Planned Maintenance Manual - Book - Engine Drilling 3512c

PLANNED MAINTENANCE
Drilling Engine
JA-428-64
Caterpillar
D-3500 Serie
PM Tasks
1.
2.
3.
4.
Department
Mechanic
Mechanic
Mechanic
Mechanic
Job plan
JA-42864-MD
JA-42864-M500
JA-42864-M10C
JA-42864-M30C
Frequency
Daily
500 Hours
1,000 Hours
3,000 Hours
5.
6.
7.
8.
Mechanic
Mechanic
Mechanic
Mechanic
JA-42864-M60C
JA-42864-M12K
JA-42864-M24K
JA-42864-M40K
6,000 Hours
12,000 Hours
24,000 Hours
40,000 Hours
Attachement:
Engine Control Sheet
Daily Check List
Description
General inspection when engine is running
Clean the fuel oil filters, sample oil
Change oil and test protection devices.
Check valves clearance, Check fuel injector timing,
complete and record a compression test.Test safety
devices
Rebuild Turbocharger
Replacement of Fuel Injector
Top Overhaull
General overhaull
PM Task: JA-428-64
KS Drilling
Equipment: Drilling engine
Manufacturer : Caterpillar
Model : 3508/3512/3516
Frequency: Daily
Department: Mechanic
job plan: JA-42864-MD
Safety Notes:
-Insure proper work permits are obtained before performing maintenance on this equipment.
-Insure personnel performing this maintenance is familiar with the manufacturer's operation and
maintenance manual before beginning
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.
30
Crankcase lube oil level

Lube Oil pressure
Fuel Oil pressure
Engine R.P.M.
Air filter service indicators
Exhaust temperature
Hours
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
Aug 2012
JA-42864-MD rev-0
PM Task: JA-428-64
KS Drilling
Frequency: 500 Hours

Model : 3508/3512/3516
job plan: JA-42864-M500
Safety Notes:
Insure personnel performing the maintenance are familiar with the manufacturer's operation and
maintenance manual before beginning the maintenance.
Insure proper work permits are obtained before performing maintenance on this equipment.
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.
Aug 2012
JA-42864-M500 rev-0
PM Task: JA-428-64
KS Drilling
Model : 3508/3512/3516

job plan: JA-42864-M10C
Safety Notes:
operations.
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
Aug 2012
JA-42864-M10C rev-0
PM Task: JA-428-64
KS Drilling
Model : 3508/3512/3516

Safety Notes:
operations.
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)
Aug 2012
JA-42864-M30C rev-0
PM Task: JA-428-64
KS Drilling

Model : 3508/3512/3516
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
Aug 2012
JA-42864-M30C rev-0
PM Task: JA-428-64
KS Drilling

Model : 3508/3512/3516
Safety Notes:
operations.
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 :_______
Aug 2012
JA-42864-M60C rev-0
PM Task: JA-428-64
KS Drilling
Model : 3508/3512/3516

job plan: JA-42864-M12K
Safety Notes:
operations.
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.
Aug 2012
JA-42864-M12K rev-0
PM Task: JA-428-64
KS Drilling

Model : 3508/3512/3516
Safety Notes:
operations.
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.
Aug 2012
JA-42864-M24K rev-0
PM Task: JA-428-64
KS Drilling

Model : 3508/3512/3516
150
Check and record, crankshaft Deflection at each counter weight of the cranksaft. (The dial indicator
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
Aug 2012
JA-42864-M24K rev-0
PM Task: JA-428-64
KS Drilling

Model : 3508/3512/3516
Safety Notes:
operations.
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
rotation)
140
Test all safety devices
150
Enter details of completion in the maintenance record form
Aug 2012
JA-42864-M40K rev-0
RIG:
CAT: D 3512
Bore in bearing for pin:
Bore in connecting rod for bearing:
Piston pin diameter (new)
D 3512
2.7559" +/- .0003"
5.6310" +/- .0006"
2.7544" +/- .0002"
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
10
11
FRONT
12
CYLINDERS LINERS BORE
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
RIG:
CAT: D 3512
6.6939" +/- .0010"
New liner:
Maximum bore: 6.6980"
11
10
12
FRONT
CYLINDERS LINERS PROJECTION

RIG:
CAT: D 3512
Average of four projection measurements from any cylinder liner
Maximun permissible difference: 0.002" (0.05mm)
1
11
10
12
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
0.0023" to 0.0078"
(0.059 to 0.199 mm)
PISTON PIN BORE
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
RIG:
CAT: D 3512
2.7552" +/- 0.0003" (69.983 +/- 0.008 mm)
Bore in piston for pin
0.0003" to 0.0013" ( 0.008 to 0.034 mm)
Maximun clearance between pin and bore in piston
Piston pin diameter:
2.7544" +/- 0.0002" (69.962 +/- 0.005 mm)
11
10
12
CRANKSHAFT
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
RIG:
CAT: D 3512
Crankpin Control
A B C
5.3150" +/- 0.0010" (135 +/+ 0.025 mm)

Bearing clearance with crankshaft:
0.0042" to 0.0086" ( 0.107 to 0.218 mm)
Original diameter :
A
B
C
a
b
c
Trunion control
Original diameter :
6.2992" +/- 0.0010" ( 160.000 +/- 0.025 mm)

0.0048" to 0.0095" ( 0.122 to 0.241 mm )
Bearing clearance with crankshaft:
1
A
B
C
a
b
c
ENGINE AND GENERATOR ALIGNMENT

RIG:
CAT: D 3512
1 -
CATERPILLAR N:
SERIAL NUMBER :
HOURS:
DATE OF RECORD :
RECORD BY:
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
4 -
ANGULAR MISALIGNMENT ( MESURED AS FACE ) FOR COLD EQUIPMENT SHOULD READ ZERO
6V2042 / 6V2043
ALIGNMENT FIXTURE YOKE AND DIAL - INDICATORS .
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 m
AT THE BOTTOM ) .
5-
6 -
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 ) .
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 .

Planned Maintenance Manual - Book - Engine Drilling 3512c

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PLANNED MAINTENANCE

Crankcase lube oil level

Frequency: 500 Hours

job plan: JA-42864-M500

Clean batteries and check electrolyte.

Inspect and adjust belts.

Test coolant additive.

Lubricate fan drive bearing.

Inspect hoses and clamps.

Clean / inspect lub oil centrifuge and magnetic grid switch.

Clean air filters elements.

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

Fill air starter lubricator

Frequency: 1000 Hours

Change oil filters.

Replace fuel oil filters if the pressure is low.

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

Clean crankcase breathers.

Lubricate governor linkages. ( Not for serie B)

Check coolant level and condition

Check function of engine protection devices and record.

Low oil pressure:_________PSI

High water temperature:_________ F

Frequency: 3000 Hours

Evaluate Turbocharger condition. Check axial Rotor movement

Check Pulleys for wear in the groove area.

Check Vee Belt adjustment Pulley Bearings.

Check Fan Bearings for movement up and down.

Lubricate Fan Bearings.

Check Fan Blades and Fan Hub for cracks.

Clean radiator core.

Visually check Linkage Connections for wear.

Grease Throttle Linkage Connections. (Not for B serie)

Frequency: 3000 Hours

job plan: JA-42864-M30C

Manually check Valves for side movement.

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

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

Ensure Oil Pump Suction Screen is clean.

Service Centrifuge Oil Filter.

Change fuel filters

Frequency: 6000 Hours

job plan: JA-42864-M60C

Inspect engines mounts for deterioration and proper bolt torque.

Clean magnetic pickup.

Inspect and Test the thermostats.

Check the starting motor for correct operation

Check water pump for leaks

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

Check and record crankcase pressure :_______

Frequency: 12000 Hours

Overhaul water pump

Replace Fuel Injectors, replace seal O ring

Sent fuel Injectors to Caterpillar dealer for testing

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

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

Check Fuel Setting and adjust as required.

Frequency: 24000 Hours

job plan: JA-42864-M24K

Steam cleaning of engine

Reconditioning of cylinder heads

Replace injectors (unit exchange)