PT Trakindo Utama COMPONENT CONDITION REPORT

Page 1 of 12

Trakindo WO : 8500215139 Reported By : INDRA. S & SIDIK. N

Original WO : Reported Date : November 23th,2022

Checked by
Approved by
Foreman / : :
Service Head
Supervisor

Donal Sudrajat Wardoyo

(Name and Signature) (Name and Signature)
SIMS Information
DEALER EQUIPMENT CUSTOMER PT. Pertamina Hulu Kalimantan
CODE J211 NUMBER GS1411B NAME
Timur
TECHNICIAN EQUIPMENT
11/16/22
DATE IDENTIFICATION 12896 LOCATION LAWE-LAWE Terminal
Mo / da / yr
CATERPILLAR CATERPILLAR INSTRUCTION
MODEL G399 SERIAL No 49C00392
Engine Detonation
HOURS 22999 KILOMETERS

DID THIS INCIDENT DESCRIPTIVE COMMENTS

PART NUMBER DESC,* GROUP NUMBER
PART NAME QTY GROUP NAME MAKE THE PRODUCT (20 SPACES MAXIMUM PER
RESPONSIBLE CODE CONTAINING PART
INOPERABLE INCIDENT)
1W-8606 Intake valve 3 62 3N-2062 CYL HEAD Yes No Carbon builds up
cyl no #4, #6, #12
Yes No
Yes No
DESCRIPTION CODES * A – Structural C – Leaks E – System Malfunction G – General Repair K - Serviceability X – Operator
(Refer SIMS Guidelines : B – Surface D – Factory Assembly F – Factory Shipping H – Adjustment N - Abuse Complaint
SEBD0850)

OBSERVATION
Part Number -Name – Modifier Code To Help Explain Progression/Stage of Failure,
(RH/LH/Upper/Lower etc) Use – Notes /Photos/Parts Book Illustration.
Identify Type, Amount, Location of Wear, Deposits, Damage,
Fractures etc.

Gas Engine Generator GS1411B.

Engine model G399 with serial number
49C00392 was operated at Lawe Lawe
Terminal.
Info from customer, this engine has a
problem with high LH Bank inlet
temperature and turbulence noise at LH
Turbocharger.

Customer immediately shutdown the

engine.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 2 of 12

LH side engine view

RH side engine view

Actual service meter unit on engine is

22999 Hrs

Actual service meter unit on panel is

37769 Hrs

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 3 of 12

Cylinder
Compression
Tool

Removed spark plug and valve cover.

Perform cylinder compression test.

Measure and record cylinder

compression.

Spec for compression test with engine

7:1 compression ratio is 965 – 1172 kPa
(140 – 170 Psi)

Injected air
pressurized

Removed rocker arms and injected air

pressurized into combustion chamber.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 4 of 12

Measure and record air pressurized

Found:
- Cylinder no #4 air passing
through inlet valve.
- Cylinder no #6 and #16 need
attention.

Check inlet valve at cylinder #2 and #4

Found:
At cylinder no #4 Carbon deposit has
detach from valve steam. Carbon
deposit

Cylinder #2 Cylinder #4

Check inlet valve at cylinder #6 and #8

Carbon
Found: Carbon
deposit
Build up carbon deposit at valve steam deposit
cylinder #6 and #8

Cylinder #6 Cylinder #8

Check inlet valve at cylinder #10 and

#12
Carbon
Found: deposit
Build up carbon deposit at valve steam
cylinder #12
Cylinder #10 Cylinder #12

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 5 of 12

Check inlet valve at cylinder #14 and

#16
Carbon
deposit
Found:
Build up carbon deposit at valve steam
cylinder #16
Cylinder #14 Cylinder #16

Replacement 3ea cylinder heads.

Clean up cylinder block surface and

install new gasket and seal.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 6 of 12

Install and torque cylinder head bolts as

per sequence.

Put 5P3931 Anti-Seize Compound on

threads.

1. Tighten all bolts in number sequence to

... 205 ± 14 N·m (150 ± 10 lb ft)

2. Again tighten all bolts in number

sequence to ... 360 ± 14 N·m (265 ± 10 lb
ft)

3. Again tighten all bolts in number

sequence (hand torque only) to ... 360 ± 14
N·m (265 ± 10 lb ft)

Install rocker arm and adjust valve

Valve Clearance Setting: Engine Stopped

Exhaust ... 0.89 mm (.035 in.)

Intake ... 0.38 mm (.015 in.)

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 7 of 12

Completed engine components and

prepare for startup

Test engine run and apply load.

Found:
- Engine detonation at load 360kw.
- Actuator linkage fully open.
- Not found high air inlet
temperature at LH Bank

Check Catalytic Converter.

Catalyst
Found:
- Much debris covered the catalytic

Temporary remove the catalytic

converter.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 8 of 12

Check waste gate.

Found:
- Both wastegates does not work
properly.
- After disassembly, found
diaphragm broken.
Replace diaphragm with new one

Diaphragm
broken

Test engine run and apply load

Found:
- Engine cannot increase load
more than 330kw.
- Actuator linkage fully open.
- Engine detonation does not
appear.
- Not found high inlet air
temperature at LH Bank

Actuator linkage fully open at load

330kw

Actuator
linkage 10/10

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 9 of 12

Adjust wastegates by decrease the

gaskets.

Found:
- Problem engine low power still
occurred.

Wastegates

Adjust carburetor linkage.

Found:
- Problem engine low power still
occurred

Carburetor Linkage

Check carburetor.

Found:
- Foreign object inside both Foreign
carburetors. Object
Remove foreign object, clean up and
replace diaphragm.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 10 of 12

Re-test engine run and apply load

Found:
- Test engine load 403kw for one
hour
- Jacket water temperature 165
deg F. Normal
- Exhaust temperature LH 961 F
and RH 965 F. Normal
- Actuator linkage open at 5/10
- Engine detonation does not
appear.
- Not found high inlet air
temperature at LH Bank

Oil Leaks
During engine operation
Found:
- Oil leaks from actuator shaft

During engine operation.

Found:
- Small among water leaks from
auxiliary water pump weep hole.

Water Leaks

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 11 of 12

Perform test load and record engine parameter.

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01

 PT Trakindo Utama COMPONENT CONDITION REPORT
Page 12 of 12

Job Outlet:

➢ Walk around inspection.

➢ Remove valve cover and spark plug
➢ Perform cylinder compression test. All pressure test within specification.
➢ Remove rocker arm and injected air pressurized into combustion chamber. Found cyl no #4
leaking through inlet valve. Cyl no #6 and #16 low performance if compare with other
cylinder.
➢ Remove intake manifold LH bank. Found carbon deposit detach from valve steam cylinder
no #4. That carbon deposit can get stuck between valve and the seat, causing
compression leaks and the inlet manifold to overheat.
➢ Replace 3ea cylinder head no #4, #6, #16
➢ Completed components and test engine running.
➢ Found engine detonation at load 360kw and actuator throttle fully open.
➢ Check catalytic converter. Found catalyst covered with debris. Temporary remove the
catalytic converter.
➢ Check wastegates. Found both wastegates diaphragm broken. Replace diaphragm with
new one.
➢ Re-test engine with load. Found engine low power. Engine cannot increase load more than
330kw. The detonation does not appear.
➢ Adjust wastegates and carburetor linkage.
➢ Check carburetor. Foreign object found inside both of carburetors.
Remove foreign object and replace carburetor diaphragms.
➢ Re-test engine run and apply load until 400kw.
- The detonation does not appear.
- Actuator linkage open at 5/10 at load 400kw
- Not found high inlet air temperature at LH Bank

Conclusion:

➢ Based on inspection there are three problems in this engine.

➢ The first is high air inlet temperature that caused by lost compression on intake valve
cylinder no #4.
➢ The second is engine detonation caused by high exhaust restriction due to catalytic
blocked and wastegates does not working properly
➢ And the last is engine low power. That caused by foreign object inside the carburetor.

Last Status:

➢ Engine operation with normal load 200 – 300 kw

Bagian dari / Part of : PSDV.SVTC.SOP.001.Rxx Form Number : PSDV.SVTC.FRM.001.R01