Alcance 2: Emisiones indirectas (Consumo eléctrico)

Disconnect the compressor washing pipework and speed measurement connector at the turbocharger.

Remove the side entry compressor inlet casing, if fitted, from the compressor outlet casing, alternatively:--

Remove the air filter / silencer, if fitted, from the compressor outlet casing. First remove the filter panel which is in two or three segments, each fastened with two toggle clips. Sling the remainder of the assembly in such a way that the risk of unexpected release from the compressor outlet casing is avoided.

Remove the nuts and washers which hold the compressor casing to the main casing, having prepared to sling or man--handle it ( with two operators ). Take off the compressor casing with extra care so that the impeller is not damaged during removal. Jacking bolts may have to be used to remove the compressor outlet casing.

Dismantling

Fig. 5.2 Example of Slinging the Compressor Outlet Casing

To remove the diffuser, unlock the countersunk ”long loc” securing screw at the rear of the compressor outlet casing.

DISMANTLING TOOL: 1032

Transfer the lifting brackets to the main casing compressor end flange. The 3/4” B.S.P. oil inlet tapping will already have been plugged, UNDER NO CIRCUMSTANCES MUST IT BE USED AS A LIFTING EYEBOLT SOCKET.

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Remove the nuts and washers which secure the main casing to the turbine outlet casing. M8 x 40 m.m. long jacking screws provided may be used to free the flange. Withdraw the cartridge without tilt or droop to protect the turbine blades.

Rest in a stand if available, ( See section 5.2 Safety of Personnel ) or on a suitable work surface. Release speed measuring probe ( if fitted ) as follows. Check whether the main casing is fitted with a speed measuring head. If fitted, loosen the screws on the locking plate and turn the speed probe at least five complete revolutions in an anti--clockwise direction. This action will avoid damaging the speed probe perception head when withdrawing the rotor shaft later.

Prepare to remove the rotor assembly parts from the cartridge. RETAIN THE SHAFT HORIZONTALLY.

Establish an ”M” mark on the end of the shaft, for re--assembly purposes.

Release the lock washer from the shaft nut, DO NOT DAMAGE OR DISTORT IT. Remove the rotor shaft nut.

DISMANTLING TOOL: 1011

Remove the lock washer and impeller drive washer. The drive washer may require a gentle tap to aid removal.

Withdraw the impeller ( assembly ) using the removal tool if necessary. Maintain the rotor shaft horizontal. ( See Fig.5.4 )

NOTE: This assembly comprises of impeller, sleeve and seal ring carrier. Under no circumstances must this assembly be separated. The compressor end seal ring or rings may be removed as required for inspection or cleaning.

1002 1003 1004 1005 1008

1025

Fig. 5.4 Removal of Impeller.

1. Lock the jacking screw onto the threaded end of the rotor shaft. 2. Screw the impeller adaptor onto the nose of the impeller sleeve.

3. Bring the assembly of the body, nut and handle up to the impeller adaptor. 4. Fit the two M8 setscrews to the assembly.

5. With the tommy bar fitted into the end of the jacking screw , rotate the nut anti--clockwise thereby pulling the impeller assembly away from the rotor shaft.

Dismantling

DISMANTLING TOOLS: 1002, 1003, 1004, 1005, 1007, 1008, 1018 & 1025.

Unlock and remove the six setscrews and tab washers that hold the compressor end seal ring bush to the main casing. Withdraw the seal ring bush using three extraction screws if necessary, together with joint washer, or shim if it is a positive stop arrangement.

DISMANTLING TOOLS: 1023, 1027.

Remove the compressor end bearing, support plate and impeller adjustment washer as follows. Remove the four ”long loc” setscrews which hold the bearing, bearing support plate and impeller adjustment shim to the main casing. Use extractor screws to remove the bearing and shim, if necessary.

DISMANTLING TOOLS: 1023, 1027.

Remove the impeller adjustment shim from the compressor end bearing.

1003

1004 1005 1009 1006 1023

1002 1025

1013

Fig. 5.5 Removal of Thrust Collar.

Remove the thrust collar from the shaft as follows.

1. Position the guide sleeve over the shaft and secure to the compressor bearing flange using the two M8 x 25 m.m. long setscrews provided.

2. Lock the jacking screw onto the threaded end of the rotor shaft.

3. Secure the body extension tube of the removal tool into the internal thread of the thrust collar which faces the compressor end of the turbocharger.

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Fig. 5.6 Removing Rotor Shaft.

9. The turbine end seal rings are now exposed and may be removed as required for inspection or cleaning.

TAKE CARE TO PROTECT THE TURBINE BLADES.

DO NOT REST THE TURBINE WHEEL ON THE BLADE TIPS AFTER REMOVAL. DISMANTLING TOOLS: 1002, 1003, 1004, 1005, 1006, 1007, 1009, 1013, 1018, 1023, 1025.

Remove the ”long loc” screw which secures the diffuser packing ring to the main casing. Remove the packing ring.

DISMANTLING TOOL: 1032

Unlock and remove the six setscrews and tabwashers that secure the labyrinth seal plate to the main casing. Withdraw together with the labyrinth seal plate adjusting shim, using three extraction screws if necessary.

DISMANTLING TOOLS: 1024, 1027.

Unlock and slacken the six bolts that secure the seal plate at the compressor end and also the outer cone at the turbine end. Do not remove the bolts at this stage. Position the main casing so that the outer cone may be released. ( See Fig. 5.7 )

Dismantling

TAKE CARE. Ensure the frame is adequate and secure before commencing.

Careful and systematic tapping on the heads of the bolts will remove a carbon seized cone. Partly slacken the six bolts.

Wooden frame to support the assembly above the bench.

Fig. 5.7 Removal of Outer Cone

Using wooden blocks to support the main casing flange so that the cone is clear of the working surface, the cone may be freed by systematic tapping of the bolt heads. The bolts will require further slackening as the cone becomes free. Remove the bolts and lift the casing away from the cone and joint washer.

DISMANTLING TOOL: 1029.

Remove the seal plate from the main casing if required.

Remove the six setscrews and tab washers which hold the seal ring bush to the turbine end of the main casing. Remove the seal ring bush and gasket.

DISMANTLING TOOL: 1027.

Remove the turbine end bearing as follows. Unlock and remove the four setscrews which hold the bearing and the bearing flange support to the main casing.

DISMANTLING TOOLS: 10.

Prepare to remove the turbine inlet casing. Sling the casing as indicated in Fig 5.8. Remove the casing nuts, spring washers and plain washers from the studs securing the inlet casing to the

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Fig. 5.8 Removal of Turbine Inlet Casing.

Unlock the tab washers and remove the six setscrews from the shroud and turbine inlet casing flanges,and remove the shroud ring from it’s spigot.

DISMANTLING TOOL: 1015

Remove the six caphead screws and disc--lock washers which hold the nozzle ring to the turbine inlet casing.

DISMANTLING TOOL: 1034.

Note and mark the position of the cooling connections and cover plates and then remove the turbine outlet casing from the engine if necessary. Remove the twelve M12 x 30 long setscrews and tab washers from the mounting foot.

Remove the mounting foot , joint and dowels. DISMANTLING TOOL: 1029.

5.4 CARE AFTER DISMANTLING