0333549 JOHNSON GASKET, Cylinder head

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 replacementsSafety 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 defendersPPE 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 ClarkOil & Gas /Materials Handling (After Sales)
Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456 800
Direct : + 44 (0) 1273 456 837
Ricky.Clark@pyroban.com
parts@pyroban.com
Secondary contact: Keith BrownParts Co-ordinator (After Sales)
Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct: +44 (0) 1273 456860
Keith.brown@pyroban.com
parts@pyroban.com
Tertiary contact: Marlon ParberyOffshore Service Coordinator
Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct : + 44 (0) 1273 456900
Mobile: +44 (0) 7786550588
Marlon.parbery@pyroban.com
parts@pyroban.com
Kit Supply Escalation: Darren BoilingGlobal After Sales Manager
Pyroban Group
23 South, 23 Dolphin Road, W. Sussex, Shoreham by Sea, BN43 6QG, UK
Direct: + 44 (0) 1273 456831
Mobile: + 44 (0) 7803 500 396
darren.boiling@pyroban.com
Technical Support:Primary Contact: Marlon ParberyOffshore Service Coordinator
Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct : + 44 (0) 1273 456900
Mobile: +44 (0) 7786550588
Marlon.parbery@pyroban.com
parts@pyroban.com
Secondary Contact: Steven KeeleyService Engineer Offshore Oil & Gas
Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456 800
Direct: + 44 (0) 1273 456 845
Mobile: + 44 (0) 7557 938 084
steven.keeley@pyroban.com
Technical Support Escalation: Steve NoakesEngineering Manager
Pyroban Group
23 South, 23 Dolphin Road, Shoreham by Sea, BN43 6QG, United Kingdom
Direct: + 44 (0)1273 456823
Mobile: + 44 (0)7803 500171
steve.noakes@pyroban.com
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.
Illustration 2 g06081924
Removal of left-hand bolt securing compressor outlet to charge air pipes.
Illustration 3 g06082018
Removal of right-hand bolt securing compressor outlet to charge air pipe.
Illustration 4 g06082025
Removal of bolts securing first charge air pipe to second charge air pipe.
Illustration 5 g06082029
Removal of bolts securing charge air pipe to charge air cooler.