233-3 Main Engine Overhaul.pdf

NOAA STANDARD SPECIFICATION 233-3 MAIN ENGINE OVERHAUL

PART 1 GENERAL

SCOPE: This specification contains the general requirements and procedures to be used in accomplishing an overhaul of Caterpillar D398 diesel engines and the attached 600KW Kato Generators on and for NOAA T-AGOS Class ships.

1.1 References

1.2 Government-Furnished Equipment

1. None.

PART 2 DEFINITIONS

2.1 Rebuilt Components

Components which have been remanufactured at the Original Equipment Manufacturer's factory.

2.2 Condition Found Report (CFR)

Is the same as Condition Report described in General Requirements for Work, Condition Reports.

PART 3 REQUIREMENTS

3.1 General

1. Except as otherwise specified, provide all labor, material, services, tools, supervision, and technical expertise to accomplish the work specified by this specification within [7, 14, 21, 30, 45] days from the start of the availability period.

2. The engines are under American Bureau of Shipping (ABS) Survey and will require attendance of an ABS surveyor at stages of the overhaul and during the testing phase. Make all arrangements necessary to secure the services of an ABS surveyor. ABS inspectors may be present for part of the inspection, or the entire inspection, depending on the individual surveyor's discretion. See ABS Rules for Survey After Construction, Part 7, Chapter 6: Machinery Surveys.

4. Perform all work and repairs :

a. Using an authorized repair facility of the engine manufacturer or under the direct

DOCUMENT 233-3 Page 1 on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer. NOAA will request that all potential offerors submit evidence that they are a Caterpillar Authorized Marine Dealer (A. M. D.) prior to start of work.

b. In accordance with the manufacturer's service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins.

c. In accordance with the manufacturer's engine specifications, clearances, tolerances, and procedures.

d. In such a manner that the manufacturer's warranty on parts and labor is not voided.

5. All parts and labor supplied by the Contractor shall be fully warranteed.

Before beginning the engine overhaul work, provide protective covering for the primary passageway to the engine room, in accordance with General Requirements for Work, Protective Coverings.

6. Before beginning the engine overhaul work, conduct an operational test of the engines in the presence of the COR and the Chief Engineer to prove correct operation prior to repairs.

The Contractor shall be responsible for shipping and/or transporting all equipment and tools to and from the worksite. Ship's crew will assist with loading by using the shipboard crane to load any palleted items from the pier to the main deck and back from the main deck to the pier. The Contractor shall load and transport all materials, equipment, tools, and miscellaneous related items from the ship's main deck to the engine room and then back from the engine room to the ship's main deck after the completion of the overhauls.

7. Provide and install "mandatory-renewal" parts and components during the overhaul as required by this specification, the Detail Specification, and other procurement documents.

8. Install additional parts and components determined to be needed as the work is performed.

These additional parts and components may be provided by the government. If not provided by the government, the additional parts and components will be negotiated by the Contracting Officer as an additional cost to the purchase order or contract.

9. Use new original Caterpillar non-surplus components , parts, and materials except where rebuilt components are authorized or specified. Caterpillar parts shall meet the most current CAT Technical Updates.

10. Where rebuilt components are authorized or specified, exchange existing components with factory-rebuilt components. The existing components become the property of the contractor in their as-found condition.

a. If factory-rebuilt components are not available, then restore existing components as follows:

1. disassemble

2. clean

3. inspect

4. repair (replace parts as needed)

DOCUMENT 233-3 Page 2

5. calibration by the manufacturer's factory or manufacturer-authorized repair facility

b. These contractor restored components shall meet the manufacturer's rebuild specifications and shall be restored to a condition of reliability equivalent to new components and parts.

c. The only replacement parts for which additional costs will be negotiated are component bodies and casings.

11. Prior to installing all parts and components, perform a visual and dimensional inspection to verify that they are acceptable for use.

12. Disassemble the engine(s), 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.

13. Thoroughly clean and conduct a thorough visual inspection of all disassembled parts for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine.

14. Within 24 hours after inspections and tests have been completed and prior to reassembling the components, submit a typed report of all inspection findings and test results, including a record of all measurements and readings taken, to the Contracting Officer's Representative (COR) or other NOAA representative named in the procurement document, in accordance with reference 2.5. Include in the report recommendations for all additional repairs, inspections, tests, and part renewals needed to insure continued reliable service of the engine.

a. Do not proceed with any additional (not covered by scope of previously required work) repairs, inspections, tests, part renewal, or reassembly until authorized by the Contracting Officer or purchasing agent who issued the procurement document.

b. After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed.

When reinstalling components, use all new gaskets, seals, grommets, and o-rings.

Remove and reinstall interferences as required to accomplish the required work, in accordance with reference 2.5, "Interferences and Restorations".

Perform a daily clean up all debris incidental to the performance of the required work. Upon completion of all work, clean all work sites to their as-found condition, in accordance with reference 2.5, "Daily Clean Up".

Dispose of all project refuse including lube oil and engine coolant unless otherwise stated in the detailed overhaul requirements in this statement of work.

Upon completion of the overhaul, provide detailed written reports of all maintenance actions and engine component conditions, including but not limited to, all critical clearances and adjustments listed in references, and all parts rebuilt, replaced, or exchanged. These reports

DOCUMENT 233-3 Page 3 are in addition to the required Condition Reports provided to the COR during the overhaul.

New parts required by sections 3.2 through 3.4 below that are not used must be credited against the work item or provided to the ship for spares as directed by the COR.

3.2 CAT D398 10,000 Hour Overhaul

1. Perform the 10,000 hour top-end overhaul as specified in references 2.1 through 2.6.

2. When reinstalling all parts, use new gaskets, grommets, o-rings and joints. Torque all items in accordance with reference 2.3 specifications.

3. Replace the following "mandatory-renewal" 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:

Mandatory Renewal parts Quantity (per engine)

New, Remanufactured, or Rebuilt / Unit Exchange

1 Cylinder heads; complete with valves, springs, guides, and pre chambers

6 New

2 Fuel nozzle injectors with o rings

12 New

3 Jacket pump 1 Rebuit or Remanufactured

4 Turbocharger cartridges, seals and gasket

All New

5 Jacket water thermostats (P/N 9N2894), seals and gaskets.

All New

4. Rebuild the existing salt water pump using the following new or Caterpillar re-manufactured parts:

a. Impeller, P/N 4L6220

b. Rebuild kit, P/N 1W7066

c. Elbow assembly, P/N 5L1549

d. New seals and gaskets

5. Remove, clean, pressure test and reinstall the aftercooler core.

6. Clean and check all valve mechanism assemblies in accordance with reference 2.4.

7. Reset tappets. Check valve rotators. Check and adjust fuel timing in accordance with reference 2.4.

8. Accomplish the requirements of reference 2.6 to verify that the the engine to generator alignment is within the specified tolerances. If realignment or adjustments are required, a change order will be issued.

9. Present all items to the ABS surveyor at the Continuous Machinery Survey Inspection.

DOCUMENT 233-3 Page 4

3.3 CAT D398 20,000 Hour Overhaul

1. Perform the 20,000 hour top-end overhaul as specified in references 2.1 through 2.6.

2. When reinstalling all parts, use new gaskets, grommets, o-rings and joints. Torque all items in accordance with reference 2.3 specifications.

3. For the following components perform an inspection for wear by checking all dimensions and tolerances in accordance with references 2.1 through 2.6. Submit written condition reports stating each component's condition and if the component requires replacement due to being out of the Caterpillar specification. Include material and labor costs to replace the component.

Properly prepare and clean all components for installation, including casings and all air, oil or water passages.

a. Camshaft

b. Camshaft bearings

c. Connecting rods

d. Cam followers

e. Fuel transfer pump

f. Prelube pump

g. Fuel injection system and governor

h. Main oil pump and relief valve

i. Governor drive group, Woodward EG-3P actuator and linkages, manual shutdown linkages.

j. Vibration damper

k. Gear train bushings

l. Driven unit alignment, generator

m. Rocker arm assembly and bushings

5. Replace the following "mandatory-renewal" parts and components on each engine. Where "remanufactured" is listed after a component, a remanufactured or "unit exchange" component may be provided in lieu of a new component:

Mandatory Renewal parts Quantity (per

New, Remanufactured, or Rebuilt / Unit

1 Pistons, piston pins, and retainers

12 New

2 Piston ring sets 12 New

3 Liners 12 New

4 Main bearings, complete including thrusts

All New

5 Rod bearings, complete All New

6 Jacket water pump 1 Remanufactured or Rebuilt

7 Front and rear cover seals and gaskets

All New

8 Fuel nozzle injectors 12 New

DOCUMENT 233-3 Page 5

Mandatory Renewal parts Quantity (per

New, Remanufactured, or Rebuilt / Unit

9 Turbocharger cartridges All New

10 Flexible jacket water heater hoses of the approximate following sizes with double male ends: (exact measurements to be done at time of overhaul):

1. One (1) fitting nr. 16 72"

2. One (1) fitting nr. 12 41"

All New

11 Lube oil cooler, non removable core complete

1 Unit Exchange

12 Fuel pump assemblies 12 New

13 Fuel injection pump group yoke screw and lock nut, P/N 5H5553 and P/N 2A5351

12 New

14 Jacket water thermostats, P/N 9N2894

All New

15 Cylinder heads, complete 6 New or 16 Exhaust pyrometers complete with leads 15 New

6. Rebuild existing salt water pump using the following new or Catepillar re-manufactured parts:

a. Impeller, P/N 4L6220

b. Rebuild kit, P/N 1W7066

c. Elbow assembly, P/N 5L1549

d. New seals and gaskets

7. Install new front and rear hydromechanical seals -directional

a. The procedure to replace the rear seal requires disconnecting the attached generator from the flywheel, engine block, and skid. Before disassembly take and record the following readings and measurements:

1. Generator shaft runout reading.

2. Deflection reading of the generator fan to flex plate.

3. Deflection reading of the crankshaft and end thrust reading, in accordance with reference 2.4.

4. Measure between faces of the connecting rod throws of the crankshaft next to the center main bearing #4 and within 0.250 inches of the counterweight in accordance with Caterpillar instructions.

b. Upon reassembly, retake the readings and measurements, and adjust the generator in accordance with the enclosure listed in reference 2.2.

c. Notify the COR and Chief Engineer 4 to 24 hours prior to taking allr readings and measurements to enable the Chief Engineer, COR, or their representative to witness the

DOCUMENT 233-3 Page 6 readings and measurements.

8. Perform the following resets, checks, and adjustments in accordance with references:

a. Adjust all piston cooling jets to proper spray angle.

b. Reset tappets.

c. Check valve rotators.

d. Check and adjust fuel timing.

3.4 CAT D398 40,000 Hour Overhaul

1. Ship's force will drain the engines of jacket water and oil (to the lowest level allowed by the installed piping arrangement) prior to the start of repairs. Any residual jacket water drained into the bilge will be disposed of by the Government.

a. Remove and dispose of any residual fuel and lube oil.

b. The government will dispose of any residual jacket water drained into the bilge.

c. Clean all filter housings and install new government--furnished filters, using new gaskets and o-rings.

2. For the following components perform an inspection for wear by checking all dimensions and tolerances in accordance with references 2.1 through 2.6. Submit written condition reports stating each component's condition and if the component requires replacement due to being out of the Caterpillar specification. Include material and labor costs to replace the component.

Properly prepare and clean all components for installation, including casings and all air, oil or water passages.

a. Connecting rods

d. Cam followers

c. Fuel transfer pump

d. Prelube pump

e. Fuel injection system and govenor

f. Main oil pump and relief valve

g. Governor drive group, Woodward EG-3P actuator and linkages, manual shutdown linkages.

h. Vibration damper

i. Gear train bushings

j. Gear train

k. Drive unit alignment, generator

l. Rocker arm assembly and bushings

3. Take and record crankshaft deflection readings and end thrust readings.

4. Replace the following "mandatory-renewal" 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.

a. Complete turbo groups, couplings, clamps

b. Camshaft kit, including shaft and lifters (remanufactured)

c. Camshaft bearings

DOCUMENT 233-3 Page 7

d. Front gear bushings

e. Govenor linkage

f. Actuator (remanufactured)

g. Thermostats and water temperature regulators

h. Cylinder head assemblies with valves (remanufactured)

i. Cylinder packs

j. Dampers

k. Fuel nozzles

l. Fuel pump assemblies

m. Fuel transfer pump

n. Oil relief valve and spring o.Fuel injection pump group yoke screw and lock nuts

p. Main bearings, complete, including thrusts

q. Rod bearings, complete

r. Front and rear cover seals and gaskets

s. Front and rear hydromechanical seals - directional

t. Jacket water pumps (remanufactured)

u. Jacket water heater hoses

v. Jacket water thermostats

w. Sea water pumps (rebuild kit and new impeller)

x. Lube oil coolers, non-removable core (remanufactured)

y. All fuel injection pump to fuel nozzle tubing, with fittings; new fuel tubing shall be double-walled

z. All thermocouples and thrmocouple wiring. Install new wiring to thermocouple box on bracket on aftercooler

aa. Zinc anodes in pumps and heat exchangers. (Government to provide new zincs)

5. The procedure to replace the rear seal requires disconnecting the attached generator from the flywheel and engine block and skid. Before disassembly, take and record generator shaft runout readings and deflection readings of the generator fan to flex plate. Upon reassembly, take the readings again and adjust the generator in accordance with Caterpillar specifications and in accordance with the enclosure listed in reference 2.2. Provide the ship's Chief Engineer and the COR 4 to 24 hours prior notification so they may witness these readings.

6. Reseal pre-lube pumps.

7. Remove piping to the aftercooler. Remove cores for industrial cleaning. The COR will bring the cores to a local radiator shop and will pay the shop separately for the cleaning. Reinstall and reseal the water sides.

8. Perform the following resets, checks, and adjustments: in accordance with references

a. Adjust all piston cooling jets to proper spray angle.

b. Reset tappets.

c. Check valve rotators.

d. Check and adjust fuel timing.

e. Adjust fuel rack actuator by setting turnbuckle adjustment to middle of range.

f. Adjust position of arm on actuator spine such that when engine is running at rated speed under no load, voltage at actuator is 1.5 VDC. Voltage is best measured in the

DOCUMENT 233-3 Page 8 switchboard, however the voltage drop across the fuse must be considered.

9. Inform the Chief Engineer in a timely manner when the engine jacket water system is ready to be refilled and tested for water-tightness. Refill the coolant system with fresh water and the appropriate amount of jacket water treatment. The treatment will be supplied by the ship's force.

10. Replace the lube oil sump pan gasket on Engine #1. This requires the generator end removal, reinstallation, and realignment per paragraph 4.4.5 above.

11. Thoroughly clean and inspect the lube oil sump pan on each overhauled engine. Notify the Chief Engineer in a timely manner when the engine sumps are ready to be refilled with new lube oil. The government will provide the new oil and the ship's force will add the appropriate amount following an inspection of the oil sump pans.

3.5 CAT 3500 First Top End Overhaul

1. Complete all work required by the Original Equipment Manufacturer (OEM) to ensure that engines and all components therein qualify for coverage under the Caterpillar [Gold, Platinum, Plus] Overhaul Protection Coverage Plan.

2. Furnish all parts, supplies, and labor to peform all tasks listed in the Work Item Table below.

Work Item

Component Action(s)

1 Aftercooler core Clean Inspect Pressure test using SAF-ACID (or equal), Reassemble using all new gasket/joint

2 Air inlet manifold (gaskets &seals)

Install new

3 Camshaft (If replacement is needed, present to Contracting Officer as growth work)

-Inspect and note wear/condition on CFR -Roll the engine inspect for damage to the journals and lobes

4 Camshaft followers (If replacement is needed, present to Contracting Officer as growth work. Recondition or h f f d

-Inspect and note wear/condition on CFR

5 Cylinder head assemblies (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-Inspect and note wear/condition on CFR -Replace with CAT remanufactured

6 Driven Equipment (alignment) -Inspect and note wear/condition on CFR

7 Engine control module -Inspect and note wear/condition on CFR

DOCUMENT 233-3 Page 9

Work Item

Component Action(s)

8 Engine Wiring Harness (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-Inspect and note wear/condition on CFR

9 Exhaust bellows shields -Inspect and note wear/condition on CFR

10 Exhaust manifold bellows (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

11 Exhaust manifold seals (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

12 Fuel pressure regulating valve (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-Inspect and note wear/condition on CFR

13 Fuel priming pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-Inspect and note wear/condition on CFR

14 Fuel transfer pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-External inspection and note wear/condition on CFR

15 Inlet Manifold gaskets -Install NEW

16 Inlet Manifold seals -Install NEW

17 Oil Pump (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-External inspection and note wear/condition on CFR

18 Oil Suction Screen -Inspect and Clean

19 Prelube Pump (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

20 Pushrods (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

DOCUMENT 233-3 Page 10

Component Action(s)

21 Rocker arms (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

22 Spacer plates (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

23 Scavenge oil pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f d )

-Inspect and note wear/condition on CFR

24 Software Update (If software updates are confirmed by Chief Engineer as needed, present to Contracting Officer as growth work )

-If recommended updates by CAT are available, discuss options with Chief Engineer.

25 Thermostats -Replace with CAT remanufactured

26 Turbocharger (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange for f d )

-Inspect radial clearances and rotate.

27 Unit (Fuel) Injectors -Install Remanufactured

28 Water pumps -Replace with CAT remanufactured

3.6 CAT 3500 Second Top End Overhaul

1. Complete all work required by the Original Equipment Manufacturer (OEM) to ensure that engines and all components therein qualify for coverage under the Caterpillar [Gold, Platinum, Plus] Overhaul Protection Coverage Plan.

2. Furnish all parts, supplies, and labor to peform all tasks listed in the Work Item Table below.

Work Item

Component Action(s)

1 Aftercooler core Clean Inspect Pressure test using SAF-ACID (or equal), DOCUMENT 233-3 Page 11

Component Action(s)

2 Camshaft (If replacement is needed, present to Contracting Officer as growth work)

-Inspect and note wear/condition on CFR -Roll the engine inspect for damage to the journals and lobes.

3 Camshaft followers (If replacement is needed, present to Contracting Officer as growth work. Recondition or

-Inspect and note wear/condition on CFR

4 Connecting rod (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f )

-Inspect and note wear/condition on CFR

5 Connecting rod bearings (If replacement is needed, present to Contracting Officer as growth

-Inspect and note wear/condition on CFR

6 Crankshaft (If replacement is needed, present to Contracting Officer as growth work)

-Inspect for deflection, damage to journals, or bearing material that has seized to the journals.

-Check journal taper and profile of k h f j l / di i /7 Cylinder head assemblies (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR -Replace with CAT remanufactured

8 Cylinder liners (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange for f t d t )

-Inspect and note wear/condition on CFR

9 Driven Equipment (alignment) -Inspect and note wear/condition on CFR

10 Engine control module -Inspect and note wear/condition on CFR

11 Engine Wiring Harness (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR

12 Exhaust bellows shields -Inspect and note wear/condition on CFR

13 Exhaust manifold bellows (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

DOCUMENT 233-3 Page 12

Component Action(s)

14 Exhaust manifold seals (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

15 Fuel pressure regulating valve (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR

16 Fuel priming pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR

17 Fuel transfer pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-External inspection and note wear/condition on CFR

18 Inlet Manifold gaskets -Install NEW

19 Inlet Manifold seals -Install NEW

20 Oil Pump (If replacement is needed, present to Contracting Officer as growth work.

di i h )

-External inspection and note wear/condition on CFR

21 Oil Suction Screen -Inspect and Clean

22 Pistons (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

23 Piston pins (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts )

-Inspect and note wear/condition on CFR

24 Prelube Pump (If replacement is needed, present to Contracting Officer as growth work.

-Inspect and note wear/condition on CFR

25 Pushrods (If replacement is needed, present to Contracting Officer as growth work.

-Inspect and note wear/condition on CFR

26 Rocker arms (If replacement is needed, present to Contracting Officer as growth work.

di i h )

-Inspect and note wear/condition on CFR

27 Spacer plates (If replacement is needed, present to Contracting Officer as growth work.

DOCUMENT 233-3 Page 13

Component Action(s)

28 Scavenge oil pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR

29 Software Update (If software updates are confirmed by Chief Engineer as needed, present to Contracting Officer as growth k )

-If recommended updates by CAT are available, discuss options with Chief Engineer.

30 Thermostats -Replace with CAT remanufactured

31 Turbocharger (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange for

-Inspect radial clearances and rotate.

32 Unit (Fuel) Injectors -Install Remanufactured

33 Water pumps -Replace with CAT remanufactured

3.7 CAT 3500 Major Overhaul

1. Complete all work required by the Original Equipment Manufacturer (OEM) to ensure that engines and all components therein qualify for coverage under the Caterpillar [Gold, Platinum, Plus] Overhaul Protection Coverage Plan.

2. Furnish all parts, supplies, and labor to peform all tasks listed in the Work Item Table below.

Work It

Component Action(s)

1 Aftercooler core Clean Inspect Pressure test using SAF-ACID (or equal), -Reassemble using all new gasket/joint

2 Camshaft (If replacement is needed, present to Contracting Officer as growth work)

-Inspect and note wear/condition on CFR -Roll the engine inspect for damage to the journals and lobes.

3 Camshaft Bearings -Replace with NEW -Note wear/condition of CFR

4 Camshaft followers (If replacement is needed, present to Contracting Officer as growth work. Recondition or h f f t d

DOCUMENT 233-3 Page 14

It

Component Action(s)

5 Camshaft Thrust Washers (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

6 Connecting rod (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange

-Inspect and note wear/condition on CFR

7 Connecting rod bearings -Replace with NEW -Note wear/condition of CFR

8 Coolant Analysis-[Level I][Level

II]

-S*O*S coolant [(Level I)][(Level II) CAT recommended - (includes level I analysis, identification of source of metal corrosion, buildup of impurities that cause corrosion and scaling)] -Give a copy of coolant analysis and recommendationreport of the results to

9 Crankshaft (If replacement is needed, present to Contracting Officer as growth work)

-Inspect for deflection, damage to journals, or bearing material that has seized to the journals.

-Check journal taper and profile of

10 Crankshaft seals -Replace with NEW -Note wear/condition of CFR

11 Crankshaft thrust washers -Replace with NEW -Note wear/condition of CFR

12 Crankshaft vibration damper (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

13 Cylinder head assemblies (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR -Replace with CAT remanufactured

14 Cylinder liners (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange for

-Inspect and note wear/condition on CFR

15 Driven Equipment (alignment) -Inspect and note wear/condition on CFR

16 Engine control module -Inspect and note wear/condition on CFR

17 Engine cylinder block -Inspect and note wear/condition on CFR

18 Engine Mounts (If replacement is needed, present to Contracting Officer as growth

DOCUMENT 233-3 Page 15

Component Action(s)

19 Engine Wiring Harness (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

20 Exhaust bellows shields -Inspect and note wear/condition on CFR

21 Exhaust manifold bellows (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

22 Exhaust manifold seals (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

- Inspect and note wear/condition on CFR -Install new gaskets and hardware after inspection

23 Flywheel -Inspect and note wear/condition on CFR

24 Fuel pressure regulating valve (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

25 Fuel priming pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

26 Fuel transfer pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-External inspection and note wear/condition on CFR

27 Gears -Inspect and note wear/condition on CFR

28 Gear Train Bushings -Replace with NEW -Note wear/condition of CFR

29 Gear Train Bearings -Replace with NEW -Note wear/condition of CFR

30 Gear Train - Front -Inspect and note wear/condition on CFR

31 Gear Train - Rear -Inspect and note wear/condition on CFR

32 Inlet Manifold gaskets -Install NEW

33 Inlet Manifold seals -Install NEW

34 Main Bearings -Install NEW

DOCUMENT 233-3 Page 16

Component Action(s)

35 Oil Cooler Core (If replacement is needed, present to Contracting Officer as growth work Recondition or exchange

-Inspect and note wear/condition on CFR -Clean -Pressure Test

36 Oil Pump (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts.)

-External inspection and note wear/condition on CFR

37 Oil Suction Screen -Inspect and Clean

38 Oil Sump -Inspect and Clean

39 Pistons (If replacement is needed, present to Contracting Officer as growth work.

di i h )

-Inspect and note wear/condition on CFR

40 Piston pins (If replacement is needed, present to Contracting Officer as growth work.

-Inspect and note wear/condition on CFR

41 Piston rings -Install NEW

42 Prelube Pump (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts.)

-Inspect and note wear/condition on CFR

43 Pushrods (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts.)

-Inspect and note wear/condition on CFR

44 Rocker arms (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts.)

-Inspect and note wear/condition on CFR

45 Rod Bearings -Inspect and note wear/condition on CFR

46 Spacer plates (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange parts.)

-Inspect and note wear/condition on CFR

47 Scavenge oil pump (If replacement is needed, present to Contracting Officer as growth work. Recondition or exchange f f t d t )

-Inspect and note wear/condition on CFR

48 Software Update (If software updates are confirmed by Chief Engineer as needed, present to Contracting Officer as growth

-If recommended updates by CAT are available, discuss options with Chief Engineer.

DOCUMENT 233-3 Page 17

Component Action(s)

49 Turbocharger (If replacement is needed, present to Contracting Officer as growth work.

Recondition or exchange for

-Inspect radial clearances and rotate.

50 Unit (Fuel) Injectors -Install Remanufactured

51 Water pumps -Replace with CAT remanufactured

3.8 Electrical Inspections

1. Inspect all electrical connections, test low lube oil pressure and high jacket water temperature safety shutdown devices, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engine and Kato generator unit and provide a condition report stating general condition and any abnormal findings. A Change Order will be issued for any additional work.

3.9 Electronics Notifications

1. Notify all personnel working on the Caterpillar engine and Kato generator unit, that electrical and electronic controls and devices are present and may require necessary precautions, isolations etc. to be protected from damage during the overhaul period.

3.10 Testing and Reports

1. Notify the Chief Engineer in a timely manner when the overhauled engines are ready to be tested under electrical load.

2. Perform an operational test on overhauled engines using ship's dockside hotel load for a minimum of two hours, as follows:

a. Prior to starting, test all alarm and shutdown systems.

b. Ship's force will line up and start engines.

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

d. Operate engines at no-load until normal no-load operating temperatures are reached.

e. Increase load incrementally up to full load and operate for one hour.

f. Monitor temperatures and pressures and compare to manufacturer's recommended limits. If a temperature or pressure exceeds or falls below the manufacturer's recommended upper or lower limits, stop testing immediately. Determine and correct the problem before resuming testing.

3. Take and record the following information near the end of the full load test. Provide

DOCUMENT 233-3 Page 18 properly calibrated test instruments as needed.

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. water pressures

g. electrical load on generator prime mover

h. turbo outlet air pressure

4. Submit a report of all test data collected. Include the actual measurements alongside the manufacturer's recommended limit for each measured parameter.

5. Submit a cost breakdown report of all parts used for the overhauls.

3.11 Final Adjustments and Tune-Up

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

3.12 Touch-Up Paint

1. Touch-up the paint on all disturbed surfaces using the standard Caterpillar paint scheme.

Remove dirt and grease from surfaces prior to painting.

3.13 Notes

1. Ship's force is available to provide shipboard crane service during normal working hours to lift parts between the pier and aft deck. 24 hour notice is required. Actual rigging of parts and moving parts to/from the aft deck and engine room shall be the responsibility of the Contractor.

PART 4 NOTES

-- End of Section --

DOCUMENT 233-3 Page 19