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Service Information M20

1. The document provides maintenance guidelines for KBB turbochargers used with Caterpillar marine engines. 2. It gives maintenance intervals and procedures for turbochargers operating on Marine Diesel Oil or Heavy Fuel Oil. 3. For Heavy Fuel Oil operation, it recommends regularly washing the turbine to remove contaminants, with the interval depending on fuel quality and ranging from 50-600 hours. Guidelines are provided for safely washing the turbine.

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440 views72 pages

Service Information M20

1. The document provides maintenance guidelines for KBB turbochargers used with Caterpillar marine engines. 2. It gives maintenance intervals and procedures for turbochargers operating on Marine Diesel Oil or Heavy Fuel Oil. 3. For Heavy Fuel Oil operation, it recommends regularly washing the turbine to remove contaminants, with the interval depending on fuel quality and ranging from 50-600 hours. Guidelines are provided for safely washing the turbine.

Uploaded by

Alexander
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Umlaufkühlwasser - Aufbereitung: Covers water circulation treatment to ensure safe operation of engines, focusing on preventive measures against corrosion and deposits.
  • Maintenance of the Lub. Oil Protective Strainer: Discusses procedures for maintaining the lubricating oil protective strainer, emphasizing the importance of keeping the component clean.
  • Chroming of Crankshaft Pins and Journals: Details policy against chrome re-grinding for crankshaft pins, citing safety concerns in accordance with classification societies.
  • Vibration Dampers, for All Engine Types: Describes the use of vibration dampers to protect engine components from structural stress due to torsional vibrations.
  • Judgment of the Engine Operating Attitude: Evaluates the operating attitude of newer engine models, highlighting improvements and operational changes.
  • Check of Injection Nozzles: Provides inspection guidelines and performance criteria for diesel engine injection nozzles.
  • Check of the Fuel Rack Zero-Position on Stop: Instructions to verify fuel rack zero-position and its impact on operational stability during engine stop.
  • Linkage of the Fuel Injection Pump: Describes linkage alignment procedures for fuel injection pumps to avoid corrosion issues.
  • Change of the Valve Clearance for Exhaust Valves: Details adjustment procedures for valve clearances to ensure optimal engine performance.
  • Valve Clearance Inspection/Adjust: Guidelines for inspecting and adjusting valve clearances, including safety precautions and tools required.
  • Fitting of the Nozzle Holder: Instructions for correctly fitting the nozzle holder to prevent alignment errors during operation.
  • Hand Pump HV 6013 for Hydraulic Tool Set: Explains the use and modifications of the hand pump design to improve operational reliability.
  • Tightening Instruction for the Lateral Screws of Crankshaft Bearings: Procedures for tightening lateral screws to ensure proper crankshaft bearings function.
  • Tightening Instruction for Crankshaft Counterweight Bolts: Lists correct tightening procedures for counterweight bolts using specific torque settings.
  • Change of the Valve Clearance for Inlet Valves: Details specific valve clearance changes to maintain optimal inlet valve operation.
  • Valve Clearance Inspection/Adjust: Procedure for inspecting and adjusting valve clearance post-initial operation hours.
  • Engine Stop Valve Warning: Warning regarding the effects of closing the stop valve during engine operation, advising against it for safety reasons.
  • Exhaust Gas Turbocharger Information: Provides updates on R 3-2, R 4-2 turbocharger exhaust systems for optimal performance.
  • Dismantling of the Turbine Housing/Bearing Housing: Step-by-step dismantling instructions to ensure safe removal of housing components.
  • Nozzle Sleeve Maintenance: Provides guidelines for maintaining the nozzle sleeve, focusing on seal integrity and replacement cycles.
  • Pickling and Passivating of Stainless Steel Components: Instructions for the chemical cleaning and protection of stainless steel components to prevent corrosion.

Service Information No.

08 / 04
Date: 27-AUG-2004

KBB Turbocharger M20 / M25


KBB Service Information S44 and S45

1. KBB Service Information S44


Subject: Maintenance interval for MDO / HFO
Valid for TC type: R2-2 to R4-2, R4-3, R5-3

2. KBB Service Information S45


Subject: Turbine cleaning
Valid for TC type: R3-2, R4-2, R4-3 and R5-3

Caterpillar Marine Power Systems, Kiel, Germany • Phone: +49 (0) 431 3995-2825 • Fax: +49 (0) 431 3995-3080 • E-mail: [email protected] •
Part S Service Information
S44(12/2003) Exhaust gas turbocharger
Subject: Maintenance interval for MDO/ HFO
Valid for TC type: R2-2 to R4-2, R4-3, R5-3
Valid for engines: All

1.1 Maintenance interval

1.1.1 Maintenance for Marine Diesel Oil (MDO) application

The operating hours given in the table below are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.

Item Maintenance work Maintenance


interval
(operating hours)

1. Check for abnormal noise 24


2. Compressor washing during operation, actuate 24 - 48
compressor washing system
3. Clean air filter at silencer approx. 250
or on demand
4. Check fastening bolts at the feet, tighten all housing once after
bolts and piping joints commissioning, then
every 1,000 hours
5. Inspection I max. 10,000
• disassembly
• cleaning
• checking of rotor and bearings
• checking of housings
• assembly
6. Inspection II max. 20,000
• like inspection I
• replacement of the bearings
7. Inspection III max. 40,000
• like inspection II
• replacement of the rotor

S_044-2003-12en.doc 1st Edition (12/03) Page 1 of 2


Service Information Part S
Exhaust gas turbocharger S44(12/2003)

1.1.2 Maintenance for Heavy Fuel Oil (HFO) application

The operating hours given in the table below are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.

Item Maintenance work Maintenance


interval
(operating hours)
1. Check for abnormal noise 24
2. Compressor washing during operation, actuate 24 - 48
compressor washing system
3. Turbine washing during operation, actuate turbine approx. 300
washing system depending on HFO
Cleaning with water quality
4. Clean air filter at silencer approx. 250
or on demand
5. Check fastening bolts at the feet, tighten all housing once after
bolts and piping joints commissioning, then
every 1,000 hours
6. Inspection I max. 10,000
• disassembly
• cleaning
• checking rotor and bearings
• checking housings
• assembly
7. Inspection II max. 20,000
• as inspection I
• replacement of bearings
8. Inspection III max. 40,000
• as inspection II
• replacement of rotor

The nozzle ring is subject to an increased wear for heavy fuel oil
operation. Therefore it is a wear part.
The lifetime of the nozzle ring is approximately 12,000 hours, but it
depends on HFO quality and operating conditions.
After exceeding the lifetime the nozzle ring should be replaced in case of
fundamental change of performance data as charge air pressure and
exhaust temperature.

Page 2 of 2 1st Edition (12/03) S_044-2003-12en.doc


Part S Service Information
S45(12/2003) Exhaust Turbocharger
Subject: Turbine cleaning
Valid for TC type: R3-2, R4-2, R4-3 and R5-3
Valid for engines: M20 and M25 from CAT / MaK

Cleaning of turbine

Heavy fuel oil operation results in contamination and deposits on nozzle


ring and turbine wheel reducing the efficiency. Due to these deposits the
charge air pressure will be increased.
The washing intervals depend on the fuel quality and operating
conditions. That's why they must be adjusted based on the experience
gained during engine operation if necessary later on. The washing
interval could be adjusted from 50 to 600 hours.
The increase of charge air pressure could be used for adjusting the
washing interval, which could adjusted within 50 to 600 hours.
Read and take down the charge air pressure and exhaust gas
temperatures at a reference point (at 75 % or 100 % of the output) before
and after washing to check the washing effect.

Legend (Example, could vary depending on engine installation)


1 Sanitary fresh water 6 Wash-water piping 10 Escape funnel or sight glass
2 Regulating valve 7 Injector
3 Fresh-water piping 8 Connection for drain 2100 Turbine inlet housing
4 Removable flexible tube 9 Valve 11 Turbine outlet housing
5 Stop valve

st
S_045-2003-12en.doc 1 Edition (12/03) Page 1 of 2
Service Information Part S

Exhaust Turbocharger S45(12/2003)

Work sequence:
1. Connect the flexible tube (4) to fresh-water piping (3).
2. Reduce the engine output to approx. 15 % of its rating until the temperature after
cylinder has come down to its specified value. (see table)
3. Wait for approx. 10 minutes!
4. Open the valve (9) of the drain (8) (if present).
5. Open valve (2) and adjust the water pressure (see table).
6. Open stop valve (5) for approx. 30 seconds and close again.
7. Wait for approx. 3 minutes so that the injected water can evaporate.
8. Repeat steps 6. and 7. twice or three times.
9. Close the stop valve (5), valve (2) and the valve (9) of the drain.
10. Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes, increase
engine load slowly!
11. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations
which did not occur before.
12. Remove the flexible tube (4).
Operating values for turbine washing

Engine Exhaust gas Exhaust gas Water pressure Total


output temperature after temperature (gauge) washing
cylinder before / after the period
turbine
max. 15% 300 – 330 °C 400 – 420 / <330 °C 1.5 – 2 bar 3-4x 30 sec

• Hot exhaust gas can escape from the drain - Risk of burning!
• Continue to operate the engine for at least 30 minutes after cleaning.
• Do not wash before a stop of operation. Corrosion risk!
• Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals.
• Pay attention also to instruction of the engine’s operating manual!

st
Page 2 of 2 1 Edition (12/03) S_045-2003-12en.doc

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