CAT 3512 B and C series Maintenance:

Before Starting The Engine:

- Walk around inspection for any type of leaks ( Fuel, Oil and Coolant).&
- Check all guards, all guards must be in their proper place.
- Ensure that the areas around the rotating parts are clear.
- Ensure that all clamps and connections are secure.
- Observe air cleaner service indicators must be in green area.
- Check level and inspect cooling system for leaks or loose connections.
- Inspect fan drive belts for cracks or deterioration.
- Inspect water pump for evidence of leaks.
- Inspect the fuel lines for loose fitting and leaks.
- Ensure that the fuel is supplied to the Engine.
- Check the oil dipstick for normal level.

After Starting The Engine- warm up period:

- Operate the Engine at Low Idle for three to five minutes to allow the jacket water
temperature to begin rise before full RPM.
- Check all gauges during warm-up period.
- Make another walk around inspection.
- Check oil Pressure must be more than 19 psi to ensure that the two sequence valves
of jet cooling pistons are open.

1- Daily:

- Cooling system check level and temperature the nominal operating range is 88
to 100°C.
- Driven equipment inspect/ replace as required lubricate when the engine is
under load.
- Air cleaner differential pressure ,clean or replace when pressure become 19
inches of H2O.
- Oil differential pressure mustn’t exceed 15 psi.
- Fuel differential pressure mustn’t exceed 15psi.
- Oil level should be between add and full at the dipstick.
- Oil pressure at low idle rpm is 27 to 50 psi, at rated rpm is 40 to 87 psi.
- Normal fuel pressure is 50 to 75 psi.
- Maximum exhaust temperature is 575°C.
- Instrument panel check.
- Drain the air sediment tank.
 - Walk around inspection.

2- Every 500 service hours:

- Engine oil and filters change.

3- Every 1000 service hours:

- Clean crankcase breather.

- Check engine protective devices.
- Fuel system primary filer inspect and clean or replace if required.
- Change the fuel secondary filters.
- Clean the Engine.

4- Every 2000 service hours:

- Inspect the crankshaft vibration damper for evidence of wears or leaks.

- Check the driven equipment ( V-belts ) or replace if required.
- Inspect the engine mounts and fixation points.
- Inspect the turbo chargers.

5- Every 4000 service hours:

- Engine Valve lash inspect or adjust if required.

- Engine fuel injectors inspect or adjust if required.

6- Every 6000 service hours:

- Change cooling system coolant.

- Inspect the water pump.
- Starting motor Inspect.
- Replace the cooling system water regulators.

7- Every 11000 service hours:

- Top end overhaul.

8- Every 22000 service hours:

- Second top end overhaul.

9- Every 33000 service hours:

- Major overhaul.
CAT 15C Maintenance:

Before Starting The Engine:

- Walk around inspection for any type of leaks ( Fuel, Oil and Coolant).&
- Check all guards, all guards must be in their proper place.
- Ensure that the areas around the rotating parts are clear.
- Ensure that all clamps and connections are secure.
- Observe air cleaner service indicators must be in green area.
- Check level and inspect cooling system for leaks or loose connections.
- Inspect fan drive belts for cracks or deterioration.
- Inspect water pump for evidence of leaks.
- Inspect the fuel lines for loose fitting and leaks.
- Ensure that the fuel is supplied to the Engine.
- Check the oil dipstick for normal level.

After Starting The Engine- warm up period:

- Operate the Engine at Low idle for three two five minutes, allow the jacket water
temperature to begin rise before load the engine.
- Inspect all parameters during warm-up period.
- Make another walk around and check for fluid leaks.

Engaging the Generator:

- Ensure that all indicators are in the normal ranges.

- Adjust the voltage and frequency if necessary.
- Close the main circuit breaker in order to apply the load.
- Make another walk around and check the indicators and the generator.

1- Daily:

- Check coolant level.

- Check electrical connections.
- Check oil level.
- Inspect engine air cleaner service indicator.
- Drain fuel system primary filter Fuel/Water Separator.
- Check jacket water temperature.
- Inspect fan drive V-belts.
- Check power factor.
 - Check voltage and frequency.
- Walk around inspection.

2- Every 500 service hours:

- Belts Inspect/Adjust or replace.

- Change engine oil and filter.
- Check Engine protective devices.
- Replace fuel system primary filter Fuel/Water Separator element.
- Replace fuel system secondary filter.
- Inspect grounding stud.

3- Every 2000 service hours:

- Clean crankcase breather.
- Check generator lead ( round cable ).
- Inspect generator set vibration.
- Check stator lead.

4- Every 3000 service hours:

- Inspect alternator.
- replace coolant temperature regulators.
- inspect crankshaft vibration damper.
- inspect engine mounts.
- Inspect/Clean the speed/timing sensor.
- Inspect starting motor.
- Inspect Turbocharger.
- Inspect Water pump.

5- Every 600 000 L of Fuel Consumption:

- Overhaul Top-End.
6- Every 1200 000 L of Fuel Consumption:
- Major Overhaul.

JC70D Draw-works:
General inspections:

- Check alignment of sprocket and shafts.

- Ensure that all bolts are tight.
- Inspect all chains for wear and broken links.
- Check all air connection and hoses for leaks Tight, clean or Replace.
- Engage and disengage clutches to verify the good function.
- Clean oil sump and section screener to ensure free oil flow.
- Check installation of chain guards to ensure the oil will have unrestricted flow back
to the sump.
- Replace any fitting that won’t take grease, replace broken and pinched grease
tubing.
- Inspect lub pump and distributor nozzles.
- With DW running check the main bearings on all shafts to ensure that they are well
lubricated and securely bolted.
- Check the water supply system for good function.
- Change oil and clean sump every 2000 service hours.

Daily maintenance:

- Open inspection covers for observation.

- Check the oil level when DW stopped.
- If oil become contaminated change it immediately.
- Maintain proper oil pressure, 21,7 to 43,5 psi.
- Check the air piping and rotor seal for leaks.
- Assure that friction pads in clutches are free of grease or other lubricants.
- Lubricate with grease every day all bearings that are under loads (Drum shaft and
eddy current brake ).
- Check the return water in the cooling system both Eddy current brake and main
brake.

PSK Hydraulic Unite and Disc brake Assembly:

- Check hydraulic oil level.

- Check working pressure must be 1100 to 1200 psi.
- Walk around to inspect for leaks and abnormal noise.
- Ensure the good function of the cooling system in the unite.
- Check hydraulic oil temperature must be less than 80°C.
- Inspect pre fill pressure of the accumulators when pumps are stopped and the
system pressure drained, pre fill pressure is 600 psi.
- Clean the calipers when become contaminated.
- Inspect clearances between disc and friction pads of both Main and Emergency
calipers, for Emergency caliper the clearance must be 0,5 to 1 mm, for the Main
caliper the clearance must be 1 to 2 mm.
- Inspect all pins and springs for good function.
- Every Six ( 06 ) months inspect the disc brake thickness shall be more than 65 mm.
- Every year replace Emergency caliper springs, and test the new one under pressure
of 16 Mpa.