GU_Cat_D398_10K_Overhaul_Spec.pdf

CATERPILLAR D398 10,000 HOUR OVERHAUL

1. SCOPE. This specification contains requirements for the

10,000 hour overhaul of two Caterpillar D398 diesel engines on

NOAA Ship Gordon Gunter. The serial numbers of the engines are as follows: Engine #2: 35Z01560; Engine #4: 35Z01566.

2. REFERENCES.

2.1 Technical manual T9312-AG-MM0-010/11083 Engine Generator

Set Model D398B T-AGOS 13-18

2.2 Caterpillar Maintenance Management Schedule for Marine

Engines (SEBU6102)

2.3 Caterpillar Operations and Maintenance Manual (SEBU5698)

2.4 Caterpillar Service Manual (SEBR0511)

2.5 Generator alignment procedure (attached).

3. REQUIREMENTS.

3.1 General. The following requirements apply to all work.

3.1.1 Except as otherwise specified, the contractor shall

provide all labor, material, services, tools, supervision, manuals, and technical expertise needed to accomplish the work required by this specification within the specified time limits.

NOTE: The 8-day performance period shall be strictly adhered to.

3.1.2 All work shall be performed by an authorized repair

facility of the engine manufacturer or under the direct on-site supervision of a factory-trained mechanic/technician currently certified by the engine manufacturer. Upon request, contractor shall submit verifiable proof of being a Caterpillar authorized repair facility or Caterpillar-trained and certified repair mechanic/technician.

3.1.3 All work shall be in accordance with the manufacturer’s service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins.

Unless otherwise specified, the contractor shall provide a copy of the applicable manuals, amendments, and service manuals at the job site. All repairs shall be made according to the manufacturer’s engine specifications, clearances, tolerances, and procedures.

3.1.4 All parts and labor provided by the contractor shall be fully warranted. Work shall be performed in such a manner that the manufacturer’s warranty on parts and labor is not voided.

3.1.5 Provide and install “mandatory renewal” parts and

components as required by this specification and other procurement documents. Other parts found to be in need of renewal may be provided by the Government (if available) and installed by the contractor. Such additional parts or components which are not provided by the Government will be negotiated by the Contracting Officer as an additional cost.

3.1.6 Except where rebuilt components are authorized or

specified, all components and parts used in the engines shall be new original equipment manufacturer (OEM) non-surplus components and parts. Prior to installing new or rebuilt components or parts, perform visual and dimensional inspections to verify that the components or parts are acceptable for use.

3.1.7 Where rebuilt components or parts are provided (as

authorized or specified), existing components and parts shall be replaced on an exchange basis with components and parts which have been manufactured at the engine manufacturer’s factory, and the existing components shall become the property of the contractor in their as-found condition. When factory re-manufactured components are not available, the existing components shall be disassembled, cleaned, inspected, repaired

(including renewal of all parts needed), reassembled and calibrated by the manufacturer’s factory or a manufacturer-authorized repair facility. Rebuilt parts and components shall meet the manufacturer’s rebuild specifications and shall be restored to a condition of reliability equivalent to new components and parts. The only parts renewal for which additional costs will be negotiated are component bodies and casings.

3.1.8 Interferences shall be removed and reinstalled, as

required, at no additional cost to the Government. Contractor is responsible for removing piping to/from the engine, engine heat exchangers, air motors, etc.

3.1.9 Disassemble the engines, components and parts to the

extent specified herein and in other procurement documents.

Whenever the extent of disassembly is not specified, disassembly shall be to the extent required to perform the required inspections, repairs, and parts renewal.

3.1.10 Thoroughly clean and conduct a thorough visual

inspection of all disassembled parts checking for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine. Ensure all passages and holes are open and clear. Whenever hydraulic, fuel, lube oil, water, or air lines are disconnected, clean the point of disconnection and cap or plug the hoses or pipes and their connection points.

3.1.11 After inspections and tests have been completed and

prior to reassembling the components, submit a report of all inspection findings and test results to the COTR. Report shall include a record of all measurements and readings taken, as well as recommendations for additional repairs, parts renewals, inspections, or tests needed to ensure continued reliable operation of the engine. Do not proceed with any additional work until authorized by the Contracting Officer.

3.1.12 After the report has been accepted and all additional

work has been completed, reassemble and reinstall all components that were previously disassembled or removed. Reinstallation of all components throughout shall be with new gaskets, seals, grommets, and o-rings.

3.1.13 At the end of each work day, clean up all debris

incidental to the performance of the required work. Upon completion of all work, clean all worksites to their as-found condition.

3.1.14 At the midpoint of the engine overhaul, the contractor shall contact the local office of the American Bureau of

Shipping (ABS) and request a surveyor attend the ship and conduct an inspection for credit toward the engines’ Continuous

Machinery Survey. The contractor shall provide the COR a minimum of 24 hours notice as to when the units will be open and ready for inspection by the ABS surveyor. The engines shall not be closed until approval is granted by ABS via the COR. NOAA will pay for the ABS services directly under a separate purchase agreement.

3.2 Mechanical/Fluid.

3.2.1 The contractor shall perform the 10,000 hour top-end

overhaul on both engines as specified in References 2.1 through

2.5.

3.2.2 Renew the following parts and components on each engine.

Where “remanufactured” is added in parenthesis after a component, a remanufactured or “unit exchange” component may be provided in lieu of a new component. Quantities listed are per engine.

a. Cylinder head assemblies, complete with valves, springs, guides and prechambers (remanufactured), 6 ea.

b. Fuel nozzle injectors with o-rings, 12 ea.

c. Jacket water pump (remanufactured), 1 ea.

d. Turbocharger cartridges with seals and gaskets

(remanufactured).

e. Jacket water thermostats with seals and gaskets.

3.2.3 Rebuild the existing salt water pump on each engine using the following parts:

a. Impeller, P/N 4L6220

b. Rebuild kit, P/N 1W7066

c. Elbow assembly, P/N 5L1549

d. New seals and gaskets

3.2.4 Clean aftercooler cores; reseal and re-gasket. If cores require industrial cleaning, it will be the subject of additional work.

3.2.5 Clean and check all valve mechanism assemblies in

accordance with Reference 2.4.

3.2.6 Test and adjust the fuel nozzles in accordance with

Reference 2.4 prior to installation.

3.2.7 Check and adjust the fuel timing, reset all tappets and check valve rotators in accordance with Reference 2.4.

3.2.8 All items are to be presented to the ABS surveyor at the time of the Continuous Machinery Survey inspection.

3.2.9 During reinstallation of all parts, new gaskets, grommets, o-rings, and joints are to be used throughout and all items shall be torque to specifications listed in Reference 2.3.

3.2.10 Check engine-to-generator alignment in accordance with the Reference 2.5. If realignment or adjustments are required, such work will be negotiated by the Contracting Officer as an additional cost.

3.3 Electrical.

3.3.1 Test low lube oil pressure and high jacket water

temperature safety shutdown devices. Inspect all electrical connections, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engines and generators. Provide a condition report detailing general conditions found, as well as any abnormal findings, along with recommended corrective action, if any. Such corrective action will be negotiated by the Contracting Officer as an additional cost.

3.4 Electronics.

3.4.1 The contractor shall make known to all personnel working on the engines and generators that electrical and electronic devices and controls are present. These components must be protected from damage during the overhaul period and may require special precautions, isolation, etc.

3.5 Painting.

3.6.1 The contractor shall restore all disturbed surfaces to

standard Caterpillar paint scheme. Surfaces to be painted shall be free of dirt and grease prior to paint application.

3.7 Testing.

3.7.1 The Contractor shall notify the ship’s Chief Engineer, COTR, and ABS surveyor 24 hours prior to the engine/generator units being ready for testing under the ship’s electrical load.

Test operate the engines after overhaul using the ship’s dockside hotel load for a period not less than two hours. Test all alarm and shutdown systems prior to starting. Ship’s force will line up and start engines and engage the generators on the ship’s main bus. Operate engines at no-load until normal no-load operating temperatures are reached, then increase load incrementally up to available load and operate for two hours.

Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record teat data.

3.7.2 Temperatures and pressures shall be monitored and

compared to manufacturer’s recommended limits. If a temperature or pressure exceeds or falls below manufacturer’s recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

3.7.3 Record the following information near the end of the

full-load test; provide test instruments as required:

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. electrical load on generator prime mover

3.7.4 Submit a report of all test data collected. Report shall include manufacturer’s recommended limits for each parameter measured.

3.8 Final Adjustments and Tune-up.

3.8.1 After satisfactory completion of operational testing, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation.

3.9 Notes.

3.9.1 American Bureau of Shipping (ABS) inspection of 10,000

hour overhauls is required for credit toward the ship’s

Continuous Machinery Survey. Contractor shall inform ABS of progress and arrange for inspections as required by the local

(Mobile, AL) office. Government will pay for ABS fees associated with the inspections under a separate purchase order.

ABS Mobile contact: Senior Surveyor Neal Powell. Tel: (251)

661-3500; cell: (251) 370-7751; e-mail: npowell@eagle.org

3.9.2 Ship’s force is available to provide shipboard crane

service during normal working hours (M-F 0830-1530) to lift parts between the pier and the ship’s aft deck. 24 hours advance notice is required. Actual rigging of parts and moving mailto:npowell@eagle.org parts to/from the aft deck and generator room shall be the responsibility of the contractor.

3.9.2 Reference 2.1 will be available for review during the

performance period of the contract. References 2.2 through 2.4 shall be contractor furnished. Reference 2.5 follows this specification as an attachment.

END OF SPECIFICATION

Reference 2.5 GENERATOR ALIGNMENT PROCEDURE

The Contractor shall take the following readings before disassembly:

a. generator fan angular deflection,

b. generator shaft runout (TIR),

c. crankshaft end play,

d. crankshaft deflection.

Above readings shall be taken again upon reassembly, after the generator to engine alignment relationships have been re-established.

Record all results on condition reports and report the results to the attending NOAA Port Engineer, or assigned representative.

Before performing the parallel and angular alignment checks, ensure that the natural clearance between the base and its foundation is properly gapped with shims at all mounting locations and check that all base-to-foundation bolts are tightened to their final torque. If deflection of the base is noted, loosen base-to-foundation bolts at affected locations, shim as necessary to eliminate deflection, and re-tighten base-to-foundation bolts to their final torque.

Inability to attain repeatability of readings may be due to cocking of the flywheel by the turning tool. An end-supporting turning tool has proven to be superior to free-gear types for taking these particular reading. If an end-supported tool is not available, good results are attainable with a free-gear type if tooth engagement is reduced to the bare minimum necessary to turn the flywheel.

The deflection dial indicator must not have a leash attached since it may change readings.

PARALLEL ALIGNMENT (SHAFT RUNOUT)

Ensure that the generator shaft surface, which is to be measured with the dial indicator, is clean. Solvent and or light sanding with emery cloth should remove any dirt or rust accumulation.

Place the base of a dial indicator on the uppermost generator adaptor frame rib and position the indicator finger, which requires extensions, on the generator shaft. Preliminary readings can be taken on the coupling; final readings will be taken on the shaft only. Zero the dial indicator at the 12 o'clock position. It is essential to ensure that the dial indicator base does not move during the run-out check. Any movement will result in erroneous readings.

Rotate the shaft one revolution starting at the 12 o'clock position, checking and recording the dial indicator readings every 90 degrees. To validate the readings, at the completion of the revolution, the dial indicator must return to 0 at the original 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired reading is 0.000 inch. Total indicator readings shall not exceed .005 inches. Adjust drive flex plate pack (discs) to flywheel installation as necessary to bring parallel alignment into tolerance.

Adjustment is accomplished by changing the diesel engine flywheel to generator drive flex plate pack relationship. If total indicator readings exceed 0.005 inches, adjustment is accomplished by removing the drive flex plate pack to flywheel bolts and turning the engine flywheel with the turning gear.

The generator can be prevented from rotating with the engine by installing a capscrew in the generator coupling and then holding the generator with a 36" long pinch bar or angle iron placed on the capscrew and generator web. The engine to flywheel relationship is changed one or more bolt holes at a time.

Reinstall the drive flex plate pack to flywheel bolts and take runout readings. Adjust as necessary to bring TIR readings into tolerance.

GENERATOR ANGULAR ALIGNMENT

Place a deflection dial indicator at the 12 o'clock position between the forward face of the fan and the drive flex plate at a point as far away as possible from the centerline of the shaft. The contact points for the deflection dial indicator fingers should be lightly punch marked.

Starting at the 12 o'clock position, rotate the shaft one revolution checking and recording readings every 90 degrees. To validate readings, at the completion of the revolution, the deflection dial indicator must return to zero at the 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired generator angular alignment readings are as follows:

12 O'CLOCK: 0.000 (starting point)

3 O'CLOCK: 0.000 TO +0.004

6 O'CLOCK: 0.000 TO +0.008

9 O'CLOCK: 0.000 TO +0.004

12 O'CLOCK: 0.000 (original starting point)

Adjust as necessary to bring angularity readings into compliance with paragraph 3 above. If adjustment is effected, a final set of angularity readings must be obtained after all bolts securing the generator to the engine and the generator to base are tightened to their final torque.

CRANKSHAFT DEFLECTION

Measure between faces of connecting rod throws of the crankshaft next to the center main bearing #4 and within .250 in. of the counterweight in accordance with Caterpillar Instructions.

Record readings.

CRANKSHAFT END PLAY

Measure crankshaft end play in accordance with Caterpillar instructions. Record readings.