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    Service Information M20

    Uploaded by

    Alexander
    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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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Service Information M20

    Uploaded by

    Alexander
    187 views72 pages
    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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    Service information M20

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    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.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    187 views72 pages

    Service Information M20

    Uploaded by

    Alexander
    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.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 72

    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: ju_tecservice@CAT.com •
    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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