Planned Maintenance Manual_Book_engine Drilling 3512c

PLANNED MAINTENANCE

Drilling Engine

JA-428-64 Caterpillar

D-3500 Serie

PM Tasks

Department Job plan Frequency Description

1. Mechanic JA-42864-MD Daily General inspection when engine is running 2. Mechanic JA-42864-M500 500 Hours Clean the fuel oil filters, sample oil 3. Mechanic JA-42864-M10C 1,000 Hours Change oil and test protection devices. 4. Mechanic JA-42864-M30C 3,000 Hours Check valves clearance, Check fuel injector timing,

complete and record a compression test.Test safety devices

5. Mechanic JA-42864-M60C 6,000 Hours Rebuild Turbocharger 6. Mechanic JA-42864-M12K 12,000 Hours Replacement of Fuel Injector 7. Mechanic JA-42864-M24K 24,000 Hours Top Overhaull 8. Mechanic JA-42864-M40K 40,000 Hours General overhaull

Attachement:

Engine Control Sheet Daily Check List

Equipment: Drilling engineCaterpillar

Frequency: Daily

3508/3512/3516Manufacturer :

Model :Department: Mechanic

PM Task: JA-428-64 KS Drilling

job plan: JA-42864-MD

Safety Notes:

-Insure personnel performing this maintenance is familiar with the manufacturer's operation and maintenance manual before beginning

-Insure proper work permits are obtained before performing maintenance on this equipment.

Job Plan:

10 Drain accumulated water and sediment from fuel oil service tanks

20 Log engine readings every 12 hours. Check and Record on the daily log sheet.

Crankcase lube oil levelLube Oil pressureFuel Oil pressureEngine R.P.M.Air filter service indicatorsExhaust temperatureHours

30 Check cooling system for leaks.

40 Check compartment for cleanliness, remove any trash or rags which may have accumulated

50 Report any unusual noises, water or oil leaks to the chief mechanic

JA-42864-MD rev-0Aug 2012


Frequency: 500 Hours




job plan: JA-42864-M500

Safety Notes:

Insure proper work permits are obtained before performing maintenance on this equipment.

Insure personnel performing the maintenance are familiar with the manufacturer's operation and maintenance manual before beginning the maintenance.

Ensure the driller is notified before performing this task and that it will not affect the drilling operations.Isolate and tag out the air supply and electric power.

Job Plan:

10 Take a representative oil sample for third party analysis. Sample of oil should be taken when the engine is warm and well mixed to insure the sample is representative.

20 Clean batteries and check electrolyte.

30 Inspect and adjust belts.

40 Test coolant additive.

50 Lubricate fan drive bearing.

60 Inspect hoses and clamps.

70 Clean / inspect lub oil centrifuge and magnetic grid switch.

80 Clean air filters elements.

90 If the fuel oil pressure is low replace fuel oil filters.

100 Fill air starter lubricator

110 Clean radiator.

120 Remove the tag and restore the starting air to the engine. Test run the engine to insure all is ok.

JA-42864-M500 rev-0Aug 2012






job plan: JA-42864-M10C

Safety Notes:




Job Plan:

10 Take a representative Oil Sample for third party analysis. Sample of oil should be taken when the engine is warm and well mixed to insure the sample is representative of the oil in the system.

20 Drains lube oil from sump and oil cooler. Take oil sample and send for analysis.

30 Change oil filters.

40 Replace fuel oil filters if the pressure is low.

50 Refill the engine with 15 W 40 API CI-4 engine oil. (Ex: TOTAL RUBIA 7400 15W40 or equivalent)

60 Clean seawater side of heat exchangers. Check anodes. (Offshore)

70 Clean crankcase breathers.

80 Check condition of air filters (Change as required) and change soot filters.

90 Lubricate governor linkages. ( Not for serie B)

100 Check coolant level and condition

110 Check function of engine protection devices and record.

120 Overspeed trip:__________RPM

130 Low oil pressure:_________PSI

140 High water temperature:_________ F

JA-42864-M10C rev-0Aug 2012







Safety Notes:




Job Plan:

10 Take a representative Oil Sample for third party analysis. Sample of oil should be taken when the engine is warm and well mixed to insure the sample is representative of the oil in the system.

20 Thoroughly inspect the entire Air Intake System. Clean filters elements.

30 Evaluate Turbocharger condition. Check axial Rotor movement

40 Check Vee Belts for breaks or cracks and replace as required. (Do not over tighten Belts)

50 Check Pulleys for wear in the groove area.

60 Check Vee Belt adjustment Pulley Bearings.

70 Check Fan Bearings for movement up and down.

80 Lubricate Fan Bearings.

90 Check Fan Blades and Fan Hub for cracks.

100 Check all Cooling Hoses for cracking and swelling and ensuring the integrity of all connections.

110 Test and record the corrosion inhibitor level with a test kit. Top up with Nalcool 2000, as required. pH should be between 7.5 - 8.5 and/or a concentration of between 10,000 PPM and 15,000 PPM. Record readings pH:__________; Nalcool___________ Note: Do not put too much Nalcool in the system. Over concentration of the inhibitor can cause sludge to form in the cooling water system.

120 Clean radiator core.

130 Visually check Linkage Connections for wear.

140 Grease Throttle Linkage Connections. (Not for B serie)

150 Ensure full and free travel of Throttle Actuator. (Not for B serie)

JA-42864-M30C rev-0Aug 2012







160 With Timing Bolt installed in Flywheel with #1 Piston on Compression Stroke ensure correct Timing Adjustment of the Camshafts as required. (Note: With the Timing Bolt installed (i.e. #1 Piston at TDC) insure that the Timing Pin is installed on both Camshafts as it is possible for one of the two, or both Camshafts to be out of Time.) (Note: If the is out of time more than 18 degrees, approximately diameter of Timing Pin out of Groove), the valves can make contact with the piston.)

170 If it has been found necessary at any time to adjust Camshaft Timing, readjustments of Valve Clearance Settings and Fuel Injector Timing will be required.

180 Check for carbon in Valve area which indicate Valve Guide wear.

190 Manually check Valves for side movement.

200 Check and adjust Valve Clearance as required. (Inlet= .020"; Exhaust +.040")

210 Visually inspect Fuel Injectors, Linkages (Not for B serie) and Fuel Line condition.

220 Using the correct Fuel Timing dimension setting (for Engine) of Dial Indicator, check and adjust Fuel Injector Timing as required.

230 Upon completion of Fuel Injector Timing check Injector Synchronization as required. (Not for B serie)

240 Check Fuel Setting and adjust as required. (Not for B serie)

250 Clean the Crankcase Breathers. Remove the breather elements from the cylinder head valve covers. Wash the elements in clean, nonflammable solvent and allow to dry before installation.

260 Remove the Crankcase Covers and inspect the Crankshaft Journals area for heat discoloration, which would indicate Bearing failure.

270 Feel the bottom of the Sump to check for foreign particles.

280 Ensure Oil Pump Suction Screen is clean.

290 Reinstall all Crankcase Covers ensuring all Gaskets are in good condition.

300 Replace the main oil filter elements. Cut open and inspect the internals of the used oil filter elements. Inspect for signs of excessive metal particles, which could indicate an engine problem.

310 Service Centrifuge Oil Filter.

320 Change fuel filters

JA-42864-M30C rev-0Aug 2012







Safety Notes:




Job Plan:

10 Inspect engines mounts for deterioration and proper bolt torque.

20 Clean magnetic pickup.

30 Check clearance between magnetic pickup and flywheel ring gear thoot(0.70+ -0,15mm)

40 Inspect and Test the thermostats.

50 Inspect both turbochargers fit new repair kit.(Or replace with refurbished turbo cartridge)

60 Check the starting motor for correct operation

70 Check water pump for leaks

80 Check and record ,crankshaft Deflection of center counter weight of the cranksaft. (The dial indicator reading must not change more than 0.30mm (.001) for approximately 220degrees of crankshaft rotation)

90 Check and record Cranksaft Thrust :_______(0,17 to 0,63mm)

100 Check and record crankcase pressure :_______

JA-42864-M60C rev-0Aug 2012






job plan: JA-42864-M12K

Safety Notes:




Job Plan:

10 Overhaul water pump

20 Replace Fuel Injectors, replace seal O ring

30 Sent fuel Injectors to Caterpillar dealer for testing

40 Visually inspect Fuel Injectors, Linkages, and Fuel Line condition.

50 Using the correct Fuel Timing dimension setting (for Engine) of Dial Indicator, check and adjust Fuel Injector Timing as required.

60 Upon completion of Fuel Injector Timing check Injector Synchronization as required.

70 Check Fuel Setting and adjust as required.

JA-42864-M12K rev-0Aug 2012







Safety Notes:




Job Plan:

10 A Top Overhaul is to be carried out before above maximum dimensions have been reached (2.3 mm / 0.09"). All cylinder heads are to be renewed with new, exchanged or rebuilt units. Ensure that all the parts are available prior to start operation

20 Steam cleaning of engine

30 Reconditioning of cylinder heads

40 Replace injectors (unit exchange)

50 Replace turbocharger cartridges (unit exchange)

60 Check liner projection and inspect liners.

70 Inspect piston top crowns.

80 Remove 2 pistons at radom to make a control of rings, cylinder, pins and con. bearings. Decision would be take according to the result of the inspection. Note:Rings and bearings must be available for this operation.

90 Remove 2 main bearings at radom to make a control pins surface. Decision would be take according to the result of the inspection. If you have to change bearing all the bearings MUST be replaced as a full set (Con. Rod Bearings, Thrust Bearings & Main Bearings).

100 Check / adjust injection timing, rack, high idle and low idle.

110 Check water pump (Rebuilt kit and seal kit must be available)

120 Inspect fuel priming pump.(Rebuilt kit and seal kit must be available)

130 Inspect after cooler core.

140 Inspect push rods and rocker arms.

JA-42864-M24K rev-0Aug 2012







150 Check and record, crankshaft Deflection at each counter weight of the cranksaft. (The dial indicator reading must not change more than 0.025mm (.001) for approximately 220degrees of crankshaft rotation)

160 Remove the tag and restore the starting air to the engine. Test run the engine to insure all is ok.

170 Enter details of completion in the maintenance record form

JA-42864-M24K rev-0Aug 2012







Safety Notes:




Job Plan:

10 General Overhaul. Ensure that all the parts are available prior to start operation. This operation could be delayed if all the analsis and controls are OK but cannot exceed 48000H

20 Reconditioning of cylinder heads

30 Change pistons & rings

40 Change liners

50 Change Con. rod Bearings

60 Change Main Bearings & thrust bearing

70 Measure and record crankshaft pin for ovality & weardown

80 Check camshaft journals and bushings (One set of bushing must be available)

90 overhaul oil pump

100 Overhaul water pump

110 Replace turbocharger cartridges (unit exchange)

120 Replace injectors (unit exchange)

130 Check and record ,crankshaft Deflection of center counter weight of the cranksaft. (The dial indicator reading must not change more than 0.30mm (.001) for approximately 220degrees of crankshaft rotation)

140 Test all safety devices

150 Enter details of completion in the maintenance record form

JA-42864-M40K rev-0Aug 2012

CATERPILLAR N:SERIAL NUMBER :

RIG: HOURS:CAT: D 3512 D 3512 DATE OF RECORD :

Bore in bearing for pin: RECORD BY:Bore in connecting rod for bearing:Piston pin diameter (new)

1 3 5 7 9 11

FRONT

2 4 6 8 10 12

2.7544" +/- .0002"

2.7559" +/- .0003"5.6310" +/- .0006"

CYLINDERS LINERS BORE CATERPILLAR N:SERIAL NUMBER :

RIG: HOURS:CAT: D 3512 DATE OF RECORD :

New liner: RECORD BY:Maximum bore:

FRONT

6.6939" +/- .0010"6.6980"

3

1

5

7

9

11

12

10

8

6

4

2

CYLINDERS LINERS PROJECTION CATERPILLAR N:SERIAL NUMBER :


RECORD BY:Average of four projection measurements from any cylinder liner 0.0023" to 0.0078" (0.059 to 0.199 mm)Maximun permissible difference: 0.002" (0.05mm)

1 3 5 7

9 11

2 4 6 8

10 12

PISTON PIN BORE CATERPILLAR N:SERIAL NUMBER :


Bore in piston for pin 2.7552" +/- 0.0003" (69.983 +/- 0.008 mm) RECORD BY:Maximun clearance between pin and bore in piston 0.0003" to 0.0013" ( 0.008 to 0.034 mm)Piston pin diameter: 2.7544" +/- 0.0002" (69.962 +/- 0.005 mm)

6

1

3

5

7

9

11

2

4

8

10

12

CRANKSHAFT CATERPILLAR N:SERIAL NUMBER :


RECORD BY:

Crankpin ControlOriginal diameter : 5.3150" +/- 0.0010" (135 +/+ 0.025 mm)Bearing clearance with crankshaft: 0.0042" to 0.0086" ( 0.107 to 0.218 mm)

1 2 3 4 5 6 7 8ABCabc

Trunion controlOriginal diameter : 6.2992" +/- 0.0010" ( 160.000 +/- 0.025 mm)Bearing clearance with crankshaft: 0.0048" to 0.0095" ( 0.122 to 0.241 mm )

1 2 3 4 5 6 7 8 9ABCabc

a b c

A B C

A B C

ENGINE AND GENERATOR ALIGNMENT CATERPILLAR N:SERIAL NUMBER :


RECORD BY: 1 - USE PRYBAR TO REMOVE ALL END PLAY FROM ENGINE AND GENERATOR SHAFTS .

DO NOT APPLY PRESSURE WHEN RECORDING DATA . 2 - INNER COUPLING TOOTH IS CENTERED IN COUPLING CAVITY WHEN COUNTERBORED SURFACE

OF COVER PLATE IS 9.7 m m TO 11.2 m m FROM REAR SURFACE OF TOOTH . 3 - ATTACH 6 V 2 0 4 2 / 6 V 2 0 4 3 ALIGNMENT FIXTURE YOKE AND DIAL - INDICATORS . 4 - ANGULAR MISALIGNMENT ( MESURED AS FACE ) FOR COLD EQUIPMENT SHOULD READ ZERO

AT THE TOP AND BETWEEN MINUS 0 . 45 m m TO MINUS 0 . 55 m m AT THE BOTTOM WHEN ALIGNING . ( REALIGN IF FIELD EXCEEDS ZERO AT THE TOP AND MINUS 0. 35 m m TO MINUS 0. 65 m mAT THE BOTTOM ) .

5 - PARALLEL MISALIGNMENT ( MESURED AS BORE ) FOR COLD EQUIPMENT SHOULD READ ZERO AT THE TOP AND BETWEEN PLUS 0. 95 m m TO 1. 05 m m AT THE BOTTOM WHEN ALIGNING . ( REALIGN IF FIELD CHECK EXCEEDS ZERO AT TOP AND PLUS 0. 75 m m TO PLUS 1. 25 m m AT THE BOTTOM ) .

6 - INDICATORS READING AT 3 AND 9 O' CLOCK POSITION FACE AND BORE TO BE WITHIN : 0. 20 m m OF BEING EQUAL . REALIGN IF FIELD CHECK EXCEEDS : 0 . 26 m m OF BEING EQUAL .

JA-428-64_Drilling EngineD3512 - Control Sheet.pdfconnecting rodlinerliner projectionpiston pin borecrankshaft (2)Alignment

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