NOAA_CAT_Standard_Spec_Rev._Dec_2017.pdf

NATIONAL OCEANIC AND ATMOSPHERIC ADMINISTRATION (NOAA)

ATLANTIC MARINE CENTER STANDARD SPECIFICATION

OVERHAUL OF CATERPILLAR 3500 SERIES DIESEL ENGINES Rev. 12/2017

1. SCOPE. This specification contains the general requirements and procedures to be used in overhauling Caterpillar 3500 series diesel engines.

2. REFERENCES: Refer to engine specific shop manuals.

3. REQUIREMENTS:

3.1. General. The following requirements apply to all work.

3.2. Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, and technical expertise needed to accomplish the work required by this specification.

3.3. All work shall be performed by an authorized repair facility of the engine manufacturer for the model of engine specified and shall be performed in such a manner that the manufacturer's warranty on parts and labor is not voided. 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 currently certified by the engine manufacturer. Contractor shall submit evidence that they are a current Caterpillar Authorized Marine Dealer(A.M.D.) or other Caterpillar Authorized Repair Facility, or proof of current certification of the Caterpillar factory-trained mechanic that will supervise the work on-site.

3.4. Provide and install "mandatory-renewal" parts and components during the overhaul as required by this specification, the Detail Specification, and other procurement documents. Renewal of other parts and components determined to be needed may be provided by the government and shall be installed by the contractor. Additional needed parts and components which are not provided by the government will be negotiated by the Contracting Officer as an additional cost to the purchase order or contract.

3.5. Except where remanufactured 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 and rebuilt components and parts, perform visual and dimensional inspections to verify that the components and parts are acceptable for use.

3.6. Where remanufactured components are provided, existing components shall be replaced on an exchange basis with components which have been remanufactured at the engine manufacturer’s factory, and the existing components become the property of the contractor in their as-found condition. When factory-remanufactured 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. Remanufactured components shall meet the manufacturer's rebuild specifications and shall be restored to a condition of reliability equivalent to new components.

3.7. All work and parts renewed shall be in accordance with the manufacturer's service, maintenance, and overhaul technical manuals, including all current/updated 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.

4. General Statement of Work:

4.1. 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.

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

4.3. 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 Technical Representative (COTR) or other NOAA representative named in the procurement document.

Include in the report recommendations for all additional repairs, inspections, tests, and part renewals needed to insure continued reliable service of the engine. 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.

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

4.5. Remove and reinstall all interferences as required to accomplish the required work.

4.6. 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.

5. Major Overhaul: Whenever a major overhaul is required by the Detail Specifications or other procurement document, the following requirements apply:

5.1. Renew all of the following mandatory-renewal parts and components.

Where "remanufactured" is added in parenthesis after a component, a remanufactured component may be provided in lieu of a new component:

a. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts

b. Rocker arm assemblies, including buttons and clips

c. Front and rear crankshaft seals

d. Crankshaft main bearings

e. Connecting rod bearings

f. Front and rear gear train bushings/bearings

g. Front accessory bushings/bearings

h. Camshaft, camshaft bushings, cam followers

i. Turbocharger cartridges (remanufactured)

j. Thermostats and water temperature regulators

k. Cylinder packs (remanufactured)

l. Cylinder head assemblies (remanufactured)

m. Cylinder head bolts

n. Fuel injectors (remanufactured)

o. Air starting motor (remanufactured)

p. Fuel transfer pump (remanufactured)

q. Governor Actuator (remanufactured)

r. Fresh water pumps (remanufactured)

s. Sea water pump (remanufactured)

t. All lube oil pumps (remanufactured)

u. CAT Hoses

v. Non-CAT Hoses

w. Aftercooler cores (remove, clean, pressure test)

x. Oil cooler core (remove, clean, pressure test)

y. Filter elements

z. Lifter assemblies

aa. Push Rods.

ab. Renew the gasket on each side of the first exhaust expansion joint from the engine. These gaskets are not Caterpillar parts.

ac. Rod ends on external governor linkages.

ad. Renew the exhaust RTD for each cylinder. RTD renewal is to include wiring/harness for the specific engine.

5.2. Clean, inspect, test, and reassemble the following components, parts, and subassemblies:

5.2.1. Crankshaft vibration damper

5.2.2. Fuel system linkage

5.2.3. Spacer plates and driven unit alignment

5.2.4. Other components to the extent required to perform the required inspections, tests, and repairs, and to the extent required to renew parts and components.

5.3. Conduct a complete dimensional inspection of all parts which have surfaces subject to wear.

5.4. Conduct visual and dimensional inspections of the crankshaft journals. Port Engineer is to be notified 48 hours in advance of crankshaft journal inspection in order to arrange an ABS inspection of the crankshaft journals.

5.5. Inspect gears for galling, scoring, pitting, excessive wear, and other defects which could affect serviceability.

5.6. Inspect and document final assembly torque of all fasteners in the drive train that were undone for the bearing renewals.

5.7. After engine overhaul inspect and provide documentation for the following:

5.7.1. Engine flywheel housing run-out.

5.7.2. Crankshaft axial end play.

5.8. Renew the Generator End bearings utilizing the KATO tech manual for guidance. For the 3516 engines there are a driven end and free end bearing. For the 3508 engines, there is only a free end bearing.

5.9. Accomplish alignment of engine to generator upon completion of repairs. Final alignment to be witnessed by COTR and ABS Surveyor.

6. Top-End Overhaul: Whenever a top end overhaul is required by the Detail Specifications or other procurement document, the following requirements apply:

6.1. Renew all of the following "mandatory-renewal" parts and components.

Where "remanufactured" is added in parenthesis after a component, a remanufactured component may be provided in lieu of a new component.

a. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts

b. Turbocharger cartridges (remanufactured)

c. Thermostats and water temperature regulators

d. Cylinder head assemblies (remanufactured)

e. Cylinder head bolts.

f. Fuel injectors (remanufactured)

g. Fresh water pumps (remanufactured)

h. Sea water pump (remanufactured)

i. Air starter (remanufactured)

j. Aftercooler cores (remove, clean, pressure test)

k. Filter elements

l. Rocker Arm buttons and retainers.

m. Lifter assemblies.

n. Push Rods.

o. Jacket Water expansion tank level switch and hose assembly.

p. Rod ends on external governor linkages.

q. Renew the gasket on each side of the first exhaust expansion joint from the engine. These gaskets are not Caterpillar parts.

q. Oil cooler core (remanufactured)

6.2. Inspect all fuel rack control rods for each cylinder.

6.3. Inspect camshaft lobes in place. Inspect all cam followers.

6.4. Upon reassembly of engine, the ship’s force will refill the coolant and lube oil systems.

7. Tests: Regardless of the type of overhaul performed, conduct the following tests of the engine after all components have been reassembled.

7.1. Test all alarm and shutdown systems prior to starting the engine.

Conduct a preliminary tune-up of the engine.

7.2. Monitor engine operations as the ship's engineers start the engine.

Check all joints for leaks.

7.3. Perform operational tests of the engine as follows:

7.3.1. Operate engines at no-load for one hour and until normal no-load operating temperatures are reached.

7.3.2. Increase the load on the engine to 25-percent of its normal operating full load and operate for one-half hour.

7.3.3. Increase the load on the engine to 50-percent of its normal operating full load and operate for one-half hour.

7.3.4. Increase the load on the engine to 75-percent of its normal operating full load and operate for one hour.

7.3.5. Increase the load on the engine to 100-percent of its normal operating full load and operate for one hour.

7.4. During and following each operational test period, make adjustments, correct leaks, and monitor performance of the engine.

7.5. Near the end of each operational test period, take and record the following information. Provide test instruments as required:

a. crankcase pressure

b. cylinder exhaust temperatures

c. lube oil temperatures

d. water temperatures

e. fuel oil pressures

f. lube oil pressures

g. water pressures

h. electrical load on generator prime movers

7.6. During the performance of the tests, continually monitor the temperatures and pressures and compare them to the manufacturer's recommended limits. If at any time a temperature or pressure exceeds or falls below the manufacturer's recommended upper or lower limits, the tests shall be stopped and the cause is to be determined. After the cause has been corrected, the tests shall be restarted from the beginning.

7.7. For main propulsion diesel engines (3516), the ship will have to get underway for sea trials in order to achieve the specified loads.

Provide qualified technicians to ride the ship, observe the operations, make adjustments, and record data.

7.8. For ship’s service diesel engines (3508), the operational test shall be accomplished dockside, using the ship’s hotel load to generate the test load. If the hotel load is not high enough, then the operational test load shall be done during a sea trial.

7.9. Prepare and submit to the COTR or other NOAA representative named in the procurement document a report of all data taken in conjunction with the test periods. Include in the report the manufacturer's recommended limits for the applicable parameter.

7.10. After satisfactory completion of the operational tests, conduct final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation of the engine.

8. After completion of all engine repairs, prepare and coat the engine with OEM paint in accordance with OEM recommendations.

9. Provide the following post overhaul reports:

9.1. Complete listing of all parts renewed with part numbers.

9.2. Overhaul report for submittal to ABS which summarizes the work accomplished, issues discovered, and how they were corrected.

END OF SPECIFICATION