1ywheel
Skr ue
S v in g h j u l
Nut
l,Jasher
M otr ik
S k iv e
0il throwring
Gearwheel
0 1i e a f s l y n g n i n g s r i n g
Tandhjul
Screw
Nut
F i t t e d b o lt
Skr ue
,401-ril'ilN:;i
244?
Screw
G e a rr i m
l4!.'t.f :/!0./3:
2531
B o lt
M str ik
t
Pasbol
Skr ue
Tandkrans
Bolt
- -----
CENERATING
SETS
rAhr
C&Uv
. DETAILS
CRANKSHAFT
PLATE30505-06
1165-n
\ #-'"'
\/
| 33
--___
,/r-
7.2
/
ols6---{_
I
\ -1132
0275--------\
\-<
\
\
\
,ru.-----l--GP
\
,/
I
0 153
052
\
0 631
072
0 8 tI
0361
02 7 5
E .b,=
F-ts
GENERATTI\G
SETS
tY|AhT
ct&ut
P L A T E3 0 5 0 5 - 0 6 v
. DETAILS
CRANKSHAFT
Item No.
Designation
Benavnelse
Afstemni ngshj u1
M str ik
Sjkrjngsskive
6poo-Oyt,_(uj!_
0 18 6
T u n i n gw h e e l
600o lt'i.l 0li,l_
0215
Nut
6ol.+ it:t't l,':.'
0364
Lock washer
6rorsr1t,10i;i:
0453
G u i d ep i n
0542
S li d e s h o e
D i s t a n c ep i e c e
tto
,;ttt 0.ii, !i:7
0631
(4c0.t7t'^Pr'"
0720
6 a r n L l / ' : :l / Y i
0 8 19
6 0 0 0 r / C I0 1 ? ?
0 90 8
11 6 s
6't. i',i'.? 'ti'tj

6 o o o . , i , t i l / , ,
6 000 0c/ 0 jrlf
lcot'
Ct, '{ C,i,i-
6000 0(//0. 0/L/ 7

!tl ^.Clrf
6oca.
lstc l ' ' , ! ' n i l 7
_ 6 ! a 0 0ti!t
_ 60000u/4
0 /.-C
0i j /
fooocq/n.c t_r'
Styr estift
G li d e s k o
Afstandstykke
F i tte d stud
E n dp l a t e
Endep' lade
134 3
1432
1521
G u i d ep i n
Fitted bolt (for
tu n i n g wheel)
Fitted bolt (for
vi b ra ti o n dam per )
Axle
V i b ra ti on dam per
Nut
Styresti ft
P a s b o l t( f o r
afstemningshju'l)
P a s b o l t( f o r
sv i ngningsdamper
)
Aksel
Svingningsdamper
Mstri k
1610
Hub
1709
1898
L o c k i n gp l a t e
Screw
S p r i n gg u i d e
Nav
Si kr i ngsp1ade
1254
1987
2055
S p rin g
Pastap
Skr ue
Fjederstyr
Fjeder
i.--
E-et
CENERATII\G
SETS
]||AhI
cr&ut
P L A T E3 0 5 1 0 - H
I.IITHPUMPS
COVER
FRONT
25ra
).1
?6167
2845
293r
N
I
Lzozs
3390
so2
2.189
_3r9t
Lub.oil pumpplate 31501

.\
,
tgss J
-/
-/
3396
Fr eshwater pump plate 31701
EEiFEH
GENERI{ru\C SETS
lulAhl
EEU'
P L A T E3 O 5 1 O . H
}{ITH PUMPS
COVER
FRONT
Item No.
Designation
Benavnelse
looa oclo o/f, 3
0 5 10
Nut
f4 pa/,1) 7/': q'
0609
Screw
18 6 6
Ga ske t
Mstr ik
Skr ue
P a k nni g
19 5 5
Screw
Skr ue
2023
?112
Gasket
Cover
Pakning
Daksel
A l ' /
2390
Screw
Bolt
{'--x
2489
C y l i n d r i c a lp j n
C y li n d e r s t i f t
2578
2667
2756
Screw
L o ck w a sher
S p ra yn ozzle
Skr ue
L s e bi lk
Sprojteror
6 O O . t 1 7 f . C / 1 , : , . 2845
S p ra yn ozzle
6C,:'t,) .'1'-t'l/
{),11'/
6oor o1'/i0 i,'.. :

'.':/.l a)/,{!i 4. .}
col
;-it.
;ool c +/i
Itto
! 4 i0
" " " " . " t

' : ' ' '
b . -
y','* a
/' | O
4
r ' 1
n /
6000 l!./it.0 )'0
troo10c10di/
?934
Gasket
Sprojtenor
P a k nni g
3002
3 19 1
Screw
Front cover
Bolt
Fordaksel
Ga ske t
P a k nni g
oo .lti'il t4,'{"
3280
3379
3390
3395
S tu d
Cy'li ndri cal pi n
Gasket
Tap
Cy1i nder sti ft
Pakning
loO9. I v'i)i/l'/
3 39 6
Cover
Daksel
*"t\i)0.!Yt.l6Y
3397
Screw
Skr ue
6 0 0 0 , 0 q 6 10 1 6
l:til
lt, ti fr/
fooo. 0vlc. CilY

oo.ottlt tpl/
41&6ooa.04//1
9e64. gyp 11/dt
-.s
- -----
--*-
GNERA'N{G
SETS
/-=?\
CRANKSHAFT
AND MAIN BEARINGTOOLS
- I 1H
PLATE
30 551
i:f.--os:
tJ
W\--'="-""
}
E!**
(fi\g-''"
\>
v''"
,,uo{
F#.EEF
GENERANNGSES
CRANKSHAFT
ANDMAIN BEARINGTOOLS
Item No.
0 10 5
i o O CC ' - . C I ) t 0? 16 4
02s4
6 o o o., { t t , oi *
0383
6 r r c - : : t c . l !i
0472
{0C0 "1q10 aG:*
PLATE
3 0 5 5 I - fI H -
Designation
Benavnelse
Tommybar
Dor n
t^l'irefor l ejeoverfald
Afstandsstykke
l .Ji refo r bear ing cap

D i s t a n c ep i e c e
C yli n d e r
0-ring with back-up
ri n g
0-ring with back-up
ri ng
P is t o n
Bleeder screb,
t^Jrench
Stempe'l
Udluftni ngsskr ue
Nog' le
Eye screw
0j eskrue
Hydr auliskvar ktoj for
hovedlejetappe, kompl
et
6 a 0 l c g t , . _ G . t . l ' j? 1 6 3
H y d r a u l i ct o o l f o r
m a i n b e a r i n gs t u d s ,
complete
Ga ske t
S n a p -o nc onnector
D i s m a n t l i n gt o o l f o r
b e a r i n gs h e l l s
Lever
S u p p o rti ngtool
Verktoj for demontering

af lejepander
Vagtstang
Ststtevarktsj
6 o t i o . q t o , 0 / E q 2618
S n a p -o nconnector
Hur t' igkob'

l
i ng
2707
2896
6cto. o,-i/o,t"){'f 2985
6 o o c 0 t i l 0 0 l t Y 3 0 00
6o o o. o L u o, o l q 3 0 5 3
Hose
S 1a n g e
H o se
DistriUuiingp'iece
H o se ,co mplete
llose
S la n g e
Fordelerstykke
{onn oLtto,0!/
6 0 0 0 . 0 l t t .i t l i :
loac. q!t. {/'f
0 5 61
0650
0749
6 o o o ' 0 Y / A , 0 / 7 6 OB38
0927
6 o o D ,c l t o , t l T
11 8 4
0o.04/o 0i7,f
6 o o oo. 1 / o0 ). 3 9
6 0 0 c q / 0 c t 7 1
oooo{Jto)tfa
6 t ro oV t a e t f l
1362
1451'
15 40
6 o o o . 0 L { i t . o l l L 19 06
6ol. !:.it: /')lf{

6000 oqla Ot t6
6 o o a .4
f r t " t ' 1 0 3142
6 o o o 0 L l l 0 0 l r N{ 3231
6ooo. s,"lto. o i qt- 3 4 19
S n a p -o nc onnector
Autolog
T u rn i n g rod
Cy1i nder
0 - r i n g m e ds t o t t e r i n g
0 - r i n g m e ds t s t t e r i n g
P a k nni g
Hur tigkobli ng
S l a n g e ,k o m p l e t
Slange
Hur tigkobli ng
Autolog
Tor nestang
+#_F=E
GNERATTNG
SETS
EngineData
z
o
E
ff
o-
Operation
of Engine
EnginePerformance
andCondition
Tracing
Trouble
Crankshaft
andMainBearings
Gearfor InletValveg
Operating
UJ
Turbocharger
System
P
E
z-fr
FuelInjectionPump
Zj'
E=
Ro
FuelInjection
= z Camshaftand CamshaftDrive
=
- <<9 Gontroland SafetySystems
Automatics
andInstruments
F
F -
d lJg
o
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
CoolingWaterSystem
l?eatmentof CoolingWater
DrivenMachinery
C Y L I N D EH
RE A DA N DC Y L I N D I R
LINER
DESCR
I PTION
306.0't
Edition 15H
Plate 30601
T h e c y l i n d e r l ' i n e r i s m a d eo f c l o s e - g r a ' i n e d p, e a r l i t i c c a s t i r o n a n d j s a t t h e
top providedwith a collar resting on top of the frame. At the bottom, the lin e r h a s a g u i d e w i t h g r o o v e sf o r t w o s e a l ' i n g r i n g s , w h i c h p r o v i d e t i g h t n e s s a gainst the frame
T h e c y f i n d e r h e a d i s m a d eo f c a s t i r o n . T h e c y l i n d e r h e a d ' i s p r o v i d e dw . i t h t w o
inlet valves and two exhaustvalves. The fuel valve is centraity placed in th
cylinder head. Further the cylinder head is providedwith an inibator valve.
T h e c y l i n d e r h e a d i s e q u i p p e dw i t h s e p a r a t e s e a t r i n g s f o r i n l e t v a l v e s a n d
e x h a u s t v a l v e s . T h e s e a t r i n g s a r e i n s t a l l e d a c c o r d i g t o t h e f r e e z ' i n gm e t h o d .
T h e s e a t _ r i n g s a r e m a d eo f h e a t - r e s i s t a n t s t e e ' I , d i r e c t l y h a r d e n e do n t h e s e a ting surface. The seat rings for the exhaustvalves are water cooled.
T h e c y ' l i n d e r h e a d . i s s u p p l i e d w i t h c o o l i n g w a t e r f r o m t h e s c r e w e d - o nc o o l i n g
w a t e r b e l t t h r o u g h r a d i a l b o r e s i n t h e t h i c k b o t t o m o f t h e h e a d . E a c hr a d j a
bore conrnunicates
with two branch bores. Further separate bores lead the cool i n g w a t e r t o t h e - s e a t r i n g s o f t h e e x h a u s t v a l v e s . F r o m t h e c o o l ' i n gw a t e r
space and bores of the cylinder head, the cooling water is led to a common
outlet chamber.
T h e c y l i n d e r h e a d a n d c y l i n d e r l i n e r a r e j o i n e d b y m e a n so r ' 4 s t u d s w h i c h a r e
s c r e w e d ' i n t o t h e f r a m e . T h e t i g h t e n i n g i s c a r r i e d o u t b y m e a n so f h y d r a u l i c
jacks.
S e a l i n g i ! p r o v i d e d b y a t h i n r i n g i n s e r t e d b e t w e e nt h e c y l i n d e r h e a d a n d t h e
cylinder liner.
Plate 30601
B e f o r e m o u n t i n gt h e c y l i n d e r ' l i n e r , t h e g u i d e ' i n t h e f r a m e s h o u l d b e c l e a n e d
of rust and sludge, and newsea'lingrings should be fitted t the liner.
R i n g s a n d _ g r o o v e sm u s t n o t b e g r e a s e d , o n l y a l i t t l e
lubricating oi1 maybe
a p p l i e d . T h e c o n t a c t f a c e s b e t w e e nl i n e r a d f r a m e s h o u l d b e c a i e f u l l y h e c k e d ,
a n d i f m a r k s o r i n d i c a t i o n s o f i n a d e q u a t ec o n t a c t a r e o b s e r v e d , t h e f a e s m u s t
b e r e c o n d i t i o n e db y a s l i g h t g r i n d i n g t o g e t h e r .
I f t h e p i s t o n r i n g s h a v e b e e n d i s m a n t l e d a n d t h e s a m eo r n e b rr i n g s a r e f i t t e d ,
t h e c o r r e s p o n d i n gc y l i n d e r l i n e r s h o u l d b e s l i g h t l y h o n e d , i n o r e r t o b r e a k
the "glaze" and to facilitate the running in.
The cylinder head is provided with a cleaning head 1227 and a plug screw 4175,
w h i c h s h o u l d b e r e m o v e da t r e g u l a r i n t e r v a ' l s f o r i n s p e c t i o n o f ' t h c o n d i t i o n
of the water chamber.
}OLEBY
GENRATTNG STS
trAhr
Er&ut
L23/30
306.51
C Y L I N D EH
RE A DA N DC Y L I N D ELRI N E R
Edition l3H
MAINTTNANCE
Plate 3065.|
a.
D i s m a n t l i n go f C y l i n d e r H e a d
l.
T a keo ff th e to p co ve r e nclosing the r ocker ar msand separ ateal' l p i pe

c o nn e ct'i o n s.A l so re mo vethe pr otective caps on the thr eadedends of
t h e b o lt s .
F i t t h e h y d r a u l i c j a c k s 0 7 9 8 , t h e d i s t r i b u t i n g p i e c e 0 1 5 4w i t h h o s e s
0 2 43a n d 0 5 1 0 , a n d a l so fit the oil pum p0421as shownand loosen the
n u t s a c c o r d i n gt o t h e d i r e c t i o n s g i v e n i n s e c t i o n 3 . | 9 .
3 . L i f t o f f t h e c y l i n d e r h e a d , . u s i n gt h e l i f t i n g d e v i c e1 9 5 5 .
b . M o u n t i n go f C y l i n d e r H e a d
l.
Be fo remo u n ti n gth e cyl i nder head, check the contact faces between
h e ada n d cyl i n d e r l i n e r. Any mar ksor scr atchesin the faces m aybe
g r o u n da w a yw i th th e to ol 30653/0192,
one side of which fits the
c y l in d e r h e a da n d th e o ther the liner . Fit a newsea' lingr ing between
c y l i n d e r I i n e r/cyl i n d e r head.
2.
I n sp e ct th e w a te r p a ssagenipples and r eplace defective r ubber r ing s .
3.
M a kesu re th a t th e n i p p les enter the cylinder headcor r ectly, and

m a kesu re th a t th e g u i d e pins enter the bor es in the cooling jacket .
T o f a c i l i t a t e t h e m o u n t i n g ,i t i s r e c o n m e n d teod a p p l y a l i t t l e l u b r i r ings befor e pr essing the cylinder headdo w n
c a ti n g o i l to th e :''ru b b er
a g ai n st th e co n ta ct fa ce of the cylinder liner .
4.
pipe, see section3ll.

F o r . m o u n t i nogf f u e l o i l h i g h - p r e s s u r e
5.
F o r a d j u s t m e not f v a l v e c l e a r a n c e ,s e e s e c t i o n 3 0 8 .
P l a t e 30 6 5 2
c.
D i s m a n t l i n go f i n l e t a n d e x h a u s tV a l v e s
M o u n tth e d i sma n tl i n gto ol 0123as shown.Befor em ounting,the thr u s t
feet 0301must be screwedcompletely inwards on the screwsof the thrust
p i ece.
2 . T u rn th e scre h rsi n a n a nti- clockwisedir ection and take out the lock i ng
rings of the valve spindles.
3 . R e l i e v et h e s p r i n g s a n d t a k e o u t t h e v a l v e s p i n d l e s .
. I 9 8 6 . 0 5 .21
E#.=EY
GNERAIGSETS
123/30
/-G\
CYLINDER
HEADANDCYLINDER
LINER
MAI NTENANCE
306.52
Edition l3H
4.
D u r i n g o v e r h a u l s , t h e c y l i n d e r head can be p l a c e do n a t i l t a b l e
w o r k t a b le 3 0 6 6 2 / 0 8 ' 1 (5o p t i o n a l e x t r a s ) t o f a c i l i t a t e a c c e s s d u r i n g
grinding of valve seats, etc.
I n c o n n e c t ' i o nw i t h d i s m a n t li n q
of the valve spindles for oveih a u l , t h e O - r i n g 3 0 6 0 /13 3 7 3 i n
t h e v a l v e s p i n d l e g u i d e ss h o u l d
be renewed.
During mounting careful hand'li ng

i s n e ce ssa ryto a vo i d d a ma ge
of
the 0-ring.
Sc r e wdri ve rs o r o th e r sh a rp tools
s h o u l dn e v e rb e u s e df o r t h i s
purpose.
C o r r e ct mo u n ti n gca n e a si l y be done
b y t h e u se o f tw o va l ve sp i ndles as
m o u n t in gto o ] i o n e sp i n d l e to be
u s e da s su p p o rta n d th e o th er spi ndle
t o b e use d fo r p u sh i n gth e O- r ing
downwards.
d.
Overhauo
l f V a l ve s
t.
I n s p e c t i o no f v a l v e s p i n d l e s e a t s / v a l v es e a t r i n g s
P o l i s h i n go f v a l v e s p i n d l e s e a t s a n d v a l v e
s e a t r in g s ca n b e ca rri e d o ut by m eansof
g r i n d i n g p a ste a n d u se o f th e suction
lifter as turningdevice.
I f t h e se a ti n g s a re b u rn t o r scam ed
b y d e nt ma rksnre co n d i ti o n i nghas to
b e c a r r i e d o u t b y ma ch i n i n gin for m
o f g r i n d i n go f v a l v e s p i n d l es e a t
r e s p e c t i v e l yv a l v e s e a t r i n g .
19 8 6 . 0 5 .21
Irt t4g
t-lrt-'
= E!===-=5
=
GENERA.rIAC SETS
L23/30
CYLTNDER
HEADANDCYLINDER
LINER
306.53
MAINTENANCT
2.
Edition I 3H
I n s p e c t i o no f v a l v e s p i n d l e g u i d e
1 4 , 2 5m m .
T o om u c hc l e a r a n c eb e t w e e vn a l v e s p i n d l e
a n d s p i n d l e g u i d e m a yc a u s ei n c r e a s e d
Iub.oil consumption
f o, u l i n g u p o f t h e
s p i n d l eg u i d ea n d t h u s g i v e t h e r i s k o f
sticking valvespindle.
Too muchclear ancealso m eansins uffi c i e n t g u i d a n c eo f t h e v a l v e s p i n d l e a n d
thus bad alignm entbetweenspindl e head
andvalve seat ring.
In connectionwith over haulof the c y 1i n d e r h e a d , t h e v a l v e s p i n d ' l eg u i d e s
s h o u l db e c l e a n e d ,i n s p e c t e da n d m e a sur ed for wear .
I f t h e i n n e r d i a m e t e ro
h5
e valve
. |f4 ,t 2
s p i n d l eg u i d e e x c e e d s
m m ,t h e v a l v e s p i n d l e g u i d e m u s tb e r e p l a c e d .
3.
R e c o n d i t i o n i nogf V a l v e S e a t R i n g s
R e c o n d i t i o n i nogf v a l v e s e a t r i n g s i s c a r r i e d o u t b y g r i n d i n g w i t h a
grinding apparatus3
, 0 6 5 2 / 0 7 6 7(.F o r m o u n t i n ga n d o p e r a t i n g o f t h e g r i n d i n g a p p a r a t u s s, e e s e p a r a t ei n s t r u c t i o n ) .
u l i ng th e g ri n fl i n g a p p a ralu!, gr ind the seat "A" r ,,ith a feed at an angl e
a d j u s t e dt o 3 0 " + 0 . 1 . G r i n d t h e s e a t u n t i l o b t a i n i n ga c l e a n a n d u n i i o r m
s u r fa ce .
0
F o r a n e wva l ve se a t ri n g, gr ind until the m easur ement
D 306- 5has been
a c h i e ve d .C a ry o u t th e finl gr inding with a feed fr om the inside outw a r d s ,a s t h i s n o r m a l l yg i v e s t h e U e s t s u r f a c eq u a l i t y .
A d j ust th e d i a me te rD 3 0 6- 5 of the seat in accor dance
with the indic ati on
o n th e d a ta p a g eb y g ri n ding the sur face "B" with the gr inding appar atus .
W h e nth e re ce ss " R " h a s beengr oundaway, the valve seat r ing is use l es s
andis to be replaced.
Ad j ust th e w i d th D 3 0 6 -6 of the seat ( sur face "A") in accor dance
with the
i n d ica ti o n o n th e d a ta p age. Car r y ou the adjustr ir ent
gr
inding
by
the
s u r fa ce " C " !,,i th th e fe e d angle of the gr inding appar :atir s- adjust
tod 50o.
A n y w o rn va l ve g u i d e s i n the cylinder headmust be r ep' laced.
I 9 8 6 . 0 5I .2
|l
tJt'lE
lFgrf
CENERANNGSETS
IvIAN
E&UV
C Y L I N D EH
MAINTENANCE
4.
306.54
Edition13H
Reconditioning
of Valve Spindle
U s i n g t h e g r i n d i n g a p p a r a t u s , 3 0 8 5/10 ? 4 1 , g r i n d t h e v a l v e s p i n d l e
seat.
( F o r o p e r a t i o n o f t h e g r i n d i n g a p p a r a t u s s, e e s e p a r a t ei n s t r u c t i o n ) .
G r i n d t h e s e a t o f t h e v a l v e a t a n a n g l e a d j u s t e dt o S O o ' ! . r ' o
c o n t i n u eg r i n d i n g u n t i l o b t a i n i n g a c l e a n a n d u n i f o r ms u r f a c e .
A f t e r g o m p l e t i n gt h e g r i n d i n g , c h e c kt h a t t h e h e i g h t D 3 0 6 - 8o f t h e v a l v e
h e a do bse rve sth e mi n i mu m
mesur ement,
as indicatd on the data page.
If D306-B
m i n . c a n n o tb e a s c e r t a i n e d ,s c r a p t h e s p i n d l e .
f l t . l . a s s e m b l l n g l h q v a l v e s , c h e c k- o n a c c o u n tt h e v a l v e m o t i o n- t h a t
t h e d i sta n ce D 3 0 6 -7b e tw e enthe upper edgeof the cylinder hedand
t h e u p p e re d g eo f t h e v a l v e s p ' i n d l e ' d o e s o t e x c e e di h e m a x i m uvma ' l u e .
e.
R e p l a c e m eonft V a l v e S e a t R i n q
W h e ni t i s n o l o n g e r p o s s i b l e t o r e c o n d i t i o nt h e v a l v e s e a t r i n g i n
a c c o r d a n cwei t h t h e p r e c e d e n st e c t i o n , t h i s r i n g i s r e p l a c e d i n t h e
f o l l o w i n gm a n n e r
D i s m o u n t i nogf V a l v e S e a t R i n g s
D i s m o u n t i nogf a v a l v e s e a t r i n g i s c a r r i e d o u t b y m e a n so f a s p e c i a l
e x t r a c t o r t o o l s e t c o m p r i s i n gf o l l o w i n g c o m p o n e n t s :
o
o
o
o
/;\
Spi nd'le
Nut
0isc
C o p p e rp i p e
\y
S u p p o r t i n gp i e c e
0isc
Nut
1986.05.12
#.EEY
GNERATI\IG
SETS
L23/30
CYLTNDERHEADAND CYLINDERLINER
3 0 6. 5 5
MAINTENANCE
Edition l3H
D i s m o u n t i nogf a v a l v e s e a t r i n g i s c a r r i e d o u t a c c o r d i n g t o f o l l o w i n g p r o c e dure:
T h es p i n d l A O * i t h t h e n u t @ a n d
t h e d i s c ( 3 ) i s p l a c e di n t h e v a l v e
s p i n d l e g u l d ew i t h t h e n u t a d j u s t e d
s o a s to o b ta i n th e p re scri bedpos' ition of the disc in the valveseat
ri ng.
A h e a t - r e s i s t a n ti n s u l a t i o n c l o t h
( g 1 a s sf i b r e o r s i m i ' l a r )p r o v i d e d
w i t h a h o l e o f sa med i a me teras the
v a l v e s e a t r i n g i s p l a c e do n t h e
c y l i n d e r h e a db o tto msu rfa ce in such
a $ r a yj u st l e a vi n g fre e a ccessto
the valveseat ring itself. This
arrangementprotects the surfaces
a g a i n s t h e a t i m p a c ta n d s p u t t e r
f r o m t h e su b se q u e nwt e l d i n g pr ocess.
E
l'\
.j
-C
l-\
+r
= o r
O
C
I
|.lJ
T h e c o p p e r " - p i p@
e i s p l a c e do n t h e s p i n d l e i n o r d e r t o p r o t e c t t h e l a t t e r
a g a i n s tw e l d i n gs p u t t e r .
B y m e a n so f a n e l e ctri c a p p ar atus,the d isc C3) is nowweldedon to the s eat
r i n g . T h ew e l d i n gh a s t o b e c a r r i e d o u t a s a Y u l l w e l d i n g ,i . e . w i t h a n u n ' i n t e r r up te da n d ci rcu mfe re ntial
weldi ng s e a m .
F u r t h er to a tta ch me n o
t f th e extr actor tool the welding pr ocessear ns the
p u r p o s et o l o o s e nt h e v a l v e s e a t r i n g .
T h e - h e a ti m p a c tf r o m t h e w e l d i n gp r o c e s sw i l l c a u s et h e s e a t r i n g t o b u c k l e
a s i t . c a n n o t e x p a n di n t h e c y l i n d e r h e a db o r e . D u r i n gt h e s u b s e q u e nc to o l i n g
d o w nd u e to te mp e ra tu ree q u alizing the seat r ing will shr ink and thus the
p r e s sf i t i s r e d u c e d .
Af t e r t he w e l d i n g th e co p p Arpipe @ and tlE- insulation cloJfr ar e r er n ov ed,
a n d t h e su p p o rti n gp i e ce (D with t- edisc ( 6) and the nut ( f is mounted.
T h e v a l v e s e a t r i n g i s n o w t o b e p u l l e d o u t b y t i g h t e n i n go f t h e n u t
O
Being welded to the extracted and scraped valve seat ring, the disc
O
not be reused.
.
can-
P l a n n i n go f a ma j o r o ve rh a ulof cylinder headsshould ther efor e compr is ea

checkof Nos. of mentionediscs availableon stock.
T h e d i s c c a n b e o r d e r e da s s p a r e p a r t s , s e e p l a t e 3 0 6 0 1 .
.1986.05.12
EE-EEF
GENERATNC SETS
]v|AT{
Et&ult
L23130
HEADANDCYLINDER
CYLINDER
LINER
306.56
MAINTENANCE
Edition l3H
M o u n t i n go f n e w V a l v e S e a t R i n g s
P r i o r t o m o u n t i n go f a n e wv a l v e s e a t r i n g , t h e b o r e i n t h e c y ' l i n d e rh e a d
has t o b e c a r e fu l l y cl e a n e da n d to be inspectedfor sur face damage.
Any mar ks
or "h i g h s p o ts" w h i ch co u l d o b stru ct the mountingor pr event cor r ect position 'in go f t h e v al ve se a t ri n g sh o u l d be r em oved.
Prio r t o m o u n ti n g ,th e va l ve se a t ring has to be cooled downin or der to obtai n
a s h r i n k i n g e f f e c t a l l o w i n ge a s y s l i d i n g o f t h e v a l v e s e a t r i n g i n t o t h e b o r e .
T h e r e f o r et h e co o l i n g d o w nsh o u l d pr efer ab' lyby m eansof liquid nitr ogen ( Nr )
o r a s a n a l t e r n a t i v e b y u s e o f a c a r b o nd i o x i d e ( C 0 2 )f i r e e x t i n g u i s h e r . L
t { h e nc o o l i n g d o w nt h e v a l v e s e a t r i n g i t s h o u l db e p l a c e di n a h e a t - i n s u l a t e d
b o x o r p l a c e d u p o na h e a t-i n su l a ti ng m at. To achieveadequatetemper atur e
of
t h e v a l v e s e a t r i n g , t h e c o o l i n g m e d i as h o u l db e a p p l i e d f o r a p e r i o d o f
a p p r o x .l 5 - 2 0 m i n u t e s .
CA U T I O N
W. h e nh a n d l i n gsu p e rco o l e dcom ponents
asbetosgloves shouldbe wor n
s Z i r e c t c o n ta ct w i th th e sk'i n ma ycausefr ost- bite.
l.lhenthe val ve seat ri ng has
b e e nc o o l e d d o w n ,i t i s ca re f u l l y p l a c e di n , t h e b o r e .
Cooleddownto adequatetempera t u r e , t h e v a l ve se a t ri n g
c a n e a s i l y b e m o v e di n t o c o r rect position.
T h em o u n t i n gt o o l , c o n s i s t i n g
of a d i s c a n d a ma n d re lo f
d i m e n s i o nas l l o w i n g i t t o b e
g u i d e di n t h e v a l v e s p i n d ' l e
guide,is placed.
l,landrel for
m o u n t in g o f
valve seat rings
-z
v71
,/t,
B e f o r e a n y s e ttl i n g ca n ta ke
p l a c e d u e t o e q u a l i z i n go f
t e m p e r a t u r e ,t he va l ve se a t
ring is driven into the bore
unti l c o n t a c t i n b o tto mp o si t ion b y k n o c ki n gth e ma n d re l
with a hanuer.
ilh e na n e wv a lve se a t ri n g h a s b e e nmountedthe seating sur face has to be
g ro u n di n o r d e r to e n su reco rre ct a lignm entto the valve spindle guide.
B e f o r e g r i n d i ng , th e te mp e ra tu reos f the valve seat r ing and the cy' linder
hea ds h o u l db e a l l o w dto e q u a l i ze to r oomtem per atur elevel.
I 986.05..I 2
t
G==E= Fttt=t
GENRATING
SETS
L23/30
CYLINDER
HEADANDCYLINDER
LINER
306.57
MAINTENANCE
Edition l3H
E x h a u s tV a l v e S e a t R i n q
I n o r d e r t o e n s u r es e a l i n g t o w a r d st h e s u r r o u n t l i n gc o o l i n g w a t e r c h a n n e l s
a
s e a ' l i ngco mp o u nhda s to b e used, whenmountinga newexhaustvalu" r "ui " i g.
T h es e a l i n gc o m p o u n ldo, c t i t e 6 4 0 , i s a p p l i e do n l y t o t h e b o r e , a n d
an acti_
v a t o r ' l o c q u i c t 7 4 7 T , s h o u l db e u s e d i n . o r d e r t o a c c e l e r a t e
te curing time.
T h e i n s t r u c t i o n s d e l i v e r e dw i t h t h e s e a l i n g c o m p o u nadn d t h e a c t i v a t o r
should
be fol lowed.
I n b r i e f t h e p r o c e s si s a s f o l ' l o w s :
-
D e gre a seth e b o re w i th trichlor ethylene.
A p p l y t h e a c t i v a t o r a n d a l r o w i t t o d r y f o r a p p r o x .3 m i n u t e s .
A p p l ya t h i n c o a t o f l o c t i t e 6 4 0 .
T h e c o o l e dd o w ne x h a u s tv a l v e s e a t r i n g i s m o u n t e di m m e d i a t e l ay f t e r . a p p l i c a t i o n o f t h e s e a l i n gc o m p o u n d .
Af t e r - mo u n ti n go f th e va l ve seat r ing the sealing compound
must be allow ed to
c u r e f o r a t l e a st 3 0 mi n u te sbefor e wor k such as gr inoing of iating r u .tu.is continued.
I n l e t V a l v eS e a tR i n g
T h e i n ne r d i a me te ro f th e i n let va' lveseat rl ngs 'ts asrnmetricdue to the
p r e s e nceo f a sw i rl fa ci n g .
To achieve the swirl effect of the chargea i r w h e nenter ing the cor nbu s ti on
c h a m b eirt i s i m p o r t a n tt h a t i n l e t v a l v s e a t r i n g s ar e cor r ectly positi oned
in the cylinder head.
P u n c hm a r k
indicating fitting
direction
Inlet ValveSeat Ring
.1986.05.t2
E*H.EEgY
GENERATINGSETS
/-C\
CYLINDER
HEADANDCYLINDER
LINER
306.s8
MAINTENANCE
E d it ' i o n 1 3 H
To e n s u r et h i s , b o th th e va l ve se a t r ing- and the cy]inder headbottom

have
f i t t i n g m a r k s ,w h i c hh a v e t o c o i n c i d e .
l^ lh em
n .o u n t ' i ng
th e i n l e t va l ve se a t r ings they have to be positioned accor ding
to the marks.
\J
o
f.
R e p l a c eme n
o tf L i n e r fo r F u el Valve
I f t h e s e a l i n g - r n g so f t h e f u e l v a l v e l i n e r s t a r t t o l e a k o r a n o t h e r
d e f e c t in th e l i n e r o ccu rs, the liner is to Oe r emove,- pr oceeding
as
f o l I o w s.
S c r e wo ff th e ri n g n u t 3 0 6 0 1/' 1693- !y
qeansof the special pin
3 0 6 5 2 / 0 4 9a0n d kn o ckth e l i n e r 3060i/1861car efully' out, usingspanner
a br ass
m a n d r e l ,o r p u l l o u t th e l i n e r by m eansof an extr ctor tool.
A f t e r c are fu l l y cl e a n i n g th e ,.,bor in
e the cylinder head, cool down
f u e l v a l v e l i n e r t o m i n u s7 0 u cf o r e x a m p l e - i nl i q u i J - i t i o o . n ( N ^ )the
.
M o u n tn ewse a l i n g .ri n g s a n d fit the linLr in the' cytinoer - "|' ) "fr r nt
t h e r i n g n u t, ti g h te n i .n gi _ t
l p_by meansof the pr n"spannerand a
torque pressurestated in D 306_9.
1 9 8 6. 0 5 .I. 2
EE.EY
GENERATTNG SETS
C Y L I N D EH
MAINTENANCE
g.
3 0 6 s. 9
Edition 13H
R e p l a c e m e notf S e a l i n g R i n g s o n C o o l ' i n gJ a c k e t
D i s m o u n t h e s c r e w s 3 0 6 0 1 / ? 4 8 4a n d r e m o v et h e c o o l i n q . i a c k e t r p o s s i b l e b y
k n o c k sw i t h a t i n h a m m e r .
Cleanthe cool'ingjacket on the inside, also cleaning the bore of the cyl i n d e r h e a da n d t h e s u r f a c e a g a i n s t t h e c o o l i n g j a c k e t .
M o u n tn e w s e a l ' i n gr i n g s , a f t e r c o a t i n g t h e mw i t h a l i t t l e l u b r i c a t i n g o i 1
A f t e r t h i s n m o u n t t h e c o o l i n g j a c k e t a n d t i g h t e n u p t h e s c r e w sw i t h t h e
torque stated 'in data 306-10.
Pla t e 3 06 5 3
h.
D i s m a n t l ' i nogf C y ' l i n d e rL ' i n e r
1 . A t t a c h t h e l ' i f t i n g t o o l 1 8 0 4t o t h e l i n e r a s s h o w n .
2.
t J h i l e t h e l e g s o f t h e c r o s s b a r1 4 4 8n e a r o n t o p o f t h e f r a m e , r a i s e t h e
c y f i n d e r l i n e r b y m e a n so f t h e e y e n u t 1 3 5 9 ,u n t i l t h e l i n e r r e s t s a g a i n s t
the crossbar.
3.
P u l l t h e c y l j n d e r l i n e r o u t o f t h e f r a m ew i t h c a r e b y m e a n so f a t a c k l e ,
a n d re mo vei t.
4.
I n t h e c a s eo f i n s t a l l a t ' i o n sw h e r et h e h e a d r o o m
is restricted, a special
l i f t i n g d e v i c e 3 0 6 6 2 / 0 1 8c2a n b e s u p p l ' i e df o r t h e c . v fi n d e r l i n e r s .
j.
L a p p i n go f C y l i n d e i L i n e r / F r a m e
T o en su reco mp 'l e te :'ti g htness
betweenthe cooling water spacein the fr am e
a n d th e cyl i n d e r l 'i n e r, the packingsur faces cylinder l' iner /fr ameare to
b e l a p p e dto ma tch .
D i s m o u ntth e s e a l i n g r i n g s o f t h e l i n e r , m o u n t h e l i f t i n g t o o l s t a y 1 5 3 7 ,
c r o s s p i e c e1 6 2 6 ,a n d e y e n u t 1 3 5 9t o g e t h e rw i t h t h e l a p p i n gh a n d l e1 7 1 5o n
the cylinderliner.
L a p t h e c y l i n d e r " l i n e r / f r a m et o m a t c h ,u s i n g p a s t e , t h e f i n a l ' l a o p i n g t o
b e ma d ew i th p a ste N o . 1 80 or finer .
B e f o r em o u n t i n gt h e c y l i n d e r l i n e r , a p p l y a t h i n l a y e r o f p a c k i n gp a s t e o n
t h e s e a l i n g s u r f a c e s ,f o r e x a m p l eS i l a s t e n e , R h o d o r s i l7 3 0 6B l a n c , o r a
similar type.
k.
H o n i n gt h e C y l i n d e rL i n e r
T h e re n o va ti o nca n b e ma dewither with dism antledliner in the wor k s hopor
w i t h l i n e r mo u n te di n th e engine fr ame by use of the belongingfunn el 0825.
19 8 6 .0 5 . 1 2
-:#h
tElEif
= E!==:E
E
GNERA'N\GSTS
C Y L I N D EH
306.60
MAINTTNANCE
Edition 13H
Before the honing, deposjts of coke and possible wear edgesin the top of the
l i n e r m u s t b e r e m o v e db y s c r a p ' i n g .
T h e h o n i n g ' i s m a d eb y m e a n so f a f l e x - h o n e r 0 7 3 6 w i t h f j n e n e s s g r a ' i n s B 0 - 1 2 0 .
A r e v o l u t ' i o n s p e e d b e t w e e nB 0 a n d , | 6 0 r p m i s c h o s e n
I n o r d e r t o a c h j e v e t h e r e q u i r e d a n g l e b e t w e e nt h e h o n i n g g r o o v e s ( s e e s k e t c h )
t h e v e r t i c a l s p e e d i s a d j u s t e d t o a b o u t 1 m / s e c . , w h i c h c o r r e s p o n d st o a b o u t
2 s e c . f o r o n e d o u b l e m o v e m e n t .( f n e t l e x - h o n e r i s m o v e df r o m b e l o w , u p a n d
d o w ni n 2 s e c o n d s ) .
8O- 160 r/min.
f{oning rpecificotion
Th e p r o c e d u r eis to b e co n ti n u e du n til about 25 per cent of the sur face is cov e re d b y h o n i ngg ro o ve s.T h i s i s n o r m ally achievedaften only a few ver tical
move m e n t sT.h e re ma i n i n gsu rfa ce i s l e f t r o u g h .
'lubricate
Duri n g t h e h o ni n g'i t i s i mp o rta n tt o
freely with cutting oil or eng i n e o ' i l . G a so i l o u g h tn o t t o b e used as it may promotescratches and conseq u e n t u n e v e ns urfa ce ro u g h n e ss.
Af t e r t h e h o n in g , th e l i n e r i s ca re fully cleanedand it must be ensur edthat
a ll a b r a s i v e p arti cl e s h a veb e e nre moved.
't2
1986.0s..
c t.E
EFlft.t
E FS=E-I5
E
CENERAIIN(]
STS
C Y L I N D EURN I T
PLAT3
E0 6 0 1 - 1 2 H
3285
01,26
05t5
3730
3829
| 591,68J
-t 772
460
0793
0882
0971
J 55 2
3 6 4'
391B
4086
3 3 7 33375
4175
t86t
| 950
__ &ZL'Hcf
la
---'; -
.Q-EF
g"i-:.
I
I
I
t,38
| 227
,3,6art
4445
4353
4 2
4443 *)
2J95
248
2573
::.. -,0 |
2662J
D' n *1.
2s73/
-2810
29J9
3007
rev. 1988.12.20
ffi.EEF
GENERATINGST5
CYLINDER
UNIT
ItemNo.
6ooa.0110,-6#lY 0'159
60,{fi &!,!::,0o/ _0L48
o& otl A*l [3_3J
fto ti#.#i,,i .0426
6t , ptr 6 p o l Y - n 5 1 5
PLAT3
E0 6 0 1 - t 2 H * -
Designation
Benavnelse
Nut
l^lasher
Mstr ik
Skive
H a n dw h eel
Hndhjul
V a l v es p i n d l e
G l a n dn u t
I n d i c a t o r v a lv e
6o*::. * /6 ;' i $3 --0793

{i '..: t o lls 0 *{ f I 8 8 2
Ga ske t
V e n t Ij s p in d e l
Pakmstrik
I n d ik a t o r v e n tIi
Pakning
C o n n e c t i np
gi e c e
Me'll emstykke
6 0 a . 1 6 ! . o 8 t r YA 9 7 1
6 e # & . r #gl* r i
J138
5s , * g llo s f 1 2 zl
Gasket
Ga ske t
Cover
Pakning
P a k nni g
Deksel
I t a : t a* * l
lo*p eilF-f$J
' . '.: 6 t : : : 3 * i . l
Screw
Screw
Skr ue
Skr ue
1 68 3
Cti"#,:dl.*#{ lttz
6 , " r; 1
O / / g t ; J ^ 1 86 1
1 95 0
{ r:tg {'}ilo z t
6a'tr . l{ !" ,.:,:
o r,l 2117
6 t::: oll o ol F ng-s
R i n gn u t
0-ri ng
S l e e vefor fue' l valve
S tu d
Ringmotrki
0-ri ng
Br. ventil foring
Tap
0-ri ng
C o oiln g j acket
0- r i ng
Kolekappe
6t'r o{/: . Qtv 24u
Screw
6t,tr..:.r6;i_
f-f t
.01/;).0 df
;:;.3;l
0-ri ng
P ip e
Skrue
0-ri ng
Rsr
litil
:t
:'dt\f{
0604
1316
1594
Z5t3
?66?
l#** , J l1 f a { ) 1 6 ? 8 4 0
(,t*1. 0/{{ pl.}r ..2g3.9
6 N 0t: , 0e{:N 3007
618sotto r,!3{ 3285
l*w o/6f lrrz 337J
6! ::;: d:r'j - 0i}} . 337_5
S e ailn g r i n g
C y li n d e r I n e r
0-ri ngs
G u i d ep i n
6: : ,; i i i' "., s ; :
P 1u g screw
VentiI sp' inde1

styr
Pr opskr ue
Ga ske t
Pakning
Coami
ng
Karm
3552
6 ' | : { ; i s r r , . 4 * , d3 6 4 - 1
g t , : ;o t i : t t j v
3730
0-ri ng
V a l v es p i n d l e g u i d e
Tetningsr ing
Cyli nder for ing
0- r i nge
Styr estift
0-ri ng
r e v . , | 9 8 8 .1 2 .2 0
E
--
sG--
CENERAT1NG SETS
]YIAfrl
Et&ut
CYLINDER
UNIT
Item No.
690*illo ot j_SAzg
l#$ ol&. fi::.5,*39lB
Cooa #// a,*38 4086
d'crr'#olf# oA37 qllS
.6W otlA a*tf_gs

6o90.qtt ,00],
44!Z
*6s
et{ga{:&i:+443
(Qf Q//o {t 4445
P L A T E3 0 6 0 1 . I 2 H
Designation
Benavnelse
Gasket
P a k nni g
Nut
M str ik
Stud
Tap
P"lug
Prop
C y li n d e r h e a d
Valve seat ring, exh.
Cy1i nderdaksel
V e n t i l s a d e r i n g ,u d s t .
disc
Skive
Valve seat ring, inlet
V e n t i l s a d e r i n gi ,n d s .
* Has to be used when

d i s m a n t li n g t h e v a l v e
seat rings. See plate
3 0 6 5 2 - 0 7 H 1i t,e m 1 0 1 9
* Skal anvendes
ved
dem onter ing
af ventiIs a d e r i n g e .S e p l a t e
3 0 6 5 2 - 0 7 Hp1o, s . 1 0 1 9
rev. 1988.12.20
=:&
-----
--G
GENERATINC
SETS
STARTING
VALVE
PLATE
30602.07H
O O
0217
l'--
't018
1296
}TOI.EBY
CENERATI{G SETS
rilAhl
Et&ut
PLATE
30602.O7H
STARTING
VALVE
Designation
Benavnelse
s * * " Qt -fi-t!"*0128
6ote d\{-/""sftlA *- 0217
S p in d le
Ga ske t
S p in d e l
Pakn' ing
. 6a e.pt_i!g_y-{-_
!306
Screw
Skr ue
6/tg CIt:r{
__6_.t_*
V a l v es e a t
S p rin g
S li d e
H o u sni g
VentiI sade
Fjeder
Gli der
Castlenut
Kronemstrik
Skr ue
Sp'li t
Item No.
0495
0584
,-.60aoflf oo*t
0673'Leo-ptt# ailvl
_f,e**!.rltoait& 0762
_:'{fll. $.t:,rr1s1018
*$Qlri t.i.jil afv
1107
- . 1?"6".#t{$.,$}"f
- 6""r)-:?ft
4
- {g.r!ol at},&('! 147
Screw
Sp1
it pin
S t a r t i n gv a l v e ,
co mpel te
Hus
Star tevent' il, kom plet
tI-
EEFIf
E IrlErIt
GENERATI{\IG
E
SETS
CYLTNDER
HEADTOOLS
PLATE
30651- 08
042't
0510
009
09?
1133
1222
131'l
=ffi-EF
GENERATING
STS
-08 PLATE30651
CYLINDER
HEADTOOLS
Designation
Benevnelse
0 15 4
D i s t r i b u t i n gp i e c e
For deler stykke
0243
0421
0 5 10
Hose
0i I pump
S 1a n g e
Item No.
0609
0 79 8
0887
0976
11 3 3
1?22
131
14 0 0
159 9
1688
1777
19 5 5
H o se
S u p p o rt
H y d r a ui cl j a c k ,
complete
Vent screw
S n a p -o nconnector ,
m a 1 e ,b o m p l e t e
Ga ske t
P i sto n
0-ring with back-up
ri ng
0-ring with back-up
ri n g
C yfi n d e r
Tornmy
bar
l,loodenbox
L i f t i n g b r a c k e tf o r
cyl i n d e r head
0f iepumpe
S 1a n g e
Holder
Hydrauli sk trekapparat,
kompl
et
. .AfI uf tn' ingsskr ue
H u r t i g k o biln g , h a n p a r t ,
komplet
P a k inn g
Stempel
0 - r i n g m e ds t s t t e r i n g
0- r ' ing m edststter ing
Cyfi nder
Dor n
Trekasse
Loftebeslagfor cyI i nderdeksel
- -----
a---
GNERATINC
SETS
IulAf\t
C&U'
PLATE
30652-O7HI
HEADTOOLS
CYLINDER
^'!
iu[
--J
l- -t
\
't----./l F
//
,.i_
\,
=,.;
l-/
" .a'
t0t5
10,l6
f01/
101B
10 1 9
I 020
1021
. 0 3 .0 3
1987
E t*,=E
FFIE
CENERATIIIG SETS
Ir;|Ahl
Et&ut
PLATE
30 652- 07H
-
C Y L I N D EH
RE A DT O O L S
Designation
Benavnelse
0123
valves,complete
Demonteri
ngsvarktoj for
et
vent' Ii er , kom pl
0212
0 3 01
Screw
T h ru st foot
0490
Wrench
for rjng nut,
fuel valveliner
Gri n d i n gm andr elfor
fuel valveliner
G r i n d i n gm a c h i n ef o r
va lve seats
Skr ue
Trykfod
N o g l ef o r r i n g m o t r i k ,
br andselsventi1for i ng
Item No-
0 58 9
0 76 7
0 94 5
1 0 51
1016
1017
1018
1019
10 2 0
1021
1657
valve seat rings
Nut
D is c
Foot
C o p p e rpipe
D is c
Nut
S tu d
Mo u n ti ngtool for
valve seat rings
Sl ibedor n for
br andselsventi1for i ng
Sl ibeappar atfor
venti I sader
Demonteri
ngsverktoj
for ventilsader inge
Mstri k
Skive
Fod
Kobberrsr
Sk'ive
Motr ik
Tap
Monteringsvarktoj
for ventilsaderinge
I 9 8 70
. 3 .0 3
-
A-
-----
--*E
GENERATIC
SETS
C Y L I N D ELRI N E RT O O L S
PLATE
30653-05H
r359
Ir,(8
I 993
9 0. 2 9 .
F#-EEE
CENER\'ING SETS
/*G\
PLATE30653{5n-
CYLINDERLINERTOOLS
ItemNo.
Deslgnatlon
Benevnelse
0192
02B1
0370
0469
0558
0647
0736
0825
0914
1082
1171
1260
1359
1448
1537
1626
1715
1804
1993
Grindingtool for cylinderliner,compl.

Handle
Gdndingdisc
Nut
Woodenbox
Gdrdstone
Honirqbrush
Wastetray,complete
Wastetray
Screw
Hoseclip
Hose
Eyenut
Crossbar
Tie-boh
Crossbar
Gdndingtool
Liftingtoolfor cylinderliner,compl.
Distancepiece
komplet
Slibevarktsj for cylinderforing,
Hndtag
Slibeskive
Mstrk
Trekasse
Slibesten
Honebsrste
Spildbakke,komplet
Spildbakke
Skrue
Slangebirder
Slange
@iematrik
Travers
Stagbott
Travers
Slibeverktoj
konplet
for cylinderforing,
Lsfteva,rlr.Jrsj
Afstandsstykke
90.29.
HCT.EBY
GETGRAI\IGSETS
]v|AhI
E&UI'
C Y L I N D EU
RN I T - E X T R AT O O L S
P L A T E3 0 6 6 2 - O 3 H
2496
2407
2 31 8
_:-'
GENERATNC
SETS
]v|AI
E&U'
'PLATE
30662-03H
UNIT - EXTRATOOLS
GYLINDER
Designation
Benavnelse
01 8 2
Liftinq tool for

c.yl'inde1
r iner,
c o m pel t e
Lsfteverktoj for
i ,
c.yl' inder for nq
et
kompl
0 2 71
Screw
Skr ue
0360
0459
2140
C o lI a r
2239
S c r e wd r i v e r f o r p l u g
s c r e b ,i n c y l i n d e r h e a d
2318
Basep'late for
grinding table
2407
Grindjng table
Halsjer n
Motrik
i sk
Pneumati
sk/Hydr aul
hojtrykspumpe
Skr uetr ekkerfor pr opskr ue i cylinder deksel
Stativ for arbejdsbor d
Sl ibebor d
2496
Grjndjng table complete

incl. item 2318, 2407
2585
Grinding tabie for

b u l k h e a dm o u n t i n g
Item No.
Nut
Pneumatic/Hydraul'ic
h i g h - p r e s s u r ep u m p
Sl ibebor d kom plet

i n k l . p o s . 2 3 1 8 ,2 4 0 7
Sl ibebor d for
skotmontering
e:
- -----
-E*-
GENERATI\|G SETS
EngineData
of Engine
Operation
o.
andCondition
EnginePerformance
E
ffi
o
Tracing
Trouble
and MainBearings
Crankshaft
Rod
PistonandConnecting
Operating
Gearfor InletValveg
UJ
PE
Turbocharger
System
FuelInjectionPump
s=
zts
FuelInjection
R
;
=z
a,g
Automatics
andInstruments
=<
F
p r
6 lJg
cl
StartingSystem
Lubricating
Oil System
Oil
of Lubricating
andTreatment
Specification
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
PISTONANDCONNTCTING
ROD
DESCR
P IT I O N
3 0 7 . 01
Edition 14H
T h e p ' i s t o n ,w h i c h i s o i l - c o o l e d a n d o f t h e m o n o b l o tcy p e m a d eo f n o d u l a rc a s t i r o n , i s e q u i p p e dw ' i t h 3 c o m p r e s s i orni n g s a n d 1 s c r a p e rr i n g .

B y t h e u s e o f a c o m b ' i n a t i oonf c o m p r e s s i orni n g s w i t h d i f f e r e n t b a m e l - s h a p e d
p r o f i l e s a n d c h r o m e - p l a t erdu n n i n gs u r f a c eo n l l r i n g s , t h e p i s t o n r i n g p a c k
i s o p t i m i z e df o r m a x i m usme a l i n g f f e c t a n d m i n . i m uwm a r r a t e .
T h e p i s t o n h a s a c o o l i n g o i 1 s p a c ec l o s e t o t h e p i s t o n c r o l v na n d t h e p i s t o n
r i n g z on e . T h e h e a t tra n sp o rt and thus the cooling effect is basedon the s hak e r e f f e c t a r i s i n g d u r i n g t f l e p i s t o n m o v e m e nAt .s c o o l i n g o i l i s u s e do i l f r o m
t h e e n g i n e ' sl u b r i c a t i n go i 1 s y s t e m .
9 i l i s s u p p l i e d . t ot h e . c o o l i n go ' i l . : p a c e t h r o u g ha c h a n n e lf r o m a n o i l g r o o v- e
i n o n e o f t h e p i s t o n p i n b o s s s .0 i l ' i s d r a i n e f r o m t h e c o o l i n g o i t s p c t h r o u g ha d u c t s i t u a t e d d i a m e t r i c a r l yo p p o s i t et o t h e . i n l e t c h a n e l .
T h e p i s t o n p i n i s f u l l y f l o a t i n g w h i c hm e a n st h a t i t c a n t u r n f r e e l y i n t h e
p i n b o s s e so f t h e p i s t o n a s w e l l a s i n t h e c o n n e c t i n gr o d b u s h .
T!" plston pin is kept in place in axial direction b! two c'irclips (seeger
rjngs)..The-p'iston.Pin equipped
w i t h c h a n n e l sa n d h o l e s t o r s u p p i yo i o 1 1
t o l u b r i c a t i o n o f t h e p]i sn b o s s e sa n d f o r s u p p l yo f c o o l i n g o i l t o ' t t r p i s t o n .
T h e _ c o n n e c t i nr ogd i s d i e - f o r g e d . T h e b j g - e n dh a s a n i n c l ' i n e dj o i n t i n o r d e r
t o f a c i l i ta te th e p i sto n a n d connectingiod assemblyto be witdr awnup thr ough
t h e c y ' l i n d e r l i n e r. T h e j o i n t faces on connectingr d and bear ing cap ar e s er r a t e d t o e n su rep re ci se l o ca tion and to pr event ielative movemen
of the par ts .
T h e c o n n e cti n gro d h a s b o re d channelsfor supply of oil fr om the big- en d to
the top-end eye.
T h e b i g - e n db e a r i n ga r e o f t h e t r i m e t a ' l t y p e , i . e . s t e e l s h e l l s l i n e d w i t h l e a d
b r o n z ea n d c o a t e dw i t h a t h i n r u n n i n g - i n i r d - p r o t e c t i o nl v r . T h e . b e ari n gsh e l l s a re o f th e pr ecision type nd ar e ther eior e to be fitt ed
w i t h o u t scra p 'i n go r a n y o th e r kind of aAaption.
T h e c o n n e cti n gro d b u sh i s o f br onzeand is pr essed' into the connectingr od
e y e - T h e b u sh i s e q u i p p e dw i th an inner cir cum fer ential gr ooveand a p c k et
f o r d i s t r i b u t i o n o f o i l i n t h e b u s h i t s e l f a n d f o r s u p p l Jo f o i l t o t i r e p i n
b o s s e so f th e p i sto n th ro u g h the holes and channe.lsih' t- he piston pin.
L u b r i c a ti n g .o i l fo r th e co n necti!' r r9od bear ingsand for the piston is su ppl i ed
f r o m t h e a d j a ce n tma i n b e a ri ng thiough bor es n the cr ankshaft.
E a c hi n d i v i d u a l m a i n . b e a r i n gi s b e i n g s u p p l i e dw i t h o i l t h r o u g ha b o r e i n t h e
f r a m ec o n n e cte dto th e e xte rnal m ain- pip' of the lubr icating l' l system.
TE-EEY
GENERAN\GSETS
IvIAI{
L?3 / 3 0
NO
GD
P I S T O NA N DC O N N E C T IR
MAINTENANCE
Er&ut
307.02
E d 'ti ' i o n 1 4 H
I n t e r v a ls b e t we e np i sto n w 'ith d ra w al
T h e i n t e r v a l be tw e e np i sto n o ve rh a ulas indicated in the schedu' led
maintenanc e
p r o g r a m m e ' isne c t i o n 3 0 2 a r e b a s e do n s e r v i c e e x p e r i n c ea n d i s t o b e u s e df o r
g ui d a n c e .
H o w e v e ra, s t h e n e c e s s i t yf o r o v e r h a u lo f p i s t o n , p i s t o n r i n g s a n d s c r a p e r
ring
' l u b rsi ct oa t a
' i nggr e a t e xte n t i s d e p e n d ingon type and condition of the fuel and the
o i 1 u s e d , a n d a l s o o f t h e o p e r a t i n gc o n d i t i o n si n g e n e r a l ,t h e a c t ua l j n t e r v a l b e tw e e np i sto n w j th d r awshould be basedon inspect' ionsof the
c y li n d e r c o n d i ti o n a s w e l l a s o b se r vationsr eveal' ingthe engine' s per for manc e
c o n d i t i o ni n g e n e r a l .
R e m o v aolf p j s t o n r j n g s
F o r r e m o v aol f p i s t o n r i n g s w h i c ha r e t o b e u s e da g a i n , a n d f o r a l l m o u n t i n g
of r i n g s , o n l y th e sp e ci a 'lri n g o p enerwhich pr eventslocal over str essingof
t he r i n g s s h o u l d b e u se d . S tra p s to expandthe r ing gap or tools wor kingon
t h e s a m ep r i n ci p l e mu st n o t b e u se d, as this would r esult in per m anent
defor mati o nw h i c h mi g h t ca u seb l o w -b yo r br okenr ings.
T h e c a u s eo f b re a ka g ema yb e th e striking against wear edgesor ir r egular ities
i n t h e c y l i n d e r w a l l , b u t m o s to f t e n i t i s " c o l l a p s e "o f t h e p i s t o n r i n g . T h i s
h a p p e n s ' i ft h e g a s p r e s s u r eb u i ' l d - u pb e h i n dt h e p i s t o n r i n g s d u r i n g e a c hc o m bust i o n i s t o o sl o w a n d th u s e xce rting an inadequateoutwar dpr essur e.In this
c ase , t h e g a s p re ssu rew i l l p e n e tratebetweencyl' inder liner and r ings and
f o r c e t h e r i n g s v i o l e n t ' l y i n w a r d si n t h e g r o o v e s ,i . e . " c o l l a p s e "o f t h e p i s t o n r i n g s w i l l o ccu r, re su l ti n g i n b' low- byand som etimes
br eakageof r ings.
T o o s l o w p r e s su reb u i l d -u p b e h i n d the r ings m aybe causedby a too sm a' llr ing
c l e a r a n c e ,p a r t i a l s t i c k i n g , o r b a d s e a l i n g b e t w e e nr i n g a n d f l o o r o f g r o o v e .
g a s p a st th e p i ston r ings is a natur al consequence
Loss o f c o m b u sti o n
of coll a p s e o f t h e s e , b u t m a ya l s o b e d u e t o s t i c k i n g r i n g s . I n t h e l a t e r s t a g e s ,
s rep e rsi ste nt. it is usually also due to advancingr ing
whe nb l o w - b ybe co memo
b re a k a g e ,c a u se db y th e co l l a p se .
C'le a n i n go f p t',sto n
Us u a 1 ' l ys o m ed e p o si ts h a vea ccu mu lated
on the sides of the piston cr ownand in
t h e u p p e nr i n g zo n e . In ca se su ch deposits ar e abnor m allythick their sur face
'is s m o o t hf r o m ru b b i n ga g a i n st th e c ylinder wall. Suchcontact m ayr emovethe
o i l f i l m l o c a l l y , r e s u l t i n gi n p i s t o n s e i z u r e .
Befo r ew i t h d r a w i n gth e p i sto n , th e upper par t of the liner must be car efully
c le a n e do f c a r b o nd e p o si ts, a s o th en ise the piston r ings maydur ing the withd ra w a l o f t h e p i sto n g e t stu ck i n this ar ea, pr obablyr esulting in br eakageof
the rings.
T-l4E= TEbET
E llE =.E-I5
CENERATTVG
E
SETS
rY|AhI
Et&Ult
L23/30
307.03
ROD
PISTONANDCONNECTING
Editionl4H
MAINTENANCE
I t i s i m p o r t a n t o c l e a n p i s t o n r i n g s a n d r i n g g r o o v e sv e r y c a r e f u l l y o f c a r b o n d e p o s i t s ,a s d e p o s i t sh e r e m a yp r e v e n tt h e r i n g s f r o m e s t a b l i s h i n gt h e i r
s e a l i n g f u n c t i o n . C h e c kf r e e p a s s a g ei n d r a i n h o l e s a t s c r a p e rr i n g g r o o v e s ,
a n d c l e a n i f n e c e s s a r yA. l s o r e m o v ed e p o s i t so n t h e p i s t o n c r o w n .
R e n e w aolf p i s t o n r i n g s
l ^ l i t ha p i sto n ri n g co mb i n a tioncompr isingdiffer ent but m atchedr ing ty pes ,
o p t i m a l f u n c t i o n sw i l l d e p e n do n g o o dc o n d i t ' i o no f a l l t h e r i n g s .
to changethe completer ing pack, including the
I t i s th e re fo re re co mme n ded
s c r a p er ri n g , i n co n n e cti o nwith each scheduledpiston withdr aw.
T o e n s u reco rre ct fu n cti o n of the piston r ing pack, it is im por tantto fi t
the piston rings in correct order.
F u r t h e rmo ree, a ch o f th e ri n gs must be fitted in cor r ect dir ection conc er ni ng
t h e p r o f i l e a n d t h e r u n n i n gs u r f a c e . C o r r e c t d i r e c t i o n i s i n d e n t i f i a b l e b y
into the ring close to the ring gap,'is fat h e i d e n t ' i f i c a t i o nm a r k , s t a m p e d
cing upwards.
Identification marks
to face upwards
881500- 3
W
t
%
I
qE
u
-rilg:
f !eqing-qI-plltss
C h e c kof p i sto n ri n g g ro o ves

T h e r i n g g ro o ve ssh o u l d b e r eslotted and the piston fitted with over siz e
r i n g s if th e w e a r g a u g e(se e section 30'l, data sheet 0307) can enter the
groove by more than 2 mm.
r r..E tFtiEtt
GENERATING SETS
}IAT
cr&ut
L23/3 0
307.04
ROD
PISTONANDCONNECTING
Edition 14H
MAINTENANCE
Pistonring clearance
l^ lit h t h e r i n g s fi tte d i n p l a ce , th e ver tical clear ancebetweenr ing and r ing
g ro o v es h o u l d be a s sta te d o n th e d ata sheet.
P ' i s t o nr i n g g a p c l e a r a n c e
higher tem per atur ethan the ljner ,' it
As t h e p i s t o n ni n g s w o rk a t a so me what
is im p o r t a n t t h a t th e ri n g h a s a g a p which is sufficient to per m it the ther mal
e x p a n s i o no f t he ri n g . T h i s g a p cl e ar anceshould be checkedwith the r ing p' lac e d a t t h e b o t t o me n d o f t h e c y l i n d e r l i n e r , w h i c h i s u s u a l ' l yn o t w o r nc o n s i derably.
l, lhe nm e a s u r e d
in th i s p o si ti o n , th e gap clear anceshould be as stated on the
data sheet.
F'itti ng of p'iston ri ngs
Pis t o n r i n g s s h o u l d o n l y b e re mo vedfr om and fitted to the piston by the use
o f a s p e c i a l t o o l , t h e s o c a l l e dp i s t o n r i n g o p e n e r .
I f t h e r i n g s a r e o p e n e dfa rth e r th a n necessar yther e is a r isk of over str esper m anently
distor ted and will not
s 'ing , w h i c h m ea n sth a t ri n g s w i l l b ecom e
c onfi r m t o t h e cyl i n d e r ru n n i n gsu rface.
T h e p i r s t o nr i n g s s h o u l db e i n s t a l l e d w i t h t h e m a n u f a c t u r e r 'm
s a r ko r i d e n t i f i c at io n m a r k , wh i ch i s sta mp e di .n to the r ing close to the r ing joints, facing
upw a r d s .
tlullq_qt_
99IL_!88Iry9_L94qsq_!!B!98_8II9
Joint pin for
coil spring.
/7
I
I
Coil springjoint to
be placed oppositeto
ring joint.
,j',r
joi nt.
;2*E
Ft.t
CENERATII\IG
STS
PISTONANDCONNECTING
ROD
307.05
MAINTENANCE
Edition l4H
B e f o r ef i t t i n g t h e c o i l s p r i n g l o a d e ds c r a p e rr i n g , t h e c o i l s p r i n g i s d i s m a n t ' l e dfro m th e ri n g b y re m ovalof the joint pin.

T h ec o i l s p r i n g i s p l a c e da n d a s s e m b l eidn t h e r i n g g r o o v e .T h e nt h e s c r a p e r
r i n g _ i s.|8
f i l0t e" d i n t h e g r o o v ei n s u c h a w a y t h a t t h e r i n g j o i n t i s a p p r o x i m a t e ' ly
o ff se t to th e spr i ng joi nt.
A s c e r t a i nc o r r e c t a s s e m b l i n b
g y c h e c k i n gt h e b a c k c l e a r a n c e .T h e b a c kc l e a r a n c e i s su ffi ci e n t w h e nth e face of the r ing is below the gr ooveedge ,.w hen
t h e r i n g i s p re sse da g a i n st the bottomof the gr oove.
W b e ni nsta l l e d o n th e p i sto n, the r ings should be pushedback and for th i n
t h e g r oo ve sto ma kesu re th at they can m ovefr eely. It is also advisabl eto
i n s e r t a fe e l e r b l a d e o f a d equatethickness betweenr ing and gr oove.
Ad e q ua te
cl e a ra n cei s p re se nt if the feeler blade can be movedall the w ay
round.
T o p r e v e n tg a s l e a k a g et h r o u g hc o i n c i d i n g r i n g j o i n t s t f i e p i s t o n r i n g s s h o u l d
b e t u r n e d i n t o p o s i t i o n s o f f s e t t i n g t h e r i n g j o i n t s l B 0 ' t o e a c ho t h e r : .
14*
- -----
--Et
GENERATII\IG sTS
L?3/30
PISTONANDCONNECTING
ROD
307.51
DISMOUNTING
OF THT PISTONANDCONNECTING
RODASSEMBLY
Edition l4H
P a g eI ( 4 )
t l
F
l . D i s m o u nt th e c y l i n d e r h e a d ,s e e 3 0 6 . 5 1 .C l e a n
t h e u p p e rp a r t o f t h e c y l i n d e r l i n e r , a s o t h e r w i s e , t h e p i s t o n m a yd u r i n g r e m o v agl e t s t u c k
i n t h e c a r b o nd e p o s i t e di n t h i s a r e a .
vT
!
2. M ounton two of the cylinder headstuds t he

t u b e s 0 5 6 9f o r h o l d ' i n gd o w nt h e c y l i n d e r l j n e r
d u r i n g t h e p i s t o n w i t h d r a w a l .S c r e wo n t h e n u t s
a n d t i g h t e n t h e ms ' l i g h t l y .
3. Rem ove
the cr ankcasecover s for the cy' lin der
unit concerned.
t*
I
4 . Tur n the cr ankshaft to br ing the crank

thr ow concer nedinto a posi.tionap pr ox .
45 degr eesbefor e TDC,per mitting ac c es s
with spannerto upper as well as low er
connectingr od scr ews.
5 . Mountthe eye screw in the threadedhole
in the piston top.
Attach a wire rope to the eye screw by

m e a n so f a s h a c k l e .
Hookthe wir e on to a tackle and pu l l the
wire ropetight.
Tightening
order
and
u n t i g h t e n in g
order.
If monoradjustmentof the crank throw

position appear snecessar yfor acces sto
the connectingr od scr ews,the wir e r ope
m ust be slackenedup befor e tur ning of
the cr ankshaftand tightenedup agai n i n
the newcr ank thr ow position.
6. Unloadthe connectingr od scr ewsin t.i ghtening or der by tur ning each scr ew60
d e g r e e si n a n t i - c l o c k w i s ed i r e c t i o n .
60v
Cor r ect tur ning angle is ensur edby c hal k ing a m ar k on the bear ing cap adjec entto
a nut- edge,and then tur n the scr ewunti l
t h e n e i g h b o u n i nngu t - e d g ec o i n c i d ew i t h
the chalk mark.
t t,=
tt =Et
E E!==-=-=5
=
GENERATINC SETS
IYlAhl
E&UI'
L23/30
3 0 7. 5 1
ROD
PISTONANDCONNECTING
Edition'l4H
P a g e2 ( 4 )
RODASSEMBLY
OF THEPISTONANDCONNECTING
DISMOUNTING
7 . U n s c r e wt h e u p p e r scre w s.
M o u n tt h e gu i d e p i n fo r th e b e a ring cap i n o n e o f t h e t h r e a d e d h o l e s .
Unscrewthe lower screws.
8 . R e m o vteh e b e a r i n gc a p , s l i d i n g i t a l o n g
R e m o vteh e gu i d e p i n fro m th e co nnection
9. N o wt u r n t h e cra n k th ro w i n d i re ction
towardsBDCuntil the connectionrod
is clear of the journal.
1 0 . P u l l t h e p ist n a n d co n n e cti n grod
a s s e m b l ys l ig h tl y u p w a rd sa n d re move
t h e u p p e rb i g - e n db e a r i n gs h e l l .
l t . L i f t t h e p ist n a n d co n n e cti n gor d

a s s e m b l yu p th ro u g hth e cyl i n d e r
l ' i n e r a n d o u t o f th e e n g i n e .
ll l=
- -----
,Fattlt
CENERA'TI\|G SETS
lv|AI\I
L23/30
cl&ut
307.51
PISTONANDCONNECTING
ROD
D I S M O U N T IO
NG
F T H TP I S T O NA N DC O N N E C T I R
NO
G DA S S T M B L Y
Edition 14H
P a g e3 ( 4 )
T h e p u r p o s e o f t h e g u " i d ep i n i s t o p r e v e n t
a n y d a m a g eo f c r a n k j o u r n a l , j o i n t f a c e s o f
\Is////l---bearjng surface to occur during dismounting
o f t h e b e a r i n g c a p , a n d t o f a c i l i t a t e e a s y h a n d li n g w h e n r e m o v i n gt h e b e a r i n g
cap form the crankcase.
I.lG=
HEt
GENERAIAIG
STS
/^,
L?3/30
f ei
PISTONANDCONNECTING
ROD
DISMANTLING
OF THE PISTONANDCONNECTING
RODASSEMBLY
3 0 7 5. 1
Editiont4H
P a g e4 ( 4 )
E#=.EEF
GENERI\NNG
SETS
]U|AhI
L?3/30
ROD
PISTONANDCONNECTING
ROD
OF PISTONANDCONNECTING
OVERHAUL
ct&ut
307.52
Edition 14H
P a g eI ( 2 )
D i s m a n t l i n go f t h e p i s t o n a n d c o n n e c t i n gr o d
l.
y a s b e e nl i f t e d o u t o f t h e
W h e nt h e p i s t o n a n d c o n n e c t i n gr o d a s s e m b l h
tightened onl y
e n g i n e , th e b e a ri n g ca p should be m ountedwith the scr eus
b y h a n d , i n o rd e r to p rotect the sematedjoint faces dur ing handl i ngof
the assembly.
2.
L a n dth e p i sto n a n d co n nectingr od assem blyon woodensuppor t to pr ev ent

d a ma g o
e f p i sto n a n d scraper r ings.
3.
R e mo ve
th e sh a ckl ea n d eye scr e!, fr om the piston cr own.
4.
P ' la ceth e p i sto n a n d co nnectingr od assem blyin upr ight position suppor t i n g o n th e to p fa ce o f the piston cr own.
W oo d ew
n e d g e ssh o u l d b e used to pr event the connectingr od to swingout
a n d i m p a c tt h e p i s t o n s k i r t d u r i n g l i f t i n g i n t o u p r i g h t p o s i t i o n .
5.
P l a ce a w i re a ro u n dth e bigend of the connectingr od, attach a tac k l e

a n d ti g h te n th e w i re ro pe.
6.
T a k eo u t t h e s e c u r i n gd e v i c e s ( S e e g e cr i r c l i p s ) , p u s ho u t t h e p i s t o n p i n
a n d l i ft th e co n n e cti n gr od away.
P is t o n
l.
th e p i sto n a n d scr aper r ings.

R e mo ve
D o a l w a ysu se th e ri n g expanderfor r emovalas well as m ountingof pi s ton
a n d scra p e r ri n g s, a s a II methodsgive a r isk of defor mationof the r i ngs .
2.
I n co n n e cti o nw i th n o rmalscheduledpiston withdr awalthe com pletepi s ton

a n d scra p e r ri n g p a ck should be r enewed.
3 . C l e a nt h e p i s t o n o u t s i d e a n d i n s i d e .
4.
I n sp e ct th e p i sto n ri n g and scr aper r ing gr oovesfor wear , ( see Data

S h e e t).
C o n n ecti n gro d
l.
I n s p e c tt h e su rfa ce o f the piston pin and the connectingr od bush.

Measurethe clearance betweenthe piston pin and the bush, ( see Data
Sheet).
R ep l a ceth e b u sh i f n e cessar y.
I lg
tFftt
E 5E=-E
II
CENERA.nNGSETS
fv|A\T
23130
ROD
PISTONANDCONNECTING
ROD
OF PISTONANDCONNECTING
OVERHAUL
cr&ut
307 .52
Edition l4H
Page 2 ( 2 )
of the connectingr od
An e x t r a c to r to o l 0 2 5 .|i s a va i 'lable for r eplacem ent
b u s h . H h e nm o u n t i n gt h e b u s h , c a r e m u s t b e t a k e n t h a t t h e o ' i l h o l e i n t h e
s i t h t h e o i ' l d u c t ' i n t h e c o n n e c l i n gr o d . I f p o s s i b l e , c o o l
b u s hc o i n c ' i d e w
d o w nt h e bu shb e fo re mo u n ti n g(to appr ox. - 20"C) .
2.
t h e co n n e cti n gro d a ssem blyaccor dingto

Ex a m i n e
RODASSEM BLY.
OF THECONNECTING
TH
F OR
GEC ONDITION
PR O C E D U
R EC H E C K IN
C y li n d e r I i n e r
l.
w i t h p i s t n o v e r h a u lt h e c y l i n d e r l i n e r s h o u l db e i n s p e c t e d ,
In connection
in section 306.
an
d
re
-h o n e d ,se e o ve rhaul r ecomm endations
measured
As se m b l o
y f t he p i sto n a n d co n n e ctingr od
in r ever se or der to the descr ipTh e p i s t n a n d co n n e cti n gro d i s a ssem bled
tion for dismantling.
E I.G.E
- -----
IF:E=.
CENERA.TI{G STS
]Y|Af{
23/30
ROD
PISTONANDCONNECTING
P R O C E D UFROERC H I C K I N G
THI CONDITION
RODASSEMBLY
OF THECONNECTING
Er&ut
307.53
E d 'ti i o n 1 4 H
P a g e1 ( 3 )
Af ter d'ismounting f rom t h e e n g i n e , t h e c o n n e c t i n g r o d a s s e m b l yi s d i s m a n t l e d ,

a n d t h e c o m p o n e n t sa r e i n v e s t i g a t e d a c c o r d i n g t o f o l I o w in g g u i d e I i n e s.
C L E A N I NAGN DI N S P I C T I O N
T h ec o n n e c t i n gr o d i s c l e a n e do n a l l m a c h i n e d
s u r f a c e s .T h e s e r r a t e dj o i n t
f a c e s a n d t h r e a d e ds c r e wh o l e s a r e t o b e d e g r e a s e w
d ith a volatile solvent
a n d b l o w nd r y w i t h c o m p r e s s eadi r .
T h e s e rra te d j o i n t fa ce s a re inspected.
T h e s e ma ti o n s o n th e co n n ectingr od m ay, due to r elative movements
betw een
t h e m ati n g su rfa ce s, sh o wd amages
in for m of wear mar ksand pittings or ev en
c r a c k s i n h i g h l y l o a d e dz o n e s .
s o u l d b e register ed in the scheme
0 b s e r ve dd a ma g esh
C0NNECTING
RODINSPEC T I0N ,
u s i n g th e sh o w nsymb o l sfo r each type of dam age.
A damage
sh o u l d b e ske tch e don the schem aticviews of the connectingr o d
j o i n t fa ce s. T h e ske tch e sshould be executedto indicate not only the t y pe
b u t a l so th e e xte nt of dam age
o f d a ma g e
ar ea.
W e a rm a r k sa r e v i s i b l e b u t n o t n o t i c e a b l ea t a f i n g e r n a i l t e s t .
P i t t i n g s a r e n o t o n l y v i s i b l e b u t a l s o n o t i c e a b l ea t a f i n g e r n a i l t e s t .
S i n g l e d i s t i n c t l y r a i s e d s p o t s c a u s e db y p i t t i n g s h o u l db e g e n t l y s m o o t h e d
b y c a r e fu l , ,l o ca l tre a trn e n twith a fi' le.
The serrations on the connecting rod and on the bearing cap can be damaged
b y i m pro p e rh a n d 'l i n gd u ri n g dism ounting,tr anspor t and over haulwor k.
The components
must therefore be handledwith care to avoid impactson the
possible, woodenb' locksor sim ilar pr otec ti on
s e r r a t e d j o i n t fa ce s. l 'l h e n ever
s h o u l db e u s e dd u r i n g s t o r a g ea n d h a n d l i n g .
Si n g l e d e n t ma rksca u se db y impact can be r ectified by gentle and car e ful
l o c a l t r e a t m e n tw i t h a f i l e .
In case of severe damage
of the serration, reuse must be rejected, and a new
c o n n e cti n gro d a sse mb l yi n cluding nev'bear
,
ing shells must be mountedin the
e n gi n e .
T h e c o nn e cti n gro d scre w sa r e to be car efully cleaned. The thr eadsar e i ns pec t e d f o r se i zu re sa n d te ste d in the thr eadedholes in the connectingr od.
The test must confirm, that the screwscan be turned into bottomposition by
hand. The contact surface of the screv',heads is inspected for seizure and
pittings.
Screws,which are damaged
as mentionedaboveor can not be turned into the
. t h r e a d e dh o l e s b y h a n d ,mu st be r enewed.
E.=#E EEEIL'
GENERANNG SETS
TYIAN
23/30
Er&ult
307.53
ROD
PISTONANDCONNECTING
P R O C E D UFROERC H E C K I NTGH EC O N D I T I O N
RODASSEMBLY
OF THECONNECTING
Edition 14H
P a g e2 ( 3 )
FB
M T A S U R E MO
EN
T I G - E N DB O R I N G
F o r c h e c ko f r o u n d n e stsh e b i g - e n db o r i n g h a s t o b e m e a s u r e idn a c o n d i t i o n ,
wh e r et h e c o n n e cti n gro d scre w sa re tightened up with the pr escr ibedtor que
a n d w i t h o u t t h e b e a r i n gs h e l l s i n s t a l l e d .
Wh e nm o u n t i n gth e b e a ri n gca p , th e connectingr od scr ewsm ust be lubr icated
RODSCREW S.
PROCEDURE
FORCONNECTING
a n d t i g h t e n e du p a cco rd i n gth e T IGHTENING
Pri o r t o m e a su re meint t mu st b e a scer tainedthat the bor ing js fr ee of depos i t s f r o m c r a c k e dl u b . o i l .
T h e m e a s u r i n gi s e xe cu te dw i th a micr om eterpin gauge.
5 d i f f e r e n t d i a me te rsa re me a su red
in the middle fo the bor ing and r egister ed
R OD
G IN S P ECTI0N.
in t h e s c h e m C
e 0 N N E C T IN
t.,t
Fittr
GENERA1INC
SETS
23/30
PISTON
A N DC O N N E C T IR
NO
GD
307.53
P R O C E D UFROI RC H E C K I NTGH T C O N D I T I O N
OF THECONNECTING
RODASSTMBLY
Edition l4H
P a g e3 ( 3 )
M a x . o v a l ' n e s si s c a l c u ' l a t e da s t h e d i f f e r e n c e b e t w e e nb i g g e s t a n d s m a l l e s t
d i a m e t e rm e a s u r e d .
l}{.l.xl
).4.
L_i:_J
felna
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irmhg
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aalnal
ri,
a rtt
ic.
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+ 3,o
9,E
co(Roo'3
Utpar
a..aallon
tttt.l
.crl..
@vq
6l rtnra
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@ l.r.ct
.rt
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toral
i.rarta
aaaratloi
o b
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fo
bc
ryck4
M a x .a l l o w a b l eo v a l n e s si s 0 , 0 8 m m .c r a c k s a r e n o t a c c e p t a b l e .
I f t h e ova l n e sse xce e d s0 ,0 8 mmor cr acks ar e stated, r eusem ust be r eje c ted,
a n d a n e wco n n e cti n gro d co mpleteincluding newr scr ews
and newbear ing-s hel l
h a s t o be mo u n te di n th e e n g ine
C o n n e cti n gro d s re j e cte d d u e to ovalnesscan be r econditionedin the m anufac t u r e r ' s w o rksh o p b
s y re ma ch iningf the ser r ations and the bigend Uor ing.- I f c r a c ks o ccu re i n th e se rrations r econditioning is im possible,and the c onn e c t i n g ro d h a s to b e scra p p ed.
The exampleshows'measurements
and damarge
observationsfor two connectingrods.
F o r c o n n e cti n gro d N o . I th e max. ovalnessis 5/100 = 0,05 nm, and r euse thus
a c c e p t a b l e .F o r co n n e cti n gro d No. z the max. ovalnessis g,sjlo = 0,095 m m ,
and reuse must therefore be rejected.
Pl e a s eno te th a t sq u a re sfo r statem entof infor m ationand identification
s h o u l da l s o b e p r o p e r l yf i l l e d i n .
EE.=EF
GENERANVCSETS
/-=G\
Lz3,3o
307- 54
PISTONANDCONNECTING
ROD
MOUNTING
OF THEPISTONANDCONNECTING
RODASSEMBLY
Edition 14H
P a s e1 ( 3 )
M o u n t h e l i f t i n g d e v i c e c o m p r i s i n ge y e s c r e b / ,s c h a k l ea n d w i r e r o p e o n
the piston.
2.
P l a c et h e p i s t n g u i d e r i n g o n t o p o f t h e c y l i n d e r ' l i n e r .
3.
L i ft u p th e p i sto n a n d connectingr od assemb' ly

and lower it downthe
c r l i n d e rl i n e r .
4.
a p p r oing
a c h etsh e g u i d e
W h e nt h e p i s t o n' lower
r ing, stop the
and coat pi ston with scr aper and compr essi on
r i ngs
with clean lubricating oil in order t
m i n i m i z ef r i c t i o n d u r i n g t h e s u b s e q u e n t
lower ing of the assembly.
5.
M akesur e that the cr ank thr ow is i n a

p o s i t i o n a l l o w i n g t h e c o n n e c t i n gr o d
to a clear of both cr ank jour nal and
cylinder liner skirt duringfurther
I owering.
A cr ank thr ow position of appr ox .45
degr eesbefor e TDCwill ensur ethi s
and also be suitable for the fur t her
m ountingpr ocedur e.
q
6.
Lowerthe assemblyuntin the

c o n n e cti n gro d b i g -e n d is clear
of the cylinder liner skirt.
Stop the lowering and mountthe
bi g -e n d b e a ri n g u p p e r shell placed
s o i n th e b o ri n g th a t the mating
s u rfa ce so f th e sh e l l ar e in
pa ra l l e l to th e ma ti n g sur faces
of the connectingrod.
7.
Co a t th e cra n k j o u rn a l with clean

l u b r i c a t i n go i l .
B.
No wl o w e r th e a sse mb lyslowly
i n to co rre ct l a n d i n g o n the cr ank
j ou rn a l .
t l
tt=rcs
GENERATI\IG SETS
tvtAhl
E&U'
L2 3 / 3 0
307.54
ROD
PISTONANDCONNECTING
Edition 14H
P a g e2 ( 3 )
RODASSEMBLY
OF THE PISTONANDCONNECTING
MOUNTING
Dur ing this the connectingr od m ust be

guided by handto ensur ecor r ect
a p p r o a c ha n d l a n d i n g o n t h e j o u r n a l .
M ountthe bear ing cap with inser ted
l o w e r s h e l l o f t h e b i g - e n db e a r i n g ,
u s i n g t h e g u i d ep i n .
&
I
10.
L u b r i ca te th re a d s a n d co n tact
face of the connectingrod
s c r e w sw i t h C o p a s l i po r s i m i l a r .
tl
Mountthe screwsand tighten them

spanner
slightly usingan open-end
( s k e l e t o ns p a n n e r ) .
12.
Sl a c k enth e ta ckl e a n d d i smount

the eye screVshackle from the
piston.
&
I
13.
Tighten the screwsaccordingto

PROCEDURE
TIGHTENING
FOR
CONNECTING
RODSCREI^,S.
t==
eF;E*af
GENERANNCSETS
]Y|Af{
Et&ut
L23/30
307.54
ROD
PISTONANDCONNECTING
Edition 14H
P a s e3 ( 3 )
RODASSEMBLY
OF THT PISTONANDCONNECTING
MOUNTING
T h e p u r p o s eo f t h e g u i d e p i n i s to ensur ecor r ect

p o s ' i t i o n i n g o f t h e b e a r i n g c a p and to pr event any
d a m a g eo f c r a n k j o u r n a l , j o i n t f a c e s o r b e a r i n g
s u r f a c e t o o c c u r , w h e nh a n d fi n g t h e b e a r i n g c a p d u r i n g t h e m o u n t i n gp r o c e d u r e .
L-,9
tFt;ErGt
GENERANIGSETS
lYIAhl
E&Ut
L23/30
ROD
PISTONANDCONNECTING
307.55
TIGHTENING
PROCEDURE
FORCONNECTING
RODSCREI.IS
M a n o e u v rni -q
( C a m s h a f)t
Side
E x h a u s tS i d e
Edition l4H
P a g eI ( l )
Initial Condition:
- Connecting
r o d , b e a r i n gs h e l l s
a n d b e a r i n gc a p i n - s i t u , p r e assembled
fr cr nmanoeuvr i ng
s i de
( c a m s h a f st i d e )
- All contactfacesclean.
- Thr eadsand contact faces of the
connectingr od scr ev' rlubri
s
c ated
w i t h C o p a s l i po r s i m i l a r .
- Connectingr od scr ewstightened
by hand.
- Cr ankthr ow in a position c l os e
to TDCin r otation dir ecti on
clockwise seenfr om flywh eel - end.
Rotat'ionI
DirectionI
I st Step
C o n ne cti n gR o dS cre w s.
T i g h t e n i n gO r d e r
M a r k i n go f s c r e wc o l l a r
a n d b e a r i n gc a p p r i o r
t o t'i g h te n i n gth ro u g h
600turningangle
Mark on
b e arin g
cap
Mark on
screw
co'lI ar
Tighten the scr ewsi n t i g h t e n i n go r d e r a s

i l l u s t r a t e d , u s i n g a n i n i t i a l t o r q u eo f
]20 Nm.
2nd Step
0nce more tighten the screwsin prescribed
t i g h t e n i n g o r d e r , s t i l l u s i n g a t o r q u eo f
1 2 0N m .
3r d Step
Mark the four screwsand the bearing cap
w i t h a f e l t - t i p p e na s i l l u s t r a t e d .
Tighten the scr ewsin pr escr { bedtightening or der by tur ning thr ougha 60" angl e,
i . e . u n t i l t h e m a r k so n s c r e wc o l l a r a n d
c o n n e c t i n gr o d c o i n c i d e r a d i a l l y .
4th Step
Checkthe scr ewtightening in pr escr i bed
or der using a tor que of 250 Nm.
Pr oper tightening condition is pr ese nt, i f
the screwsare not turned further during
this test.
5th Step
Checkthat clear anceis pr esent in th e bi gend bear ing assem bly.
T h i s i s c o n f i r m e d ,i f t h e b e a r i n gc a n
easily be movedon the journal by means
o f a h a n d - s p i k eo r s i m i ' l a r .
*
Tolerance 20
EE.E=Y
GENERA'I\|G SES
tv|AhI
Er&ut
PISTONANDCONNECTING
ROD
307.56
CHECK
O F C O N N E C T IR
NO
G DS C R E W S
T 'I G H T E N I NCGO N D I T I O N
C o n n e c tni g r o d s c r e w s .
T i g h t e n in g o r d e r .
Edition l4H
P a g e1 ( l )
C h e c ko f t h e t i g h t e n i n g c o n d i t ' i o no f
connectingr od scr ewshas to b e ex ec u t e d w i t h i n a s h o r t r u n n i n gp e r i o d
after r emounting/m ounting
of t he
p i s t o n a n d c o n n e c t i n gr o d a s s e m b l y .
T h i s c h e c kc a n b e f u l f i l l e d a f t e r
only a few r unning hour s at m ax . r pr n
at full load but hasto be fulfilled
not later than 200 r unning ho ur s
after starting up
T h e t i g h t e n in g c o n dti i o n ' i s c h e c k e d
with a tor que of 250 Nmexecuted'i n
p r e s c r i b e ds c r e wt i g h t e n i n g o r d e r .
M a r k i n go f s c r e wc o l l a r a n d b e a r i n g
c a p w i t h c o i n c i d i n gm a r k sp r i o r t o
c h e c ko f t i g h t e n i n g c o n d i t i o n .
Con
i c i d in g
m a r ko n
b e a r i n gc a p .
Ma rko n
s c r e wc o l l a r .
P r o p e rt i g h t e n i n g c o n d i t i o n i s p r e sent, if the scr ewsar e not tu r ni ng

further during the test.
In or der to ensur eobser vatio nof
any movement,the screwsand the
c o n n e c t i n gr o d s h o u l db e a p p l i e d
w i t h c o i n c i d i n gf i l t - p e n m a r k sp r i o r
to the test.
Any tur ning of the scr ewsdur ing the
2 5 0 N mt e s t i n d i c a t e s i n s u f f i c i e n t
t i g h t e n i n gc o n d i t i o n , a n d i n t h i s
case the bigend assemblyhas to be
d i s m a n t l e da n d i n v e s t i g a t e df o r e v a l u a t i o n a n d c o r r e c t i o no f f a i l u r e .
Torque250 Nm
fo r ch e ckof
ti g hte n i n g
co n d ti
i o n.
As part of reconrnended
overhaul and
r o u t i n e w o r k , t h e t i g h t e n i n gc o n d i tion of the connectingr od screw s
should a' lso be checkedfor eac h
6000 r unn' inghour s.
E#.=EY
GENERATT\IG SETS
fv|AfrT
E&Ul'
L23/30
347.57
ROD
PISTONANDCONNECTING
NO
G DB I G - E N DB E A R T N G
O F C O N N E C T IR
IN-SITU REPLACEMENT
NTGI
OISMOUN
Edition 14H
P a g e1 ( 2 )
j.e. withoutdismount'ing
The b i g - e n d b e a r i n g s h e l l s c a n b e r e p l a c e d j n s i t u ,
e
n
g
i
ne.
t
h
e
t h e p ' i s t o n a n d c o n n e c t i n g r o d a s s e m b l yf r o m
the top cover from the

Remove
c y 1i n d e r h e a d .
2 . R e m o vteh e fu e l i n i e cti o n va ]ve,
s e e s e c t i o n 3 11.
the crankcasefor
3 . Remove
the cylinder unit concerned.
4 . T u r n t h e e n g i n e u n ti l th e cra n k
t h r o w c o n c e rn e di s 'i n a P o si ti o n
close to TDC.
in two
Unloadthe connectingr od scr ews
'
in
executed
be
to
steps, each step
tighteningorder.
Dur ing fir st step the scr ewsar e tur ned
6 0 0 i n a n t i - c l o c k w i s ed i r e c t i o n , s e e
3 0 7 . 5 1 ,i t e m 6 .
Procedure
In secondstep the screwsare to be tot a l l y u n 1 o a d eadn d t h e n s l i g h t l y t i g h t sPanner .
enedwith an open- ended
6.
T u r n t h e e n g i n ei n r o t a t i o n d i r e c t i o n
( clockwiseieen fr om flywheel) until
the cr ank thr ow concer nedis in TDCposition.
7 . M o u n tt h e s p e c i a l p i s t o n l ' i f t i n g d e v i c e
by placingthe guide in the iniection
valve sleeve and by tur ning the eYe
scr ew into the thr eadedhole in the pis ton crown.
8.
Attach a tackle to the eYe screwand

tighten the wire.
l1r=,8
tFktg
!t==--85
E
GNERATTI{G SETS
TvIAI{
C&U'
L23/30
307.s7
ROD
PISTONANDCONNECTING
RG
O DB I G - E N DB E A R I N G
I N - S I T U R E P L A C E M EONFTC O N N E C T I N
NG
DISMOUNTI
Edition 14H
P a g e2 ( 2 )
q
the bearing cap ac c or 9 . Remove
ding to Pr ocedur e3 0 7 . 5 1 ,
item 7-9.
'lower
Takeout the
b' ig- end
bear ing she' ll for ' i n s p e c t i o n .
1 0 . T u r n t h e e n g i n ei n a n t i - c l o c k w i s e
d i r e c t i o n , s e e nf r o m f l y w h e e l e n d ,
u n t i l t h e c r a n kj o u r n a l i s c l e a r
o f th e co n n e cti n gro d a nd am ple
spacefor removalof 'lthe upper
b i g-e n d b e a ri n g sh e l i s achieved.
T a k eo u t t h e b e a r i n gs h e l l f o r
'inspection.
E t,E!
tFtf=g
E Et==:E3
GENERANNG SES
/**G\
LZ3,,a
PISTONANDCONNTCTING
ROD
307.58
I N - S I T U R E P L A C E M TONFTC O N N E C T IR
NO
GDB I G - E N DB E A R I N G
MOUNTI
NG
1.
Edition l4H
P a g e1 ( 2 )
B e f o r e r e m o u n t i n go f i n s p e c t i o n o r n e w b e a r i n g s h e l l s a l 1 c o m p o n e n t cs o n c e r n e dm u s t b e c l e a n e d .
2 . T h e b e a r i n gs h e l l s a r e p l a c e d
i n t h e b o r i n g , t h e m a t ' i n gs u r facesof the shells to be in
para11e1
t o t h e m a t i n gs u r f a c e
of the connectingr od r espect i v e ' l y t h e b e a r i n gc a p .
C o a tt h e j o u r n a l w i t h c l e a n
I u b r i c a t i n go i 1 .
Ascer tain that the cr ank thr ow
c o n c e r n e di s i n a p o s i t i o n a p p r o x .
50 degr eesbefor e TDC.
4 . L o w e rt h e p i sto n a n d co n n e cti n gr od
a s s e m b l sy 1 o w 1 yi n t o c o r r e c t l a n d i n g
on the journal.
D u r i n gt h e l o w e r i n gt h e c o n n e c t i n g
r o d m u s t b e g u i d e db y h a n dto e nsur e
c o r r e c t a p p ro a cha n d l a n d i n g o n the
j o u r n a l.
t.*,!
l-lllG.rlr
GENERATII\IG
SETS
307.58
ROD
PISTONANDCONNECTING
Edition14H
P a s e2 ( 2 )
NO
G DB I G - E N DB E A R I N G
I N - S I T U R E P L A C E M EONFTC O N N E C T I R
NG
MOUNTI
5.
Mount the bearing cap w i t h i n s e r t e d

lower big-endbearings h e l l , u s i n g
the guide pin.
6.
Lubricate threads and contact face

o f t h e c o n n e c t i n g r o d s c r e w sw ' i t h
C o p a s ' l ' iopr s i m i l a r .
7.
M ountthe scr ewsand tighten t hem

s l i g h t l y u s i n g a s k e l e t o ns p a n n e r .
B . S l a c k e nt h e t a c k l e a n d d i s mountthe eye screw from

t h e p i sto n cro w n .
o
T ' i g hte nth e . scre w sa cco rding

to
TIGHTENING
PROCEDURE
FOR
CONNICTING
RODSCREI,|S.
LG,=
=.;ErEg
GENERAN!\G SETS
]Y|AI{
EEUI'
PLATE
30701-15H
ROD
PISTONANDCONNECTING
AT,"
D
\\\\\J/Y-t---,L-otod
\ \-0297
) )
/t
Y
E#.EEY
GGNERA'IT{G SETS
lvlAIrl
E&U'
- I5H \PLATE
30701
PISTONANDCONNECTING
ROD
Item No.
6*aa #t!#,p6t f
o108
6006.t d8e6 0291

60 tt& t|t 0386
6oao Zf TAIJ'
0475
6*q ::1$&,,, 0653

f$',*ll 0Zl /t'i{}i
.t098
6#,t# # t l 0 O o 8 tw
00# pJ;0A0*? J215
6 a* t i0 - 0 a t 0
{ * 9 . 0218/."} 6
{gq6 6?ls :rf}cj
I 365
145_!
1 8 51
Designation
Benavnelse
Pistonp'in
S t e m p epl ' i n d
Circlip
Bush
Fjedersikring
C o n n e c t i nrgo d , i n c 1 .
i t e m N o . 0 3 8 6 ,1 8 1 5
Big endbearing
Plejl stang, incl

pos. nr. 0386, ffS
P i s t o nr i n g
P i s t o nr i n g
Pistonring
S t e m p erli n g
S cra p e rri ng
P isto n
C o n n e ctingr od scr eur
S k r a b e r in g
B o s n ni g
Plejlstangsleje
S t e m p erli n g
Stempelri ng
Stempel
P le j ' l s t a n g s s k r u e
- -----
E-*g
GENERANC
SETS
IYfAhl
cr&ut
PLAT3
E0 7 5 1 . 1 3 H
TOOLSFORPISTONANDCONNECTING
ROD
S"-
,;,\
\$**
\\
\,
0470
0569
19 8 7 0
. 3 .0 2
E#.EEY
GNERAN{CSETS
]U|AhI
E&U'
PLAT3
E0 7 5 1 . 1 3-H
ROD
TOOLSFORPISTONANDCONNTCTING
Designation
Benavnelse
029?
Internal limit gauge,

please state size
0381
Internal Iimit gauge,

c o m pel t e
0470
Guideri ng for p'iston
T o l e r a n c e d o r na,n g i v
venligst storrelse
To'lerancedorne
,
kompl
et
Styr er ing for stempel
0569
Retaining tool for

cyl inder I iner
0 65 8
0 66 0
Piston ring opener
Modholdfor cylinder for i ng

ri ngsbner
Stempel
Seegers forceps
T a n gf o r s j k r i n g s r i n g
10 9 3
G u i d ep i n
Styreror
Item No.
19 8 7 . 0 3 . 0 2
r^*.=
- -----
E-lg
GENERATX\ICSTS
ROD- EXTRATOOLS
PISTONANDCONNECTING
PLATE
3076I.O3H
0251
0895
0984
1052
0984
E=EY
GENERATI{G SETS
tU|Ahr
cl&ut
PLATE
30761.03H
ROD- EXTRATOOLS
PISTONANDCONNECTING
Designation
Benavnelse
Pull-lift
Trakverktoj, komplet
0 34 0
Pull-lift
E xtra ctor too1, compl
E x t r a c t o rb o l t
0 43 9
t,lasher
Sk'ive
0 52 8
0617
0706
Afstandsror
0895
D i s t a n c ep i p e
l.lasher
D i s t a n c er i n g
Nut
0984
A xia l b al' l bear ing
Aksial kugleleje
10 5 2
1230
1231
l,,|asher
Eye screw
S h a ckl
e
S k iv e
1329
Collar for connecting

ro d , co mplete
Nut
S h a ckl
e
C o lI a r
Screw
Item No.
0162
0251
1418
I s07
I696
178 5
Trakbolt
S k iv e
A f s t a n d s r in g
Mstri k
0jeskrue
Sjakkel
Halsjernfor plejlstang, komplet
Mstri k
Sjakkel
H a ls j e r n
Skrue
-*r
- ----
---:
GENERI{NNG
SETS
EngineData
z
o
E
^=G
LI IJ
o-
Operation
of Engine
EnginePerformance
andCondition
Tracing
Trouble
and MainBearings
Crankshaft
Rod
PistonandConnecting
OperatingGearfor InletValves,
lJ
Turbocharger
System
C)
PE
GG
Zj-
FuelInjectionPump
s=
FuelInjection
R
;
=z
Gamshaftand CamshaftDrive
=
-- <
4 , 9 Automatics
andInstruments
F
| -
a,
d lJg
o
StartingSystem
LubricatingOil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
CoolingWaterSystem
Treatment
of CoolingWater
DrivenMachinery
SpecificPlantlnformation
L23/30
\--
PUMPS
ANDFUELINJECTI0N
SPINDLES
OPERATING
GEARFORVALVE
PTION
DESCRI
IYIAt\t
E&UT'
308.01
Edition10H
Plate 30801
E a c hc y l i n d e r h e a di s p ro vi d edwith two inlet and two exhaustvalves whic h ar e
a c t r u t e d b y ro cke r a rms ru n n i ng in bear ingson a shaft suppor tedin a brac k et
o n t o p o n th e cyi i n d e r co ve r.
T h e r o c k e r a rm mo ve me ni st tra nsfer r ed to the valve sp' indlesthr ougha spr i ngl o a d e dv al ve b ri d g e fo r e a ch of the two valve sets. The br idge is positio ned
b e t w e e nth e va l ve sp i n d l e s a n d ha.sat one end a fir mly pr esses- onthr ust pad,
w h i l e a t t h e o t h e r e n d t h e r e i s a t h r u s t s c r e wf o r a d j u s t i n g t h e v a l v e c l e a r ance.
\v
T h e b r i d g e i s co n tro l l e d fro m aboveby a spher ical thr ust pad on the r ock er
a r m a n d i ro m b e l o wb y a g u i d e which r ests in a spher ical socket in the cy l i nder cover.
T h e v a l v e s p i n d l e sa r e m a d eo f h e a t - r e s i s t a n ts t e e l . T h e i n l e t v a l v e sa r e m a d e
o f a u s t e n i t i c s t e e l , a n d t h e e x h a u s tv a l v e so f N i m o n i c8 1 , w h i c hi s a s p e c i a l l y c o r r o s i o n - r e s i s t a nm
t a t e r i a l.
d i t h a w e l d e d - o n i c k e l - b a s e da l l o y .
T h e s e a t o f t h e e x h a u s tv a l v e s i s a r m o u r e w
which is caus i ng
T h e e x h au stva l ve s a re p ro vi d edwith a mechanicalar r angem ent,
sequence.
for
each
opening/closing
th
e
sp
indle
mo
ve
me
n
o
t
f
a r o t a t i on
T h e v a l v e g e a r i s e n cl o se db y a fr ameand a top cover .
Plate 30802
T h e c a m s h a fti s p ro vi d e dw i th camsactuating the r ocker ar m sthr oughr oller s ,
r o l l e r g ui d e s a n d p u sh ro d s. The r o1' ler guides for fuel pum pand for inlet and
housingfor each cylinder . T he
e x h a u s tva l ve s a re i n co rp o ra tedin one comnon
h o u s i n gis b o l te d to th e fra me.
T h e r o l l ers 1 2 9 4 a n d 3 8 9 6 ro l l on bushes1383and 3707fitted on the pins 1472
a n d 3 6 1 8i n t h e r o l l e r g u i d e s 1 0 1 6a n d 3 4 3 0 . T h e e n d so f t h e p i n s a r e s h a p e d
a s k e y s w h i ch sl i d e i n ke yw ays,thus pr eventingthe r oller guides fr om tur ni ng.
T{OI.EBY
GENEIEAN\G SETS
IYIAT{
L23/30
Er&urt
308.02
GEARFORVALVESPINDLESANDFUELINJECTIONPUMPS
OPERATING
MAINTENANCE
Edition 10H
Plate30851
Adju s t m e not f t he va l ve g e a r sh o u l d be car r ied out whenthe engine is cold.
Th e v a l v e c l e a r a n cemu st b e a d j u ste d and checkedwheneverthe valve gear has
b e e nd i s m a n t l e df o r i n s p e c t i o ne t c .
B e f o r ee f f e c t i n g th e a d j u stn re n t,tu rn the eng' ineuntil the r o1ler for the valv es c o n c e r n e dr e sts o n th e ci rcu l a r par ts of the cam.
Inlet Valves:
Loose nl o c k n u ts a n d th e a d j u stme n tscr ewson valve br idge and r ocker ar m .
P lace t h e c o r r e ct fe e l e r b l a d e fo r i nlet valves abcvethe valve spindle near est to the rocker arm bracket.
of the
Adju s t t h e c l e ara n ceb e tw e e nva l ve br idge and va' lvespindle by r neans
(above
is
push
blade
r od) . The feeler
the
a d ju s t m e n ts c r e wo n th e ro cke r a rm
t o r e m a i ni n t h i s p o s i t i o n w h e na d j u s t i n g t h e c l e a r a n c eo f t h e o t h e r v a l v e .
P lac e a n o t h e rf ee l e r b l a d e w i th th e samedimensionabovethe other valve spind le . A d j u s t t h e cl e a ra n ceb e tw e e nva lve br idge and valve spindle by meansof the
a d ju s t m e n ts c r e wo n th e va l ve b ri d g e
Tighten up the counter nuts of both adjustnent screws, and check that the
c l e a r a n c ei s c o r r e c t s i m u l t a n e o u s lay t b o t h v a l v e s p i n d l e s .
E x h a u s tV a lv e s:
Ca rr y o u t a d j u stme n ti n th e sa mew a y as descr ibedfor the inlet valves, using
f eele r b l a d e s f o r e xh a u stva l ve s.
The feeler gaugesfor checking the clearance have two blades which are marked
" inco r r e c t " a n d " co rre ct" , th e l a tte r to be usedwhenadjusting the valve
c le a r a n c e .A f t e r ti g h te n i n g u p th e counter nuts on r ocker ar m sand valve br idge, b e s u r e t h at th e fe e l e r b l a d e s mar ked"cor r ect" can be' inser ted into the
w h e r easit must not be possible to inser t the
t wo c l e a r a n c e ssi mu 'l ta n e o u sl y,
blades marked"fftdmeErrT h e p r e m i s s i b l ecl e a ra n ce sa re sta ted in D 308. If ther e is no clear ance,or
i f i t i s t o o s m a l l , t h e v a l v e c a n n o tc l o s e t i g h t l y , w h i c hw i l l c a u s eb u r n i n g
of t h e v a l v e s ea ts, p o o r co mb u sti o nand r ising exhausttem per atur es.
"Molykote"
I f t h e r o l l e r g u i d e s h a ve b e e nd i smantled, it is advisableto apply
t o ro l l e r a n d b u sh p ri o r to re -a sse mbly.It is impor tantto pr eventdir t and
c hip s f r o m e n t eri n g b e tw e e nro l l e r and bush, which might block the r oller and
causedamageto this as well as the cam.
FFlEBY
CENERAIT\G SETS
lvlAhl
E&UT'
L23/30
PUMPS
ANDFUELINJECTION
OPERATING
GEARFORVALVESPINDLES
308.03
E d i t ' i o n0 1 H
ROTOCAP
VALVEROTATOR,
1. R e t a ' i n e r b o d y
1
2
3
2 . B a ' Il s
3. Ball race
4. Spring washer
5 . S e a t i n gc o 1 l a r
6 . R e t a j n e rr i n g
9pgglj ng_prlgrp.Lg
T h e r e a ti n e r b o d y (1 ) h a s a numberof pockets, ar r angedin cjr cumfer enti al
d j r e c t i o n , w i t h b a l ' l s t h a t a r e f o r c e d a g a i n s t t h e u p p e re n d o f a n i n c l i n e d r a l i r e c t i o n . T h eb a l l r a c e ( 3 ) s e r v e s
c e b y c o i l s p r i n g sa c t i n g i n t a n g e n t i a ' d
a s b a l l t r a c k i n t h e o p p o s i t ed i r e c t i o n . T h e s p r i n g w a s h e r( 4 ) s e a t s a g a i n s t
t h e i n n e r r i m o f t h e r e t a i n e r b o d ya n d i s e n c a s e db y t h e s e a t i n gc o l l e r ( 5 )
valve r otator is held together , whenr e m ov ed,
w h i c h o ve rl a p s i t. T h e a sse mbled
b y t h e r e t a i n i n gr i n g ( 6 ) .
As t h e va l ve sta rts to o p e n , the incr easing valve spr ing- loadcausedthe s pr i ng
w a s h e rt o fl a tte n , a n d th e l o ad app' liedto the ba' lls' in the pocketsof the r et a i n e r b o d y fo rce s th e b a l l s in the ball r ace to r oll downthe inclined r ac es .
T h e t r a nsfe r o f th e re a cti o n load of the ball r ace to the spr ing washerr ed u c e st h e re a cti o n l o a d o f the spr ing washeron the inner r im of the r etai ner
b o d y . B a l l r a c e , s p r i n g w a s h e r ,s e a t i n g c o l l a r a n d v a l v e s p r i n g sa r e , h o w e v e r "
f o r c e - l o c k e db y f r i c t i o n g r i p . T h e r e a c t i o n l o a d o f t h e b a l l s o n t h e i n c l i n e d
r a c e s i n d u ce sro ta ti o n to th e r etainer bodyand valve with r elation to the
s e a t ' i n gco l l a r a n d th e va l ve spr ings. As the valve closes, load is r e' leas ed
f r o m t h e sp ri n g w a sh e ra n d thus fr om the balls, allowing themto be r etu r ned
t o t h e i r o ri g i n a l p o si ti o n s without r ol' ling by the tangential for ce of the c oi l
s p r in g s .
I n s t a ' lI ati o n
W h e ni n s t a l l i n g v a l v e r o t a t o r s , n o t e t h a t o n l y o r i g i n a ' l v a l v e s p r i n g s s h o u l d
b e u s e d a n d th a t th e d e vi a ti on fr om the ver tical axis of the valve stems houl d
not exceed1/2o. Should parts have becomedirty due to long storage or in
t r a n s i t , th e y mu st b e w a sh e din TN Tr ilene, dr ied and then put into a vat fi l l e d w i t h l u b ri ca ti n g o i l o f l ow m ediumviscosity wher ethey ar e to be left for
a f e w m i n u te s.
Disturbances
D i r t : e sp e ci a l l y i n th e b a l l pocketsdue to r esidues in t h e o i l ( a b r a s i v e ,
Su s t i o n p ro d u cts). T h e d e posits causethe individual parts to beconestuck
and hinder the movement
of the balls. The valve rotator should be removed,car e f u l l y w a sh e da n d l u b ri ca te d befor e installation.
E{+.ÊBY
CENERANNG SETS
tv|Af\t
L23/30
Et&urt
308 .04
GTARFORVALVESPINDLESANDFUELINJECTIONPUMPS
OPERATING
VALVEROTATOR,
ROTOCAP
E d i t i o n0 1 H
H i g h r e a c t i o n t o r q u e : d u e t o h i g h f r i c t i o n b e t w e e nr o c k e r a r m a n d v a l v e s t e m
a n d - s t e n rs e a T s .T s o u r c e o f c o n s ' i d e r a b l et o r s i o n a l f r i c t i o n b e t w e e ns e a t i n g
c o l l a r ( 5 ) a n d r e t a i n e r b o d y ( 1 ) t h a t m a y l e a d t o i m m o b ' i l i t yo f t h e v a l v e r o tator could also be a larger deviation of the valve springs from.the vertical
ljne. The parts or the valve springs causing torsional friction should then
be replaced.
R e p l a c e m e not f t h e v a l v e r o t a t o r m a y b e n e c e s s a r y i n b o t h c a s e s i f t h e r e a r e
d e p r e s s i o n si n t h e b a l l t r a c k s c a u s e db y p o i n t l o a d s o n t h e b a l ' l s d u r i n g ' i m mobility of the valve rotator.
Ma'intenance
Ro t o c a pv a l v e r o ta to rs n e e dn o se rvicing in nor m aloper ating conditions.

U n u s u aol p e r a t i n gc o n d i t i o n sm a y ' l e a dt o d i s t u r b a n c e s .R o t a t i o no f t h e v a l v e
s h o u l db e c h e cke da t th e i n te rva l s specified in the M aintenance
Schedule.Roi s sa ti sfa cto ry w henthe valve r otates visibly and evenly.
t at o r p e r f o r m a n ce
O v e r h a us l
Valv e r o t a t o r s sh o u l d b e c'l e a n e da n d inspectedfor wear and ball im pr essions
whe n e v etrh e v al ve s a re re mo ve dT. h e individual par ts can be disassembled
afl f th e re ta i n i n g ri n g b y meansof which the seating collar is fastter removao
ened to the retainer body. Parts showingwear groovesor depressionsformedby
t h e b a l l s s h o u l d b e re p l a ce d .l ,l h e ni nser ting the balls and the tangential
s p r i n g s , n o t e t h a t a l l b a l l s o n t h e i n c l i n e d r a c e s o f t h e b a l l p o c k e t sp o i n t
d i r e c t i o n . ( S e ei l l u s t r a t i o n ) . T h e i n n e r r i m o f t h e s p r i n g w a s h e r
in the sarne
ffiainerbody
Havi n ga s s e m b l eth
d e va l ve ro ta to r i n dr y condition, ' it should be placed in
clean lubricating oil for a short periodof time.
Storage
P a rt s k e p t i n sto ck sh o u l d b e w e l l packedand pr otected against dust, water ,
humi d i t ya n d a gg re ssi vern e d i a .D u st causesthe par ts to becom e
stuck and hinde rs o r p r e v e n tso p e ra ti o n o f th e va l ve r otator .
FT=.EBll
GNERAru{CSETS
VALVEGEAR
PLAT3
EO B O 1 . I O H l
t 68l
t770, 8 69
,95
202
796
5885
s971
2
2201
2J93
079|---6:
0 88 0
0 979
| 017
0t57
16
6861
6953
702l
7"0
2660
2 75 9
6 t3 l
6220
,9
3t94
3283
I 372
628 fi-uoe
7r7
?--SSSZ
fureoa --sao
l).tsss
3t1
03
-t'--0602
506J
J 82 7
39r6
1 08 1
t7
J"''
0 9 .0 5 . 8 5
T{OLEBY
GENERAN\|G SETS
PLAT3
EO 8 O 1 . 1 O H ' I
VALVEGEAR
Designation
Benavnelse
P 1u g
R o cke ra r m
Ba'll thrust piece
Prop
Vi ppear m
Bush
For ing
t'lasher
C i r c fi p
Nut
S k iv e
S i k r i n g s r in g
Mstri k
6$*# Offro*S,::#ff OBBO

6 * * * * $ u / ; 3 o *T 097_9
6 *:'i, G 9/0 f,i:'il$ 1Q47
6 ,r":'* *'t $irf;' 11 3 6
6,*t * ; '\ Y t & f t t , r 13 1 4
S tu d
Tap
Stop screw
B ra cke t
Stopskrue
Buk
Nut
P 1u g
Mstri k
Pr op
l *e lrf f d 0 { } t $ 140 3
6 g*t # ls ii#t {- 1 6 8 J
6t)0& $fff ,*p/.1-1 7 7 Q
* f i't A P f I 869
6 t r*.
T h ru st scr ew
Trykskrue
Hndtag
Fjeder stift
Item No.
{as* }t&
: qi!"rr{ olsl
.{a::# d8l *tL'*{. . .946
6e#t 0f/#' S!{r,*"}. _0_335
6o$.*7to
q0v oLu
6*t'* G!'/#dq*
f * * 1 1 i i S t t ,9.].#*{
6 0 0 { : Y t # 'f elg $
_05-13
060_2
0-791
6 0 f r . t l t i # t i 1958
6 o a 8 ' i 6 f t t f ' #t ?026
6 * t r : 0 8 1 { a $ r V 2294
$ t t \ t . !/ t v 2393
, s S s0.E t * . A # 2482
6 & 8 Y t /. i * e t 2571
6'f**l 081&* 'e2660
o w P # t o e Z J 2759
f 29-37
6 o s a 6 f * # JY
6o** s116srrri30[5
# rr& a*3 3194
6CI00.
6*# g/ {j17 3283
6 # . # Y / 0s s i ' ; f337
6 g a * $ f / s d r \ I 34"6J
6 a o 0 r t f 0 e 0 : 0 35s0
6 s * * f l 0 3 1 3827
H a n del
S p rin g p' in
l.lasher
Kug'letrykstykke
S k iv e
C o ve r
Daksel
0-r'ing
blasher
Screw
Crossbar
S p rin g p' in
0- r ' ing
Sk' ive
Rockerarm
Ball thrust piece
Ball thrust piece
Skr ue
Travers
Fjeder stift
Vi ppearm
Kug'l
etrykstykke
Nut
P 1u g
Kug'letrykstykke
M otr ik
Pr op
T h ru st p' iece
Trykstykke
T h ru st s cr ew
Trykskrue
S p r i n gr i n g
B a 'lI th rust pi ece
C o n i c a lr i n g i n 2 / 2
Fjeder r ing
Kug'letrykstykke
Konisk r ing i 2/2
con t.
ETH.ETF
GENERATTArc SETS
lY|Ah|
PLATE
3OBO1.1OH1
VALVEGEAR
Designation
Benavnelse
flfr o#S,t_3s16
{ q a o 8/3" oot 4oB4
6#tI 0 f / f , 0 { . 4 1 7 . 3
S p r i n gd i s c
Internal spring
Fjeder sk1
E xte rn a I spr ing
Indvend' igfjeder
Udvend' ig
fjeder
6-d's*?0 t. #41t4262
I n l e t v a lv e
Bush
I n d s u g nni g s v e n t ' i 1
For ing
P 1u g
Prop
P lu g
Prop
P lu g screw
S p r i n gf o r t h r u s t p i e c e
Pr opskr ue
Tr ykbosni
ng
6 s $ e d_f/}#3# +gqs
Thrustbush
S p r i n gr i n g
S 0 * # , {}Ft} cCI1f SOO:
T h ru st foot
Trykfod
Rotationsg' iver
Udstsdsventi
I
Item No.
"
s&#of 0.8&3$51
6.# af ,{# Arf .4M0
6e6{"t of{# 6o3fsg
0f{# d$d 4628
-- \6ost#l{, 06## 4711
f-os,
O?f*:#*rlta+e06
*$*tr# 8 l* tiv&*515?
" 6dj#
*fJ: ta$t s5-19
6':':r':ld7ff8 t) 1y/ 5796

.6$ur+ot{f
dfjd} 58-85
& ',.'l;
'4
trt8 A6F:&59.74
.6.*{,$ f#t 00{'# 6042
6 # ,!,:' atlO 0*ir3 6131
#Yi0Wazzo
'gt .##lf ffiLe
6 oe* e{f& ?av{ 64gg
q0e o fl* *,st?ASgl
--6aP*# f1l?d.Sffl 66gG
##/ #sff 6g6a
_{-s#
ogss
,{*:e1so*to *r,*fb
.6'lurO08t 0g{l- J021
6 #* s r , 1 #s s . i * 7 1 1 0
V a lve ro tator
0utlet valve
H a n del
0 -r i n g
Top cover
Fjeder for trykstykke

Fjeder r ing
Hndtag
Ga ske t
Nut
0- r i ng
Topdeksel
P a k nni g
Mstri k
P lu g
Pr op
T h ru st scr ew
Ball thrust piece
Trykskrue
Kugletrykstykke
Fjeder r ing
S p r i n gr i n g
Ball thrust piece
Circlip
t^lasher
S h a ft
Kugletrykstykke
Si kr i ngsr ing
Sk' ive
Aksel
Plugscrew
Propskrue
*For details see

plate 30801-12H
* L s s d e l es e
plate 30801-12H
Ftr-EEE
GENERATI{G SETS
]YtAhI
cl&urt
ROTOCAP
VATVEROTATOR,
PLAT3
E0 8 0 1 . 1 2 H
7209
7398
7 487
7576
7665
HOTEBY
GENERA:N{G SETS
tvlAhl
ct&u,
308 01.12H
PLATE
ROTOCAP
VALVEROTATOR,
Item No.
oo"o QT-LIL!:::*-LHS
a_a#tlgt0 ao3 7398
6oc! ltrt #,ji'{ 74Bl
6,! fif *f 5!l 7575
6 o r a o l ! t ' 1o o { l 7 6 6 5
Designation
Benavnelse
S p r in g
B a lI
Fjeder
Kugle
B a lI r a c e
Kugleplade
Spring washer
Fjeder skive
Retainer ring
Lser ing
EFHY
GEI\ERA'NNG SETS
rY|Ahl
Er&ult
PLATE
308 02.05H 1
VALVEGEAR
hL},j:j,
J/245'
@-
0t26
2817
Y2s
0493
05 82
0 6 7|
0760
0948
,0t6
a-
2Bt7
6,--..-F- 2so6
gl="1':'
g-3252
n05
| 294
r383
| 472
,650
t749
3707
3896
r838
| 927
}FI."EB\f
GENERA'ThGSSTS
tYlAf{
Et&ut
PLATE
30802- 05H-1
VALVTGEAR
Designation
Benavnelse
fc*g dfll1i r;41} 0126

_ 6-s08lo t{,f- 04L3
Cover
S p r i n gg u i d e
Deksel
Fjederstyr
6 a0* QY!,fi$ili"- _058i?

6!{:f'0 tt* f;:d,* 0671 d , f t r t
0,3r"t
8!# os$*
" dEpe
,yl&.*fs
,
6**
f*rr
0760
$tr:':/{ ('
T h ru st p i ece
Trykstykke
T h ru st w asher ,please
sta te th i ckness
0 . 1 - 0 . 3 - 0 . 5m m
T h r u s tp i n
T r y k s k i v e ,a n g i v
venl'igst tykke'lse
0.1- 0.3 - 0.5mm
Item No.
6 t , ] ! l ' ' ! i t : f - 0948

6 t , ; ' :t ' { i ( f i t 0 t 6
Ro'lI er guide
C u pp o i n t scr ew
Ru1I estyr
RolI er
B u sh
Kraterskrue
Rulle
Foring
Pin for roller
T a pf o r r u l l e
1 83 8
Screw
H o u sin g
Gu d
i e p 'i n
Skr ue
Hus
Styresti ft
19?7
Screw
Skr ue
Stopskrue
Trykstykke
Stodstang
Trykstykke
11 0 5
6** r{l# #{Y 1?94
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Tryktap
Fjeder
16 5 0
1 74 e
2095
6*i:* #tli' fi*f 2273
6.?1: i::3/;' i:*7Y
2451
Stop screw
T h ru st p i ece
Pushrod
T h ru st p i ece
6i *r: ty
2639
Protective tube
Beskyttelsesror
0 -ri n g
Screw
Fl ange
C u pp o i n t scr ew
0- r i ng
Skrue
Fl ange
Kraterskrue
Spring
Thrust piece
Roller guide
Fjeder
Trykstykke
fi
'
: {Y.!: ^t 3 2362
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6 i : 9 j f * t l , . . f 0 {2817
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Stop screw
P i n fo r r oller
RulI estyr
Stopskrue
Tap for r ulle
6Js* ffft# Fd']f*i 3747

6s#ut 9to f# fV 3896
B u sh
Ro'ller
Fori ng
Rulle
la'l
-----
t+rltcg
r
CET{EFANNGSETS
]Y|AhI
E&U'
VALVEGEARTOOLS
PLATE
30851.03H
*
021r1
\--l
./
\LR-,-:a
TOI.EB\f
GENEEA'fIG SETS
30851.03H
PLATE
VALVI GEARTOOLS
Item No.
0 15 2
*0?41
0330
0429
Designation
Benavnelse
Wre n chfor thr ust piece

i n f u e l p u m pr o l l e r
g u id e
Nogle for trykstykke i

e-l
br andsel
spumper ul'
styr
ne
Sl i bem aski
G r i n d i n gm a c h i n e
F e e l e r g augefor inlet valve
Feeler gaugefor exh a u st va l ve
soger for indstrsmni ngsventi1

Soger for udstsdsventiI
*Extra tool s
*Ekstra verktsj
E#.gEE
CENERA'N\G SETS
EngineData
z
o
E
ff
o-
of Engine
Operation
andCondition
EnginePerformance
Tracing
Trouble
and MainBearings
Crankshaft
GylinderHeadand CylinderLiner
Rod
PistonandConnecting
ll
Turbocharger
System
? e FuelInjectionPump
Grt
s=
Zl-
FuelInjection
R
;
:z
CamshaftandGamshaftDrive
ee
Controland SafetySystems
Automatics
andInstruments
FE
StartingSystem
6 lJg
Lubricating
Oil System
Oil
of Lubricating
Specification
andTreatment
FuelOil System
CoolingWaterSystem
Treatment
of GoolingWater
=<
--
1=
g9
l - r
DrivenMachinery
TURBOCHARGER
SYSTEM
3 0 9 . 0|
Editionl2H
DESCR
P IT I O N
T h e t u r b o c h a r g e r s y s t e mo f t h e e n g ' i n ec o n s i s t s o f a n e x h a u s t g a s r e c e i v e r , a
t u r b o c h a r g e r ,a c h a r g i n ga i r c o o l e r a n d a c h a r g i n ga i r r e c e i v e r , t h e l a t t e r
being intergrated in the engine frarne.
Outlet from T.C.
hose
Watrr warhlng - T urblnc side
Smokc
limitcr
\
Exhaut gas to
\
Water
washing
compressor
side
Orain from
I
l_-
T h e e n g i n ei s s u p p l i e dw i t h c h a r g e - a i r f r o m a t u r b o c h a r g e r .
T h e t u rb i n e w h e e lo f th e tu r bochar geris dr iven by the engineexhaus tgas , and
t h e t u rb i n e w h e e ld ri ve s th e tur bochar gercompr essorwh'
, ichis mounted
on the
s a m esh a ft. T h e co mp re ssor
sucks air fr om the engine r oom,thr oughthe ai r fi l ters.
F r o mt h e tu rb o ch a rg e rth e air is pr essedthr oughthe char gingair cool er w her e
t h e a i r i s c o o l e dd o w n ,t o t h e c h a r g i n ga i r r e c e i v e r . F r o mt h e c h a r g i n ga i r r e c e i v e r , t h e a i r f l o h , st o t h e i n d i v i d u a l c y l i n d e r , t h r o u g ht h e j n l e t v a l v e s .
F r o mt h e e xh a u stva l ve s, th e exhaust is led to the exhaustgas r eceiver w her e
t h e p ul sa to ry p re ssu refro m the individual exhaustis equalizedand pa s s edto
t h e t u rb o ch a rg e ra s a co n stant pr essur e.
C I-t
FTIEG'
GE{ERAT$GSENS
lv|A\I
cr&ut
L23130
309.02
SYSTEM
TURBOCHARGER
Edition l2H
DESCRIPTI ON
Pla t e 3 0 9 0 2 , E xh a u sta rra n g e me n t

T h e e x h a u s tg as fro m e a ch cyl i n d e r unit passesthr ougha water cooled inter m e d i a t ep i e c 1 9 7 6to th e e xh a u stgas r eceiver wh' ichis madeof pipe sections
a n d f u r t h e r t h ro u g hth e tu rb o ch a rgerto the exhaustoutlet and silencer ar rangement.
for r eading the exhaustgas
I n t h e c o o l e d i n te rme d i a tep i e ce a ther mometer
p
o
s
s
i
b
i l i t y o f f i t t i n g a s e n s o rf o r
t e m p e r a t u r ies f i t t e d a n d t h e r e i s a ' l s o
re m o t er e a d i n g .
T h e e x h a u s tg a s re ce i ve r i s ma d eo f h e a t - r e s i s t a n c ea l l o y s t e e l . T h e c o n n e c t io n s t o t h e c o o l e d i n te rme d i a tep ieces ar e of the flange type. In the r eceiare fi tted to pr event excessivestr ess in the
ver a numberof compensators
p ip e s d u e t o h e a t e xp a n si o n .
To a v o i d e x c essi veth e rma l l o ss a n d to ensur ea r easonablylow sur face tem pe ratu r e t h e g as re ce i ve r i s i n su l a ted.
t.-L
!F.!E.
GENERAM\GSETS
SYSTEM
TURBOCHARGER
309.20
TURBOCHARGER
WITHJTT ASSIST
E d i t i o n0 1 H
Jet Assist System

The turbochargelis
a r r a n g e df o r j e t a s s i s t a n c e .
J e t a s s i s t a n c ei s a s y s t e m f o r s u p p l y o f e x t r a d r i v i n g t o r q u e t o t h e c o m p r e s sor performance.
Ar Fftcr./Slencer
C o m p r e sseadi r fro m
a n e x t e r n a l s o u r c ei s
l e d t o a n a n n u l a rc h a m b e r
i n t h e c o m p r e s s ohro u s i n g
a d j a c en tto th e vo l u te .
Compreesor
Houcing
Turblnc
Houeing
F r o mt h e a n n u l a r ch a mb eth
r e
c o m p r e sseadi r i s p a sse d
t h r o u g ha n u mb e o
r f n o zzle s
t o t' lheer )co mp re ssowr h e e l (i mpe'l
.
W h e nt h e a i r fl o w s th ro u g h
t h e n o zzl e s th e p re ssu re
e n e r g yi s co n ve rte di n to
kinetic energy.
Englne'e Charge Ak
lnlet Celng
Yolutc Cmlng
Dlllurcr Ring
Nozzle
Annulr Chambor
T h e h i g h - v e l o c i t ya i r j e t s
will give extra driving torque and thus the speedof
the compressorwhee'lis increased.
Increasedrotation speed
will incr ease the per for manceof the compr essorr, esulting i n
r aised boost pr essur e( char geair pr es sure).
Compressed
air for the jet assistance
systemis supplied by the sur plus ai r
arrangement.
lnl.t AL lor
J.t A..bt
L.l#
gEE
E3r==S
E
GENERAIINCST5
L23/30
SYSTEM
TURBOCHARGER
T U R B O C H A RTGYEPRTM A NN R 1 5 R , N R 2 0 , N R 2 0 R ,
- TURBINESIDE
I.IATER
I,IASHING
]|tAht
Et&ut
309.30
Edition 02H
Page1 ( 3)
T h e t e n d e n cyto fo u 'l 'i n go n the gas side of tur bochar ger sdependson the c om b u s t ' i o nc o n d i t i o n s , w h i c h a r e a r e s u l t o f t h e l o a d o n a n d t h e m a i n t e n a n cceo n d i t j o n o f t h e e n g i n ea s w e l l a s t h e q u a l i t y o f t h e f u e l o ' i l u s e d .
F o u l i n go f t h e g a s w a y sw i l l c a u s eh i g h e r e x h a u s tg a s t e m p e r a t u r easn d h i g h e r
and w' ill also l ead
s u r f a c e te mp e ra tu re so f th e combustioncham bercom ponents
t o a l o we r p e rfo rma n ce .
T e s t s a n d p ra cti ca l e xp e ri e ncehave shownthat r ad' ial- flow tur bines can be
s u c c e s s f u l l yc l e a n e db y i n j e c t i o n w a t e r i n t o t h e j n l e t p i p e o f t h e t u r b i n e s .
T h e c l e a n i n g e ffe ct i s b a se don the !,,atersolubif ity of the deposits and on
t h e m e c h a n i caal cti o n o f th e im pingingwater dr oplets and the water flow r ate.
T h e n e ce ssa ryw a te r fl o w i s dependenton the gas flow and the gas temper atur e.
E n o u gw
h a t e r m u s tb e i n j e c t e d p e r t i m e u n j t s o t h a t , n o t t h e e n t i r e f l o w w i l l
e v a p o r a t e ,b u t a b o u t 0 , 2 5 l / m i n . w ' i ' l l f l o w o f f t h r o u g ht h e d r a i n a g eo p e n i n gi n
t h e g a s o u t l e t . T h u se n s u r i n gt h a t s u f f i c j e n t w a t e r h a s b e e ni n i e c t e d .
S e r v ' i c ee xp e ri e n ceh a s sh o wnthat the abovem entionedwater flow gives the opt i m a l c l e a n i n ge f f e c t . I f t h e w a t e r f l o w i s r e d u c e dt h e c l e a n i n ge f f e c t w i l l
water flow is exceed,ther e i s a
b e r e d uce do r d i sa p p e a r. If the r ecom m ended
c e r t i n r i s k o f a a c c u m u l a t i o on f w a t e r i n t h e t u r b i n e c a s i n g , w h i c hc a n r e e n th e tu rb o c har ger .
s u l t i n d a ma g
T h e b e s t c l e a n i n ge f f e c t i s o b t a i n e db y c l e a n i n ga t l o w e n g i n el o a d a p p r o x .
2 0 %M C RC
. l e a n i n ga t l o w l o a d w i l l a l s o r e d u c et e m p e r a t u r seh o k s .
E x p e r i e n ch
e a s s h o w n ,t h a t w a s h i n ga t r e g u l a r i n t e r v a l s i s e s s e n t i a l t o s u c gt i n t e r v a l s
c e s s f u l ' l c l e a n i n g , d s e x c e s s i v ef o u l i n g i s t h u s a v o i d e d .l , l a s h i n a
on the fuel quality thes e i nDepending
o f 1 0 0 ho u rs i s th e re fo re re comm ended.
tur bine must be washeda t the
,
t e r v a l s ca n b e sh o rte r o r l o nger . However the
l a t e s t w h e nth e e xh a u stg a s tem per atur eupstr eamof the tur bine has r is en
about 20o C (680 F) abovethe normal temperature.Heav'i'lycontaminatedturb i n e s , w h i ch w h e ren o t cl e a nedper iodically fr om the ver y beginningor after
a n o v e rh a u '|,ca n n o t b e cl e a nedby this m ethod.
has beencarr i ed
I f v i b r ato n i n th e tu rb o ch ar geroccur after water - washing
s
t
i
l
l
e
x
i
sts, this'is pret
h
e
w
a
s
h
i
n
g
b
e
r
e
p
e
a
t
e
d
.
I
f
u
n
b
a
l
a
n
c
e
out,
should
and the tur bom
ust
be
stopped
d
u
e
to
the
engine
s u m a b ly
h e a vyfo u l i n g , and
d
i
s
m
a
n
t
l
e
d
charger
a n d m a n u a l l yc l e a n e d .
The washingwater should be taken from the fresh water systemand not from the
f r e s h c o o l i n g w a te r syste mor salt water system .No cleaning agents ar e s ol vents need to be addedto the water.
T o a v o i d c o r r o s i o nd u r i n g s t a n d s t i ' l l , t h e e n g i n em u s t , u p o nc o m p l e t i o no f w a t e r w a sh i n gru n fa r a t l e a st t hour befor e stop so that all par ts ar e d r y .
tG,=
FtrEt
GNERATTGSETS
lv|Ahl
CIEU'
L23 / 3 0
309.30
SYSTEM
TURBOCHARGER
TY
PE
MA NN R 1 5 R , N R20, NR20 R,
T U R BO C H A R
GE
R
- GT U R B INSEID E
,IASHIN
WAT TIR
Edition 02H
P a g e2 ( 3 )
l,Jaterwash'ingsystem
T h ew a t e r w a s h i n gs y s t e mc o n s i s t s o f a p i p e s y s t e me q u i p p e dw i t h a r e g u l a t i n g
v a l v e , a m a n o e u v i i nvga l v e , a 3 - w a yc o c k a n d a d r a i n p i p e w i t h a d r a i n v a l v e
fromthe gasoutlet.
T h ew a t e r f o r w a s h j n gt h e t u r b i n e , i s s u p p l i e df r o m t h e e x t e r n a l f r e s h w a t e r
s y s t e mt h r o u g ha f l e x i b l e h o s ew i t h c o u p l i n g s .T h e f l e x ' i b l e h o s em u s tb e d i s c o n n e c t e da f t e r w a te r w a sh i n g .
B y a c t i v a t i n g t h e m a n o e u v r i nvga l v e a n d t h e r e g u ' l a t i n gv a l v e , w a t e l i s l e d
t -h r o u g ht h e 3 -w a yco ck to th e xh austpipe inter m ediateflange, equippedwith
a c h a n n e lt o l e a d th e w a te r to th e gas inlet of the tur bochar ger .
T h ew a t e r w h i c h i s n o t e v a p o r a t e di,s l e d o u t t h r o u g ht h e d r a i n p i p e i n t h e
gasoutlet.
3-way cock \\
Plate wth
cleaning
instr.
Manoeuvrng
valve
Draincock
Jf Cr""ningwaterirtet
E-:#
t=Flt
EI==.EE'
E
GEI\IERA'NNG SETS
}IAhl
Et&urt
L23/30
\...
309.30
SYSTEM
TURBOCHARGER
E d it ' i o n 0 2 H
P a g e3 ( 3 )
TY
PE
N R1 5 R , N R20, NR20 R,
T U R B OC H A R
GE
R
- TURBINE
SIDE
IÎASHING
WATER
-4: -{: #
cLosED 1
@N 2
WASH 3
TC = TT REOCHARGER
IY = WATER
F = FREEAR
C l e a n i n gp r o c e d u r e :
a n d l e t t h e e n g i n es t a b i l i z e f o r
1 . A d j u s t t h e e n g i n el o a d t o a p p r o x . 2 0 %
1 0m i n .
?.
0 p e nt h e d r a i n c o c k a t t h e T C o u t l e t a n d c h e c kf o r f r e e p a s s a g e .
3.
T u r n t h e 3 - w a yc o c k t o p o s i t i o n ( 2 ) a n d c h e c kf o r f r e e p a s s a g eI.f 0 K t u r n
t o t h e w a t e r w a s hp o s i t i o n ( 3 ) .
4.
C o nn e ctth e w a te r su p p l y to the water washsystem.
5.
valve. Thenopen the r egulating valve and a dj us t

A c ti va te th e ma n o e u vr.ing
t h e w a t e r f l o w u n t i l t h e d r a i n f l o w i s a p p r o x .0 , 2 5 L / m i n -
6.
C o n t i n u et h e w a t e r w a s h i n g5 - 1 0 m i n . o r u n t i l t h e d r a i n w a t e r i s f r e e o f
partic'les.
7.
and disconnectthe water supply. Tur n the

g
R e l e a seth e ma n o e u vri nvalve
3 - w a yco ck to th e cl o s d position ( 1) and check that the water dr ain fl ow
has stopped.
8.
C o n t i n u ea t t h i s l o a d a t l e a s t 5 m i n . b e f o r e i n c r e a s i n gt h e l o a d t o t h e
n o r m a lc o n d i t i o n .
9.
Af t e r th e w a te r w a sh i n g,the engine should r un for at least I hour befor e

stoP.
N 0 T E : T h e re g u l a ti n g va l ve has to be openedslowly.
T h e m a n o e u v r i nvga l v e m u s tn o t b e l o c k e d i n o p e np o s i t i o n .
T h e w a te ri n j e cti o n ti me m entionedin point 6 must not be exceed.
ta.b
=-=ErE^g
CENERA'NArc SETS
TURBOCHARGER
SYSTEM
OVTRHAU
OLF C H A R G I NAGI R C O O L E R
3 0 95
.1
Edition01H
1987.01.15
T h ec o o l e r e l e m e n ts h o u l db e r e m o v e fdo r c ' l e a n i n ga n d i n s p e c t i o ns i m u lt a n e o u s l y * i t h _ g e n e r a l v e r h a u lo f t h e t u r b o c h a r g e ro, r i f o b s e r v a t j o n sp r o v e t h a t

t h e c o o l e r d o e sn o t w o r k s a t i s f a c t o r i l y . S e es e c t i o n 3 0 3 .
P l a t e3 0 9 0 1
C l o s et h e c o o l i n gw a t e r i n l e t a n d o u t l e t v a l v e sa n d d i s c o n n e ctth e c o o l i n g
w a t e r pi p e s. R e mo ve
th e screws0928which secur e the end cover of the c ooe"
e l e m en tto th e co o l e r
and pull the cooler elementhilf- way ou t.
p ] 1 . 9 a . w i r e r o p e r o u nl odut hieng,
o o l e r l e m e n ta n d a t t a c h a t a c k l e r r o o i , - i ; i l o w i n g
w h i c ht h e e l e m e n ti s l i f t e d a n d p u l l e d o u t o f t h e c o o l e r h o u s i n ga n l a n d e do
a c o u p l e o f w o o d e np l a n ks o n the f:loor .
D i s m o u net n d c o v e r 1 0 9 6 ,r e v e r s a l c h a m b e2r 1 6 4a n d t h e s i d e p l a t e s .
c l e a n t h e c o o l e r e l e m e n to n t h e w a t e r a n d a i r s i d e s .
I t i s r e c o m m e n dt e
hd
a t c l , e a n i n go f t h e w a t e r - s ' i d e( p a r t i c u l a r l y t h e t u b e s ) i s
e x e r c ' i se db y me a n so f a d e ter qent.
L o w e r i n gt h e c o o l e r e l e m e n t ' t oa - c l e a n i n gv e s s e ' le q u i p p e dw i t h a g o o dc i r c u l a t i o n d e v i c e i s o n e w a yo f e x e c u t i n gt h i s " t a s k .
I f t h e e x t e n t o f f o u l i n g a n d d e p o s i t i ' n t h e t u b e s r e q u i r e sm e c h a n i c arle m o v a l
t h i s c a n b e d o n eb y m e a n so f a c i r c u l a r w i r e b r u s h . ( i n n e r - i a m e t esr l 3 m m ) .
T h ew i r e b ru sh w i '1 1 , h o w e v er ,r emovethe pr otection iuv"" or iinat ng f r om i he
p u r p o se l yco rro d e di ro n b l o cks.
T h e g r e a t e s tc a r e m u s t b e e x e r c i s e dw h e nd i s m a n t l i n g ,c l e a n i n ga n d m o u n t i n g
t h e c o ol e r e l e me n t,a s th e thin fins of the tubes cannot stan im pactsand"
p r e s s u re . If, n e ve rth e l e ss,the metal fins have beendefo*eJ tney
sho ul dbe
c a r e f u l l y stra i g h te n e d ,a s bent fins will consider ablyincr is t- hepr es s ur e
d r o p a cro ss th e co o l e r. S h ouldone or mor ecooler tubs become
leaky, ii i i tv
m u s t i m m e d i a t e iby e
. . m a d e - t i g h te, i t h e r b y e x p a n d i n gt h e t u U e n A si n t o t h e
t u b e p l a t e s , o r b y b ' l a n k i n go f f t h e t u b e i s ) t o n c e r e dw i t t r p l u g s .
I t i s - i mp o rta n t th a t th e ch ar gilg air cooler s ar e not leaky as any sea br ater
t h a t l e a k s i n w i l l b e c a r r i e d a l n g w i t h t h e a i r t o t h e c y i i n d e r s w h e r et h e
s a ' l t c o n t a i n e di n t h e w a t e r w i l l d m a gvea l v e s , p i s t o n r i g r i c y l i n d e r
liners.
Al s o c l e a n b o th e n d co ve rs and coat themon the inside with an anti- cor r os i on
a g e n t . In sp e ct th e a n ti -co rrosion blocks and r enewas necessar y.
N o t et h a t p a i n t o r s i m i l a r m u s t n o t b e a p p l i e d t o t h e s e b ' l o c k s .
Renew
all gaskets.
E#H.EEF
GENERATII\IC SETS
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Er&ut
- 16H
PLATE
30901
SYSTEM
TURBOCHARGER
0295
0384
0473
0740
0839
0928
1096
1185
1274
1363
145?
1541
16 3 0
1729
1818
1907
2075
2164
314
323?
3321
5570
6't ,ltg '
t0
5 5 71
5572
]\#llgE/.- 5478
>-/t;',fN,
5567
--{
5 5 7 3)
lu 5 s 6 6
r.L5568
I
I
4033
5 10 1
4300
41?2
4123
4124
4125
4211
89.43
G C.+.!E
TFGIEG'
GNERA'TII\IC
SETS
Oo f\ I
PLATE
3090-1f6H
SYSTEM
TURBOCHARGER
Item No.
6oort /O/{.7oool
0295
6ooO /o6/ o0o{ 0384

6OoO/Clt ag 0473
Designation
Benavnelse
Compensator
Gasket
Kompensator
P a k nni g
G a so u t l e t
Gasudl
sb
Screw
l:li'(| 6 lt,t''t.;'0839
too/0t0. oP 0928
Gasket
Skr ue
Pr op
Pakning
Screw
Skrue
6ooo /oto ootl 1096

6 oo o I o/0 '3li 1185
End cover
- .li oo,io/i 2r.'''t

/ 0651
, 6ooo/!{l l,::",. o74o
P 1u g
{ooo ic/c a3111274

6oa0 t{lt {}5 1363
Stud
L o c k i n g p 1a t e
Endedeksel
Anode
Tap
Lseplade
6oao/cto to/6 1452

6 0 c 0t 0 6 i 0 c 0 31 5 4 1
16 3 0
Nut
Mstri k
Gasket
0 9 2 8 ,f 0 9 6 , 1 1 8 5 ,1 ? 7 4 ,
1 3 6 3 ,1 4 5 ? ,1 5 4 1 ,1 7 2 9 ,
1 8 1 8 ,1 9 0 7 ,? 0 7 5 ,2 1 6 4 ,
3 1 4 3 , 3 2 3 2 ,3 3 2 1 ,3 4 1 0
and 3509
Ga ske t
Pakn
i ng
Ladeluftksl erel ement,
i n k l . i t e m 0 7 4 0 ,0 8 3 9 ,
0 9 2 9 ,, 0 9 6 ,11 8 5 , 1 2 7 4 ,
1 3 6 3 , 1 4 5 2 ,1 5 4 1
, 1729,
2
0
7
5
.-2164,
1 8 1 8 ,1 9 0 7 ,
3143, 323?, 3321, 3410
og 3509
Pakni ng
P la te
Plade
S tu d
Tap
Pakn
i ng
('ta/
lr',,r,
6oco /06/ ) i : 1 : 1729

a
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(,^,
i l ,t,.'
/' ...fi
,jl
\)11
::".' 7.:,\.
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1818
1907
2075
Air cooler element,

incl. item 0740,0839,
| ,):, ti
3143
Ga ske t
End cover
Screw
; 1 , ,. ' . '
3232
l,{asher
6 r r r , ' o l r , . . / / 2164
,lla.io,it
Anode
Endedeksel
Skrue
3 4 10
3509
P la te
Nut
l,lasher
Skive
Plade
Motrik
S k iv e
3876
Screw
Skrue
3965
l,fasher
4 0 33
6000. t pt':- ,;! i. .\' 41?2
Screw
F 1a n g e
Skive
Skrue
Fl ange
ton / 0C')::;: 3321
,ra0'cil
lool ".J)
600CI/0/0.002"7
89.43
E.E+E gEStIE
- -----
GENERA.n\|GST5
tUlAh|
E&U'
PLATE
30901- 16H
TURBOCHARGER
SYSTEM
Designation
Eenavnelse
[.lasher
Skive
Screw
Skr ue
4125
0-ri ng
0-ri ng
4211
Screw
Skr ue
4300
4305
Inlet bend
Protective rack
I ndstrsmni ngsbsini ng
Beskyttelsesbojle
Gasket
Pakn
i ng
Turbocharger
Turbolader
Diffusor
Item No.
6to0 ,'tn ,lliz 4123

j;lrl
, i ' : ) t tt , i r : 4 1 ? 4
6000 1061ss26
$s() P/ooor/
6o /P 64' '
60oo /t/0.0)J3
6,,14rl1,, ,.1i 4499

6,tot/t,/oaoil4588
6,:,1/{/! ra:j-5101
600o10100)36
6rs i 1, ,)i /
'i?
' c'!' " 1/ 'i1
'
5478
Bracket for turbocharger
5566
Spring washer
Konsol for turboI ader

Fjeder sk' ive
Screw
Skr ue
Screw
Skr ue
Skr ue
Tatningsring
5567
nt: ? 5 5 6 8
_ 6oJt t/r.
6411 i./.lrit'n
5570
_ _
(ooa f'16 oa0l
5571
\'
6ll i,.,Lt1.
.:'t;':''
D if f u s o r
ssl?
6ooo /061000 5 5 7 3
89.43
Screw
S e a li n g r i n g
Inlet p'ipe
Gasket
ngsr or
Indstr sm ni
Pakni ng
E L,=
- -----
=-g=rc
GENERAN\C SETS
rY|AN
cl&ull
PLATE30902-O8H
PIPE ARRANGEMTNT.
EXHAUST
23 1 1
2866
2955
311?
295s
_s
I
tl
I
26BB
2133
2777
1887
1976
1977
C o o li n g w a t e r n i P P l e
See plate 30502/4739
E t!!
9 0 . 0 7.
tFt!!g
GENERA'TTNG
SETS
I|tAhl
Et&ut
PIPE ARRANGEMENT.
TXHAUST
Item No.
PTATE
30902-08H
Designation
Eenavnelse
_6 ooo/ 0 / 0 t ( / z
0719
Sc[qw.
Skrue
-6a00 /0/C /0t13
OBOB
Screw
Skrue
1BB7
1976
Screw
Skrue
I ntermedi ate p i e c e
w a t e r c o o le d
Mel1emstykke,
v a n d k oel t
Ga ske t
Pakning
1978
Ga ske t
Pakning
2133_
2222
2311
Nut
Mstrik
Screw
Skrue
Gasket
Pakning
2400
F 1a n g e
F 1a n g e
?599
Screw
Screw
C o mp e n s ator
E x h a u spt i p e i n l e t
tu rb o ch ar ger
Skrue
P a k ni n g
6000. /o/0 0o//
_!!"Q0 _ILQ_Q_Q!1{,_
a o *l 0 { i e : ? . 19tl
_ _an2,lQ61
00/0
60Qg_.,1,01Q
,2tl /
- 60!410/0 00yx
__6ooplc4_ln01,
- 6000lCIk)0cq7
6000t01r)0oJ-0
_ 6000.t1/a 03t/
6aoo.ott.c*s;!
6oooba. h: j
26BB
2777
2866
Skrue
Kompensator
U d s t o d s r s r t i 1g a n g
t u r b oI a d e r
:\,4i1/o/0c\f,l
/o/0.0{
*__6000
3023
Ga ske t
E x h a u sp
t ipe section
3112
Compensator
Kompensator
6doo toi, to{t
3201
Nut
Motrik
3 3 90
Screw
E n dco ver
Skrue
dism antling
S p a n n e for
r
o f w a te r cooled
piece
i n te rme d' iate
Nogle for demontering

a f v a n d k s l e tm e l l e m stykke
6c00./06/oo/Z
6t:tC./tltC C,::Y
6000/0/0 00r'l
2955
3489
2050
U d st o d s r s r s e k t i o n
Endedeksel
-a^-
9 0. 0 7 .
GENERA'TVCSETS
]YIAN
Etckr t
A I R C O O L E(RE X T R AT O O L S )
PLATE
30 95I- Os H
o478
0834
0567
| 05
- t-,I
F-rat
E Er==g!!g
E
GENERA'il\|GSETS
A I R C O O L E(RE X T R AT O O L S )
Item No.
PLATE
30951- O5H
Designation
Benavnelse
0478
C l e a n i n gv e s s e l f o r
ai r cooler
R e n s e k a rf o r l a d e I uftksl er
0567
0656
0834
Heatingelement
Varmeelement
Heatjng element
Varmeelement
C l e a n i n gv e s s e l ,
complete
R e n s e k a r ,k o m p l e t
Drain cock
Aftapningshane
0923
ffi#
\-
M A N U A TF O R
OPERATING
EXHAUST-GAS
TURBOCHARGERS
TYPE
N R2 O I R
S E R I A LN O .
1181540-5{2
\-
MAN B&W DIESEL

AKTIENGESELLSCHAFT
STADTBACHSTRASSE
1
D-8900
AUGSBURG
D35649-3E
l0 g. gt.
INTRODUCTION
M.A.N. furbochorgersqre lhe resulfof decodesof syslemoticreseqrchond developmenfwork.
of lhe owner, provided
They will meef oll serviceregulremenlsot ony llme lo lhe full solisfocfion
fhey ore properly servlced.Timely execullonof lhe specifiedmoinlenoncework will ensure
efficienloperolionond long life.ThgOPERATING
MANUAL is inlendedfo help ochievelhis obiect.
The Opercting Monuol confoinsoll necessoryinformofionfor plonned moinfenonceos well os
for fhe generol overhoul ofthe lurbochorgersond should fherefore be ploced in fhe hqnds of
the operoting personnel. A fhoroughstudyond repeotedreoding lo commif lhe insfruclionsfo
. ifh
o f t h e l u r b o c h o r g e r sW
m e m o r y w i l l e n o b l ef h e p e r s o n n etlo g o i n c o m p l e l eu n d e r s l o n d i n g
lhis knowledgelhe personnelwill be in fhe posilionlo run fhe lurbochorgersproperly, recognize
possibleirreguloriliesof on eorly slogeond reclifyfhem beforeseriousdomogeoccurs.
o n d o v e r h o u lo f l h e f u r b o c h o r g e r sd e f i n i f e l yr e q u i r e s k i l l e d p e r s o n n e l .
P r o p e rm o i n f e n o n c e
It is undersloodthof the personnelossignedfo this work hos hod lhe necessorytroining ond no
f u r l h e r m e n l i o nw i l l b e m o d eo f i l i n f h i so p e r o t i n gm o n u o l .W e s h q l l . n o et n l e r f o i no n y g u o r o n t e e
c l o i m sb o s e do n o l o c k o f p o r l i c u l o ri n s f r u c l i o nisn f h i s m o n u o li n f h e e v e n to f d o m o g ec o u s e d ' b y
f o u l l yh o n d l i n g .
t ilhouf
Individuop
l o r f s o f l h e f u r b o c h o r g e rm o y b e o l t e r e dd u e l o f e c h n o l o g i c odl e v e l o p m e nw
c o r r e s p o n d i n cgh o n g e sb e i n g m o d e i n f h i s o p e r o l i n gm o n u o l .T h e t e x f o n d o l l d o t o o p p l y o f f h e
t i m e o f g o i n gt o p r i n l .
L e t t e r o n d e n q u i r i e s r e l o f i n gf o f h el u r b o c h o r g e sr h o u l di n c l u d el h e t y p e q n d s e r i q l n u m b e r
w h i c h w i l l b e f o u n do n l h e n o m ep l o l e .
.)
This publicotionir copyrlghf.Reprlntingond olher dupllcolionond for.

wording to fhird porlicsmoy only ioke plocewifh our wrillen opprovol.
VE
NR 20lR
D36s649-3
TABLEOF CONTENTS
Sheef
Section
TECHNICAL
DATA
B r i e fd e s c r i p t i o n . . . .
Operoting doto
P i p ec c r n e c t i o n s . . .
Weights
Longitudinolsection .
Gopsond cleoronces
Section2
5l
5l
5l
5l
5l
.52
DESCRIPTIONS
OF SYSTEMS
Lubricoting qystem
Section3
Section4
OPERATION
Stortino
5I
Operotion
Shut down
Meosuresfor loying up . . .
Trouble-shooting
Bosicossembly
Emergencyoperotionduring turbochorgerfoi lure
Foult diognosischort
5l
5l
5l
52
52
53
il
.O
@
F\
D3549-3E
""'
5l
52
53
il
55
500.01
SPARE
PARTS
LIST
Orderingsporeports
Listof sporeports . ,
IvtAINTENANCE
lvloi ntenonceschedule
A 4 o i n t e n o nw
c eo r k . . . .
Form"TEstReport"
Workcords(descripti on)
Hints
Workcords
Section
5l
so}.o2/2
5oo.
o3l3
TURBOCHARGER
EXHAUST
TURBO.COMPRESSEUR
IMENTADOR
OBREAL
TURBOS
SOBREALIM ENTADORES
A GAS DI
TURBOSOFFIANTI
DATEN
TECHNISCHE
DATA
TECHNICAL
CARACTERI
TECHNIQUES
STIQUES
D A T O ST E C N I C O S
DADOSr CN|COS
D A T IT E C N I C I
D3550
I . 5 0- l
T E C H NI C A L D A T A
N R2 O l R
B ni e f s p e ci f c o t i o n , o p e n o ti n g d o t o'
- p i p e c o n n e c it o n s , v e i g h t s
B R I E FS P E C I F I C A T I O N
T u n b o c h o nrgi tehno n en o d i o t - f I o tvu n b i n es t o g eo n do n en o d i o L - f L oc rol n r p n e ssstoong e
i ndb o o n d
R o l o rm o u n t eodn t r o f t o o l i n gp t o n eb e o n i n gosn n o n g e
o
n
n o n goends h o f ts u b s e q u e n t t
r
h
e
e
L
c
o
m
p
n
e
s
s
o
n
i
h
o
t
t
,
i
n
t
e
g
n
o
t
v
h
e
e
l
r
i
t
h
Iurbine
p
i
p
e
g
o
s
e
s
o
n
n
ongement
1
o
e
x
h
o
u
s
t
motched
A d m i s s i oonf e x h o u s t
C o m o r e s sr loi tnh o n eo u t t e ts o c k e t
A i n i n t o k ec o s i n go n s i I e n c e n
l u b eo i t c i n c u i t
B e o n i nt gu b n i c o t i oi n t e g n o t ei nd e n g i n e
N or o t e nc o o L i n g
OPERATI NG DATA
. . . . ( s e et l p e p t o t eo n c o m p n e scsoosni n g )
p e e d m o x .
d m i s s i bol p
e e n o t i ns g
M o x i n uom
e p e n o t iM
n go n u o l )
. . . ( s e eE n g i nO
ue
n feo n teu n b i n e
E x h o u sg to st e m p e n o t b
e e o s u n ipnogi n t d i n e c t l yb e l o n e
L u b eo i t p n e s s u n( m
....bon 1 , 1 1 . 3
t h ec o n n c t ioonnt h e b e o n i ncgo s i n g ) . ,
3 0 /6 0"C
on SAE40/70' C)
tsA E
L u b eo i l n e q u i n e n e n(S
o f o t u n b o c h o nsgpeeneodf 1 0 , 0 0n0p m . . .
o f o t u n b o c h o nsgpeer e od f
4 0 , 0 0 n0 p r n . . .
t so l l efnh o n . .
L u b eo iL f i l t e n e dt o c o n t o m i n osnm
M o x i moudr nm i s s i bol iet i n l e t t e m p e n o t u n e
Moxinu
om
d m i s s i boliel o u t l e t e m p e n o t,u n e
800- 900
. . . . . . . | ' l h 500- 600
. , , . . ' . . ' r l l l n 0,05
75
....''C
105
........'C
. , . . . . .t / h
o p e n o t i ndgo t o ,s e ee n g i n eo c c e p t o nnc e c o n d .
F o nf u n t h e n
I ONS
P I PE CONNECT
L u b eoi I
S u p p loyn t o po f b e oin gc o si n g . .
i ot n
A d d i t i o n ol uI b n i c o
L o t e n toyt o n b e oinn g c o si n g . .
D n o i no f b o t t o norf b e o n i ncgo s i n g
" J e t o s s i s t "( i f l i t t e d l ,
f L o n gceo n n ei cotnf o n p i p e
1 5x 1 . 5
. s m e vc o n n e ci ot n l o n p i p e
. f t o n g ec o n n e ci o" [n f o n p i p e
8x1.5
30x2
. f t o n sceo n n e ci ol n f o n p i p e
25x2
W E I G H T S( o p p n o x i m o t e v o L u e s )
t hn s i l e n c e n
C o m p [ ettuen b o c h o nvgie
y
i
C o m p t et tuen b o c h o n g tehno i n i n l o k ec o s i n g
... .kg
....'..kg
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C o m p n e scsoosni n g
G o so d m i s s icoons i npgl u sL o g g i n g
t iffusen
G o so u l l e d
o z z lnei n g . .
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C - C . . C
L + L
C _
O - - . - - o c o ( D o ( 1 ) o - o < ) o o ( t )
(t) >
dJ O) )
E
E
@ C
A) C_ A+
ct o
oJ
<D oJ
< D o
c . - .o
f
| ' (-/> ()
o)
<- (J
o -l
[-rJ
CD F- t-t1 aY -
q\
an l--OQ-_-C\--f
|.r) L<-) t.l) [l)
IO
tr)
C\ .-l-J.-.f
LO L.l)
\O C\
=J\O
Lr) L<-)
q.
r>
|.r)
=q
I()
Poge2 of 2
TECHNICAL
DATA
NR 20^
Gopsond Cleoronces
52
Meosurerodiol gops @ond

@ usingfeeler (thickness)
gouge,
ond oxiol gops@ ond @ by
meonsof soft metol imprint
(leod wire). Alwoys meosure
ot 3 points on the circumference ond colculote meon
volue.
Apply diol gougeto sutoble
oxio I surfoceond meosure
oxiol ploy@ of rotor by
vigorouslymoving the rotor in
the directionsA ond B.
Posit i on
in
Fig.
R e p l a co
er r e -
llhen llev
Designation
of Parts
Part llo.
Clearancs
Gap
trl n-
tax-
!! n^
lachine parts
Eax-
oax.
lnl n-
lmpeller- Conpressacosingu
rodiol
520.005
0 . 5 0 0.0
54.001
0.40 0.70
lmpeller- Canpressccosing,
r x i oI
520.005
0.30 0 . 8 0
54.001
0.25 0.90
Turbinerotor - Gos odmission

c o s i n g ,r o d i o l
520.001
0.50 0.57
50'l. 00r
0.40 0.70
Turbine
odmission
*Gos
'
c o s i n g ,o x i o l '
520.001
0.5
501.00r
0.55
r .t 5
Beoringbush-Lobyrinth
Ring
0 . 2 2 0.30
0.3
Admissibleoberrotionfran the plone of rototim of the impeller

( m e o s u r ew
d t h d o l g o u g eo t l o r g e srt o d i o l d i s t o n c e )
A d m i s s i b lter o n s v e r spel o y o f r o i q i n b e o r i n g s. . . . . . . . : . . . . .
+
#
1.25
0.0 m
S e eW o r k C o r d5 0 0 . 0
meosuredwith rotor purhed up in the direction,AJ

m e o s u r ew
d i t h r o t o r p u s h e du p i n t h e d i r e c t i o n t J *
* with the rotor pushedup in oppositedirection, withdrowmeosured

oxiol ploy
r\
@
D365649E
r.52-3
EXHAUST
TURBOCHARGER
TURBO.COMPRESSEUR
TURBOS
OBREAL
IMENTADOR
SOBREALIMENTADORES
TURBOSOFFIANTI
A GAS DI
scARrco
HREIBUN G EN
SCHEtvlABESC
DESCRIPTI
ONS OF SYSTEMS
D E S C R I P T I ODNESSC I R C U I T S
ICAS
DESCR
PCI ONES ESQUEAAAT
AS
DEESQUEA
DESCR|COES
SCHEM I
DESCRIZIONE
3 550
2 . 5 0- l
P TI O N O F S Y S T E M S
D E S CIR
L u b ni c o t i n g 0 i L S y s t e m
e ont
Pn i mi nngi g h tb e fo n sl
LEGEND
5
1 S u p p pt yi p e( e n s i n e J
pipe(tunbochonsen)
6
2 Suppty
1
I
3 lhnotttp
eoint
point
gouge)
check
4 Pnessune
Ipnessune
I n t e n v ot yL p ep n i m i n g
o n c o n t i n u opunsi m i n g
cosing)
Ibeoning
Iunbochongen
pipe( tunbochongen)
Dischonse
( checklvotve
Non- netunn
S u p p Ipyi p e( p n i m i nogf t u n b o c h o n g e n )
F o np n i m i nogn dd u n i nogp e n o t i otnh,et u n b o c h o nigs ecno n n e c t teodt h e l u b eo i l c i n c u i t

. h eo i I s e . u . .f o n b e o n i nLgu b n i c o t ioonndo t s of o n d i s s i p o t i oonl h e o t '
of the.nginrT
L u b eo i I s u p p l yc, o n n e c tteodt h e t o po f t h eb e o n i ncgo s i n g ( 5 ) t
m m e d i o t be eI yf o nset o n l - u p
E n o i n ebse i n op n i m ei d
) it h t h n o t t l ep o i n t ( 3o) n dp n e s s ucnhee c pk o i n(t4 ) .
S u p p tpyi p e ( 2w
[ n a i n e rsi t h i n t e n v ool nc o n t i n u otuvsp ep n i m i nsov s t e m
S u p p lp. ti p e [ 2r)i t h t h r o t t t ep o i n t t Sc] n dp n e s s ucnhee cpko i n t ( 4 )A. d d i t i o n so uI p p tpvi p e ( 8 )
f o n t u n b o c h o npgnei m
n i n gc ,o n n e c t i Ioont e n o I ro f b e o n i ncgo s i n g .
p n i m i nogn d ^ t i t h
7 Ju sbi ec I o s eddu i n g
I n c o m p I i o n c e -pr ti o
t hn iI c y o u tn, o n - n e t uvnonL v e ( m
p
n
e
v
e
n
t
i
n
g
t
h
e
t
u
n b o c h o nf gn eo nm
t
h
u
s
p
u
p
s
o
p
e
n
d
u
n
i
n
o
g
p
e
n
o
t
i
o
n
,
n
e
s
t
o
n
d
oi
t h e I u b eo i L
p
n
i
m
i
n
g
,
f t o o d eddu n i n g
being
o f t h eb e c n i ncgo s i n g ( 5 ) :
o i I d i s c h o n oceo,n n e c tteodt h eb o t t o m
Lube
) .c o s eo f
p e ( 6t)o b e t o l e dr i t h o m o x i mpuoms s i b lsel o p e I m i1n5, d e g n e e sI n
D i s c h o npgi e
e so nteh o nm o x i mpuoms s i b Ii en c I i n o t i oonf s h i p .
m o n i npet o n t sAr t l e o s t5 d e g n em
T h ed i s c h o nogfel u b eo i L m u sbt eu n n e s t n i c t e d .
t ,p e n o tounr des n o doef f i t t n o t i o n :
Lube
o i I o n e s s u rI eu .b eo i l n e o u i n e m teenm
S e eo p e n o t i dn og t oi n s e c t i o 1n , s h e e5t 1 .
Lp
T h en e q u i n e d - | o
' ui b
e n e s s u inseo d j u s t ebdl o t h r o t t l ep o i n t ( 3c) o n n e c t iendt h es u p p l y
ptote.
p i p e ( 2 )e,. g .b / o no n i f i c e
p
n
e
s
s
u
n
e
c
h
e
c k [ 4i s) t o t o k ep I o c ei m m e d i o t be et rf o nteh es u p p Ipy i p e
C o n n e c t ilo n
c o n n e c t itoont h eb e o n i ncgo s i n g ( 5 ) .
o?
DJ65649E
2.51-2
II
ABGASTURBOLADER
TURBOC
HARGER
EXI.IAUST
TURBO-COMPRESSEUR
OBREAL
IMENTADOR
TURBOS
SOBREALIMENTADORES
TURBOSOFFIANTT
A GAS Dl
sctRlco
3
50
I
N
BETRI
E.BUND BETRIEBSSTRUNG
D FFICULTIES
AND OPERATING
OPERATION
TS
ETNCIDEI'
ONNEM ENT
FONCTI
DEFONCTIONNEMENT
E\ E L
E IRREGULAR DADES
SERVICIO
FUNCIONAMIENTO
E ANO^ ALIASDURNTEA OPERA9O

oPERACO
EDAVARIEDI FUNZONAMENTO
ESERCIZIO
(\
m
\t
D3550
3 . 5 0- l
ION
OPERAT
Storting, Operotion, Shutting, Down
NR
3
5l
P r e p o r o t i o n sf o r O p e r o t i o n
The beoring points of the turbochorgerneed be primed (prelubricoted)prior to stort-up of the
engine. Depedingon plont loyolt, two types of priming systemsqre ovoilqble: Primingright
before stort-upr or intervol type priming with breoks not exeedingo durotion of 2 hours.
For lube oil system,refer to section 2, sheet51.
S t o r t n g
The turbochorgcrbeing driven by the exhoustgosesof the engine will stort up outcnoticotly
os the enginc is storted.
O p c r o t i o n
Inshr.rncntrcodingshould bc tokcn ot rcaulor intcrvols during opcrotion to the exteni
instrr,nrsntotionis p ovided:
I, Exhouttompcrotursot inlct of turbine
2, Chorgc oir prcrsurcot outlct of ccnpressc
3. Lubricotingoil prcssuraot inlet of turbochorger
Frrthermse,thc following chccksshouldbe modeot regulor intervols:
4,
5.
6.
7.
Exhoust,chorge oir ond oil pipes for tightness

Air filfer ond silencerfor fouling (if fitted)
Turbinerotor whetherit s runningfreely
Turbochorger
whetherit is running,rooihly
Incipientrotor c beoringdomogeis usuolly indicotedby errotic operotioncousedby

imbolonces contoct of rototing portswith stotionoryconponents. Errotic operoti con
often be determinedot on eorly stogeby listeningfi rnrruol operoiingnoises. In such
cosesthe engineshouldbe stoppedimmediotely,if possible,ond the turbochorgerinspected.
Seriousdomogecon thus usuolly be prevented.
Rotorspeedond chorge oir pressureore interdeperdont,i. e. the rotc turnsot o certoin spee(
ot o given chorgeoir presgurepovided the oir ducts of the ccmpressor
ore in cleon condition
The chorge oir pressurecon fhus be usedto opproximotethe rotor speed.
Shutting Down
After shut-downof engine, the rotor of the turbochorgercontinuesrunning for someperiod
of time due to its flywheel effect. Suddenstoppogeis indicotive of mechonicoldefects
(defectivebeorings, compressor
or turbine wheel moking conioct with stotionoryports,
obstructionscousedby foreign motter etc. ).
On stoppingthe engine, ihe turbochorgerrcquiresno odditionol meosures
for lubricotionos
il is conncctcdto thc fccc-fccd lubricotingsnicmof the rngine.
M c o s u r c s
f o r
L o v i n g
U p
Fc prcscrvingthc turbochorgcr, if it is to be loid up fc o long pcriod of time, procecd in

occsdoncc with ihc instructions,os opplicoblc, givcn fa the Dicscl engine (See Engine
OpcrotingMonuol).
\o
@
D36 5649E
3.51- I
OPERATIOf.
Qer otingDifficulties
O p e r o t i n g
D f f i c u l t i e s
by obnormolinstrument
ore occomponied
A.so rule, foultsdevelopingin ihe turbochorger
reodings(exhoustgos temperoture,chorgeoir presureond speed),high noise level or leoking
l u b r i c o t i n go i l p i p e s . l f o n y i r r e g u l o r i t i essh o u l db e n o t i c e di n o t u r b o c h o r g edru r i n gs t o r t - u P
or operotionof the engine, ihe couseshouldbe determinedoi once ond remedioloction token.
F o i l u r et o o t t e n dt o w h o tm o y b e o m i n o rd e f e c ti n i t i o l l y i s l i o b l e t o g i v e r i s e t o s e r i o u sc o n s e ond even to the engine. lf there ore ony irregulorities,
quentioldomogeio the turbochorger
reducethe engine lood 9r shut-downthe engine, if passible,ond do not restortit untl ofter
the couseof the troublehosbeenremoved.
H i t - o n d - m i s tso d i c s i n o t t e n d i n gt o t r o u b l es h o u l db e o v o i d e do s t h e y o r e r o r e l y s u c c e s s f u l .
'lhe
instructionsgiven hercunderond the foult-finding chort orc iniendedto ossistin diognosing
thecouseofirregu|oritiescxpericnccdo@sthowtheproblemconbeoVercqn
q u i c kl y .
C o r t r i d g e
R e p o i r o f o d e f e c t i v e r o t s i n g e n e r o l r e g u i r e st h e s k i l l o n d . t h e t o o l s o f s p e c i o l i s e ds h o p s ,o s
the ports rototing ot very high speedsore sensitive to ony unbolonce. However, with o sPore
c o r t r i d g e k e p t o n s t o c k t h e o p e r o t o ro f o p l o n t w i l l b e o b l e t o b r i n g o d e f e c t i v e t u r b o c h o r g e r
c o n d i t i m w i t h i n o s h o r t i i m e o n d w i t h o m i n i m u m o f o s s e m b l y* o r k '
ffioperoting
J h e c o r t r i d g e , c o r n p r i s i n gt h e c o m p l e t eb e o r i n g c o s i n g w i t h t h e 2 b e o r i n g so n d t h e b o l o n c e d
r o t o r , i s r e o d y f o r i n s t o l l o t i o n . E f f e c t i v e , o n t h e s p o t o v e r h o u l o f t h e t u r b o c h o r g e ri s i h u s
q u i t e s i m p l e o s t h e c o s i n g so n t h e c n p r e s s o sr i d e o n d o n t h e t u r b i n e s i d e c o n b e r e m o v e df r q n
t h e c o r i r i d g e w i t h t h e u s e o f s t o n d o r dt o o l s o n l y .
W e w o u l d t h e r e f o r er e c o r n m e n dt h o t o c o r t r i d g e b e i n c l u d e d i n y o u r s p o r ep o r t s s t o c k s o o s i o
h o v e i t o v o i l o b l e w h e n n e e d e d . T h e c o r t r i d g e c o n b e o r d e r e du n d e r t h e o r d e r n o . 5 9 9 . 0 0 1
'lhe
defective ccrtridge
e i t h e r f r s n i h e m o n u f o c t u r e r ' sw o r k s o r o n e o f o u r r e p r e s e n t o t i v e s .
c n nt h e n b e s e n t i n f o r r e p o i r e i t h e r t o u s o r o n e o f o u r r e P r e s e n t o t i v e s .
D36 5642E
J.J-
O P ER A TI O N
NR
0 p e r a t i n 9 D if f i c u l t ' i e s
E m e r q e n c y0 p e r a t i o n w i t h
53
I n o p e r a t ' iv e T u r b o c h a r g e r
If, for the time being, there is no possibifity to_repair the inoperative turbocharger(s), the engine can, in absolute emergencleS'
b e f u r t h e r r u n w i t h r e d u c e dl o a d .
I n s u c h a c a s e , f u e l a d m i s s i o na n d t h u s t h e e n g i n e o u t p u t m u s t . b e r e d u c e d
a d m i s s i b l e e x h a u s t g a s t e m p e r a t u r e sa n d , o n
so far that the maximum
p e r m ' i s s i b l es p e e do f t h e o n e
e n g i n e sw i t h 2 t u r b o c h a r g e r s , t h e m a x i m u m
tuibocharger sti11 in operation are not exceeded.
In addi ti on, the fo1lowingapplies to the inoperative turbocharger:
I n t e r r u p t i o n o f e n g ' i n eo p e r a t i o n n o t
possible:
T h e i n o p e r a t i v et u r b o c h a r g e r e m a ' i n isn p 1 a c e .
of
T h i s e m b r g e n csyi t u a t i o n h o u l d b e c o n f i h e dt o a n a b s o l u t em i n i m u m
to the tur bochar gercannot be excluded.
t i me a s a i ti o n a l d a mage
I n t h e e v e n t o f r o t o r b i n g s t a t i o n a r y , l u b e o i l s u p p l yt o t h e f a u l t y
t u r b o ch a rg e rmu st a t a ny r te be cut off due to r isk of fir e.
?.
I n te rru t i o n o f
lne
er ati on
ssible for
r i od
time
F or me a su re sto b e ta ke n on the engine' r efer t o 0 p e r a t i n g I n s t r u c t i o n s

c o n c e r n i n gt h e e n g i n e .
I n ca se th a t fu rth e r co nductionof the exhaustgasesthr ough the f aul tY
'l y:
t u r b o ch a rg e ri s co mp usor
ca rtri d g e o f faulty tur bochar gerand r e p l a c e b y s e a l i n g c o v e r
R e mo ve
( r e f e r t o s e c t i o n 4 , w o r kc a r d 5 0 0 . 0 5 ) .
I f , i n c a s e o f e n g i n ew i t h 2 t u r b o c h a r g e r sc, l o s e - o f f o f t h e c h a r g ea i r
a n d / o r e x h a u s tl i e o n t h e f a u l t y t u r b o c h a r g e irs r e q u i r e d :
R e m o vfea u l t y t u r b o c h a r g e cr o m p l e t e( c f s e c t i o n 4 ' w o r k c a r d 5 0 0 . 1 0 ) .
D e p e n d i nogn e n g ' i n ev e r i i o n , c l o s e o f f ( s e a l ) o r r e c o n n e c t h e l i n e s
co n ce rn e d .
r.O
@
(o
D36 564?
3.53-2
NA
NR
FAULT- FINDING
CHART
54
DEFICIENCES
o
L
g
f
L
L
6
I
a
L
L
q
E
c
6
L
=
o
Silencerresp.air fiiter clogged

Conoresso
d ri r t y
l,Jozzl
e rj n9 di r"ty
r irty
ir cooled
h j o h i n i a k ea i r t e m p e r a t u r e
:iii:ii|:'.ii:i:
: 3 i ' I f i t K a l r t e m D e r a t U n e
i r a nf io l d 1e a k ni 9
i x h a u s tp i p e i e a k ni g
aftenturbine
Highgasbackpnessune
Fa ut ' iy f u e l i n j e c i io n o n e n gni e
B e a rni g d a m a g e
T u r b i noer j m p e 1 ' ldear m a g e d

Rotorcontact
F o r e i gm
n a t t ejrn t u r b i n eo r i n p e l l e r
L a b y r i n trhi n go r l o c a t i n gr i n g d a m a g e d
S e as' l o a m a g ecdo, n n e c o
t i n s 1e a k ni g
L u b eo j i p a s s a g e fsj ,l t e r c l o g g e d
[ x c e s svi e p r e s s u r ei n o i I d i s c h a r g eo r i n c r a n k c a s e
valvesdirty
lnlet ano/orexhai.st
L o c k - a i rn e f f e c t i v e
gauge
ve
defecti
0iI pressure
HighoiI aonjssion temperature
o.
r\
D36542 E
3 . 5 4- r
L
I
P O S S I B LCE A U S E S
a
L
ABGASTURBOLADER
EXHAUST
TURBOCHARGER
TURBO-COMPRESSEUR
TURBOS
OBREALIMENTADOR
SOBREALIMENTADORES
A GAS DI
TURBOSOFFIANTl
WARTUNG
AAAINTENANCE
ENTRETIEN
ENTRETEN
IMIENTO
A4ANUTENco
AAANUTENZIONE
D3550
4 . 5 0- l
I.IA
I NTENANCE
Man
' i t e n a n c eS c h e d uel
NR
5't
T h M A I N T E N A NSCCEH E D U iLsE a s u r n m a royf a l ' l m a i n t e n a n c ew o r k u p t o a m a j o r

o v e r h a u ' lo f t h e t u r b o c h a r g e r e v e r y 1 2 ' 0 0 0 t 1 8 ' 0 0 0 o p e r a t i n g h o u r s '
A ' l w a y sw h e na m a j o r o v e r h a u l o f t h e t u r b o c h a r g e r h a s b e e n c a r r i e d o u t - f o r
p r a c t i c a ' l c o n s i d e r a t i o n s i n c o r n m owni t h a n e n g ' i n em a i n t e n a n c eb e i n g d u e t h e m a i n t e n a n c se c h e d u l ei s t o b e s t a r t e d a n e w .
I n c o n s i d e r a t i o no f t h e o p e r a t i o n a ' ls a f e t y o f t u r b o c h a r g e ra n d e n g i n e' l,at theer
m a i n t e n a n cw
e o r k s h o u l d b e c a r r i e d o u t a s t ' i m e 1 ya s p o s s i b l e a n d n o t
t h a n s c h e d uel d .
C r o s s - s e c t i o n so f t h e c o m p r e s s obr e i n g r e d u c e db y l a y e r s o f d i r t w i l l a d v e r s e l y
o f t h e e n g ' i n e .T h e r e f o r e , ' i f o p e r a t i n g i n a r e a s o f
effect the performance
h e a v yd u s t c o n c e n t r a t i o n si n t h e a ' i r , s h o r t e n i n go f t h e c l e a n ' i n gi n t e r v a l s
s a yb e r e q u i r e d .
f o r t h e c o m p r e s s o cr o m p o n e n tm
F o r c h e c k st o b e c a r r i e d o u t d u r i n g o p e r a t i o n i n r e g u l a r i n t e r v a l s , r e f e r
t o s e c t i o n 3 , s h e e t5 . l .
WORK
P o s n . MAINTENANCE
S er V1 c e
I nterval
i n Hours
Work
Card
No.
50.l
u r in g o p e r a t ' i o n :
C O M P R E SC
SL
OERA N I NdG
A c t u a t e c o m D r e s s ow
r a s hni g a p p a r a t u s
every 24
500.08
502 * )
d r y c l e a n ' i n)g d u r i n g
T U R B I NCEL E A N I N(G
o p e r a t io n : A c t u a t e t u r b i n e c l e a n in g
a p p a r a t us
every 24
5 0 0 0. 7
503*)
w e t c l e a n in g) d u r i n g
T U R B I NCEL E A N I N(G
o p e r a t io n: A c t u a t e t u r b i n e w a s hni q d e v ' i c e
every 100
5 0 0. 0 7
5 0 4+ )
A I R F I L T E RC L E A N i N G :
from si I encer
Air filter removed
every
250 - 500
5 0 0 I. I
505
INSPECTION:
C h e c ka l l m o u n t i n gs c r e w s ,c a s i n g s c r e w s
a n d p i p e l i n e c o n n e c t i o nfso r t i g h t f i t
by tapping, retighten if necessary
5 0 0 .I 0
w i t h n e wo r
o v e r h a uel d
t u r b o cha r g e r
once after
I 000
506
n d i s m a n tel d c o n d ti i o n :
C O M P R E SC
SL
0E
RA N I Ni G
C o m p r e s s o l i n n e rc o m p o n e n t sf ,i n a ' l d ' i f f u s o r ,
c o m o r e s s ow
r heel
every
5000- 6000
5 0 0 .I 4
5 0 7+ )
CR
LTANINGd
' i 'ni s m a n t l ecdo n d i t ' i o n :
SILENCE
S iI e n c e rf e l t l ' i n in q s
every
5000- 6000
5 0 0 I. 2
508
( G E N E R)A O
MAJOR
L V E R H A: U L
D is m a n ti ln g , c l e a n in g , i n s p e c t ' i o n ,
c h e k ni g a n d c l e a n in g c a r t r i d g e , c h e c kni g
b e a r i n gc l e a r a n c e s ,c h e c k i n gg a p s a n d
c l e a r a n c e so n r e a s s e m b l v
every
1 2 0 0 0- i 8 0 0 0
5 U U 06
* ) I f o p e r a t e d o n h e a v y o i I : E ' ti h e r P o s.
D365649E
4. 5 1 - ?
502or 503depending
o n v e r s io n
'l
+ ) V e r si o n w it h s i e n c e r o n 1y
5 0 0t 0
trLL
E C
I,IAI1{ TENAl{
M a in t e na n c e l , l o r k
tl
NR
52
M a in t e na n c e b l o r k
I n o r d e r to e n su reco n ti n uedsafe and r eliable oper ation, and to keepthe tur boc h a r g e ri n g o o dc o n d i t i o n , i t i s n e c e s s a rtyh a t t h e i n s p e c t i o n sa n d c h e c k st o
b e ma d ea t ce rta i n i n te rva' ls ar e car r ied out in accor dance
with the M ai ntenanc e
S c h e d u l e(sh e e t 4 .5 1 ). C a r eful obser vationof the tur bochar gerper foi Ei ffi i T f
e6"lEThe personnelto detect any deficiencies in goodtim.
Dismantling
o r p a r t i a l d i s a s s e m b loyf t h e t u r b o c h a r g esr h o u l d ,h o w e v e rb, e l i m i t e d to th e w o rk to b e ca rr ied out within the scopeof the M aintenan cSc
e hedul e.
M i n or d e fj ci e n c'i e sca n n o rm allybe r epair ed by the enginer oomper sonnel .But
a l y l n ve sti g a ti o n s o r w o rk beyondthis scopeor the r epair of m ajor da m age
s h o u l do n l y b e c a r r i e d o u t i n t h e m a n u f a c t u r e r 'ws o r k so r b y o n e o f t h e s e r v i c e
s t a t io n s b e ca u seth e y a re equippedwith the necessar ybalancingmachi nesfor
d e t e rm'i n i n g
a n y ro to r i mb a' lance,
r otating par ts are s ens i as these h' igh- speed
t i v e to a n y ro to r-ma sse ccentr icity.
e da t a car tr idqe be keot on stock or be or der edin t he ev ent
I t i s re co mme n dth
of rotor or bearing damag-lflifi ls thb quickest way of repair and resum'ing
e f t g i ! 9o p e r a t i o n .T h l s c a r t r i d g e c o m p r l s etsh e b e a r i n gc a s i n gw i t h b e a r i n g sa n d
t h e f itte d a n d b a l a n ce dro tor nd thus a' ll wear par ts. Theseals and g as k ets
n e c e s s a r fyo r i n s t a l l a t i o n o f a n e wc a r t r i d g e a r e s u p p l i e dw i t h i t .
T h ew o rk to b e p e rfo rme do n the tur bochar geris exactly descr ibedon t he w or k
c a r d ss t e p b y s t e p i n s e q u e n t i ao
l r d e r . T h eq u e s t i o nw h e t h e ri t w i l l b e e a s ' i e r
l e e tu rb o char ger in place or after r emovingit, dependson the
t o d ' i sa sse mb th
s p a c ec o n d i t i o n si n t h e e n g i n er o o m .I n m o s tc a s e s ' i t w i l l b e s u f f i c i e n t f o r t h e
p u r p o seo f ca rryi n g o u t maintenance
and inspectionwor k to r emoveonly s ec ti ons
o f t h e u n i t . D i s m o u n t ' i nt hge c o m p l e t et u r b o c h a r g efrr o m t h e e n g ' i n ei s n o r m a l l y
n e c e s s a roy n l y f o r a g e n e r a lo v e r h a u l .
I f ' d u r i n g d i s a s s e m b ' ld
y , y b o l t o r n u t s h o u l dr e s i s t r e m o v a lb e c a u s e
it has
s e i z e d , a vo i d u si n g e xce ssivilfTcE- llffich
is liable to destr oy the par t and
fitate
replacmenA
t . l s o , t h i s m a yr e s u l t ' i n t h e n e e dt o r e c u t t h r e a d so r
t o d r i l l o u t f r a c t u r e d b o l t s t h a t a r e s t u c k i n t h e c a s i n g . T h e b e s t m e t h o dt o
s t a r t w i t h i s t o t r y t o f r e e t h e t h r e a d sb y t u r n i n g t h e b o l t s o r n u t s c a r e f u l l y
b a c ka n df o r t h , u s i n g D i e s e lf u e l o r a h i g h l y f l u i d s p e c ' i a a1 g e n t( e . g . C a r a m b a
o r O m n i g l i s s )T. h e s es o l v e n t ss h o u l db e a p p l i e dl i b e r a l l y a n d a l l o w t o a c t u p o n
t h e bo l te d o r scre w e dj o 'i n t for sometim e ( 1/2 hour or mor e) so that they w i l l
b e a b l e to p e n e tra teri g h t downinto the thr eads. The r ecomm endations
i s s ued by
t h e m a k e r so f s u c hs o l v e n t ss h o u l db e o b s e r v e d .
B o l t s a n d n u t s u s e di n j o i n t s e x p o s e tdo e l e v a t e dt e m p e r a t u r e s ' a rme a d eo f n o n s c a T gm te ra l s. In o rd e r to
e' ing sub s tituted
b y m i s t a k e ,n o n - s c a f i n n
g u t s a r e i d e n t j f i e d b y a s m a l lc o l l a r a t t h e i r e n d f a c e ,
a n dn o n - s c a l i n g
bolts are marked
b y i d e n t i f i c a t i o n l e t t e r s o n t h e i r h e a d .B o l t s
a n d n u ts ma d eo f n o rma lmater ia1ar e unsu' itablefor assem blyof these c om ponents
D u r i n gd i s a s s e m b l yc,a r e s h o u l db e t a k e n t o s e e t h a t t h e s e n o n - s c a l i n gb o l t s a n d
n u t s a r e n o t m i x e du p w i t h n o r m a lo n e s ; ' i f n e c e s s a r yt,h e y s h o u l db e k e p t s e p a r a t e u n t ' i l r e a s s e m b l yI.n o r d e r t o p r e v e n tb o l t s a n d n u t s f r o m c a r b o n i n gi n
p l a c e a n d t o f a c i l ' i t a t e f u t u r d i s m a n t l i n g ,s u c hs c r e w e d
c o n n e c t i o na
s n dt h e
s e a t i n ga r e a ss h o u l db e c o a t e dw i t h s p e c i a l l u b r i c a n t s e v e r y t ' i m et h e y a r e a s s e m b l e dT. h i s a p p fi e s e s p e c ' i a l 1t yo a l l b o l t s a n d n u t s o n t h e t u r b ' i n ee n d . S u i t a b le l u b r i c a n t sa r e , f o r i n s t a n c e ,M o S z - b a s el udb r ic a n t s w h ci h a r e a v a il a b le i n
e S C f) o r - t h i s p u r p o s eB
f o r m o f p a s t e s( e . g . M o 1 y k o t H
. e f o r ea p p l y i n gt h e s e 1 u b r i c a n t s , t h e t h r e a d ss h o u l db e t h o r o u g h l yc l e a n e df r o m a l l f o r e i g n m a t t e r .
T h r e a d so f s t u d b o l t s r e m a i nu n t r e a t e d .
D 3 65 6 4 9
52-2
T.0
CI e a n in q A i r F i I t e r a n d S i I e n c e r
T h e a j r f i l t e r a n d th e si l e n ce r mu st be cleanedas necessar y'the inter vals
betw e e nc l e a n in g b e i n g d e p e n d e not n the contam lnationof the air dr awnin.
CI e a n in g C o m P r e s s o r
nill r educethe am ountof air
F o u l i n g o f t h e a i r p a ssa g e isn th e compr essor
i i v e i e . T h is i s i n d i c te d b y a d ecr basein char geair pr essur eat a given
and
pu . u i i n g p o i nt o f th e e n g i n e n d ,as a r esult, exhustgas temper atur es
vary
i
s
.
r
e
q
u
i
r
e
d
c
l
e
a
n
i
n
g
n i l l g o p . T h e - i n t e r v a l sa t w h i c h
i l c o n i u i n p t i ow
the
air
pur
ity
qf
r
elative
the
a i o r d i n gt b sp e ci fi c p e rh ti n gco nditions and
the
when
washed
or
be
cleaned
ttrt ttre compressor
.*n in] tt ii recomreirded
c h a r q ea i r p r essu rea t a g i ve n o p e rating' polnt and a given temper atur eof the
4%thoughthe air filter is
h a s h ropped- m brthan
e
f f ip r e s s r
i n a c l e a n o n d i t i o n .
Th e r ea r e t w o me th o d so f cl e a n i n g :
Cll e a n i n g
l. Mechanica
I n o r d e r t o c le a n o u t d i rt d e p o si tsmechanically,it is necessar yto_r emove- wheel.( im peller
casing. The compr essor
i. s i i e n c e . an d th e co mp l e teco mpr essor
is l e f t o n t h e ro to r sh a i t (tu rb i n e shaft) dur ing the cleaning oper ation.
Fu e l o r a n o t he rl i q u i d so l ve n t i s usedto washoff the deposits. Gr eat car e
m u s t b e t a k e n to ke e pth e l i q u l d o ut of the bear ingbush and the char geair
p ip e .
d-urijlgOperationby WashingSystern
?. Cleaningof Compressor
A w a s h i n gs y s t e mi s a v a i l a b l et o c l e a n t h e c o m p r e s s oarl s o : ! ' l ri n g - :p ' . r r a t i o na s
l o n - s e p s i t b u i l d - u p i s n o t t o o f a r a d v a n c b(dc f w o r k c a r d 5 C 0 . 0 8 ) .
CI e a ni n g o f T u r b in e
I t i s p o s s i b l et h a t a w a s h i n gd e v ' i c ef o r c l e a n i n gt h e _ t u r b i n ed u r i n g o p e r a t ' i o n
( o p t i o n a l e q u i p m e n t-) ( c f w o r kc a r d 5 0 0 . 0 7 ) .
is mounted
I n s p e c t in g / C h e c kni g C o m p o n e nPt a r t s
0n o c c a s i o no f a g e n e ra l (ma j o r) o v er haulof the tur bochar ger ,or whenunder to
ar e concer ned,we r ecomm end
g o i n g r e p a i r s , a n w h e ne sse n ti a l c om ponents
into
a k e - n o t b so n th e co n d 'i t'i o no f th e individual par ts and to enter them
the log book.
A b l a n k f o r m " T e s t R e s u l t s "' i s a t t a c h e da s a s a m p l e .
F o r j u d g e m e notf w e a r , r e f e r t o t a b l e " G a p sa n dC l e a r a n c e s " ' i ns e c t i o n l .
D 3 6 5 6 4 9 E/
4.52-2
@
G'
52)
1, sheet
i sfoctonr
Goos
ondcteononces(section
o sot
bent
.... ... nil
mocked
T r o n s v e npst o
el o f n o t o n .
B
leoding
edges AxioInunout
o on
on
btodes
. . . .. . ,, . . . . . .. . . t n
o
o f c o n p n e srshoere l
of contoct. o no
tnoces
O rr.
. . . . . . . .n n
R o d i so ot p . . . ' . . . . O
locoI
o totoIcircurfenenceA x i osl o p . . . , . . . . . @ . . . . . . . m n
o nodio[ oxiol, R o d i 0o 0t p . . . . , . ' . , . . . . . O . . . . . . . .n r n
o
O
C o n p n e sr hs e
oe
r .t . .
Ibtodes)
b foneign
donoged
notten.
(599.001
)
Contridoe
B
o
neused
neptoced
disosserbted
A x i ogt o p ...... . . . . . . . . . @
A x i ocl t e o r o n c e . . . . . . . . . O
, . . . ., . . r r r !
. . . . . . . .l n n
IDGE
C O N D I T I OO
N F S I N G L EP AR T S O F C A R T R
I
Q neused
cosino(517.0011
Beonno
Q neused
+
517.017 t517.087)
Q neptoced
Q neptoced
possoses
lock-oir
-r
p
o
s
s o g e t - . \ X ; ' - 8 :|||1. covoned
oil
neused
Tunbine
roton(520.ffi)
Q
O neptoced
\,/ \,/ cl,oon
O O nestnicted f i c t i o n o Ix i d c l i o n
O O ctossed
ne0s0n:
. . . . . . . . . r . r . r . . . . . . . . . . . .. . .
Ono
O rtt
ne0s0n:
bush(517,m2) O neussd
Beonino
(520.005)
rhee[
Corpnesson
Q neptoced
Q t u n b i n es i d e
Q c o t p . e t t o n si d e
B
o
soti sfoctonr
i um
med
q u o t i tor f f i t
p00n
spocen
sreeve(bl7.oo3t
B ffii:l.o
nins(520.006)
Lqbyinth
n 0 0 s 0 n.. , .
neused
o
o nepI oced
B e o n i n o s t e e v e ( 5 1+7 . 0 0QSn1e u s e d
Q neptoced
C neused
O neptoced
(520.000J
Roton
Coven[517.ffi9)+
Q neused
Q neptcced
nebotonced..
c o n d i t i obne f o n e
rebotoncing...
S e o t i ncoo v s nt u. n b i nsei d e O n e u s e d
( 5 1 7 . 0 1+7 )
Q neptoced
Peos0n:
Qo^lo
Ono
O r.t
....O sotisfoclonl
C o
.C) no,,"o.l
.rp[...
+ if pnovided
Rsnorks:
';i;;;i;;'
036564eE/4.53-2
AAAINTENANCE
WorkCords
NR
Ir
W o r k C o r d s
'lhe
Wqk Cordssupplied with the Qcroting Monrol ore consecutive
'ly numberedond orronged
in the ordcr of operotionsrequired fq mointemnce ond inspcction o well os the replocement
of the cortridge (cf List of Work Cords500.01). The instructionsgir/en on the individuol cords
relote only io the iob stotcd in the heoding. Dependingon the scrpe of overhoul or repoir
wdk, one or severolWak Cordsmoy be required (see ReferenceToble).
lhe numbering of the Wqk Cqrds is bosed on o fivc-digit code, the 'iirst 3 digits of which ore
the ccnponent code which is 500 fq turbochorgers, the lost 2 digits being o consecutivenumber.
&omple:
500
t-I
12
-r
I
CoruecutiveNumber(l 2 Cord)
CodeNumberfq Turbrrchorger
the Work Cords include guiding informotion on fhe omount of time or'd monpouer required
(monhours).Thefime indicotcd oppliesarly to the set of opffiF
TorffiJob eescribed
(1. fo disqssembly
or removolond 2. fo ossemblya irstollotion) orr the cord concerned.
The informoiion given is on the uridcrslsrdiogthot the personnel employed is fomilior with the
wsk involved ond thot oll necessoryiools ore ot hond. lt is olsoosrumedthot the turbochorg,
is reodily occessibleond thot o hoist is ovoiloble for lifting off the Ireovy ports. Furthermore,
the times shownore bosedon o ndmol condition of mointenonce. T1
re nomedtimes moybe
consideroblyexceededwhen ports hove suffereddomoge.
.O
o
N
D36 5&2 E
4.y-3
E
1.IAI NTENANC
Brief Hints
B r i e f H in t s
T h e t a b l e b e l o w l i s t s t h o s e w o r k c a r d s w h i c h a r e r e q u ' i r e df o r t y p ' i c a 1
m a i n t e n a n c ej o b s .
M a 'ni t e n a n c e J o b
l , l o r kC a r d s r e q u i r e d
C L E A N I NC
GO M P R E S S O R
during operat'ion
i n d ' i s a s s e mebdl
500.08
5 0 0 . . | 0t h r o u g h5 0 0 . . | 4
C L E A N I NTGU R B I N E
during operation
i n d i s a s s e m b l ecdo n d i t i o n
500.07
5 0 0 . . | 0t h r o u g h5 0 0 . 1 9
C L E A N I NAGI R F I L T E R
i n d i s a s s e m b l ecdo n d i t i o n
5 0 0 I. I
C L E A N I NSGI L E N C E R
i n d i s a s s e m be ld c o n d it ' i o n
5 0 0 . . | . t| h r o u q h 5 0 0 . . | 2
( cEh e c k o f b e a r i n o
C H E C K I NCGA R T R I D G
c I e a r a n c e )s
with cartridge rernoved
i n d ' i s a s s e m b l ecdo n d i t i o n
5 0 0 I. 0 t h r o u g h 5 0 0 I. 7 a n d 5 0 0 . 0 6
5 0 0 I. 0 t h r o u g h5 0 0 I. I
REMOVAL
AND MOUNTING
OF COMPLETE
TURBOCHARGER
5 0 0 t. 0
GAPSAND CLEARANCES
seesection 1, sheet 5
D36 56 4 9
4 .5 5 - 3
NR2O/R
L I S T O F } I O R KC A R D S
Arb.ilrkortc-Nr.
il'.lli.. 500.0l
3.T:
Torielo trobojo No.
D e sig n ation
5OO.05
500.06
|
|
500.07
500.07
P U T T I NEGX H A U S
TU
RU
G IEORF O P E R A T I O N
T R E O C H AO
( e m e . s e n c yo p e r a t i o n o f e n g i n e)
eT
aring clearance)
C H T C K I NRG0 T 0 RF 0 R T R A N S V E R| S
t ,E| 0 V E I , I(EbN
CLEANIN
TU
G R B I N( w
E e t c l e a n i n g )d u n i n go p e n a t i o n
C L E A N I NTGU R B I N(Em e c h a n i c a l / d n cy l e a n i n g ) d u r i n g o p e n a t i o n
500.08
CLEANIN
CG
0 l 4 P R E SdSu0rR
inoooenation
5OO.1O
R E | t l O V IANNGD| l I O U N T ITNUGR O C H A R G E R
S e p a r a t i n ga n d n e c o n n e c t i n gt h e c o n n e c t i o n s
soo.11 *
CLIANIN
AG
I RF I L I T R
R E | t { O VA
I NNGDR E F I T f I NS
GI L E N C E R
500.12
D i s m a n t il n g a n d c l e a n i n g
500.13
500.14
R E l , t o V IANNGDR E F I T T I NAGI R - I N T A KCEA S I N G
R E | O V IA
NN
GDR E F I T T I NCGO I I I P R E SCSAO
SR
ING
R e m o v i n fgi n a l d i f f u s o r
R e m o v i n rge v o l u t i o n t n a n s m i t t e n
R e m o v i n gi . n s e n t
Cleaning
s00.16
R E l i | o \ / IANNGDT N S T A L L TCNAGR t R T D G E
500.17
C H E C K IA
NN
GDC L E A N i N
CG
ARfRIDGE
500.18
D ] S t 4 A N T LA
I NNG
DR E A S S E I l B LCI A
NR
GT R I D G E
I N S P E C T IO
OF
NC O l ' , | P O N
PE
AN
R IT S
500.19
R t t o \ / r NAGN DT N S T A L L TANDGl ' | I S S i C

0N
ASING,
G A SO U T L EDTI F F U S OTRU, R B I NNEO Z Z LREI N G
R e m o v ao lf i n s e r r
D 3 65 6 4 9E
500.01-3
T h e s ew o r k c a r d s a n e r e q u i n e do n l y i f t h e y a p p l y
t o t h e t u r ^ b o c h a r " gveerr s i o n i n q u e s t i o n
NR2O/R
P U T T I I { GT U R B O C H A R G E R
O U TO F O P E R A T I O N
( E n g in e E m e r g e n c 0y p e r a t ' i o n)
a s s o c i a t e d w o r k c a r d s.
.. 500.10
through 500.16
. T 0 0 j sR E Q U T R E p
596.027
I
1
1
I
1
1
501.072
501.005
501.007
50r.008
0 p e ne n d r l r e n c h ,A / F l 3
0 p e ne n d r r e n c h , A I F L 7
S o c k e t r n e n c hA, I F L 7
S o c k e tw r e n c h , A /1F9
Screwdniven
L i f t i n g g e a nw i t h r o p e
S P E C I AILO O L
7---:?-i:(available on special onden)

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(diameten
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thickness
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st
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LEGEND
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501.001
G a sa d m i s s i o cna s i n g
5 0 1 . 0 0 5C l a m p i n sgh o e
5 0 1 . 0 0 7L o c k w a s h e n
5 0 1. 0 0 8 H e x a g onnu t
5 0 1 . 0 7 2C o v e r i n gr i n g
GENE
RAL
F o r g i v e n p o s s i b i il t i e s a n d i n s t n u c t i o n sw i t h r e g a r d t o e n g i n e e l n e n g e n coyp e n a t i o n , r e f e r
t o s e c t i o n3 , s h e e t5 3 .
STARTIN
PG
OSITION
F u l l d o w n f l o wo f t h e e x h a u s t g a s e s t h r o u g h t h e d e f e c t i v e t u r b o c h a r g e rm u s t b e m a i n t a i n e d .
SEQUENC
OTF O P I R A T I O N S
1.
2.
3.
4.
5.
D i s c o n n e c ta l l c o n n e c t i o n su n t i l t h e c a n t r i d g e c a n b e r e m o v e d( c f w o r k c a r d 5 0 0 . 1 0 ) .
R e m o v ei n d i v i d u a l l y o r i n c o m m o n a: i n - i n t a k e c a s i n g , c o r n p n e s s ocra s i n g a n d c a r t r i d g e
( c f w o n k c a r d s 5 0 0 . 1 2 t h n o u g h5 0 0 . 1 0 ) .
U s i n g c l a m p i n gs h o e s ( 5 0 1 . 0 0 5 ) , l o c k w a s h e n (s5 0 1 . 0 0 1 ) a n d h e x a g o nn u t s ( 5 0 1 . 0 0 8 ) , m o u n t
c o v e n i n gn i n g ( 5 0 1 . 0 7 2 )a n d c o v e r ( S s O . O z z t) o t h e g a s a d m i s s i o nc a s i n g ( 5 0 1 . 0 0 1 ) .
S e a l u p l u b e o i l s u p p l y L i n e a n d l u b e o i l d i s c h a r g el i n e .
SeaIup line for jet assist (if fitted).
Note:
D e p e n d e not n e n g i n e v e r s i o n i t m i g h t b e n e c e s s a r yt o a l s o s e a l u p t h e c h a n g e
a i r l i n e ( n e f e r t o t h e 0 p e r a t i n g I n s t r u c t i o n s f o r t h e e n g i n e) .
I n c a s e o f e m e r g e n c oy p e n a t i o no f t h e e n g i n e , i t s p e r f o n m a n c he a s t o b e i i m i t e d
t o s u c h a d e g r e et h a t t h e m a x i m u m
p e r m i s s i b l e e x h a u s t t e m p e n a t u n easr e n o t e x c e e d e d .
T h i s h a s t o b e d o n e b y r e d u c i n gt h e f u e l d e l i v e r y t o t h e c y l i n d e n s .
D 3 65 6 4
500.05-2
Arbcrlszcrt
Worliq limc
Oure dc lrovoil
Tiemoo dc trqboio
Studcn
Hours
Hcvrct
Horos
Alle
E"ery
Tourer rci
LOOO
AS
feqUifed
Sclricbrstude
Ooeroltnq hours
Heurerdc mqr.he
O . O SO e i e r v r ( r o
NR2O/R
C H E CIK
NGROTOF
RO R
T R A N S V E RP
S LEA Y
( B e o n i n gC L e o n o n c e )
Tcjlo
tnobcjo No.
q11 n)
TOOLS
REOUIRED
1 DioIgouse
hotden
1 Diotsouse
LEGEND
517.002
Beoning
bush
520.W Tunbine
nolor
rheet
520.m5Compnesson
36156t4lx
GENERAL
J u d g e moenncto n d i l i oonf b e o n i nbg m e o s u nt innogn s v e pn tsoeyi s o n l yp o s s i b li e
n c o s eo f
l o b t n i n tshe o t so t r e o dnyu ni n ( o f t e no p p n o x , 5o0p0e n o t ihnogu r s ) .
S T A R T IPNO
GS I T I O N
S i t e n c eo no i n i n t o k ceo s i nogn dc o m p n e sc soos n
i nnge m o v oe ndc, o n t n i drgeem o v e d ,
SEOUENCE
OFOPERATION
1 . A t t o c dh i o [g o u grei t h h o t d einn s u c h
o r o r t h o tl h em e o s u npi inngo f t h eg o u gceo n t o c t hs e
c o m p r e sesnodon f t h en o t o snh o l ti n t h en o d i apl o s i t i o n .
2 . T i L tt h en o t osnh o l b
t yh o nvdi g o n o u isnt b
y o t hd i n e c t i opnesn p e n d i ct uo liot sn o x i s ,w h i t e
t o k i n gg o u gnee o d i n g
r hsi c ho n et o b en o t e d o r n .
J . R e c o m m ernndeeods u neesso, e c i a t rt yh e nc l . o steo l h eu o p eIni m i t :
[ l e o su ri nngo n g Immi
e
R
l e mo nks
R o n goef o d m i s s i btlneo n s v e npst o
e l I c o n n e s p o1nodt h
s et o t e n o n c e s
o l t h e n o d i obLe o n i ncgL e o n o nf oc n
en e r t u n b o c h o n g e n s )
1. 0 0 t o 1 . 2 5
o b o v e1 . 2 5
r-
o
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500.06-3
Anbitzit
forking liro
Duncc do lrovcil
Tirapo dc lrcbojo
I n s p e c t i o fns i n g I ep o n l so f t h ec o n t n i d b
g res p e c i iozIe ds e n v i c e
p e n s o n ndeuIn
i n g t h en e x lo p p o n liul yn.
C h e c k i nO
gu
: oi tI y o n dp n e s s uonfet h e l u b eo it .
0 p e n iant gn e ti o b L
i itt endongened.
n
e
s
p
e c t ipv o
e n t st h n o u gshp eico Ii z e ds e nivc e p e n s o n n e I
R e p I o ct h
ee
o ne x c h o ncgoen t r i d g e .
C h e c k i n g : O u oot ni tdyp n e s s uonfet h e I u b eo i l .
Stundon
Hous
Hcurcl
Honor
ll:,
Toulcc (cs
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Hcunca dc nonchc
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NR,NA
TURBII{E
CLEANI]IG
W e t C l e a n in g ( t . l a s hni g)
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Arbrilrko.-Nr.
y.T:;T"a"il"".500.07
Torilo troboio No.
LEGEf{D
I E x h a u s gt a s t u r b o c h a r g e r
2 E x h a u sm
t anifold
3 l a t e r s u p p l y( f r e s h r a t e r )
4 t f a t e rd n a i na f t e r t u r b i n e ( i f i n s t a l l e d )
A S t o pc o c k
B P n e s s u nnee d u c i n gv a l v e r i t h p n e s s u r eg a u g e
NU
GT - } A S H I N G
I h n e e - r a y - c o c k i t h p l a t e : Z E R 0 - B L 0 l { I O
(
Z
e
r
o
p
l
a
t
e
:
position)
U
w
i
t
h
Three-way-cock
I
OO
OOO
D r a i n a g ec o c k i f i n s t a l l e d )
( = C h e coko s i t i o n )
( = I t a s h i npgo s i r i o n i
36 12260
N o t e N u m b e ra n d a r r a n g e m e n o
t f e x h a u s t m a n i f o l d s d e p e n do n e n g i n e t y p e a n d m a y n o t c o i n c i d e w i t h
i l l u s t n a t i o n . F o n w a s h i n gt h e t u n b o c h a n g e ne,a c h i n d i v i d u a l e x h a u s tg a s l i n e i s e q u i p p e d
w i t h a s e p a r a t e t h r e e - w a y - c o c k( D ) .
Useonly fresh raten for washing.
f o a v o i d d a n g e no f b u r n s , u s e p r o t e c t i v e g l o v e s .
GEIRAL
C l e a n i n gi n t e n v a l : R e f e nl l a i n t e n a n cSec h e d u l S
eection
S h e e t5 l
In order to savetime, rashing is recommende

bd
riefly after stanting the engine,as at that time,
t h e p a n t s t o b e w a s h e da r e n o t y e t t o o h o t . I h u s , o p e r a t i o n a s p e r s t e p 2 o f s e q u e n c eb e c o m e o
sbsolete
S E O U E NOCFEO P I R A I I O N S
A l s o r e f e n t o p l a t e o n t h e e n g i n ew i t h c l e a n i n g i n s t r u c t i o n s .
1 . R e d u c ee n g i n e l o a d t o 1 0 - 1 5 o/6 .
2 . Fo l l o w i n g n e d u c t i o no f e n g i n e I o a d f n o m a h i g h e r r a n g e , r r a i t f o n a p p r o x. l 5 m i n u t e s
(status of iner"tia).
3 . E x a m i n ea l l t h n e e - w a y - c o c k(s0 ) c o n s e c u t i v e l y ,f i r s t i n C h e c kp o s i t i o n = a O ( i f e x h a u sgta s
d o e s n o t b l o w o u t , t h e a p e n t u r et o t h e e x h a u s tq a s l i n e i s b l o c k e d a n d m u s b
t e f n e e dw i t h a
2 . 5 m md i a . p i e c eo f w i r e ) ,
t h e n s e t t o l i a s h i n gp o s i t i o n= O O O .
4 . 0 p e n d n a i n a gceo c k ( E ) o f w a t e rd r a i n ( 4 ) c h e c k i f e x h a u s to a s b l o w s o u t
i f n e c e s s a r y ,f r e e
pnovided).
5 . S e t t h r e e - w a yc o c k ( C ) t o B I o w o u t p o s i t i o n .
6 . 0 p e n s t o p c o c k ( A ) o f w a t e n s u p p l y ( ) , s e t r a t e n p r e s s u r e t o 2 b a r a t p r e s s u r e n e d u c t i o nv a l v e ( B )
c n e c Kp n e s s u n eg a u g e .
7 . S e t t h r e e - w a yc o c k ( C ) t o l , l a s h i n g
position.
8 . l { a s h i n gp e r i o d i s l 0 r n i n u t e sa t 2 b a r n a t e n p r e s s u r e ( c h e c k a t p n e s s u ngea u g e ) .
9 . C l o s es t o p c o c k ( n ) o f w a t e r s u p p l y ( ) .
1 0 . S e t t h r e e - w a y - c o c k( C ) b r i e f l y t o p o s i t i o n B l o r i n g o u t , t h e n t o p o s i t i o nZ e r o . .
1 1 . S e t a l l t h r e e - r a y - c o c k(sO ) t o p o s i t i o n Z e r " o= |
J . 2 . C l o s e d r a i n a g ec o c k ( E ) ( i f p n o v i d e d ) .
I 3 . R u n t h e e x h a u s tg a s t u n b o c h a r g e ar t n e d u c e de n g i n e I o a d f o r l 0 m i n u t e st o a l l o w t u n b i n et o d n y ,
o p e n i n g( i f
t h e n g r a d u a l J . yi n c n e a s el o a d . I f v i b n a t i o n s o f t u r b o c h a r g e ra r e o b s e n v e tdh a t d i d n o t e x i s t b e f o n e c I e a ni n g , n e p e a t w a s h
i ng process.
I f v i b r a t i o n sc a n n o tb e e l i m i n a t e db y r a s h i n go n a c c o u n ot f e x t r e m ed e p o s i t so f d i r t , t h e
t u r b o c h a r g emnu s tb e d i s m a n t l e ad n d t h e r e s p e c t i v ep a r t s m u s tb e c l e a n e dm e c h a n i c a l l y .
Note
UJb
5b49
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A.bc,tizcrr
Ticmgo dc lroboro -
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^
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NR:100,NA:250
le
a
AS
.
fequlfgd
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Hcvras dc rura he
Ho'o< dc 'crvr<io
NR, NR/R
CLEANI NG TURBI NE
( D n r C Ie o ni n s)
500.07
1
2
3
l+
5
A
B
C
D
E
gostunbochorgen
Exhoust
gosIine befone
tunbine
Exhoust
Contoiner
Coven
Hosefor coprsesod
oin
Slopcock
Stopcoch
Slopcock
Couptins
Coupting
GENERAL
ondonnongenenl
rith
Nunber
of exhoust
onsnginet/pe ondno/ not coincide
nonifotds
depend
g
o
s
r idt h
ittustnotioF
n .o nc t e o n i ntgh e t u n b i n ee,o c hi n d i v i d u oelx h o u s t t i n e i s e q u i p p e
connscton
before
o ssponoto
rith stopcock(A)
nippteof shortdislonce
ondptugging
turbine,so thot thecontoinen(3)
noybecoupted
on.
gnonutoted
Foncteoning.lhe
tunbins,
or niceof 1 rm
conbon
nut shetts,octivoted
( n o x1. . 5 n n )o n o i ns i z ec o nb eu s e d .
penexhoust
gosIine fon lunbochongen
Ftl.-nquonlities
t/pe
NR20, NR15/R, NR20/R r
0 . 3 Li t e n s
A,2
NR26, l',R2/+/R,NR26/R :
0.t- Ltens
0.3
(, Sheet
intervot: Refen
Cteoning
51.
to l'|ontenonce
Secton
Schedute
C l e o n i nt og b ec o n r i eodu to f n o n n ootp e n o t i o nt ooot do f e n g i n et ,h e n e f o ndeo,n o tu s e
rotenrhencteoning
tunbine@
Toovoiddongen
of bunns,
gtoves.
usepnotective
D u n i ntgh ec t e o n i npgn o c e si ts i s p o s s i b tteh o l d i n l r p o n t i c t ensr ob/ ee m i t t etdh n o u gt h e
chi nner.
SEOUENCEOF OPERATI ONS
A t s on e f e nt o p t o t eo n t h ee n g nyei t h c t e o n i nign s t n u c t i o n s .
1 . C h e cokt I e x h o u g
s to sI i n e so s t o r h e t h eenx h o u g
g en e s p e c s to sb l o v so u tb l o p e n i nt h
t i v e s t o pc o c k ( A i)f, n e e b
d e ,f n e eo p e n i nygi t h o p i e c eo f r i r e . C t o s set o pc o c k ( A ) .
2 , C o n p n e sosiend
h o s e ( 5t )o b ec o u p t eodno l l o c o t i o n ( DA) i. np n e s s uonpep n o x .-47 b o n .
o nq u o n f i t y
3 . 0 p e nc o n l o i n e n (b3/ )u n s c n e r icnogv e n ( / f*i)l,. l . i n g n o n u t o tseudb s l o n(cl e
nelen
l o t o b t e )C
. t o s ceo n t o i n e
t i ng h t t ro n dc o u p toeno l I o c o t i o n ( E ) .
lr, Open
stopcocksin sequenco
is beingblornin. DunoA - B - C. Gnonutoted
substonce
t i o n o l b I o r i n g - ipnn o c e sd se p e nodnsc o n p n e sos endo n de x h o u g
s fo sp n e s s u n e .
5. Close
s t o pc o c k si n s e q u e nAc -e B - C . C o n t o i n teonb ed i s c o n n e cot ef L
docotion{E).
B t o vo f l o i n p n e s s uinnec o n t o i n eb nr b n i e fo p e n i nogf s t o pc o c k ( B ) .
h o ug
s to sI i n e s .
0 . R e p e o tp e n o t i o3n -s 5 f o nn e r r r o i nei nx g
7, lf openotin
oo
n t i n gns o t i n p n o v ende, p s oodp e n o t i o3n-s 6 o f t e nl 5 n i n u t e s .
Note Lightsungng
duning
of conpnesson
on tenpoonl
spood
dnopof tunbochongen
p
n
o
c
e
s
s
cteonin0
i s n oc o u soef c o n c s n .
C'\
4'
0365619E
500.07-2
.Fkll llr.
u do lcvoit
lrr
dr thJo
- lu.
- llu
- l|l.o
rr
2l+
i ned
As nequ
llc
d aaFvlol.
CLEAIII]IG
COTPRESSOR
TEGEI{D
I
2
3
4
5
6
7
8
9
ilote
C h a r g i nagi r l i n e
lubc
H y d r o ; c t ccr o c k
Hoc
.Containcr
S c r c rp l u g
Hoe
S p r a yt u b c
E x h u sg
t a st u r b o c h a r g e r
(conprcsso
r sing)
ca
Dependino
g n t y p e o f e n g i n e a n d / o r t u r b o c h a r g e r ,t h e i n d i v i d u a l c o m p o n e n tms a yb e a r n a n g e d
in a slightly different nanner.
GEIIERAL
C l e a n i n gi n t e r v a l :
R e f e r l l a i n t e n a n cSe c h e d u l e
S e c t i o n4 , S h e e t5 l
C l e a n i n gi s o n l y t o b e c a r r i e d o u t h e n e n g i n ei s n u n n i n ga t o p e r a t i n gt e m p e r a t u r ae n d f u l l l o a d .
0 o n c t s t o p e n g i n e i n r r n e d i a t e layf t e r c l e a n i n g .
U s ef r e s h r a t e r o n I y , f o r c l e a n i n g .
S E Q U E l {O
CF
EO P E R A I I O I { S
A I s o r e f e r t o p l a t e o n t h e e n g i n er i t h c l e a n i n gi n s t r u c t i o n s .
l . R u ne n g i n ea t f u l l l o a d .
2 . 0 p e n s c r e r p l u g ( 6 ) a n d f i l l c o n t a i n e r( 5 ) r i t h c l e a n f r e s h r a t e r .
3 . C l o s ec o n t a i n e rr i t h s c r e r p l u g ( 6 ) .
4 . D e p r e s sp u s h - b u t t o no f h y d r o n c t e rc o c k ( 3 ) f o r a b o u t 2 0 s e c o n d s .
T h u s ,c o n p r e s s eadi r f l o r s f r o r t h c c h a r g i n ga i n l i n e ( l ) v i a t u b e ( 2 ) , h y d n o m e t ec ro c k 3 a n d
h o s e( 4 ) i n t o t h e c o n t a i n c r( 5 ) .
I h e c o n p r e s s eadi r i s f o n c i n g t h e r a t e r f r o r t h e c o n t a i n e rt h r o u g ht h e h o s e ( Z ) t o t h e s p n a y
t u b e ( 8 ) a n d f i n e l y d i s p e r s i n gi t t h e r e .
Causeb
d y t h e h i g h s p e e do f t h e r o t o r , t h e r a t e n d r i p l e t s a r e i r n p i n g e rdi t h h i g h v e l o c i t y o n
t h e i r n p e l l e rv a n e sa n d t h e f i n a l d i f f u s e r , t h u s r a s h i n go f f t h e d i n t l a y e r n r e c h a n i c a l l y .
@
(D
@
0365649
500.08-2
Abailrrar
Wo?lg lia
Ovra. c. trovoil
Ti.mgo d. Irobcio
Slua
Hoe.r
H.u.rr
Ho.o
Afla
Ercty
0.
,A
3-
rovtcrer As required
Sclrrebtelve^
Oocrotrg hou"
l::::*",fii:,:'
NR2O/ R
R E } I O V I NAGN DI , I O U N T I N G
Arbcilrkorlc-Nr.
g.'.i:,':J"t
ilRi". 5oo.I o
Torjctq lrobqio No.
TURBOC
HARGE
R
TOOLSREQUIRED
I
I
I
I
l
l
I
0 p e n - e n dw r e n c h
LEGEND
SI{I3
0 p e n - e n dw r e n c h e ssti l7
0 p e n - e n d r i r e n c h sti l9
Socketwrench
s}l I7
Socketwnench
slr 19
544
545
I
2
3
4
Scnerdniven
Lifting gear with r0pe
l , l o S-,l u b r i c a n t
Silencer
5
A i n - i n t a k ec a s i n g
6
Air admission
7
C o n n e c t i o cno t n p n e s s o r 8
c l e a n i n ge q u i p m e n t
9
Revolution
transmitter I0
C o n n e c t i oj ne t a s s i s t l l
Air outlet
ShieId,2-pant
L u b eo i I a d m i s s i o n
L u b eo i I o u t l e t
Casing foot
t x h a u s te x i t
E x h a u sitn l e t
I i l E I G H To f t u r b o c h a r g e r
with ain intake casing.
.305 kq
....320 kq
xith silencen.
GENERAL
D e p e n d i nugp o nt h e s p a c ec o n d i t i o n si n t h e e n g i n er o o m ,t h e d e c i s i o n m u s t b e m a d ea s t o w h e t h e r
t h e t u r b o c h a r g eirs t o b e d i s m a n t l e dc o m p l e t e l yo n i t w il I s u f f i c e m e r e l v t o r e m o v es u b - a s s e m b l i e s
fromthe tunbocharoer.
S T Q U E | \0' F
| C0EP t R A T I 0 NI ,S R e m o v i n(gr e l e a s i n g )c o n n e c t i o n s
I.
2.
3.
4.
5.
R e m o vl ei n e a t a i r a d m i s s i o (n1 ) o f t h e a i n - i n t a k ec a s i n g( i f i n s t a l l e d ) .
R e m o vI ei n e a t c o n n e c t i o fno n c o m p n e s scol re a n i n ge q u i p m e n( 2
t ).
D i s c o n n e ccta b l e t e n m i n a ol f n e v o l u t i o nt r a n s m i t t e n( 3 ) ( i f i n s t a l l e d ) .
R e m o vl ei n e a t c o n n e c t i o on f j e t a s s i s t ( 4 ) ( i f i n s t a l l e d .
D e t a c ho n r e r n o v lei n e a t a i r o u t l e t ( S ) o f c o r n p n e s s owr a
, t c ho u t f o n s e a l .
Note
6.
7.
8.
R e m o v aol f c o m p n e s s o
ca
n s i n g i s n o wp o s s i b l e .
R e m o vseh i e l d , 2 - p a r t ( 6 ) f r o m I a g g i n go f g a s - a d m i s s i o
n s i n g( i f i n s t a l i e d ) .
ca
D i s c o n n e cl u
t b e o i l a d m i s s i o (n7 ) a n d l u b e o i l o u t l e t ( 8 ) l i n e s .
R e m o vsec r e i l sf r o m c a s i n g f o o t ( 9 ) d e p e n d i n og n a n n a n g e m e(ni ft i n s t a l l e d )
Note
R e m o v aolf b a s i c a s s e m b l(yb e a n i n g as n d n o t o n )i s n o wp o s s i b l e .
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PointsI to 8 as above.
9 . 0 e t a c h o r r e r n o vlei n e a t e x h a u s et x i t ( 1 0 )
I 0 . H a n gt h e c o r n p l e t teu n b o c h a r g eorn t o t h e l i f t i n g g e a r w i t h r o p e s l u n g a n o u n db e a r i n gc a s i n g ,
u a t c hc e n t e ro f g r a v i t y a n d l a g g i n go f g a s - a d m i s s i ocna s i n g ( i f i n s t a l l e d ) .
l l . D e t a c ho r n e r n o vl ei n e o f e x h a u s ti n l e t ( l l ) , w a t c ho u t f o r s e a l .
1 2 . R a i s et h e t u n b o c h a r g ecra r e f u l l y a n d d e p o s i t o n w o o d e sn u p p o r t .l { h e nd o i n g s o , p a y a t t e n t i o n
t o l a g g i n go f g a s - a d m i s s i ocna s i n g a n d s i l e n c e r ( i f i n s t a l l e d ) .
l ' l o t e D u r i n gp e r i o d so f s t o r a g ea n d f o r t h e p r o c e s so f m o u n t i n ga l l a p e r t u r e sf o r a i r , e x h a u s t
g a s a n d l u b e o i l a r e t o b e s e a l e dc a r e f u l l y t o a v o i d p e n e t r a t i o no f f o r e i g n p a r t i c l e s o r
t{aIen.
3S
, R e m o u n t i nt g
h e c o m p l e t et u n b o c h a r g earn d i n s t a i l i n g c o n n e c t i o n s .
S E Q U E N0CFE0 P E R A I I 0 N
R e m o u n t i nogf t h e t u r b o c h a r g eonr s u b - a s s e m b l i ea ss r e l l a s i n s t a l l a t i o n o f c o n n e c t i o n iss
e f f e c t e d i n o p p o s i t es e q u e n coef n e m o v a l .
Note
P n i o nt o n e m o u n t i n gn,e r n o vper o t e c t i v e p l u g s f r o m p i p e s .
I ' l h e nr e m o u n t i n gu, s e o n l y s e a l s a n d l o c k i n g p l a t e s t h a t a r e i n p e r f e c t c o n d i t i o n .
S c n e w as n d n u t s f o r c o n n e c t i o nt h e e x h a u s tg a s l i n e s a n e t o b e t r e a t e d w i t h l l o S ,
h i g h t e m p e n a t u lr ue b r i c a n t s( f . i . l l o l y k o t eH S C ) .
D 3 6 s 6 4 9 E/
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514.031
hotecticn grid (perforated plate)
W.20L Air filten mat
54/,.n2 Claryig collar
W.ns Corer plate
GN.ITRI
1tn dirty air filter mat (544.201)carbe clearedsereral ties or replacedby a nen qe.
Replacwnt is required if the a filten mt is cansiderablydilated, pluckedor perforated.
Ite increase of pressure les by qtaninatiq of the air filter rnat is insignificant arddoes
not sene as an irdicatis of the tim cleanirg is required.
CX.EAilNG
IilITRV1IS
q tle dirt cqtert of tle air pa.ssirgthrcqgh tle itake, everl' 250 - 500qeratirg tsrs.
Oeeerirg
lte optitnal tinirg for cleanirg is attained wterthe irside of the air fiLter rnat cmnces to discolcnr. ther the filter is satrratedard the catariaticn starts to advancetcrnrds the qpressor
ard the intercoler. Ite irside of the a filter mat maybe irspectedbV losenirg the external
clapirg collar (W.202l-.
SM'NS OFOPEATTONS
1. Icer clapitg collars (W.2021, rerove cover plate $44.nil
ard air filter mat (544.201).
2. ttr filter mat to be clearedR flushig with wanrwater to wtich fine cleanser had beenadded.
Aroid intersenectnnical stress (e.9. wrigi9, slnrp water jet) . Ssequently.,blor air filter
mat tlucnghrith ccrpresseda.
In caseof interse cqtminaticr it mayalso be necssaryto imnse tle air filter mat j the
cleanserard soa(it for several tsrs. It is, therefore, advisable, to keepa seccrdair filter
nat available for exctrangre.
3. Placeair filter nat (544.201)over protecticr grid (514.03)
arrdcorrerplate (544.205)over joint
of air filter rnatard fasten, usirg the clalpug collars (W.2021.
lhntirg positicn of air filter rrat: ecnpressed(mre sold) side of fleece facrg the irside.
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s f c l a r n p i nsgh o e( 5 4 6 . 0 0 5t)o t h e v o l u t e c a s i n g( 5 4 6 . 0 0 1 ) .
T h i g h t e n i n gt o r q u e t o b e a p p l i e d o n e i t h e r s i d e 8 N m .
S E Q U E N0CFE0 P E R A f I 0 N3 S
: D i s m a n t l i n g c, l e a n i n ga n d r e a s s e m b l i n g
F o n c l e a n i n gi n t e r v a l s , n e f e nt o M a i n t e n a n cSec h e d u l es,e c t i o n4 , s h e e t5 1 a n d i n s t r u c t i o n
c o n t a i n e di n s h e e t4 . 5 2 .
D e t a c ha n d c l e a n a i r f i l t e r h a l v e s( 5 4 4 . 2 0 1-) s e e w o r kc a r d 5 0 0 . 1 1 .
U n s c n ehwe x a g onnu t s ( 5 4 4 . 0 7 4 a) n d t a k e o u t f r o n t w a l t ( 5 4 4 . 0 4 1 )p, r o t e c t i o ng r a t e ( 5 4 4 . 0 3 4 ) ,
d a m p i npgl a t e s ( 5 4 4 . 0 2 1 a) n d s p a c e rt u b e s( 5 4 4 . 0 3 2o) n e a f t e n t h e o t h e r .
3 . C l e a na l I c o m p o n e pn at r t s o f t h e s i l e n c e n .
C l e a n i n gt h e f e l t i i n i n g s . I f t h e f o u l i n g m a t t e r i s d r y , t h e f e i t I i n i n g i s c l e a n e db e s t u s i n g
a n e i r h o s eo r a b r u s h y h i c h i s n o t t o o h a r d . I n c a s e o f r f s m e atry p e f fc o n t a m i n a t i o on r d i r t ,
D i e s e l f u e l o r c o n v e n t i o n ahl o u s e h o l cd L e a n s e r cs a n b e u s e d . S o l v e n t sc o n t a i n i n ga c e t o n ea r e
n o t t o b e u s e dt h o u g h ,e s p e c i a l l y i l T r i n ( t r i c h l o r e t h y l e n e ) ,b e c a u s et h i s v i l l d i s s o l v e t h e
a d h e s i v ej o i n t s .
I f f e l t l i n i n g s h a v eb e c o m e x t r e m e l y , a v yo r c o r r u g a t e d( w i t h t h e r e s u l t t h a t t h e c r o s s s e c t i o n f o r i n c o m i n ga i r i s r e d u c e d ) ,t h a s e a r e t o b e r e p l a c e d .
{ . R e a s s e m bilsy a r e v e r s a l o f t h e d i s m a n t l i n gp r o c e d u r e .
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A i r l i n e h a s b e e nr e m o v e fdr o r ni n l e t p o r t o f a i n - i n t a k e c a s i n g .
S E Q U T N0CFE0 P E R A T I 0 1
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1.
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L o o s e nc l a m p i n g
s h o e( 5 4 6 . 0 0 5 ) .
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supports.
S E Q U E NOCFEO P E R A T I O N SR e f i t t i n g
F i t a i n - i n t a k e c a s i n g b y m e a n so f c l a m p i n gs h o e( 5 4 6 . 0 0 5 t)o t h e v o l u t e c a s i n g( 5 4 6 . 0 0 1 ) .
T h i g h t e n i nt go r q u et o b e a p p l i e do n e i t h e r s i d e I N m .
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} | EI G H T o f c o m p n e s s ocna s i n g . . . 6 5 k g
P i p i n g a t a i r o u t l e t o f c o m p n e s s o nr e m o v e d .
C o n n e c t i o nf o r c o m p r e s s o rc l e a n i n g e q u i p m e n t ,j e t a s s i s t a n d r e v o l u t i o nt r a n s m i t t e r ( i f i n s t a l l e d )
ane loosened.
S T Q U E N0CFE0 P E R A T I 0 II ,' SD i s m a n t l i n q
1.
2.
3.
4.
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Loosen
t e n s i o n i n gc l i p ( S / + 0 . 0 0 5e) x, t n a c tc o m p l e t ce o r n p r e s scoans i n gc a r e f u l l y i n a x i a l d i n e c t i o n
f n o mc a r t n i d S . ( S g g . 0 0 l )a n d d e p o s i t o n w o o d e n
supports.
I f f i n a l d i f f u s o n( S C Z . O O I )ti os b e n e m o v e d :
U n s c r e hwe x a g o n anlu t ( 5 4 0 . 0 2 1f)r o m c o u n t e ns u n ks c n e w( 5 4 6 . 0 0 8 ) .
I f n e v o l u t i o nt n a n s m i t t e n( 5 6 2 - 0 4 0 i) n s t a l l e d a n d t o b e r e m o v e d :
L o o s e nt h r u s t s c r e wo f s c r e r c o n n e c t i o n( 5 4 6 . 0 6 0 )a n d p u l J .c a b l e o f r e v o l u t i o n t n a n s m i t t e r
t h r o u g ht o i n s i d e . T a k eo f f c o v e r ( 5 4 6 . 0 8 5 ) ,u n s c n e w
h e x a g o n anl u t ( 5 6 2 . 0 0 5 )a n d n e r n o vre- e t e n t i o n
d i s k ( 5 6 2 . 0 0 4 )E. x t n a c tr e v o l u t i o nt r a n s m i t t e rw i t h c a b l e c a n e f u l l y .
A t t e n t i o n : D o n o t b e n dt h e t r o p o l e t e r m i n a l sa t e n d o f r e v o l u t i o nt n a n s m i t t e r .
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R e m o u n t i n tgo b e e f f e c t e d i n o p p o s i t e s e q u e n c eo f d i s m a n t l i n g .
I n p n o c e s so f r e r n o u n t i n g ,w a t c h 0 - r i n g s ( 5 1 7 . 0 1 8 a n d 5 4 6 . 0 2 2 ) a n d c o r n p r e s s own h e e L .
U s eo n l y l o c k i n g p l a t e s a n d s e a l s t h a t a n e i n t a c t .
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C l e a n i n gi n t e r v a l :
R e f e r f i l a i n t e n a n cSec h e d u l eS e c t i o n 4 , S h e e t5 l a n d i n s t n u c t i o n s o f S h e e t 4 . 5 2 .
1 . C l e a n v o l u t e c a s i n g ( 5 4 6 . 0 0 1 )a n d f i n a l d i f f u s e r ( 5 4 2 . 0 0 1 )w i t h f u e l o r a n o t h e r l i q u i d c l e a n s e r
a n d a b r u s h u n t i l a l l d i r t , e s p e c i a l l y i n t h e a i n d u c t s , h a s b e e nr e m o v e d .
2 . C l e a n c o m p n e s s ownh e e l i n t h e s a m ew a r .
T h e c o m p r e s s owr h e e l i s t o b e L e f t i n s t a l l e d i n t h e b a s i c a s s e m b l y( 5 9 9 . 0 0 1 )
l ' , l o t eT h e c l e a n i n g f l u i d a n d t h u s t h e d i s s o L v e dd i r t m u s t n o t b e a l i o w e d t o p e n e t n a t ei n s i d e
t h e b a s i c a s s e m b l ya n d t o e n t e n t h e b e a n i n g s o n t h e l u b e o i l c i n c u i t . T h e g a p b e h i n d
t h e c o m p r e s s own h e e l s h o u l d , t h e n e f o r e , b e c o v e r e dw i t h s u i t a b l e m e a n s .
3 . D r y a l . l .c l e a n e dp a r t s w i t h c o m p n e s s eadi r .
4 . C h e c kw h e t h e r r o t o r r . o t a t e s f r e e l y a n d e a s i J . y .
0 3 6 5 6 4 9 E/
500.14-3
Page2 of 2
RE]IOVINC
AND INSTALLING
CARTR I DGE
Arbclrkorle.Nr.
Work cord No.
flii',1'il,1li"..sBo-1
associatedworkcards 500.06,500.10through500.14
IMLS RNIIRD
591.070
591.060
Tool ltb.
3 Rirq segnent
. 596.008
3 Spindle
596.009
5 Ho<agon
nut
.. 596.010
I Openerd wrench17 A/f
2 openend wrenct19 A/f
1 lfrench socket t7 Alt
1 llrerctsocket 19 A/f
1 Screwdriver
1 Lifting gear with rope
501.005
50r.007
50r.008
LMID
501.001Gasanissioncasing
501.005Clampingshoe
501.007lockrmsherpar
501.008Hexagon
nut
591.060Stield, 2-part
591.070Se1f-tappingscrew
599.001Cartridge
(=517.000
and520.000)
WEIGIil
of cartridge .... 70 kg
.-g zorzzzz
GN\IRAL
Rervalof cartridge for inspectior ard, if necessarl', replacenentis crly required in the
foDoring cses:
1. rf adnissibletrarsversenpvability is exceeded(cf mrk card 500.06).
2- For major overhaulof tr:rbocharger(cf ilaintenarceSchedule,Section4, Sheet51).
3- If there are any sigmsof irregmlarities in ser,ice wtrichrnight lead to subsequentdamage
of the turbocharger,e.g. rrnusualnluring noise, turbine or cqnpressorside oil 1eakage,
previottsly rrot elperienced turbochargervibratiqs or abnormalreadings (extraustgas
temperature,chargeair pressr:re, trrbocharger speed)- if crnrpressoror turbine cleaning
durirg operation prorrernsuccessful.
4. In case of danageto turboctrarger, .g. bearirgdamage,(cnringto oil starvaticn or co]tarinated oil), damage
causedby foreigm matter or fracture of turbine rotor or ccmpressor
wheeldue to yibration, casing eracks.
s'mRrnrc
PosmoN
\ q(,
J'f'f
Silencer ard/or air-intake casing rsp., and ccnpres*r ""iih rqpred. Ihe gas anission
casirg is not nonrally rqrved ard remairs cmrectedto the o<tawt gas line.
SffiItl*E 0E OPBATIONS
1: Renval
1- Remveself-tappirg screw(591.070)andtake off shield, 2-part, (591.050).f fitted.
2. Rsnveoil supply line, additiqal h.bricating systemanoit discharge line from bearjg
casing.
12.n
551,98
16-3
Workiq lic
TicDo
Hourt
D u r ed c r r o v o i l - H e u . . c r
dc t.qbqro
Hgror
2.2
2.5
^^^ lil'],,,",
aS fe{ifgl
Hcuredc mo.(h.
Horos de tcrvi(o
3. Deperdirgcr type of rrcuntirry, loosen or relrpvecasirg fot.

4. itith the rseof rope, attact cartridge to liftirg gear, cauticnsly
take the slack ot of rope.
5. Screwoff hexagcrnuts (501.008),rmrre lalnraster pairs (501.007)ard clampirgshoes
(501.005)
.
6. Pressout cartridge (599.01)uniformly at 3 points of circrnference,usirg tols (595.008.
596.009,596.010),cautiosl.ynpveit cut in axial directis (clonot danageturbine rotor in
the process), andcarefully deposit it q roodersupport.
Q,1)
36 t.2 980
CHtrlCItrlG
Al,lDCl,FlND6CARIRIDGE:
Refer to work card 500.17
SJIIUE OFOPRATICNS
2: Installing
1. Checkingthe gaps, (refer to Section1, CapsardClearances).
- Screwcartridge (temporarily for reasrrreurert
only) to cunpressorcasirg wtrile neasuringa:<iaI
gap (point 2) by lead inprnt adradial gap (point 1) by feeler (thiclmess) gaugethree
tres on the circrnference.
- Insert cartridge (temporarily for rpasurqren, *tt) carefully into the gas adrnissioncasing
ardscren together. Measureaxial gap (point 4) W lead inprit and ratlial. gap (point 3) by
neansof feeler (thiclmess)gatge (only if gas outlet side is accessible)three tires on the
sironference.
2. Using the rope, suspendcartridge to lifting gear and insert it cautiousLyinto the gas
anissiq casing (do not danrage
turbine rotor).
3. Fix cartridge rith clanpingshoes(501.005),lock washerpairs (501.007)andhe:<agm
nuts
(501.008)to gas adnissiq casirv (tightening torgrre34 tlnl).
m6 5AtS
5m.15-3
n.n
Pagp2d3
4. Recqrectoil scharge line, aditiqraf lubricatg systeurard oil supply line. Esure
that protective phgs, if any, harebeerrencvedbefore recqrnecticn.
5. Fastercasirg fot <Ieperdirg
cr type of nruntirg, if fitted.
6. }tatnt shield, 2-part (591.060),if fitted.
lbte Apply I'lcs2-baseat
higr-ternperature
lubricants (e.9. lblyoote IISC)to bolts ard nuts,
do not cpat sererrin tlread.srith this lubricart if strds had beerreplaced.
lockwasherpairs (501.007):Iang rvedge-shaped
surfacesfacirg qe another (on inside).
Othenrise, there is rn secrrringeffect.
ut6 5698
5m.16-3
U.n
PagB3of3
IlIG
C HECKIIIG
AfID CLEAI{
CARTRIDGE
Aib.ilkoGNr.
500.17
TiH*iP.
Tod.to lroboio No,
a s s o c i a t dr o n k c a r d s . . . 5 0 0 . 0 6a n d 5 0 0 . 1 6
C h c c k i n ga n d c l c a n i n g i s r c s t r i c t a d t o t h r c a r t r i d g ci n a s s c r b l c dc o n d i t i o n .
D i s a s s c b l yo f c a r t r ^ i
for clranin andrcplacinq individual parts nust be carried out
spccializcd srvicc
s o n n c lo n l
s r c n o t c s i n s c c t i o n 3 s h c c t 5 2 - C a r t r i d g e- , s e c t i o n 4
s h c c t 5 2 - l l a i n t c n a n c c- . a n d o k c a r d S 0 0 . 0 6 ) .
l { o t e I f a c a r t r i d g ei s t o b c s c n t t o r a n u f r c t u r . ro r s c r v i c cp o i n t f o r o v c r h a u l ,i t m u s t
'
b c p a c k a g ccda r c f u l l y t o r v o i d d d i t i o n I d a r a g ci n t r a n s i t .
STARTII{G
POSITIOII
Cartr?ii r.ilor,fifor tubochargor.
C H E C I ( I IT
{G
H EC A R T R I O G E
to be taken
@Iincludcsdtaforvlutionand,ifnrcrs3ary'm!a9ur!9
for rrpairing thc crrtridgc.
llot: Ihr cvrral porribiliti ac rrkd off, thc tchnical optinun is to be s c l c c t c d .
TVALUATIOl{
CRITERIA
onprnt onpoint
condition
CARTRIOGE
- d i r c n b l c ,c h c c kc o n p o n c n t sr ,c p l a c e w h e r e
c c i a l i z c d s c r v i c c o c r s o n n e ol n l
- Gu9?,clcan
TRAI{SVERSE
I,IOVABILITY
OF ROTOR
c f r o k c a r d5 0 0 . 0 6
i l e a s u r e dv a l u e : p c r n i s s i b l c
. i l e a s u r e vd a l u e : c x c e s s i v e
T O U CiH
IARKS
B t - . d ; ; n t o u r t u r b i n e h e e l ( r o t o n) a n dl o r c o n p r e s s o n
xheel
o n e - s i d e do n c i r c u n f e r e n c eS! i g n s o f i n b a l a n c e
u n i f o r ro n c i r c u n f e r e n c eC
: h e c kg a p sa n d c l e a r a n c e s( s e c t i o n l , s h e e t 5 2 ) . .
FOULII{G
on gapafter turbine rheel (rotor) disc
n a r r o uo i l t r a c e : h a r l e s s , n a y b e c a u s e db y r u n d o r n l u b r i c a t i o n .
h e a v yf u e l r e s i d u e s
t h i c k c o v e no f o i l c o k e d i s t r i b u t e d o v e e n t i r e c i r c u n f e r e n c e i:n d i c a t e s s e v e r e
o i l l e a k a g e ,l e a d s m o s t l y t o s l u g g i s hr u n n i n go f t u r b i n e w h e e l( r o t o r )
I u r b i n e r h e e l ( r o t o r ) - ( v i s i b l e p a r t o f b l a d e dy h e e l )
h e a v yf u e l r e s i d u e so r o t h e r f o u l i n g c o v e r .
C o n p n e s s or hr e e l ( v i s i b l e p a r t o f b l a d e dy h e e )l
dusty, oily cover
-DA
I.IAGE
Uine
r h e e l ( r o t o r ) , c o n p r e s s orrh e e l , b e a r i n gc a s i n g
t u r b o c h a r g i n sg e v e n e l yi n p a i n e d ,s e v e r eo i l I e a k a g e ,s t r e n g t h i n p a i r e d
SLUGGIS
RH
UNNIN
OG
FR O T O R
@ed:oiIcokedcpositsaftenturbinerhecl(notor)orin
l a b y n i n t hs e a l , o r b e a r i n gd e f c c t
l { o t e : R u n n i n g - i nl a b y r i n t h s n a y c a u s es o n es l u g g i s h n e sisn r o t a t i o n o f n e wo n
u s e d t u n b o c h a r g e n Ish. i s i s h a r r l c s sb e c a u s ei n o p e r a t i o nt h e r o t o n f l o a t s
a n d t h c n n u n sf n e c .
T e s t : L i f t r o t o r t o c o n c e n t r i cp o s i t i o n a n d r o t a t e .
(.o
o
@
0 3 6 5 6 4 9E
5 0 0 .I 7 - 2
Arbailrcir
Worl^g lima
Derc dG t.qvoil
Ticmpo de t.o!'oio
studa
Hours
Heu.c!
Ho.ot
15000 . * 900
ej:.,,
io','l,", As required
LOdO
3"J:,,..T;';*,1
;;;;;; ;; ;;..^.
OrO< Cle tcrvt(to
C L E AIlI{{ G T H I C A R T R I D G E
B u n n t - i nl a y e r s o f d i r t , p a r t i c u l a r l y o n t h e t u r b i n e s i d e ( c . g . h c a v yf u c l l a y c r s , o i l c o k c ) ,
a r e t o b e r e n o v c db y s o a k i n gi n P 3 r a t c r s o l u t i o n a n d b r u s h i n g . I f n c c c s s a r y ' r e p c a t t h i s
D r o c e s ss c v e r a l t i n e s . l l e x t n e u t r a l i z c i t h s o d av a t e r .
Renovo
e i l y l a y e r s b y n e a n so f f u e l o r s o n eo t h e r I i q u i d c l e a n i n ga g c n t .
N o t e : l h e c l e a n i n gl i q u i d a n d t h c d i s s o l v c dd i t r u s t n o t c n t c r t h c i n t e r i o r o f t h c c a r t r i d g e
a n d t h u s t h e b e a r i n g so r t h e l u b e o i l c i r c u i t . T h c A a p sa f t c t h c t u r b i n e r h c c l ( r o t o r )
d i s c a n d t h e c o r p r c s s o rr h e c l s h o u l d t h c r c f o r c b e c o v e r c dv i t h s u i t a b l e r a n s .
F o r s o a k i n gl a y e r s o f d i r t o n t h e t u r b i n c r h c c l ( r o t o r ) d i s c , t h c c a r t r i d g e c a n b c
p l a c e dv e r t i c a l l y , t u r b . i n es i d e d o r n r a r d s ,i n t o a c o n t a i n e rr i t h s u i t a b l e s c a t i n g s .
F i l l t h e c o n t a i n e n i t h c l c a n i n gl i q u i d o n l y t o a c e r t a i n l e v c l l h i c hr u s t n o t b e
e x c e e d c idn o r d e r t o p r e v e n tt h e I i q u i d f r o m e n t e r i n gt h c i n t e n i o r o f t h e c a n t n i d g e
( s e ei l l u s t r a t i o n ) .
,001=
lsrr.ooo
fszo.ooo
el
F
{
I
0365649E /
500.17-2
500
NR2O/R
I lIG
DI SI,IAI{TL
IIIC AIID REASSEIIBL
DIG E
CARTR
IT{SPECTIO
OlF{ C O } I P O I I EPNATR T S
5oo.l8
3"T:;fflilii..
Taricto troboo No.
A p p l i c a b l el o r k C a n d s . . . . 5 0 0 . 0 56 0, 0 . I 0t o 5 0 0 .l 7
TOOLSREOUIRED
I O p e n - e n rdr e n c h S l l 0
I
L
0 p e n - e n dr r e n c h S X 3 0
I P o u n d i n Igo g o n c o p p e nb o l t
I
I
5 17 . 0 3 2
Ha m mr e
l l e a s u r i n gi n s t n u n r e n t
5 r7 . 0 3 3
5 17 . 0 0 4
5 17 . 0 0 1
520.001
5 2 0 . 0I1
7.002
5 17 . 0 0 9
5 17 . 0 10
LEGEND
5 I 7. 0 0 1B e a r i n gc a s i n g
5 1 7 . 0 0B2e a r ni g b u s h
5 1 7 . 0 0S3 p a c e rs l e e v e
517 . 0 0 4H o l d i n gs c n e w
5 1 7 . 0 0 I9n t e r m e d i a t en i n g
Shielding
517.0I0
5 1 7 . 0 3H2e x a g o n anlu t
L o c k i n gp l a t e
5I7.033
5 17 . 0 0 3
5 1 7002
520.006
362266
520.005
520.009
520.121
PG
OSITIOI{
STARTIN
C a r t r i d g e( 5 9 9 . 0 0 1 )i s d e t a c h e df r o m t u r b o c h a r g e n .
D i s a s s e m b l i nogf c a n t r i d g ei s r e q u i r e d , r e f e n H o n kc a n d5 0 0 . 1 7 .
D i s a s s e m b l i nogf c a r t r i d g e m u s tb e c a r r i e d o u t b y s p e c i a l i z e d
s e r v i c ep e r s o n n e l .
5 2 0 . 0 0 IR o t o r
o rh e e l
5 2 0 . 0 0 5C o m p r e s s w
5 2 0 . 0 0 6L a b y r i n t hr i n g
5 2 0 . 0 0 9C a r n i e n
5 2 0 . 0 I 8F e a t h e rk e y
5 2 0 . 1 2 4l l a g n e t i c n u t
l{ =
B a l a n c i n gm a r k s
S E 0 U E N0CFE0 P E R A T I 0II,i S D i s a s s e m b l y
l.
2.
3.
U n s c r e rn r a g n e t inc u t ( 5 2 0 . 1 2 4 )( r i g h t h a n dt h n e a d ) ,h o l d r o t o r i n p o s i t i o n
Extractcanrier (520.009)
) y hand.
E x t r a c t c o r n p r e s s rohne e l ( 5 2 0 . 0 0 5 b
l , l o t e I f c o m p r e s s ownh e e ls h o u l dh a v es e i z e d ( f . i . d u e t o f r e t t i n g c o r r o s i o n ) ,f e e d f l u i d s p e c i a l
s o l v e n t ( a s C a r a m b ai n
) t o g r o o v eo f s h a f t s e a t a n d a l l o r t o r e a c t . T h e nr i t h d n a rcl o t n p r e s s o n
r l h e e lw i t h \ r e c i p r o c a t i n gm o t i o n .
4.
L i f t r o t o r ( 5 2 0 . 0 0 1 s) l i g h t l y a n d m o v eo u t i n d i r e c t i o n o f t u r b i n e s i d e a s c e n t r i c a l l y a s p o s s i b l e
Note
Adhesion
o f I a b y r " i n t h s( f r o m r u n n i n g - i n )o n c o k e d e p o s i t sm a yi m p e d et h e ' p r o c e s s ,i f s o ; u s e
p o u n d i n gl o 9 . B y r e m o v i n gt h e r o t o r , t h e I a b y r i n t h r i n g ( 5 2 0 . 0 0 6 ) i sb e i n g s t r i p p e d o f f . T h e
t r o f e a t h e r k e y s ( S Z O . O I 8a) n e n o n m a l l yn o t t o b e d e t a c h e d h, o w e v e nt ,a k e c a n et h e y a r e n o t
lost.
T.0. + sheet
(o
@
rt
D36
s64e
elffSilil,Ti-.:',*#;^ l.
-Hrurc
500.18-1
| D v r c d c t r o v o l|
| lampo Oe l.ObOtO
liOTOt
2
)
A^
re
rov,e
tcr
As required
3"J1"":::!l'.1
i::;:i:",fff,:.
5.
6.
I a k e o u t l a b y r i n t h r i n g ( 5 2 0 . 0 0 6 )f r o r b e a r i n gc a s i n g .
f a k e o u t b o t h b e a r i n gb u s h e s( 5 1 7 . 0 0 2 f) r o r b e a r i n gc a s i n g .
l{ote
7.
8.
I f t h e l a b y r i n t h r i n g s h o u l ds t i c k r i t h i n t h e b e a r i n gc a s i n g , i t n a y b e f o r c e d o u t t o g e t h e r
) n d t h e b e a r i n gb u s ho n c o n p r e s s osr i d e a s d e s c r i b e di n 7 .
r i t h t h e s p a c e rg l e e v e( 5 1 7 . 0 0 3 a
a n d 8 . , a f t e r r e m o v a ol f t h e b e a r i n gb u s ho n t h e t u n b i n es i d e .
S c r e r o u t h o l d i n g s c r e r ( 5 1 7 . 0 0 a )( r i S h t - h a n dt h r e a d ) .
s ir d e .
P r e s so u t s p a c e rs l e e v e ( S l Z . O O i)n d i r e c t i o n c o t n p r e s s o
J { o t e I n t h e e v e n t o f t h e s p a c e r s l e e v e s e i z i n g , i t n r a yb e f o r c e d o u t b y n e a n so f s l i g h t s t r o k e s
r i t h t h e h a m n eor r b y a p r e s s ' u s i n g a r o o d e nb o l t o r o n e o f c o p p e r .
) n d s c n e wo f f h e x a g o n anl u t s ( 5 I 7 . 0 3 2 ) .
9 . L o o s e nl o c k i n g p l a t e s ( 5 1 7 . 0 3 3 a
(
5
1
7
.
0
09a
) n d s h i e l d i n S( S t Z . O l O ) .
i n t e r m e d i a t er i n g
10. Renove
o f o p e r a t i o n s3 .
I N S P E C T I 0 IF{ I l { D M O U A LP A R T Sr e f e r s e q u e n c e
sr7.00r
r7.033
r7.03?
5r7.00
517.009
.-5i7.010
520.12t, 5 20 .0 r8
5 2 0 .0 0 9
0 3 6s 6 4 9E /
5 0 0 .l 8 - l
fiL2271
520.006
517.003
520.00r
s20.005
517.002
5t7.002
c o n t i n u e do n s h e e t
2, R e a s s e n b l y
0F oPERAIIof{S
sEouEilCE
of the
l h e n r e n o u n t i n gb a s i c a s s e n b l y ,p a r t i c u l a r a t t e n t i o n r u s t b e p a i d t o t h e c l e a n l i n e s s
cleanlube oil'
r
i
t
h
o
o
i
s
t
e
n
e
d
s
l
i
g
h
t
l
y
i n d i v i d u a l p a r t s . S l i d i n g s u r f a c e so f b c a r i n gp o i n t s n u s t b e
U s eo n l y l o c k i n g p l a t e s t h a t a r e i n p e r f e c t c o n d i t i o n .
l.
z.
3.
4.
5.
6.
p l a c e i n t e r n e d i a t er i n g ( 5 1 7 . 0 0 9 r) i t h s h i e l d i n g ( 5 1 7 . 0 1 0 )o v e r s t u d s i n b e a r i n gc a s i n ga n d
(517.033).
n o u n tb y t i g h t e n i n gh e x a g o n anl u t s ( 5 1 1 . 0 3 2 r) i t h l o c k i n g p l a t e s
p l a c e s p a c e rs l e e v e ( 5 1 7 : 0 0 3 i) n b e a r i n gc a s i n g r a t c h n o u n t i n gp o s i t i o n . A x i a I d i s t a n c eo f
b o r e f o r h o l d i n g s c r e r ( 5 1 7 . 0 0 4 )i s s ; a l l e r t o r a r d s c o r n p r e s s osri d e .
Screr in holding screr up to stop position, tighten only slightly'
p l a c e b e a r i n gb u s h e s( 5 1 7 . 0 0 2 )i n b c a r i n gc a s i n go n t u r b i n e s i d e a n d c o m p r e s s osri d e '
E e a r i n gb u s h e sa r e s y n n c t r i c , t h u s , n o u n t i n gp o s i t i o n a t d i s c r e t i o n '
abyrinthpoints.
C a r e f u l l y i n s c r t r o t o r ( 5 2 0 . 0 0 1 i) n a x i a l d i r c c t i o n , d o n o t d a r n a gl e
r
r
r
t
of labyrinth ring andnotonmust
i l o v e i n I a b y r i n t h r i n g ( S Z O . O 0 6 )b, a l a n c i n gn a r k s I
c o r r c s p o n rda d i a l l y r c g a r d i n ga n g l c p o s i t i o n .
7 . I n s e n t f c a t h c r k c y s ( 5 2 0 . 0 1 8 i) n t u r b i n c s h a f t , i f t h c y h a d b c c n n e m o v e d .
h a n do n w i t h
B . F i x r o t o n a t c n d p o s i t i o n t o r a r d s c o n p r c s s osr i d c a n d a g a i n s tt u r n i n g , e i t h e r b y
(
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r r o f r o t o r ( 5 2 0 . 0 0 1 ) ,l a b y r i n t h n i n g
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shaft up to
) n d c a r r i e r f 5 2 0 . 0 0 9 )c o n r e s p o nnda d i a l l y n e g a r d i n ga n g l e
( 5 2 0 . 0 0 6 ) ,c o n p r e s s orrh c e l ( 5 2 0 . 0 0 5 a
position.
9 . S c r e r o n l l r a g n e t i cn u t ( 5 2 0 . 1 2 4 ) ,t i g h t e n i n g t o r q u e 6 0 ( t { m ) .
gauge'
1 0 . l l e a s u r ea b e r r a t i o nf n o n p l a n c o f n o t a t i o n a t l a r g e s t r a d i a l d i s t a n c e ,u s i n g d i a l
p e n m i s s i b l rea t e : r e f e r 0 p e r a t i o nl l a n u a lS e c t i o nl , S h e e t5 2 , G a p sa n d C l e a a n c e s .
e f r o t o r , u s i n gd i a l 9 a u g e .
l l . i l e a s u r ea x i a l c l e a n a n c o
penmissible
r a t e : r e f e r 0 p e n a t i o nl l a n u a lS e c t i o nI , S h e e t5 2 , G a p sa n d C l e a n a n c e sP,o i n t 5 .
S E 0 U E I {0CFE0 P E R A T I O3t I' S
I n s p e c t i o no f i n d i v i d u a l p a r t s
I h e i n d i v i d u a l p a r t s t o b e i n s p e c t e da r e t o b e c l e a n e da s d e s c r i b e dh e r e u n d e r .
B u r n t - i n d i r t l a y e r s , p a r t i c u l a r l y o n t u n b i n es i d e ( s u c ha s r e s i d u e so f h e a v yf u e l , o i l c c k e )
t . b . s . . L A r i t h p - y a t e r s o l v e n t a n d b r u s h e do f f . I f r e q u i n e d ,t h i s p r o c e s si s t o b e
r e p e a t e ds e v e r a l t i m e s . S u b s e q u e n t l yn ,e u t r a l i z ew i t h s o d ax a t e r '
L a y e r so f o i l y d i r t
t o b e r e r o v e rdr i t h f u e l o i I o r a n y o t h e r l i q u i d c l e a n s i n ga g e n t .
B o r e sf o r s e a l i n g a i ' n a n d l u b e o i l t o b e f l u s h e dr i t h f u e l o i l a n d t h e n t o b e b l o r i nt h r o u g hw i t h
c o n p r e s s eadi r j e t .
I h e f o l l o l i n g C H E C K L IcSoTm p r i s e ds e t a i l s o n e v a l u a t i o na n d n e q u i r e dm e a s u r efso r r e p a i r i n g
r r r r ,t h e a l t e n n a t i v en o n ef a v o u r a b l e i t h
t h e b a s i c a s s e m b l yI.f m o r et h a n o n e c o l u m ni s m a n k e d
r e s p e c tt o t h e s i t u a t i o n u n d e rc o n s i d e r a t i o nm a yb e c h o s e n . .
0 3 6 5 6 4 9E /
s00.18-l
s h e e t2
P .T. 0 .
Part llo. Individual Part

Condition
O r d e rD i r n e n s i oon" f
ilo.
D - External,
r el e c t l 0 n
Part to be sent in for repair

d .- Internat ,, b . lidth
Part to be replaced
5 1 7 . 0 0 1 B e a r i n gc a s i n g
D a m a goer i n c i p i e n t c r a c k s , i f s t a b i l i t y o r o i l - l e a k - p r o o f c o n d i t i o ni r p e r i l e d .
T r a c e so f s e i z u n eo r H e a r i n b c a r i n gb o r e : d ) , 5 2 . 0 3 . . . .
A b n o r r E ar ul n n i n g - i n p a t t e r n c a u s e db y p o i n t s 6 f l a b y r i n t h r i n g s .
N o t e T h e l a b y r i n t h p l a y i s s n a l l e r t h a n t h e . b e a r i n gp l a y . T h e r e f o r e ,t h e I a b y r i n t h
p o i n t s p e n e t r a t ei n t o t h e b o r e o f t h e b e a r i n g c a s i n g . T h e r u n n i n g - i n s c o r e s a r e , d e p e n d i n go n p o s i t i o n o f n o t o r , s o r e r h a t o n e - s i d c da t t h e c i r c u f c r e n c e .
5 1 7 . 0 0 2 B e a n i n gb u s h ( 2 u n i t s : i d e n t i c a l f o r t u r b i n e a n d c o r p r e s s o rs i d e )
T n a c e so f s e i z u r e i n t o u c h i n gp a t t e r n o f a r i a l s u r f a c c s .
t { e a r :D ( l 5 1 , 8 2 n r n , d 0 3 1 , 0 4n n , b < 3 0 , 9 3r r . . . .
l { o t e U n i f o o I a y e r o f l c q u e r i n gi s n o i a u s e o f c o n c e r n , i n t c r n a l a n d e x t c r n a t d i a r n e t c r sc a n n o tb c e v a l u a t e db y v i s u a l i n s p c c t i o n .
5I 7 . 0 0 3 S p a c e ns l e e v e
I n a c e so f s e i z u r eo n a x i a l s u r f a c c s .
..........
5 1 7 . 0 0 9 I n t e r m e d i a t er i n g
D a m a g ei f, f u n c t i o n o n s t a b i l i t y a f f c c t c d .
520.001 Rotor
D a m a gt eo b l a d e s , f o r i n s t a n c eb y f o r e i g n n a t t e r .
I n c i p i e n t c r a c k s ( C r a c kt e s t : f . i . S o u n dt e s t , f l u o r e s c e n td y e - c h e c k )
T r a c e so f t o u c h i n ga t b l a d e o u t l i n e , u n i l a t e r a l a t c i r c u n f e r e n c ea, r e i n d i c a t i o n o f
irbalance.
I r a c e s o f t o u c h i n ga t b l a d e o u t l i n e , o v e r e n t i r e c i r c u n f e r e n c eI:f p e r m i s s i b l eg a p
e x c e e d e (dr e f e r 0 p e n a t i n gl l a n u a l :G a p sa n d c l e a r a n c e s p, o i n t s 3 a n d 4 )
L a b y r i n t hp o i n t s d a m a g eodr , o r n :D < , 6 4 , 8 5 l n m . . . .
E e a n i n gp o i n t s d a m a g eodr , o r n ,O ( i l 3 0 , 9 4 r m .
C o n c e n t n ircu n n i n gt e s t : C l e a nc e t e r i n gp o i n t s , m o u n tf o r c e n t e r i n g ,r n e a s u rceo n c e n t
r i c r u n n i n ga t b o t h b e a r i n gp o i n t s a n d a t s e a t o f c o n p n e s s oynh e e l ( 3 l o c a t i o n s ) , i f
g,01 rnr.
d e v i a t i o ne x c e e d i n 0
N o t e I f e c c e n t r i c i t y a t t h o s e 3 l o c a t i o n s i s i n s a m ec i r c u m f e r e n caen d c u n s l i n e a r ,
t h e c e n t e r i n gp o i n t s a r e d a m a g eadn d t h e r e a l d e v i a t i o nf r o r nc o n c e n t r i cr u n n i n g
i s s m a l l e r( m a x .p e n m i s s i b l0e. 0 1 n n ) .
s 2 0 0. 0 5 C o m p n e s srohre e l
D a m a g et o b l a d e s , f o r i n s t a n c e b y f o r e i g n r n a t t e r .
I n c i p i e n t c n a c k s , ( C r a c k t e s t : ( f . i . S o u n dt e s t , f l u o r e s c e n t d y e - c h e c k ) . .
T n a c e so f t o u c h i n ga t b l a d e o u t l i n e , u n i l a t e r a l a t c i r c u m f e r e n c ea,r e i n d i c a t i o n o f
imbalance.
T n a c e so f t o u c h i n ga t b l a d e o u t l i n e , o v e r e n t i r e c i r c u n f e r e n c e I: f p e r n r i s s i b l eg a p
e x c e e d e (dn e f e r 0 p e n a t i n gl l a n u a l :G a p sa n d c l e a r a n c e s p, o i n t s I a n d 2 )
5 2 0 . 0 0 6 L a b y r i n t hr i n g
L a b y r i n t hp o i n t s d a m a g eodr r o r n : 0 < 6 4 , 8 5n o . . . .
0 3 65 6 4 9E
s h e e t2
E}IOVII{G
A 1 { DI I { S T A L L I l I GA D } I I S S I O N N R 2 O / R
C A S I I { G ,G A SO U T L E T
500.19
[T:ff"..ilii".
D I F F U S o R ,T U R B I I | El { o Z Z L ER I i l G
torFtc lrebcio No.
A p p l i c a b l el o r k C a r d s5 0 0 . 0 6 , 5 0 0 . 1t0o
500.17
T O O LR
SE Q U I R E D
I
I
I
I
I
s0r.00r
59r.
59r.
( ) p e n - e n rdr e n c h
st 17
sr l3
S o c k e tr r e n c h
Flat chisel
Piercer
Haner
l{D
LEGE
50r.001
50t.0t7
50r.025
50t.024
5 0 1 . 0 0 1 G a sa d n i s s i o nc a s i n g
5 0 1 . 0 0 9 C o l l a n e db o l t
5 0 1 . 0 1 7 L o c k i n gp l a t e
5 0 1 . 0 2 5 H e x a g o n anlu t
5 0 I . 0 7 2 C o v e rr i n g
5 0 9 . 0 0 1 G a so u t l e t d i f f u s o r
5 0 9 . 1 0 5 H e x a g o n anlu t
5 0 9 . 1 0 7 L o c k i n gp l a t e
5 1 3 . 0 0 1 T u r b i n en o z z l er i n o
541.00t Insert
509.r07
509.r0
S
} EI G H T
G a sa d m i s s i o n
casing
rith lagging.....
. . 1 2 0k 9
(laggins.
30 k9)
G a so u t l e t d i f f u s o n .
30 kg
T u r b i n en o z z l en i n 9 . . . . . . . 3 k S
513.
50r.009
STARTIIP
{ GO S I T I O N
E x h a u s tg a s l i n e a f t e r t u r b i n e i s n e m o v e do n f l a n g e c o n n e c t i o n d e t a c h e d ,
r e s p . , o r c o m p l e t et u r b o c h a r g e ri s n e m o v e df n o m e n g i n e .
E a s i c a s s e m b l yi s n e m o v e d .
,r5*iti
G EN E R A L
R e m o v a ol f g a s a d m i s s i o nc a s i n g i s o n l y n e c e s s a r yi n c a s e o f e x c h a n g eo n i f e x h a u s t g a s l i n e a f t e n
t u r b i n e c a n n o t b e d i s m a n t l e da n d g a s o u t l e t d i f f u s o r , i n s e r t a n d t u n b i n e n o z z l e n i n g m u s t b e r e p l a c e d .
StQUEI'C
t 0 P E R A T I 0 N1S,
0F
t.
2-
R e m o v ce o v e n n i n g ( 5 0 1 . 0 7 2 ) .
I n c a s e t h e g a s a d m i s s i o nc a s i n g ( 5 0 1 . 0 0 1 )m u s t b e n e r n o v e dl o
, o s e n f a s t e n i n g s c n e w sa t e x h a u s t
i n l e t . R e m o v eg a s a d m i s s i o nc a s i n g a n d d e p o s i t o n r r o o d e ns u p p o n t . l { h e n d o i n g s o , p a y a t t e n t i o n
to the seal (and lagging. if installed).
3.
L o o s e nl o c k i n g p l a t e s ( 5 0 9 . 1 0 7 )a n d h e x a g o n a nl u t s ( 5 0 9 . 1 0 5 )a n d n e m o v eg a s o u t l e t d i f f u s o r
4.
R e m o vt eu n b i n en o z z l en i n g ( 5 1 3 . 0 0 1b) y r e a n os f p o u n d i n rgi t h i n v a r i a b l ef o r c e i n d i n e c t i o nA ,
r i t h a h a m m eann d a p i e r c e no n t o 4 c o l l a r e db o l t s ( 5 0 1 . 0 0 9 ) .
Loosen
I o c k i n gp l a t e s ( S O l . O t z a) n d h e x a g o n an lu t s ( 5 0 1 . 0 2 5a) n d r e m o v e
i n s e n t ( 5 4 1 . 0 0 1a) x i a l l y .
5.
rE)
co
(.o
Removal
(sos.oor).
0 3 65 6 4 9E
5 0 0l.9 - r
Afb]lrtair
Worlg lma
Ourr da t?ovol
Tirmoo dc lroboto
Sledr
Hovrl
Hrvrcl
Horor
A^
AllG
E"crr
T o v r c r e
Codo
AS rgOulreo
Fclf icbrsrudc^
Oo?rolrghosr
H c u . . rd c m o r ( c
o . o rd e c r ' ( i o
2, R e n r o u n t i n g
0F 0PERATI0IIS
stQUEt{cE
R e m o u n t i ni sg e f f e c t e d i n o p p o s i t es e q u e n coef r e o v a l .
I n p n o c e s so f r e n o u n t i n gu s e o n l y l o c k i n g p l a t e s i f p e r f e c t c o n d i t i o n .
A p p l yi l o S r - b a s ehdi g h - t e r n p e r a t ulrueb r i c a n t ( e . 9 . i l o l y k o t eH S C )t o b o l t s a n d n u t s , h o r e v e r ,d o
n o t a p p l y t h i s l u b r i c a n t t o s c r e r - i n t h r e a d si f s t u d s a r e r e p l a c e d .
t f h e nm o u n t i n gt h e t u r b i n e n o z z l e r i n g ( 5 i 3 . 0 0 1 )t h e f o l l o r i n g i n s t r u c t i o n sa r e t o o b s e r v e d :
l.
2.
3.
P r e s st h e 4 c o l l a r e d b o l t s ( 5 0 t . 0 0 9 )r i t h t h e i r l o n g e n ,t a p e r e dp o r t i o n i n t o g a s a d n r i s s i o n
c a s i n gu p t o s t o p p o s i t i o n .
p l a c e t u r b i n e n o z z l er. i n g ( 5 1 3 . 0 0 1 ) o n tcoo l l a r e d b o l t s ( 5 0 1 . 0 0 9 )i n a ' | a n n e rs o t h a t t h e
E o r n e ns h a p e dn o z z l e v a n c sa r e c o n g r u e nrti t h t h e s e p a r a t i n g a l l s o f r t h e g a s a d r i s s i o n
r a r k so f i l l . ) D e p e n d i n g
c a s i n g ( n e f e r t o r r Z rm
o n e l e c u t i o n ,t h e r e a r e 1 , 2 , 3 o r 4 s e p a r a t i n g
xalls.
P n e s si n u u r b i n en o z z l en i n g e v e n l y , d o n o t t i l t a n d d o n o t a p p l y p r e s s u r eo n n o z z l ev a n e s .
T--
0 3 65 6 4 9E /
s 0 0 t. 9 - 1
ABGASTURBOLADER
EXHAUSTTURBOCHARGER
TURBOCOMPRESSEUR
A GAZ D'ECHAPPEMENT
TUREOSOBREALIMENTADOR
DE GAs DE ESCAPE
V E R Z E I C H NDI S
E RE I N Z E L T E I F
L
ER
ABGASTURBOLADER
LISTOF SINGLEPARTSFOR
EXHAUSTURBOCHARGER
LISTEDEs PIECES
POUR
CONSTITUTIVES
TURBOCOMPRESSEUR
A GAZ D'ECHAPPEMENT
INDICEDE LAS PIEZASINDIVIDUALES

PARA
TURBOSOBREALIMENTADOR
DE GAs DE ESCAPE
( D35Ue-3 )
D365650
500.01/1
2.88
500.01
I
E RE I N Z E L T E I L E
LISTOF SINGLEPARTS
LISTEDS PIECES
CONSTITUTIVES
INDICEDE LAs PIEZASINDIVIDUALES
500.01
2
Ersatzteilbestelluno
Frdie Bestellungvon Ersatzteilen
ist dasVerzeichnis
der Einzelteile
mit den dazugehrenden
Bildernzr
verwenden.Die ersten3 Stellender Teilnummernbezeichnendie Baugruppeund die restlichenZahlen
sind eine Zhlnummer.Um Rckfragenund Unklarheitenzu vermeiden,sindbei Bestellunofoloende
Anoabenerforderlich.
1.Anschrift MAN B&W DiesetAG
Stadtbachstr.I
D-8900Augsburg 1
Telefon:
Telex:
Telegrammanschrift:
Telefax:
Teletex:
(0821)3221
53 796-0man d
manbw
(0821)322-3382
821861
2 . f y p d e sT u r b o l a d e r s
3. Werk-Nr.desTurboladers
(4.TypdesMotors)
(5. Werk-Nr.desMotors)
6. Bestell-Nr.
7. Benennung
8. Stckzahl
9. Versandadresse
xxx.xxx
xxx
xxx
xxx
xxx
x xxx xxx
xxxxx
x xxx xxx
Reserveteile
Auf gesonderteBestellungwird eine Grundausstattungvon Ersatzteilenals sogenanteReserveteile
geliefert,dgren Umfangim Verzeichnis
der Reserveteile
aufgefhn ist.Die NJmmernin der Listesind
gleichden Bestell'Nr.und stimmenmit den an den TeilenangebrachtenNummernberein.Alle Teile,
soweit nicht in Plastikbeutelverpackt,sind stetsgut gefettet aufzubewahren.Rostiggewordene Teile sind
zu reinigenund einzufetten.
Eswird empfohlen,verbrauchteReserveteile
sofortnachzubestellen,
da Transpo(und Zollabfertigung)
die Anlieferungder Teilesehrverzgernknnen.FrReparaturarbeiten
ist esjedochwesentlich,die
erforderlichenTeilemglichstsofortgreifbarzu haben.
Werkzeuoe
Die dem TurboladermitgegebenenWerkzeugesindin einer Kisteverpacktund in einer Listeam Deckelder
werkzeugkisteaufgefhrt.Frdie.Behandlung
und Nachbestellung
von werkzeugengelten die gleichn
Anweisungenwie fr Ersatzteile.
Die Baulruppefur werkzeugeist596.... .
O r d e r i n o S o a r eP a r t s
Referenceshould be made to the list of singlepartsand the releventdrawings in preparing ordersfor spare
parts.The first three digitsof the part numbersdesignatethe equipmentgroup and the lait digits
representa consecutive
number.
ln order to avoid confusionand queriesmakeit a point to includethe followino informationin vour orders
1 .O u r f u l l n a m e M A N B & W D i e s e l A G
|
( 0 8 2 13) 2 2 1
Telephone:
and address
StadtbachstraBe
1
I
Telex:
53 796-0man d
D-8900Augsburg 1
Cabl,es:
manbw
I
Telefax:
(0821) 322-3382
Teletex:
8 2 18 5 1
2. Typeof turbocharger
3. Work-no of turbocharger
(4. Typeof engine)
(5. Work-No.of engine)
xxx
x xxx xxx
xxxxx
x xxx xxx
6. OrderingNo.
7. Designation
8. Quantity
9. ShippingadiJress
xxx.xxx
xxx
xxx
xxx
R e s e r v eP a r t s
lf ordered separatlya basicprovisionof sparepartswill be deliveredassocalled"reservepas", the range
of which is listedin the table.The numbersin the listshouldbe quoted in your order and coincidewith the
numberswith which the partsare marked.All parts,unlesspackedin plasiicbagsshouldbe kept well
greasedduring storage.Any partsshowingrustdepositsshouldbe cleanedand coatedwith grease.
It is recommendedthat any reserveparts installedshould be re-orderedat once,seeingthat iransport (and
customsclearance)may causeconsiderable
delaysin the deliveryof the parts.promptiepairsdependon
any necessary
partsbeing at hand when needed.
Tools
Thetools suppliedwith the turbochargers
are packedin a caseand tabuatedin a listattachedto the lid of
the tool box. In handlingand re'orderingtools,the sameinstructions
asgiven for sparepartsshouldbe
followed. The code numberfor tools is S-g6.
... .
t . s . v . p- s i g u ea l d o r s o
D 3 65 6 5 0
500.01/2
389
C o m m a n d ed e o i c e sd e r e c h a n o e
Pour la commandede picesde rechange,il convientd'utiliserla listedespicesconstitutives
avecles
figurescorrespondantes.
Les3 premierschiffresde numrosde picesdesignentle sous-groupe,
tandisque
lesautreschiffresconstituentun numrocompteur.
Afin d'viterdesdemandesde renseignementg
et desimprcions,
il s'imposede donner lesrenseiqnemen$
s u i v a n t sl o r sd ' u n e c o m m a n d e :
1.Adresse
MAN B&WDieselAG
Stadtbachstr.1
D-8900Augsburg1
2. Typedu turbo-compresseur xxx

3. No.d'usinedu turbocomoresseur
x xxxxxx
(4.Typedu moteur)
xxxxx
( 5 .N o .d ' u s i n ed u m o t e u r )
x x x xx x x
Tlphone:
Tlex:
Clble:
Telefax:
Teletex:
( 0 8 2 13) 2 21
53796-0mand
manbw
(0821)322-3382
8 2 18 6 1
6. No.de commande
7. Dsignation
8. Nombre
9. Adressed'espdition
xxx.xxx
xxx
xxx
xxx
P ' e c e sd e r s e r v e
Surdemandespciale,il est fourni un guipementde basede picesde rechangeen tant que picesdites
de rserve,dont l'tendueest portedansla listedespicesde rserve.Lesnumrosindioussur la liste
sont en mme temps lesnumrosde commandeet correspondent
ceuxappliqusaux picesmmes.Dans
l mesureo lespicesne sont pasemballesdansdessacsen matireplastique,il convientde lesstocker
bten graisses.
Despicesdevenuesrouillesdoiventetre nettoyeset graisses.
ll est recommandde commanderde nouveaudespicesde rserveusestout de suiteaprsleur consommaton,parceque le transport{etlesformalitsdouanires)
peuventbeaucoupretarderla livraisondes
pices.Or, pour destravauxde rparation,il est essentield'avoirlespicesncessaires
sur place.
Outils
Lesoutilesfournisavecle turbo-compresseur
sont emballsdansune caisseet numrssur une listeaoposau couverclede la caisse outils.Pourle traitementet la commandedesoutilss'appliquentlesmmes
instructionsque cellesdonnespour lespicesde rechange.Lesous-groupo
pour lesoutilsest 596.... .
P e d i d o sd e r e p u e s t o s
Parapedir repuestos,
se debe utilizarel indicede laspiezasindividualescon susfigurascorrespondientes.
Lasprimeras3 cifrasde los nmerosde referenciaindicanel grupo parcialcomponentedel turbosobrealin"rentador,
lascifresrestantessonde enumeracin.
rrra evitardemandasde aclaraciny confusiones,
esnecesarioindicarlossiouientesdatosen los oedidos:
'1.
Seas
MAN B&WDieselAG
Tlphone:
( 0 8 2 13)2 2 1
Stadtbachstr.1
Tlex:
53796-0mand
D-8900Augsburg I
Direccintelegrfrica: manbw
(0821) 322-3382
Telefax:
Teletex:
8 2 18 5 1
2. Tipo del turbosobrealimentador xxx
6. No.de pedido
xxx.xxx
3 . N o .d e f b r i c ad e l
7. Designacin
xxx
tu rbosobreal
i mentador
x x x xx x x
8. Cantidad
xxx
( 4 .T i p o d e l m o t o r )
xxxxx
9. Seasa donde
( 5 . N o .d e f b r i c ad e l m o t o r )
x xxx xxx
m a n d a re l p e d i d o
xxx
P i e z a sd e r e s e r v a
Porencargoespecialse suministraun equrpobsicode piezasde recambiocomo piezasllamadasde
reserva,cuyo volumense halla indicadoen el registrode laspiezasde reserva.Losnmerosde la listason al
mismotiempo losde referenciay coincidencon los nmerosmarcadosen laspiezas.Todaslaspiezas,
menosaquellasque vienenen bolsasde plstico,debenalmacenarse
siemprebien engrasadas.
Laspiezas
q u e s e h a y a no x i d a d o ,d e b e nl i m p i a r s ey l u b r i c a r s e .
5e recomiendapedir laspiezasde reservautilizadasen seguidade nuevo,ya que el transporte(y el
despachoen la aduana)puedenretrasarmuchoel suministrode laspiezas.Sinembargo,para poder
efectuartrabajosde reparacin,esde importanciafundamentaltener laspiezasnecelariasen sguidaa
m a n o o l o a n t e sp o s i b l e .
Herramientas
Lasherramientasque se entreganjunto con el turbosobrealimentador
vienenembaladasen una cajay
estnenumeradasen una listaque estpegadaen la tapa de dichacaja.Paraeltratamientoy los pedidos
de herramientasvalen lasmismasindicaciones
que para losrepuestos.
El grupo de herramientasllevael
n m e r o5 9 6 .. . ..
D 3 6 5 6 5 0/ 5 0 0 . 0 1 / 2
BAUGR
UPPINUBERSICHI
LISTOFASSEMBLIES
LISIE SURTOUS
LESGROUPES
LISTADETODOS
LOSGRUPOS
B e n e n n u n g
qnn
qnr
I
ta
c,4,)
q[r
.l
5\5*
\n/
599*
Iurbolader,
komplett
Iurbinen-Zust
rOmgeh
use
Turbinen'Abst
rmdi
ffusor
Turbinenieitapparat
Lagerung
L?i
ufer
Einsatzstck
Nachleitaooarat
SchaIl
dmofer
Ansauggehuse
Verdichtergehuse
Ilektronische
Drehzahlmesseinrichtung
Reinigungseinrichtung
fr Turbine
Reinigungseinrichtung
fr Verdichter
Verschalung
Turbinenzustrdmgehuse
am
(51?)
Rumpfgruppe
bestehend
ausLagerung
(520)
undLufer
+ DieseBaugruppen
sind im Bild 1 nicht sichtbar
D s i g n a t i o n
qn
qnl
q2n
qLr
a1/
F l
)'+'l
5\5 +
)'10
q0r
599*
Turbo-compresseur,
compl.
Corps
dradmission
de turbine
Diffuseurd'chappement
de turbine
Distributeur
de turbine
Logenent
Rotor
Insert
ulTT
USeUr
Trnat
Silencieux
Corpsdraspiration
Corpsde compresseur
Dispositifiectronique
de mesure
de rgime
Dispositifde nettoyage
pourturbine
Dispositifde nettoyage
pourcornpresseur
Rev6tement
sur corpsd'admissionde
turbine
Groupe
bascomprenant
longement
$ll) et
rotor(5zo)
+ Cesous-groupe
nrestpasvisible sur la
f i g u r e1
.O
@
N
'
Turbocharger,
complete
Gas-adrnission
casing
Gasexit diffuser
Turbine
nozzlering
Beari
ng
Roto
r
Tncort ni oo
ulTTUSer
Silencer
Air-intakecasing
Conrpressor
casing
[lectronicspeed
measuring
device
lJashing
devicefor turbine
trJashing
devicefor compressor
Coveron gas-admission
casing
Cartridgeconsistsot bearing(5'1?)
anorotor (520)
'1
+ Theseassemblies
are not shown
in the fiqure
D e s i g n a c i n
Turbosobrealimentador,
compl.
Cajade afluenciade turbina
Difusorde evacuacin
de Ia turbina
Distribuidor
de gasesde turbina
Alojamiento
Rotor
Piezade insercin
ulTusorTlnal
Silenciador
Cajade aspiracin
Cajadel compresor
Instalacin
electrnica
oarael medicin
nmero
de revoluciones
Dispositivo
de lavadoparaturbina
Dispositivode lavadoparacornpresor
Revestiniento
en cajaafluencia
turbina
Grupobaseintegradopor alojarniento
$tl) y rotor (5zo)
Estegrupoconstructivo
no estvisible
e n l a f i g u r a1
BAUGR
UPPENIJBTRSiCHT
LISTOFASSTMBLIES
LISTTSURTOUS
LESGROIJPES
LISTADETODOS
LOSGRUPOS
BiIdl - Figurel-
Figurel-
N R2 0/ R
500.03
Ltnt2
Figural
J
I
f
l
M
WTi\?Wdl :ffi-j-J
w
T
:
\*Fifl-
- f f i
--ffiH4i@
| 4ltHiFH
ru
D36 549
s00.03/4
VENZTICHNIS
DER
EINZTLIEILT
LISTOFSINGLE
PARTS
DES
LISII
PITCTS
CONSTIIUIIVTS
INDICTDTLASPIIZASiNDIVIDUALES
lloomNr.
Standardllo.
No. standard
No de norma
EesteIl-flr.
Benennung
0rderl{0.
Dsignation
No.de commande
t01.001
501.005
Tu r b oal d e r komplett
Bild 1
I u r b o c o m p r e s s ecuorm
. pl.
F i g u r e1
Turbocharger,
completei:.,r,::,!c t,i
t i g u r e1
T u r b o s o b r e a l i m e n t a cdoom
r.pl.
F i o u r a1
I urbinen-Zustrmqehuse
Bild 2
C o r p sd r a d m i s s i odne t u r b i n e
t i g u r e2
G a s - a d m i s sci ao sni n q 6 t , t . t 0 l
F i g u r e2
C a i ad e a f l u e n c i ad e t u r b i n a
F i o u r a2
casingf ",'1! !''| '

Turbinen-Zustrmgehuse Gas-admission
Cqj,de afiuencia
de turbina
lorps dlgdm!.ssion
Qeturbine
Clamping
Spannpratze
claw l.'i: r t !! t:.!c/5
Griffede serrage
'- 0rejade aPriete
Studscre
Stiftschraube
l0/o'^p6.
.Goujon--,hisio-n9!L-!:D-0
S i c h e r u n g s s c h e i b e n p a a r L o c k d i s c s ( p a r ) 6 c o r , : ' t ; t l i : ./ i
P a i r e d e r o n d e l l e sd t a r r 6 t
Slsk-anfmulter-
/)
811.r9901-00?t
811.59901-007E
'-) jl
-0495
i)0:)
-MAN
'61-a;i-;i-sT
P a r d e a r a n d e l a sd e s e g u r i d a d
---Hexasi,n
nilii'
llo lltt-
tcrou-i9ixl.a.9__--_-Tu.er-cahexa-9-ol-a-I
Collarbolt 6':''' .'' )"' - - r

Bundbolzen
. B,qUlg!
i ,c0,1-1et, ,
_ . Penocon-cgllar
161-8,4-nrSt
L o c kd i s c s ( p a i r ) 6 n n ol c ' / 00 l MAt,
Sicherungsscheibenpaar
P a r d e a r a n d e l adse s e g u r i d a d
P a i r ed e r o n d e l L edst a r r 0 t
AM1701-M8x1B
S t u ds c r e w r ^ , s
Stiftsch
raube
Il'",'f.''f'
rr,,t. .,
501.025
-"-
iot.olz-
Sechskantmutter
. fgfou six pans
Abdeck
ring
Bague
de recouvrement
rrrsl0ner0
" ' ^ ') "
Hexagonnut lac:
T u e r c ah e x a g o n a l
Laggingring r' :) r ),!' ''l::':"
AnilIo de recubrimiento
AM1702-M8
4097
G a se x i t d i f f u s e r
I urbinen-Abst
rmdi
ffusor
:"'ij
ffir'a.;i,'1
Bild 2
Di.ffuseur
deturbine D i f u s o rd e e v a c u a c i dne 1 a t u r b i n
drchappement
-r-isule-.?Abstrmdiffusor
f i g u r a2
00
q-qq
It -!!llv: q[*{l .qlEsp
cnn 4^tr
--
irio' ini'
/ v ) .
t w l
D365&9
Sti ftschraube
Gouion
AM1701-MBx18
antmutter'
[crou six pans
Al1ii-Mt
Distributeur
de turbine
Figure2
lurbinenozzlerinq
Figure2
Distribuidor
deturbina
de gases
tigura2
Turbinenleit
apparat
Distributeur
deturbine
ring 6oao tntC

I u r b i n en o z z l e
deturbina
Distribuidor
de gases
5 0 0 .0 3
'. r,tb
(-
- PI0
sieheRckseite
t.s.v.p. - sigueaI dor
Bestell-Nr.
Benennung
OrderNo.
No"de commandeDsignation
Nopedido
t1i.000
Lage
rung
Bild l
Loqenent
lig.re_
3
-
Lagergehuse
" Boitierde paliers
5;x?::ao-2 Lageibuchse
Douillede palier
Abstandshise
517.001
I6c.a
DoiI i e__d
rtget
raube
517.00q Haltesch
_V_iLde
.1elgnup__*r_
517.009 Zwischenring
Baque
intermdiaire
Absch
rinblech
517.010
prgt.eqllo4
*>,1;,1.0* T-61e..de
VerschI uBsch
raube
Bouchon
filet _
q4? n4E
Dicht
ri ng
Anneau-joint
517.001
517.018
51?.r?9
Joint-torique
S[iftscnraube
Goujon
Sechskantmutter
_0168
Bearing {OO: l:t 1..1/:
tigure1
A1o
iamiento
Figura3
B e a r i ncga s i n g{ a A O . l O ! rA
t 0? 7
Cajade cojinetes
B e a r i nbgu s h " r r p t 1 1 , , ) ^ , ? n
Casquillo
de coiinete
Spacer
sleevelooo.t{t'lt). )odi
Manguito
distanciador
Holdings$ev lo (10/ o / o t1.: ./il,
l91nilIq fildqr
Intermediate
,i,lgro. /()/a t.,-l AnrlI0 Intermeolo
P r o t e c t i o sn h e e t r r : ^ , , . t , o ! r . l
" C ? " t
'
uapa 0e proTecclon
Screwplug 6tac. /r,!J 1/a1;"
TorniIlode cierre
'"
* : 1 , : t :,l, ^ , i : , a , ,
illru
uv
DI|'{90&al6x2-5.8
Drt'l7663-i6ri2-u
JuilLd
O'ring 6rrr
!cf; :'?"ttr
{i119 circular le jrlte
Studscrew
AM1701-M6x18
p?rs
.i .-s-ix.
.!crs,u
517.033
;r :r,r:s.l:0_nêr:0^ t ' t t t i / C / , . 4 0 ? {
M 1?02-l'46
H e i a g onnu t f r , , ^
t. n ,- , I u e r c ah e x a g o n a l
i6i:6;?-niJt
L o c k d i s c s ( p a r ) 6 p / o l 0 0 o q Y r4AN
P a r d e a r a n d e l a sd e s e g u r ' i d a d
517.061
Flansch
Bride
f^ranje
6'6,.t,rpl t
lt
tr4i AL
-517.065
517.066
--ti.-
D
, r"unr. l rul iu uhr*r!i r t rnr ay
l'lorm
Nr.
Standa-rd
No.
No.standard
Node norma
Designation
Designacin
5tz.oos
Dicht
ri ng
_!9au1j9irt
517.082
.\,4q,l
{,"ti,t.,t^dO
1,)J.-
Cizr-ivixaa
14618-27x1&Cu
AnilIode junta
rngl+roxro-e.b
Hexagon
Sechska
bolt6'66. 1O/ O/ 0O
ntsch
raube
pans
Iornillo
Boulon
six
frexggona!
S i c h e r u n g s s c h e i b e n p a a r Lockdiscs (par).^ /c,,ll,
MAN
, 6 1 - 1 0 , 5 - nSrt
a,/
P a i r ed e r o n d e l l e sd t a r r t
P a r d e a r a n d e l adse s e g u r i d a d
R5?1-A96
' ^ , l , l g " * . . , t^ i
r Ianscn
C/1,,
url0a
Bride
ll 61&96xt-j8-AF /
Dicht
G a s k e -t 1 ) ! \ ^ l / - . , , ,
ung
ri
t^;.+
.v:&u^__.
517.078
r10a
SeaI ring
"
JUnta
' MAf
S i c h e r u n g s s c h e i b e n p a a r ro.t Jir., (pa,ir)6r,a6
St
J61-1r,0'-nr
,)' "( t
P a i r ed e r o n d e l l e sd r a r r 6 t
P a r d e a r a n d e l a sd e s e q q l i d a d
-:,, .,
DIN9ll-M12xl0-8.8
Secniitscn
Hexagon
rauue
bolt *1..;., ,,.'1,':
517.090
Versch
I uBsch
raube
Bouchon
filet
517.098
Meta1I kI eber
AChsivde mtal
D36s&9 / ,00.03/5
TorniIlohexaoonal
S c r e wp l u g ( 4 6 . l o 8/t
Tornillo de cierre
Metal adhesiv
e {olC. tt:
{} ?
Adhesivode netal
M564-lfiOxr
VERZIICHI'|IS
DER
EIIIZILTEiLE
LISI OFSINGLE
PARIS
LISIEDESPiECES
CONSIIIUIIVES
II1DICIDELASPITZAS
INDIVIDUALES
Bestell-l{r.
Eenennung
0rderllo.
llo. de conande
0signation
NR 20 / R
6
lloonllr.
tlo.
Standard
llo. standard
l{o de nora
Designation
Designacln
lin de nedido
',0.*o
|
t
|
|
.rn
" " ' "nn.,'
"'
'Ji.0r
520.006
520.009
q?n nra
qr^l 12L
Roto
r
Figure1
Rotor
: o.
Figure3
Roto
r
FiguraI
Turbinenlufe
r
Rotor
Turbinerotor
Rotor
Verdichter
rad
Rouede cotnpresseur
Cornpressor
nhrrl
ronr. // / 1...!,^?
K0oetec0m0resor
Lufe
r
Labyrinthring
{!_neqt_lqU'i!h9
Mitnehmer
Entraineu
r
PaBfeder
Clavette
-Nsiil?nttei
Ecrou aimant
5i1.000
Einsatzstck
Bild 2
Insert
479'
/t0 ai)j
Labyrinthring 6.o,,,.t,-,,n,
Juntalaberintica
-1
Carrier
500.03
6 O O C , t ( . , t , .1 ! l I
Arrastrador
F e a t h ekr e y , : . i1 ^ t n l / . ,l ! r f
Chevetade ajuste
Maqnetn
i cu t t ^ :
' ' "
, ' f
.
, . O ! / ' t .
l u e r c ac o n l f n a n
Tneprt
ni pnp
DIll 688!A5x5x20-C45K
/
-0002
Figure2
Piezade insercin
rjgya2
541.001
Iinsatzstck
I nsert
Insert piece 640 '1 i,J".

Piezade insercin
542.000
Nachleitaoparat
Biid 5
Diffuseur
final
5\?.001
ri9qr9
5
Difusorfinal
Figura5
Nachl
eitappa
rat
urTtuseur
Tlnal
Diffuser {,1it)!:."
Difusorfinal
t . o
q
r\
D365&9
ulTTUSer
500 03/6
- PT0
sieheRckseite
t . s . v . p . s i g u ea l d o r s o
BesteIl-Nr.
0rderl.io.
Benennung
No.de commande
Dsignation
Node pedido
SchalldEmpfer
ulLo 1
)1,i.uuu +
Siiencie
ux
Figure4
Rckwand
Paroiarrire
Dampfungsplatte
544.001
iLI'nr
ary_ti_s9egr
!!9_que
qL[ nz?
/
..vt
t.w /
----;ir
/
Distanzroh
r
Tuyau
drcartement
;;t
sChuttsittl
go_tegt$qq_
"Qt1!tg
Vorderwand
Paroign avant
Stiftschraube
._Q,o-ttjon
Sechskantmutter
Ecrou six oans
Luftfilter (zweiteilig)
Filtre d'air (deuxpi6ces)
Yechskants chr au-***Boulon
six oans
)i1.u0y
,^2
(radial)
5\5;0ooh Ansauqqehituse
l,,lorm
Nr.
Standard
No.
N o .s t a n d a r d
Node norma
Designation
Designacin
Silencer:ltil
Figure4
Silenciador
Figura4
'
''
CI67
RearwalI60C: li) t,? fi I l5

Perad nncfori nr
Damping
plate5oon/!t{ 4,,i^
PIacaamortiguadora
'^^n
Spcer
fube
r,..e r ; ,.
Tubodistanciador
P r o t e c t i ognr a t e 5 o j nt A t 0 ( , l t t
Rejilia protectora
F r o n tb o a r d6 0 6 . , ' ' . ! pf . , 1 , : ti
Pareddelantero
S t u ds c r e w6 o a l i a l 0 a . , i
rrlsl0ner0
DIN985-1"110-8
Hexagon
nut 5;rl. /:1i ,.:,,
Tuerca
hexaqonal
Air filter (two-part)
{},){.{cf a A t ? )
(dos
piezas)
- fi$to" de aire
Hexagon
bolt 546. /n,r0 ,tt I _! olrlqtruti1aa.8
Tornillo hexagonal
-0146
(radiale)
Corps
draspiration
F_igu1e
a
Air-intakecasinq(radial)
Figure4
(radial)
Caiade aspiracin
Figura4
545.oot
Ansauggehuse
Corps
draspiration
Air-intakecasing eoJr.lth)
Cajade aspirecin
545.014
Sechskantsch
raube
Hexagon
DIl'{9ll-M10xl5-8.8
screhr
Iornillo hexagonal
l0/0
,16
6000.
110 +
lqslgLi-sLrat:
(axial)
5\r.00012 Ansauoqehuse
Bild 4
(axial)
Corps
draspiration
lin:,'-1
qLq nn,l
Ansauggehuse
Corps
draspiration
all.s vorhanden
f
nrnri dorl
'il existe
i existe
>365&9 / 5(, 0 . 0 3 /6
Air-intakecasino(axial)
Figure4
(axial)
Caiade aspiracin
Fjsura
4
Air-intakecasing
Cajade aspiracin
tc
2 r
-0150
VERZTICHNIS
OER
EINZELIEILE
IISI OFSIIIGLIPARIS
LISII DESPITCES
CONSIIIUIIVTS
I'|DICTDELASPIEZAS
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No.de commande
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BesteIl-ltr.
Benennung
Orderllo.
Dsignation
llo. de commande
N R2 0 / R
500.03
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COI{SIITUIIVES
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llo. de commande
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lioomllr.
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casing
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( o . 0 17 )
A b b o u R u m p f s n u p p e ( 5 9 9 . O 0 1)
R e m o vi n g c o n t n i d g e ( 5 9 9 . O O 1)
Demontoge du gnoupe de bose(599.001
D e m o n to j e d e L g n u p o b o s e ( 5 9 9 . 0 0 1 )
D3656/-9
500.03/3'l
42.90
EngineData
z
o
Operation
of Engine
E
fr
andCondition
o
lioubleTracing
and MainBearings
Crankshaft
IJ
PE
G
Zl-
Turbocharger
System
FuelInjectionPump
E=
R;
FuelInjection
=z
=<
ee
Automatics
andInstruments
FE
StartingSystem
6 lJg
LubricatingOil System
of LubricatingOil
Specification
andTreatment
FuelOil System
GoolingWaterSystem
Treatment
of CoolingWater
- ^ 3
g9
l - r
cl
DrivenMachinery
L23/30
PUMP
DESCR
P IT I O N
310.0'l
Edition 09
Plate 31001
T h e r e ' i sa f u e l p u m pf o r e a c hc y l i n d e r . T h e p u m p ' i s
m o u n t e idn t h e e n g i n ef r a m e b v m e a n so f tw o stu d s th r ougirthe pumpolr r ng fr ;;;.T h e b a r r e l ' i s f a s t e n e d . i nt h e p u m ph o u s i n gb y a f ' r a n g e
T h e b a r re l i s p re ve n te dfro m tur ninn ut u- tii ng pin w i t h f o u r s c r e w s .
on the top of the pum p
h o u s i n g 'T h e b a r r e l a n d p l u n g e ro r i r r e " f u e l
u . " m a t c h i n gp a r t s w h i c hc a n f
r
*
p
n o t b e r e p l a c e di n d i v i o u t t y a s t h e p a r t i - a r - i a p p e ot o g e t h e r .
T h e i n j ecti o n a mo u n t 'q pumpis r egulated by
of a
t o o t h e dr a c k i n t h e s9i d{ e o f t h e ' p u m p - r r u s i nv. tr ansver sal displacement
a n so f a g e a r r i n g , t h e
p u m pp l u n g e rw i t h t h e t w o h e l i c a i m i l l i ; s , ' i r , " - c umt tei n
g - o 1 " i J " r , i s t u r n e d
w h e r e b yth e l e n g h t
p
um
p
str
oke
is"r
clone,o
fr
om
"when
i plunge rc l os es
9
I
"
t h e i n l e t h o l e s u n t i l t!1
h e l u t l i n g - o f f e d g e sa g a i n u n c o v e r st h e h o l e s . T h e r e l e a s e o f h i g h p r e s s u r er h r o u g ht 9 c u t i ; : o i i - e a g e s p r e s s e s
the oil with
a g a i n st th e w a i l of- the pum por r ing.
fAE
l i . lrln^ e
f glsp
ceo t, tw o
e xch a n g e able
plug scr ewsar e mounted.
Leakage
of fuel
a r o n gt h e p u m pp l u n g e r . i s p r e v e n t e d
f i l t e r e d l u b r i c a9t ji ro n o i l ' t o t h b p i r h g i ' n ; . , g n e rp r ebsys su ur ep p r y i n gs p e c i a l r y
tfan the fuel
q r l m q ry p u mpp re ssu re . P ar t of te teat- oii t"o* a' longthe ptungeri s
9
i
l
i ns t e a d l e d b a ck to th e p u mph ousingand t;;;
r etur ned to the ser vice tank
t h r o u g ha s e p a r a t ep i p i n g .
T h e r e g u l a t i n gr o d i s c o n n e c t " dy j t h . t h e r e g u l a t i n g g e a r
a f l e x i b l e c o n n e c t i o ns o t h a t a u l o c t J - " " g i i t i n g r o d o f t h e e n g i n et h r o u g h
w i l l n o t p r e v e n tn o r m a l
r e g u l a ti n g o f th e o th e r fu e l pumps.
f t h e to p o f th e p u mpb a rre l' a non- r etur n valve has
built- in to ens ur e
t h a t a su i ta b l e p re ssu rere mainsin th; itn- p"..r ur e. been
pipe betweenthe pum p
a n d t h e fu e l i n j e cto r a t th e momentthe pr ssiir ein
bur - ar "el is r el eas e d ' T h i s p r e s s u r e . s a f e g u a r tdhse i n j e c t i n - i r l e a nthL
d
t
h
ei p i n g
f r o m c a vi ta ti o n a tta ck. T h e fuel oli iupiv"to- ' " pr *p e h i g h - p r e s s u r p
o.lr
ii
tn"or
gh
a
s epar a t e l y - dri ve n p u mph a vi n g a pr essur eof 4_5 bar .
I n e o ] | i s s u p p l , i e d . t h r o u gahc o n n e c t i o no n t h e f r o n t
o f t h e p u m ph o u s i n g .
I n a d d i t i o n t o f e e d i n g t h P u m p t, h e f u e l - o i i i t
u s e df o r c o n s t a n tc i r c u l a t i o n
a r o u n dt h e p u mpb a rre l a n d i êtir inedthr ug th"' connection
on the back of the
p u m ph o u si n g . In th i s b ra yth e pumpcan be- kept
constantiy heateddur ing oper at i o n w i t h h e a v yo i r , a n d a r s o i c e p th e a t e da u i : i n gs h o r t
e n g i n es t o p s .
===H
ceruecanruc sEts
L23/30
PUMP
FUELINJECTION
310.51
O V E R H A U L IO
NFGF U E LP U M P
Edition 03
P la t e 3 10 5 1
I f n e c e s s a r y ,c'l e a nth e e xte ri o r o f the injection pum p.

F a s t e nt h e i n j e c t i o n p u m p ' i nt h e c l a m p i n gb r a c k e t 0 1 9 9a n d i n v e r t t h e p u m p .
Pre s s t h e t a p pe t d o w n w a rdbsy me a nsof the lever and r emovethe cir clip.
Rem o vteh e t a pp e t w i th l o w e r sp ri n g plate and plunger . Be sur e not to dam age
the plunger.
T a k eo u t t h e p l u n g e rs p r i n g , u p p e rs p r i n g p l a t e a n d p i n i o n . I f n e c e s s a r yr, e mov et h e s t o p b o l t a n d d i smo u n tth e r egulating r od as well as the cap scr ew.
\-
I n v e r t t h e f u e l i n j e c t i o n p u m p( c o n n e c t i n gp i e c e a t t h e t o p ) .
Un s c r e wt h e f o ur A 1 l e n scre w sa n d removethe connectingpiece. Takeout the
v a l v e s p r i n g a n d t h e n o n - r e t u r nv a l v e .
Loo s e nt h e f o ur scre u ,sa n d ta ke o u t the bar r el.
A ll p a r t s m u st b e cl e a n e d , u si n g ker oseneor gas and a har d br ush ( never use
a s t e e l b r u s h ) . I n s e r t p l u n g e ra n d n o n - r e t u r nv a l v e i n t o t h e p l u n g e rg u i d e
a f t e r c o a t i n gw i t h c l e a n g a s o i l .
T h e a x i a l c l e a ra n ceb e tw e e nl o w e r spr ing plate and plunger foot m ust not exc ee d 0 . 2 5 m m .T h e cl e a ra n ceo f th e piunger foot has to be 0.05 to 0.1 m mwhen
new.
T h e p l u n g e ra nd n o n -re tu rnva l ve must slide into the guide by their or ,,nweight.
\,
Checkthe plug screv{sfor wear.

Bar r e l , p l u n g er a n d n o n -re tu rnva l ve ar e m anufactur ed
to ver - vc' losetoler anc es. A n y a t t e mp t to re fi n i sh th e se par ts causesalter ations of the toler ances
and m u s t t h e r efo re N OTb e ca rri e d o ut. If, dur ing the visual inspectionof the
p a rt s , h e a v ya b ra si o nsymp to ms
o r d amage
can be obser ved,the par t in question
m u s tb e r e p l a c e d .
Wh e na s s e m b l in gth e i n j e cti o n p'lu mp,pr oceedin the r ever se or der to disassembi i ng. Pay attent'ion to the fol owing:
App l y m o ' l y b d e n udm
'i su lp h i d e to a l I thr eads.
Renew
all 0-rings.
Wip ed r y w i t h pa p e r th e p l a n e se a l i ng sur faces on bar r el and connectingpiece.
Befo r e i n s e r t i n g th e p i n i o n th e e a sy motion of the p' lungerin the bar r el must
b e ch e c k e d -
t L.,E
t-llltb.ill
t= 5E =-E5
E
GENERATIT\GSETS
Ln/34
]YIAI
ct&ut
PUMP
O V E R H A U L IO
NFGF U E LP U M P
3 10 . 5 2
Edition 03
W h e na s s e m b l i n tgh e p i n i o n , a s c e r t a i n t h a t t h e t o o t h ( r e c o g n i z a b l e
by the
c h a m f e r )w i l l e n t e r t h e s p a c eo f t h e r e g u l a t i n g r o d m a r k e db y z s i g n i .
T h em a r k e ds l o t o n t h e v a n eo f p l u n g e rm u s t b e i n l i n e w i t h t h e m a r ki n t h e
slot of pinion.
A f t e r a sse mb l y,th e e a sy mo tion of the r egulating r od must be checkedand the
p l u n g e rm u s tb e m o v e df r o m t h e n o - l o a ds t o p t o f u l l - ' l o a d s t o p .
=l#=
tE==E
E lr==r=-g
E
GENERAI1NGSETS
]v|AN
C&UI'
F U E LP U M P L ' 0 r a n g e P y OG 0 6 1 A
P L A T 3EI O O I - 1 2 H
2241
--=--<'-t606
\-_-/
8n
3045
\
f995
0203
25t6
27
2796
| 173
016tI
0372
@r--roza
&'"'
O-'*
E#-=EY
GENERATI\IG SETS
]Y|AI
ct&ut
FUELPUMP L 'Ora n g eP yOG 061 A
Item No.
q#$&".,qru4
{grttt 51ff.{q
6 .$#&$1a_
o typ ozg.3
6 'fr; #tfi # ooo7 w2
6_*&#vt0 fi&a? os61
I,8* F/ I0 ."06!te
5 #$ #-?/srffi{ {
.6t,*'l !?l s,#s6
6 * * 0v,i,dst'/{
*+*,#?$. {/#l*q
0916
1084
1173
1262
Designation
Benavnelse
F u e l p u mp,complete
Brandsel
spumpe,komp'l
et
Pumpehus
P u mph o us' ing

P1ug screw
Joint washer
B a r r e l , p l u n g e r ,a n d
n o n -re tur nvalve,
compl
ete
Screw
C i r c li p
R e g u l a tionr od
G u i d ep i n
?t ##fy !3qi
,6{.1*s
6"*,#Vrs ##t{ 144!
Ge a rri m
U p p e rs p r i n g p l a t e
fpdt df#f 1539

-{s,*,
S p rin g
L o w e rspr ing p' late
$ *i'#{teFW cisdd 1628

f 17L7
loo* oVi# '?s,r
6o,s:C I f 6 t ' i . 1 t : . Y # 1 8 0 6
6 gp#,oq6/ Q$#A !ee5
{'f t. of I d 2063
fS:i'l#,,
6*:#{},::flg ",3## 2152
$$0 , aYto FfF 22U
6r:t7q{f' #,Jf}S 2330
6 #,::.tr:!{f 0* u'Y 24?9
6 a*u f f# 00{ y 2s-18

6#i'rCy{# s{if# 2601
6a*,*' * , r / , s $ I f 2 7 9 . 6
a9t#, ,*v,e2885
6''*r'
{rs*g ollt"d$"3?sta
I sP* $?n'i7ff#f ? 30-42
6* {}"J:f-fd #* .r 3o4s
P L A T 3E1 0 0 1 - 1 2 H -
Propskrue
Tatningsr ing
Cy1i nder, stempe'log
kontraventil, komplet
Skr ue
Regu'l
eri ngstandstang
Styretap
Tandkr ans
T h ru st cap
0 -ri n g
0-ri ng
Circlip
Overste fjederp'lade
Fjeder
Nederstefjederp'lade
Trykhette
0-ri ng
0-ri ng
S p rin g
Fjeder
C o n n e ctingpiece
For bindelsesstykke
0 - ri n g
0 - ri n g
t.lasher
P o in te r
0- r i ng
0-ri ng
Skive
V is e r
Nut
Screw
Capscrew
Mstri k
Skr ue
Hetteskrue
Joint washer
S e c u r i n gr i n g
Tatningsring
Beskyttelsesr ing
=#-F=E
GENERATTNGSftS
]v|Al
Et&urt
TOOLSFORFUELOIL PUMP
PLATE
31051-O4H
#.EEY
CENERA'N\IGSETS
tUtAhI
Er&ut
TOOLSFORFUELOIL PUMP
PLATE
3 1051.04H -
Designation
Benavnelse
0 19 9
C l a m p i n gb r a c k e t f o r
testing fuel oil pump
Provevarktsj for
brendoliepumpe
O2BB
Lever
Vegtstang
0290
S p e c i a l s p a n n e rf o r
fastening for fuel
oi I pump
S p e c i e ln o g l e f o r
fastspendingaf br andol 'iepumpe
Item No.
.-'=
tF-rg
GENERAIII\IC
SETS

Instruction Book Part 1

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Instruction Book Part 1

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1I|AN

MAN B&W D|ESCIA/S

Instructionsfor Plantsbasedon EngineType23

E xh a u s t side ,/ Right side

Engine viewed from Flywheel

The plantconsistsof 3 high-pressure

kbricating Clil System

Pressure drop across filter

l-ub. oil, evel in oase trale

Fuel Oil System

Fuel oil leakingoit

Cooling Water System

Press. HTcircu! intet engine

Temp. HT-cirol( inletengine

Temp. HTciratt ouet cyl. unts

EdraustGas and Charge Alr

Exh. gastemp. after TC

Ch. ar press. after cooler

Ch. air temp. afl cooler V28E2A

Speed Control Systcm

S p e c i f i c p l a n t s w i l I n o t co mpr isealar m equipm entand autostopfor all par am et e r s l i ste d a b o ve .

For newor real ignedaggregate

For aggregate in service realignment

" Cl o s i n g " o f t h e th ro w i n to p d e a dc entr e is r egar dedas negative ( com pr essi on

Near bottom (starboard)

C a n d D s h o u l d b e near ly the sam e.Readingsfor cyl. 4 to

Valve seat ring, exhaust

N o t e : A l l p i s t o n r i n g s must be changedat normal p i s t o n o v e r h a u l ,see s e c t i o n 3 0 7

Vertical clearance, ne!{ rings in new or renewedring grooves.

Ring groovesmust be renewedwhentest-tool can be pressedmore than 2 rrn

tor que 120 Nm

repeat torque 120 Nm

6o0 tur ning ansle

Pr i o r t o a sse mb l yl u b ri ca te thr eads and contact faces of the scr ewswit h

Inlet valve clearance

1o turning of camshaft gear wheel changes

P1ug screw 037?

INCREASED Reduced I Increased Advanced Increased

N u t f o r a d j u sti n g scre w , 'i te m N o . 0 9 6 5

Pin gaugefor camshaft, check measurement

Pi n g au g efo r cra n ksh a ft, cyl. 1 top deadcentr e,

T i g h t en i n go f b o l ts o n sh a ft end for inter m ediate

T i g h t en i n go f b o l ts fo r a ssem blyof inter m ediate

F u e l c a ml e a d (se e a ctu a l value, test sheet)

F o r i n stru cti o n s, se e th e separ atel,{ oodwarmanual

720 rpn 60 Hz:

T h e p u mpd o e s n o t w o rk a fte r star t.

R u n n i n gtro u b l e s w i th the pum ps,apar t fr om mechanicalfaults, ar e

En s u reth a t th e se a l sp ring is cor r ectly located and r efit Im peller Ke- v ,

pum pwith liquid befor e oper at i ng.

Datafor Pressureand Tolerance

C h e ckth e a l i g n mentof the cr ankshaft as pr escr ibed( section 305 C ) .

C h e ckth e o i l l e vel in engine bedplateand in tur bochar ger s .

L u b ri ca te th e i o i n ts of the r egulating gear . Checkthe oil lev el

and check that the filter

elementsar e not da-

C a msh a ftb e a rings, gear wheelsand r oller guides.

S p e e dse tti n g : C h e ckbefor e cutting in the gener atoron the

A d j u sti n g sp e e d : C ut in the gener atoron the switchboar dand

H u n ti n g : R u nth e e n ginewithout load at synchr onous

c h e c k1 2 . ch e ckp re ssu rea n d temper atur esaccor djngto Data 303.

C h e c k1 3. T h e a l a rm a n d mo nitor ing systemcan be checkedas follows:

C h e c k, |4 . T h e g o ve rn o rmu st be able to movethe fuel pum pgear to 0- po s i ti on.

ne for normal start or stand-b