Aluminum Charge Air Cover Replacement Procedure for Certain C18 Engines {1052, 1061, 1379} Caterpillar

Marine Engine

C18 MARINE ENG (S/N: T2P1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This document outlines the procedures required to be followed to change the intake systems on the Caterpillar C18 twin cementer CPS 678.

This work instruction must be complimented by Pyrobans Offshore Installation Manual OG003 for more guidance, safety notes, and fastener torque tables. Refer to product Material Safety Data Sheets (MSDS) as required.

During the unit build, the latest versions of drawings P0578, Pyroban 300829477/1 (Insulated Charge Air Pipe Kit) shall be consulted in association with this document. Refer to WI403 for instructions on HCTB application for the turbocharger recesses.

Appropriate care when handling must be taken to avoid any damage to the component parts or personal injury. Some items are heavy and require appropriate lifting equipment during the process of handling and installation. Prior to installation, ensure that all packing material is removed and also ensure that the engine is rigidly installed and level.

During installation, refer to the appropriate installation drawing.

For torque specifications, refer to the Pyroban Offshore Installation Manual OG003.

Do NOT modify any parts without authorization from Pyroban. Failure to observe any instructions in this manual may invalidate any warranty agreement.

Only genuine Pyroban parts should be used for replacements

Safety Section

The installation will be conducted by suitably trained personnel. All persons supporting / working on the installation must be inducted into the safety requirements before work commences.

The safety requirements for the specific location where the system is installed must be adhered to, and any necessary risk assessments conducted.

The person in authority for the specific location has full authority regarding safety and requests in relation to safety are final.

Safety equipment:

• Gloves

• Safety glasses

• Coveralls

• Dust masks

• Ear defenders

PPE must be worn always.

Ear defenders, must be worn when the engine is running.

Hard hats must be worn if engaged in activities where there is a risk of head injury (overhead lifting, working within the package space).

Overalls must be worn when conducting the rework to minimize the risk of injury.

Required Parts

Note: All part numbers in this Special Instruction are Pyroban part number and not Caterpillar.

There is one upgrade kit available for the inlet upgrade. Refer to drawings Pyroban 300829477 (Insulated Charge Air Pipe Kit). For each twin cementer package, the appropriate quantity of inlet kits will be provided, assigned to each engine serial number. All engines will require the inlet upgrade, some engines do not require the exhaust upgrade.

The charge air cooler covers of the engines to be upgraded are made from aluminum. As new charge air covers are supplied with the upgrade kits, the specific version of the inlet kit will be provided to match the engines cover type. Drawing 300829477 shows the parts which are specific to the Aluminum and cast iron cover versions. Replacement turbochargers are also included in each kit.

Kit Supply:

Primary contact: Ricky Clark

Secondary contact: Keith Brown

Tertiary contact: Marlon Parbery

Kit Supply Escalation: Darren Boiling

Technical Support:

Primary Contact: Marlon Parbery

Secondary Contact: Steven Keeley

Technical Support Escalation: Steve Noakes

As part of the upgrade kit process, the original aluminum charge air cover and turbo charger must be returned to Pyroban.

Illustration 1	g06091488
Aluminum charge air cover and turbo charger

Disassembly of Engine Components

Before the engine conversion can take place, several of engine components must be removed to allow unobstructed working access to the turbo compressor shell.

A good practice is to "bag and tag" all removed components along with plugging all apertures to aid a quicker and easier reassembly process.

The photographs below show the components that are to be removed in the preferred order.

Note: The new coated turbochargers will have been supplied with a 5 ° downward rotation to align with the new charge air pipes.

The photos below illustrate the various stages of removal of the old cross over pipes.

Show/hide table

Illustration 2	g06081924

1. Removal of left-hand bolt securing compressor outlet to charge air pipes.
   Show/hide table

   Illustration 3	g06082018

2. Removal of right-hand bolt securing compressor outlet to charge air pipe.
   Show/hide table

   Illustration 4	g06082025

3. Removal of bolts securing first charge air pipe to second charge air pipe.
   Show/hide table

   Illustration 5	g06082029

4. Removal of bolts securing charge air pipe to charge air cooler.
   Show/hide table

   Illustration 6	g06082032

5. Separation of charge air pipes.

   Remove the old cross over pipes with SCTB installed.

   Show/hide table

   Illustration 7	g06082038

6. Old cross over pipes removed.

Installation of the New Turbocharger Procedure

The turbocharger replaced with a new turbocharger that has Pyrobans SCTB coating on the entire compressor shell with a 5 ° rotation incorporated.

The existing turbocharger removed and replaced with the new supplied turbocharger 300827837-0.

The photos below illustrate the various stages of the removal and installation process.

Show/hide table

Illustration 8	g06082052
Compressor intake pipe with clamps removed

1. Remove the clamps on the rubber cuff on the compressor shell and air intake.
   Show/hide table

   Illustration 9	g06082063
   Clamps removed from compressor air intake

   Show/hide table

   Illustration 10	g06082072
   Turbo band clamp

2. Remove or loosen the clamps on the side of the turbo.
   Show/hide table

   Illustration 11	g06082320
   Turbo oil connections

3. Disconnect the oil feed and drain connections to the flexible hoses.
   Show/hide table

   Illustration 12	g06082325
   Air intake pipe assembly

4. Remove the nuts and bolts on the round flange on the intake pipe.
   Show/hide table

   Illustration 13	g06082336
   Air intake pipe bracket

5. Loosen off the bracket nuts and bolts on the air intake pipe, but do not remove completely to hold in place.
   Show/hide table

   Illustration 14	g06082341
   Air intake pipe connection to turbo

6. Remove the nuts and bolts on the round flange on the intake rubber cuff.

7. Lift off the air intake pipe, using the correct procedure for lifting.
   Show/hide table

   Illustration 15	g06082350
   Compressor air intake pipe and hose connection

8. Once the air intake is removed, remove the round intake flange, the rubber cuff, and the compressor shell.
   Show/hide table

   Illustration 16	g06082358
   Old turbo with band clamp and inside compressor shell uncoated

9. Unbolt the existing turbocharger from the connection to the flexible exhaust pipe and install the new turbocharger. The pictures above illustrate the appearance of the turbocharger before and after the rework.
   Show/hide table

   Illustration 17	g06082391
   New turbo with inside compressor shell coated - (300827837/0)

10. After installations of the turbocharger refer to WI403 for installation of hard compound thermal barrier in the turbocharger bolt recesses.

    Note: The hard compound thermal barrier must be done on all four bolts securing the turbine housing to the exhaust manifold.

Replacement Charge Air Cover

The charge air covers are replaced with units modified with thermal barrier material on the outer surface.

The charge air cover is further protected by a stainless steel cover plate attached to four standoff bolts.

Refer to Caterpillar service manuals for the process to remove and install charge air covers. Four standoff bolts are replaced with stud-bolts to provide fixing for the stainless steel plate.

Illustration 18	g06082402

Illustration 19	g06090607
Typical standoff (1) Bolt (2) 110-8314 Washer (3) Cover (4) Standoff - 93.5 mm long for aluminum (5) Charge air cover (6) Stud bolt - For aluminum cover 1W-1038

Illustration 20	g06082409

Replacement of Cross-Over Pipes

Illustration 21	g06082442
Old cross over pipes

Illustration 22	g06082455
New cross over pipes (Note: the pipes in the picture have been painted for test purposes. The pipes used in this installation will have an uncoated stainless steel appearance).

Installation Of New Cross Over Pipes

The photos below illustrate the various stages of the installation process. Refer to the latest version of drawing Pyroban kit part number 300829477/1 for this stage of the installation process.

1. Clean all surface flanges on the charge air cooler cover.
   Show/hide table

   Illustration 23	g06082491
   Aftercooler cover with sleeve inserted

2. Place the rectangle sleeve (part number 300829430/1) inside the charge air cooler cover flange, and using 2 gaskets (part number 300814750), 1 on the charge air cooler cover flange and another on the outside of the sleeve.
   Show/hide table

   Illustration 24	g06082493
   SCTB coated adapter

3. Install the SCTB coated adapter onto the charge air cooler cover.
   Show/hide table

   Illustration 25	g06082500
   O-ring installation onto crossover pipe

4. Inspect the new cross over pipes and install the O-rings 300461017 on the first flange that installs into the turbo compressor shell.
   Show/hide table

   Illustration 26	g06082502
   Gaskets

5. Install the gasket 300829506 on the first flange. Two gaskets are supplied to compensate for variations in casting tolerances. Install both gaskets if required to give full contact surface between the flange and turbo compressor scroll.
   Show/hide table

   Illustration 27	g06082510
   300828227 Installed

6. Install the new first cross over pipe 300828227.
   Show/hide table

   Illustration 28	g06082520
   300828224 Installed

7. Ensure a suitable distance between the new cross over pipe and the frame.
   Show/hide table

   Illustration 29	g06082526
   Crossover pipes viewed from the top

8. Install the second new cross over pipe 300828224. Ensure the square and round gaskets (part numbers 300828233 and 800261/13) are installed.
   Show/hide table

   Illustration 30	g06082527
   Cross over pipes viewed from the rear/side

9. After installing the new cross over pipes, tighten up all nuts and bolts to correct torque while checking the alignment of the inlet system assembly.

Post - Rework Activities

After installing the new heat exchanger assembly, follow the following steps to prepare the engine for running.

1. Tidy the work area and clear any tools, scrap equipment, and debris from the area surrounding the engine.

2. Clean the engines as far as practicable.

3. Run engine for 15 mins and check for coolant leaks.

4. Fill the coolant system with 50% water and 50% glycol anti-freeze.

5. Carry out a test run on engine, and checking around engine at the same time.

6. While the engine is running, the coolant system needs to be bled to remove trapped air using butterfly valves on engine coolant pipes. Follow instructions in the SLB engine maintenance service book for bleeding coolant system.

Cleaning And Inspection For Dispatch

Once all work is completed. The surrounding areas should be cleaned thoroughly to remove any excess material and then photographed to proved evidence of the parts condition prior to leaving work site. These photographs should be attached to the SIMSi entry.

Returning turbo charger and aluminum charge air cover

The original turbo charger and aluminum charge air cover from both engines are to be returned to Pyroban for upgrade and subsequent use in PCA kits.

The replacement turbocharger is supplied in a bespoke shipping box which is to be used for the return of the original turbocharger.

Pack the turbocharger and aluminum charge air cover and return to Pyroban at the following address :

For attention of goods in

Serial Number Records Table