Work Card
Assembly and Maintenance - Compressor Side
Compressor Casing and Diffuser 500.42
Short Version
Disassembling the compressor casing in order to check the diffuser.
Required Personnel and Time
Amount Qualification Required Time/h
1 Qualified mechanic 2.0
1 Assistant 2.0
Required Tools/Appliances
Amount Designation Number Status
1 Open-jaw wrench 19 – Inventory
1 Open-jaw wrench 30 – Inventory
1 Torque wrench – Inventory
1 Screwdriver – Inventory
- Lifting tackle with ropes, chains – Inventory
- Wood (for placing underneath) – Inventory
2 Wood blocks – Inventory
3 Hexagon bolt 12 x 40 596.280 Standard
2 Eye bolt M12 596.051 Standard
2 Eye bolt M16 596.058 Standard
Spare Parts
Amount Designation Number
1 O-ring seal 517.063
Corresponding Work Cards
Work Card Work Card Work Card
500.32 500.33 500.34
500.41 500.53
Technical Data
Designation Specification
TCA55_50042_E.fm
Compressor casing 546 kg
Diffuser 36 kg
6670 C2 500.42–01 E 02.06 TCA55 151
WARNING
Danger of injury from suspended loads!
A rocking compressor casing is difficult to maneuver and can
therefore seriously injure people and damage material (i.e. the
compressor wheel)!
Use tackle line/chains to guide the silencer!
For attachment of the lifting equipment, use only the lifting eye
bolts intended for this purpose, as described under „Required
Tools/Appliances“!
xx
Work Sequence 1 – Compressor Casing Removal
Starting Condition Emergency and post-lubrication system [500.34], silencer [500.32] or
air intake casing [500.33] as well as insert with speed transmitter
[500.41] removed.
Important!
The insert must be disassembled before removal of the
compressor casing!
Work Steps 1. Dependent on the position of the compressor casing (546.000),
fasten 1 or 2 lifting eye bolts (596.058) to the compressor casing.
2. Insert the wire rope of the lifting tackle. Make sure that the rope is
tensioned.
3. Loosen the hexagon nuts (546.104) alongside the circumference.
4. Screw in three forcing-off bolts (596.280) and evenly loosen the
compressor casing.
5. Move the compressor casing away in axial direction, and place it
on a wooden support.
Important!
Secure the compressor casing against rolling off.
596.058
506.099
506.104
546.000
TCA55_50042_E.fm
546.000 Compressor casing 506.104 Hexagon nut
506.099 Undercut bolt 596.058 Eye bolt
Fig. 19. Assembly of a single-stage compressor casing to the turbocharger
6670 C2 500.42–01 E 02.06 TCA55 152
Work Sequence 2 – Diffuser Removal
Starting Condition Compressor casing (546.000) disassembled and positioned on a
wooden support (e. g. two wood blocks) while properly secured against
rolling off.
Work Steps 1. Fasten lifting eye bolt (596.051) to diffuser (542.001) and attach
to lifting tackle.
546.000
546.045
546.047
546.000 Compressor casing 546.045 Countersunk bolt
546.047 Lock nut
Fig. 20. Diffuser fastening
2. Loosen lock nut (546.047) of countersunk bolt (546.047) in
compressor casing.
3. Loosen countersunk bolt.
4. Remove diffuser (542.001) in axial direction.
596.051
546.045
546.000
542.001
542.001 Diffuser 546.045 Countersunk bolt
546.000 Compressor casing 596.051 Eye bolt
Fig. 21. Removing the diffuser from the compressor casing
TCA55_50042_E.fm
6670 C2 500.42–01 E 02.06 TCA55 153
Work Sequence 3 – Compressor Casing Installation
Starting Condition Compressor wheel [500.43] mounted on turbine rotor [500.53].
Important!
The insert [500.41] must not be mounted for assembly of the
compressor casing, otherwise the compressor wheel may
become damaged upon assembly of the compressor casing.
Work Steps 1. With the lifting eye bolt (596.051), hang the diffuser to the lifting
tackle.
2. Mount the diffuser (542.001) to the compressor casing (546.000)
with the countersunk bolt (546.045). Save countersunk bolt with
lock nut (546.047).
546.000
542.001
546.045
542.001 Diffuser 546.045 Countersunk bolt
546.000 Compressor casing
Fig. 22. Installation diffuser
3. Depending on the position of the compressor casing, fasten 1 or
2 lifting eye bolts (596.058) to the compressor casing and insert
the rope of the lifting tackle. Ensure that the rope is tensioned.
4. Check the O-ring seal (517.063) at the seat of the compressor
casing/ bearing casing for damage and renew, if required.
Important!
For assembly, lightly oil O-ring seal with oil!
5. Guide the compressor casing axially to the turbocharger, slide
onto the undercut bolts (506.099) and tighten hexagon nuts
(546.104) with the specified tightening torque.
Important!
Do not damage the compressor wheel with the compressor
casing.
Important!
Lubricate contact surfaces and thread (e. g. Molykote HSC)!
Important!
TCA55_50042_E.fm
Observe tightening torques upon installation!
Countersunk bolt diffuser (546.045): 60 Nm
Hexagon nut compressor casing (506.104): 250 Nm
6670 C2 500.42–01 E 02.06 TCA55 154
