EDC Work Instruction Report

Asset Activity:
Asset Description:
Rig: RIG2
Asset Activity CDE.DAY.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / DAILY

Last Update Date 07-08-2023

Op Seq Num 10 Department Mechanic

Long Description Basic Engine:
Keep unit and surroundings clean and tidy.
Beware of abnormal running conditions such as heat, noise or vibration.
Wipe all caps and plugs before the engine is serviced.
Op Seq Num 20 Department Mechanic
Long Description Lubrication System
Inspect the lubrication system for leaks
Check oil level in engine crank case; refill as necessary, record the amount of oil that is added.

N.B.: Make sure to keep your oil drums closed at all times; DO NOT keep clean oil in open containers, this oil will be contaminated and NOT to be used on any engine
Op Seq Num 30 Department Mechanic
Long Description Cooling System
Check cooling fluid level in expansion tank or radiator. Also the common expansion tank if used.
Ensure that cooling lines are properly clamped and tight. Check for leaks
Inspect the water pumps for coolant leaks
Check inlet and outlet temperature of the cooling water on the radiator the difference between the readings should be 10-15 degree, If the difference less than 8,
Carryout the radiator cleaning.

Make sure to record the engines cooling water inlet/ out let temperatures at the hottest time a day and place these readings in the Rig Morning Report

N.B.: This is the reading we find useful; do not place average temperatures in the morning report.

Make sure that the radiator pressure cap is correct installed and verify that the cap and the seal is intact.

Be aware: closed cooling systems which are intact are not consuming any water
If water has to be added frequently to the systems; it means there is a leak somewhere, locate and repair it
Check the cooling systems PH values to be between 8-10
Op Seq Num 40 Department Mechanic
Long Description Pillow Block
A visual inspection when the engine is running is very important
Check for any abnormal sounds or vibrations; if a bearing is worn the pulleys or fan will be in an incorrect angle and you will most likely experience a non circular
movement
Make sure that the grease is actually entering the bearings when the bearings are being greased daily It's possible the remote grease system (if such exists) is either
blocked or
Defected, you need to check
Op Seq Num 50 Department Mechanic
Long Description Fuel System
Drain fuel oil or day tank for water and sediment
Inspect the fuel system for leaks. Look for loose fuel line clamps

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 EDC Work Instruction Report

Asset Activity CDE.DAY.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / DAILY

Last Update Date 07-08-2023

Op Seq Num 60 Department Mechanic

Long Description Electrical and Starting System
Check the starting alternator
Check the batteries for charging clean if required
All engines with air starter motors
Observe the oil level in the sight gauge of the air starter motor lubricator, refill when necessary. Make sure the lubricator suction hose is in its correct place
Op Seq Num 70 Department Electric
Long Description Operator Station
Inspect the instrument panel for good condition
Check the condition of the gauges
Check engine alarm system
This also include the seawater low pressure system

Ensure that electrical cables connected to batteries and starter motor are protected from short circuit
Op Seq Num 80 Department Mechanic
Long Description Enclosures, guards and bases
The guards must be in the proper place. Repair damaged guards or replace missing guards
Inspect the wiring and the wiring harnesses for good condition
Inspect the ground strap for a good connection and for good condition
Op Seq Num 90 Department Mechanic
Long Description Test run the engine and checks the following default settings values

Kpa) Lube oil pressure Min. 45 psi Max. 70 psi (310-480

Lube oil temperature Min. 60 degC Max. 110 degC
Cooling fluid temperature Min. 77 degC Max. 95 degC

Op Seq Num 100 Department Mechanic

Long Description Make sure the engines harness is fixed well with tie raps and not rubbing against anything.

Op Seq Num 110 Department Mechanic

Long Description If the engine has been stopped for more than one day; turn it over by hand and turning tool at least two full revolutions before starting it make sure it turning freely
This in order to avoid equipment damage due to a hydraulic lock if there is an
Internal fluid leak inside the combustion chambers
Op Seq Num 120 Department Mechanic
Long Description If the engine has been stopped for more than one day; turn it over by hand and turning tool at least two full revolutions before starting it make sure it turning freely
This in order to avoid equipment damage due to a hydraulic lock if there is an
Internal fluid leak inside the combustion chambers

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 EDC Work Instruction Report

Asset Activity CDE.DAY.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / DAILY

Last Update Date 07-08-2023

Op Seq Num 130 Department Mechanic

Long Description Daily check that the fuel inlet temperature is maximum 60 deg. C
If the fuel temperature exceeds 60 Deg. C there?s a risk of causing damage on the fuel system components.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.1000.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 1000 HRS

Last Update Date 16-03-2017

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 500 hours maintenance.
Op Seq Num 20 Department Mechanic
Long Description Lubrication System
Take an oil sample; send it to EDC Cairo office for analysis
Change oil
Change oil filters and cut the old filters open to check for contamination
Use a magnet to differentiate between the ferrous and non-ferrous metals found in the oil filter.
Ferrous metals may indicate wear on the steel and cast iron parts of engine. Non-ferrous metals may indicate wear on the aluminum parts of engine, such as main and
rod or turbo charger bearings.
Due to normal wear, friction, etc., it is not uncommon to find small amounts of debris in your oil filter an excessive amount of debris in the oil filter element may be
indicative of a pending failure.
Immediately notify the Maintenance Section in Cairo to arrange for further analysis if an excessive amount of debris is found in your oil filter element
Op Seq Num 30 Department Mechanic
Long Description Cooling System:
Clean heat exchanger.
Check cooling fan bearing for abnormal noise and temperature.
Op Seq Num 40 Department Mechanic
Long Description Pillow Block
Stop the engine; Check the level of wear in the bearings; horizontally / vertically.
. Make sure there are no cracks or fractures in the pillow blocks
In order to perform these checks it might be necessary to remove fan guards and fan belts.
Make sure all parts are back in place and correct adjusted before the engine is being operated.
Op Seq Num 50 Department Mechanic
Long Description Air Inlet and exhaust system
Turbochargers Inspection
Check the end play and bearing clearance on the turbine wheel and shaft
It should be difficult to detect movement of the shaft in the bearing
If the shaft is loose in the bearing, an inspection of the internal components should be made.
Check endplay on turbocharger shaft. Max. Permissible endplay of shaft:( 0.25 mm or 0.010)
Inspect the air compressor (if equipped)
Op Seq Num 60 Department Mechanic
Long Description Fuel System:
Clean and inspect the fuel system primary filter, Replace it if required.
Check the fuel control linkage for proper operation and make adjustment if necessary.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.1000.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 1000 HRS

Last Update Date 16-03-2017

Op Seq Num 70 Department Electric

Long Description Electrical and Starting System
Inspect zinc plugs (anodes) for condition, replace as required (offshore only)
Visually check the condition of all sensors and wiring. Look for loose, broken, or damaged wiring and components
Repair or replace any damaged wiring or components immediately
Check all engine protective devices
Op Seq Num 80 Department Mechanic
Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.2000.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 2000 HRS

Last Update Date 16-03-2017

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 1000 hours maintenance.
Op Seq Num 20 Department Mechanic
Long Description Basic Engine
Inspect the crankshaft vibration damper for evidence of dents, cracks, and leaks of the fluid.
. Ensure that the mounting bolts are tightened to the proper torque
Check flexible coupling (engine - generator). If coupling appears dry remove and clean boots, re-grease boots with silicon grease
Check Valve Bridge and Valve Lash adjustment With the engine stopped and cooled off, check the valve adjustment
Valve lash is measured between the rocker arm and the bridge for the valves.
The valves must be in the following position: FULLY CLOSED

If the measurements of the valve lash are in the acceptable range, no adjustments are necessary
Acceptable Valve Lash Range as follows:
Intake: 0.38 mm (0.015 inch)
Exhaust: 0.76 mm (0.030 inch)

If the measurements are not within this range, adjustment is necessary

Adjust the valve bridges before you make the valve lash adjustments
After checking the valve bridge adjustment for each cylinder, proceed with the valve lash adjustment
Ensure that the number 1 piston is at the top center position.
Refer to testing and adjusting "finding top center position for the No. 1 piston

End Play:
- Is the axial movement of crank shaft
- movement measured by thou (0.001 inch)
- If end play is out of range, this indicates problem with the attached equipment to the engine(alignment problem) or thrust plate problem(wear)

For Models (3400 series & C-15)

Measurement steps:
1. Remove all belts on pulley
2. Install a magnetic dial indicator on front housing, adjust dial indicator to be perpendicular to damper ( or pulley )
3. Use a bar between generator fan and housing
4. Make a horizontal moving by bar at damper side
5. Reset dial indicator at zero reading
6. Make a horizontal moving by bar at generator side(opposite direction)
7. Record dial indicator reading
8. Repeat crank shaft moving at damper direction and at opposite direction to get the same reading at both directions ( it mean dial indicator will read +/- reading and
when you move it at opposite direction the dial indicator will go to zero)

Permissible Range
By Thou(0.001 inch) From To Maximum limit
3400 series & C-15 6 20 35

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 EDC Work Instruction Report

Asset Activity CDE.HRS.2000.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 2000 HRS

Last Update Date 16-03-2017

Op Seq Num 30 Department Mechanic

Long Description Lubrication System
Take oil sample; send it to EDC Cairo office for analysis
Change the oil
Change oil filters and cut the old filters open to check for contamination
Clean and check lube oil crankcase suction screen

Op Seq Num 40 Department Mechanic

Long Description Cooling System
Check the water temperature regulator condition before the water temperature regulator fails
Cooling water level alarm switch
Dismantle the hoses / tubes and clean them inside and the switch as well; they tend to clog with dirt and the alarm does'nt work after assembling; verify the function.

Op Seq Num 50 Department Mechanic

Long Description Air Inlet and exhaust system
Turbochargers Inspection, Check the end play and bearing clearance on the turbine wheel and shaft. It should be difficult to detect movement of the shaft in the
bearing. If the shaft is loose in the bearing, an inspection of the internal component should be made.
Inspect the air compressor (if equipped).
Air filter indicator:
1. Check all the function
2. Clean the elbow and fitting with electro clean and press-air
Op Seq Num 60 Department Mechanic
Long Description Electrical and Starting System
Ensure that the fuel supply to the engine is closed (off)
Inspect alternator and fan belt for wear and for cracking
Adjust the drive belt tension in order to minimize belt slippage
Ensure a full charge for batteries in order to help prevent it from freezing
Check the condition of the electrolyte with the coolant/battery tester
Check the condition of the speed/timing sensors

Op Seq Num 70 Department Electric

Long Description Operation Station
Remove all pressure sensors; clean the sensors and the fittings / connectors.
They will malfunction or give wrong readings whe n the passages are blocked with dirt.
Op Seq Num 80 Department Mechanic
Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.250.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 250 HRS

Last Update Date 07-08-2023

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out weekly maintenance.
Op Seq Num 20 Department Mechanic
Long Description Basic Engine
Keep unit and surroundings clean and tidy
Be aware of unusual running condition
Wipe all caps and plugs before the engine is serviced. Inspect unit for leaks (water, oil, fuel and air) remedy as required
Note: Any leaks must be attended to before the engine is put back in service
Op Seq Num 30 Department Mechanic
Long Description Lubrication System
Take an oil sample; send it to EDC Cairo office for analysis
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover.
Observe the oil filter differential pressure frequently during engine operation.
Clean the crankcase breather
Op Seq Num 40 Department Mechanic
Long Description Cooling System
Check cooling fluid level in expansion tank or radiator. Also the common expansion tank if used.
Ensure that the level alarm is functioning properly.
Remove the two air chamber drain plugs in the after cooler to check for oil or coolant fluid.
Ensure that cooling lines are properly clamped and tight. Check for leaks
Inspect the water pumps for coolant leaks
Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for small amount of Leakage to occur when the engine cools and the parts
contract.
Need to replace the water pump seal Excessive coolant leakage may indicate the
Grease fan drive bearing
Check Fan belts
Cooling fluid PH of water is: Cooled down engine: 7.5 - 8.0. At operation temperature 8.0 - 10.0
Check the engine cooling water corrosion inhibitor concentration
Op Seq Num 50 Department Mechanic
Long Description Air Inlet and exhaust system
Check air receiver service indicator
Inspect the hoses and clamps replace if required
Clean air cleaners and precleaner as required. (Sand storms
Change the air intake filters elements
Op Seq Num 60 Department Mechanic
Long Description Fuel System
Change fuel oil filter if needed
Drain fuel oil or day tank for water and sediment

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 EDC Work Instruction Report

Asset Activity CDE.HRS.250.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 250 HRS

Last Update Date 07-08-2023

Op Seq Num 60 Department Mechanic

Long Description Inspect the fuel system for leaks. Look for loose fuel line clamps
Observe the fuel filter differential pressure frequently during engine operation
Op Seq Num 70 Department Mechanic
Long Description Electrical and Starting System
Ensure that the fuel supply to the engine is closed (off)
Inspect alternator and fan belt for wear and for cracking
Adjust the drive belt tension in order to minimize belt slippage
Ensure a full charge for batteries in order to help prevent it from freezing
Check the condition of the electrolyte with the coolant/battery tester
Op Seq Num 80 Department Electric
Long Description Operator Station
Inspect the instrument panel for good condition
Check the condition of the gauges. Replace any gauge that is damaged or can not be calibrated
Test engine alarm system

Ensure that electrical cables connected to batteries and starter motor are protected from short circuit
Op Seq Num 90 Department Mechanic
Long Description Enclosures, guards and bases
The guards must be in the proper place. Repair damaged guards or replace missing guards.
Inspect the wiring and the wiring harnesses for loose connections and for worn or frayed wires
Inspect the ground strap for a good connection and for good condition
Op Seq Num 100 Department Mechanic
Long Description Test run the engine and check the following default settings values :
Lube oil pressure Min. 45 psi Max. 70 psi (310-480 kPa)
Lube oil temperature Min. 60 degC Max. 110 degC
Cooling fluid temperature Min. 77 degC Max. 95 degC
Op Seq Num 110 Department Mechanic
Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.500.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 500 HRS

Last Update Date 16-03-2017

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 250 Hour maintenance.
Op Seq Num 20 Department Mechanic
Long Description Basic Engine
Keep unit and surroundings clean and tidy
Be aware of unusual running condition
Wipe all caps and plugs before the engine is serviced
Inspect unit for leaks (water, oil, fuel and air) remedy as required
Note
Any leaks must be attended to before the engine is put back in service

Op Seq Num 30 Department Mechanic

Long Description Lubrication System
Take an oil sample; send it to EDC Cairo office for analysis
Change oil
Change oil filters and cut the old filters open to check for contamination
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover
Observe the oil filter differential pressure frequently during engine operation.

Op Seq Num 40 Department Mechanic

Long Description Cooling System
Check cooling fluid level in expansion tank or radiator. Also the common expansion tank if used.
Ensure that the level alarm is functioning properly
Remove the two air chamber drain plugs in the after cooler to check for oil or coolant fluid.
Ensure that cooling lines are properly clamped and tight. Check for leaks
Inspect the water pumps for coolant leaks. Make sure to keep the water pump weep holes clean from dust
Check the inner & outer temperature of the cooling water on the radiator the difference between the reading
Should be 10-15 degree, If the difference less than 8, Carryout the radiator cleaning
Note:
The water pump seal is lubricated by coolant in the cooling system. It is normal for small amount of leakage
To occur when the engine cools and the parts contract. Excessive coolant leakage may indicate the need to replace the water pump seal
Grease fan drive bearing
Check Fan belts
Cooling fluid PH of water is: Cooled down engine: 7.5 - 8.0. At operation temperature 8.0 - 10.0
Check the engine cooling water corrosion inhibitor concentration
Record the PH in the work order. (Recommend to use PH device model HI 98129or model hi 98130)

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 EDC Work Instruction Report

Asset Activity CDE.HRS.500.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 500 HRS

Last Update Date 16-03-2017

Op Seq Num 50 Department Mechanic

Long Description Pillow Block
Stop the engine; Check the level of wear in the bearings; horizontally / vertically.Make sure there are no cracks or fractures in the pillow blocks.
In order to perform these checks it might be necessary to remove fan guards and fan belts.Make sure all parts are back in place and correct adjusted before the engine
is being operated.
Op Seq Num 60 Department Mechanic
Long Description Air Inlet and exhaust system
Check air receiver service indicator
Inspect the hoses and clamps replace if required
Clean air cleaners and precleaner as required. (Sand storm
Change the air intake filters elements

Op Seq Num 70 Department Mechanic

Long Description Fuel System
Change fuel oil filter
Drain fuel oil or day tank for water and sediment
Inspect the fuel system for leaks. Look for loose fuel line clamps
Observe the fuel filter differential pressure frequently during engine operation.
Op Seq Num 80 Department Mechanic
Long Description Starting System
Ensure that the fuel supply to the engine is closed (off
Open the drain valve that is on the bottom of the air tank. Drain the moisture and sediment.
Inspect alternator and fan belt for wear and for cracking.
Adjust the drive belt tension in order to minimize belt slippage
Ensure a full charge for batteries in order to help prevent it from freezing.
Check the condition of the electrolyte with the coolant/battery tester.
Op Seq Num 90 Department Electric
Long Description Operator Station
Inspect the instrument panel for good condition
Check the condition of the gauges. Replace any gauge that is damaged or can not be calibrated.
Test engine alarm system

Op Seq Num 100 Department Mechanic

Long Description Enclosures, guards and bases
The guards must be in the proper place. Repair damaged guards or replace missing guards.
Inspect the wiring and the wiring harnesses for loose connections and for worn or frayed wires.
Inspect the ground strap for a good connection and for good condition

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 EDC Work Instruction Report

Asset Activity CDE.HRS.500.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 500 HRS

Last Update Date 16-03-2017

Op Seq Num 110 Department Mechanic

Long Description Test run the engine and check the following default settings values :

Lube oil pressure Min. 45 psi Max. 70 psi (310-480 kPa)

Lube oil temperature Min. 60 degC Max. 110 degC
Cooling fluid temperature Min. 77 degC Max. 95 degC
Op Seq Num 120 Department Electric
Long Description Inspect the alternator for proper operation, and rotate it by hand to check bearing condition. Remedy as required.

Op Seq Num 130 Department Mechanic

Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.7500.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 7500 HRS

Last Update Date 18-03-2019

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 2000 hours maintenance.
Op Seq Num 20 Department Mechanic
Long Description Basic Engine
Check the crankshaft end play max 0.8mm, 0.030inch
Inspect the crankshaft vibration damper for evidence of dents, cracks, and leaks of the fluid.
Ensure that the mounting bolts are tightened to the proper torque
Check flexible coupling (engine - generator). If coupling appears dry remove and clean boots, re-grease boots with silicon grease

Check Valve Bridge and Valve Lash adjustment

With the engine stopped and cooled off, check the valve adjustment
Valve lash is measured between the rocker arm and the bridge for the valves
The valves must be in the following position: FULLY CLOSED

If the measurements of the valve lash are in the acceptable range, no adjustments are necessary.
Acceptable Valve Lash Range as follows
Intake: 0.38 mm (0.015 inch)
Exhaust: 0.76 mm (0.030 inch)

If the measurements are not within this range, adjustment is necessary

Adjust the valve bridges before you make the valve lash adjustments
After checking the valve bridge adjustment for each cylinder, proceed with the valve lash adjustment.
Ensure that the number 1 piston is at the top center position.
Refer to testing and adjusting "finding top center position for the No. 1 piston"
Op Seq Num 30 Department Electric
Long Description Electrical and Starting System
Inspect the alternator for loose connections, and proper battery charging. Remedy as required.
Inspect the starting motor for proper operation. Listen for grinding when the engine is started.
Inspect the prelude pump for cracks, pin holes, wear, and proper operation. Remedy as required.
Check - Inspect and adjust the magnetic pickup.
Check the starter motors (Electric & air starters)
Dismantle the starter motor check the pinion drive (bendix) for wear and defects
Check the bearings for wear
Check the vanes, cylinder and rotor in the motor (Air starter)
Perform the necessary repair when needed
Abnormal sound from the starter motor indicates a problem as well as low cranking speed
A normal crank speed is between 100 to 130 RPM on the crankshaft
Check the flywheel gear starting ring for wear and defects as well
All engines with pre lube systems.
Dismantle and check the pre lube air motors for wear and defects.
Same procedure as the air starter motors.

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 EDC Work Instruction Report

Asset Activity CDE.HRS.7500.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / 7500 HRS

Last Update Date 18-03-2019

Op Seq Num 40 Department Mechanic

Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity CDE.SWI.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / LUBRICATION CHART SPECIAL WI

Last Update Date 28-01-2015

Op Seq Num 10 Department Mechanic

Long Description 1) Engine Crankcase & Main Shaft Bearing
? Lubricant Type: Engine Oil
? OEM Recommendation :API CG-4 & CF-4 SAE 15W40 at -15'C to 50'C
? Exxon Mobil Equivalent: Mobil Delvac MX15W40
? Volume approximately: 34 Liters for 3406
? Volume approximately: 45 Liters for 3408
? Volume approximately: 60 Liters for 3412 (38S, 81Z)
? Volume approximately: 140 Liters for 3412 (S/N 1EZ)
? Oil Changing: 500 operation hrs
? Oil Samples: 250 operation hrs. / 3 Months

Notes:
1. Drain and fill with clean oil
2. Change Oil and Filters-Clean breather(s)

Op Seq Num 20 Department Mechanic

Long Description 2) Fan Bearing (1 Fitting)
? Lubricant Type: Grease
? OEM Recommendation: Use Multipurpose-type Grease NLGI No.2 Grade NLGI 2 is suitable for most temperatures
? Exxon Mobil Equivalent: Mobil XHP 222
? Greasing Interval : 500 operation hrs
? Strokes: 2-5 S

Op Seq Num 30 Department Mechanic

Long Description General Notes:

? EDC Use Mobil Grease XHP 222 Instate of Mobil Grease XHP 221
? EDC Use Mobil Grease XHP 222 as a general propose grease
? The minimum changing or greasing interval for Synthetic lubricant is double the mineral lubricant interval
? Changing the oil earlier than the schedule interval is must be based on oil analysis results reports or if oil appears dirty or contaminated
? Oil has to be changed when oil viscosity change of 5% from original value
? The Filter replacement with the oil changing interval and every 3 Months or sooner on indication
? Oil filters check every month if they are dirty
? The oil filters replacement
? Do not clean Air Filter Element or Motor Exhaust Spark Arrestor with flammable solvent. Use soapy water only.
? The EDC ware house code for the oil samples pump is 5790-099-1325 and the its hose is 5790-099-1310
? The listed lubrication is a recommendation according to ISO viscosity grade & SAE.
? It is necessary to use the qualified lubricant. The period of lubricant adding or replacement can be adjusted according to the working condition together with the
quality of lubricant inspected.
? Don?t Mix 2 types of grease.

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 EDC Work Instruction Report

Asset Activity CDE.SWI.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / LUBRICATION CHART SPECIAL WI

Last Update Date 28-01-2015

Op Seq Num 30 Department Mechanic

Long Description ? Always clean grease nipples before pumping grease to help prevent contaminants from entering the system and to increase the life of the components.

Generators and Blowers Grease:

? Long life grease (EDC Ware house code is 5520-006-129)
? Mobilith SHC 100

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 EDC Work Instruction Report

Asset Activity CDE.WEK.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / WEEKLY

Last Update Date 07-08-2023

Op Seq Num 10 Department Mechanic

Long Description Basic Engine
Keep unit and surroundings clean and tidy
Wipe all caps and plugs before the engine is serviced
Inspect unit for leaks (water, oil, fuel and air) remedy as required

Op Seq Num 20 Department Mechanic

Long Description Lubrication System

Check oil level in engine crank case; refill as necessary, record the amount of oil that is added.
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover.
Observe the oil filter differential pressure frequently during engine operation.
Clean the crankcase breather

Op Seq Num 30 Department Mechanic

Long Description Cooling System
Check cooling fluid level in expansion tank or radiator. Also the common expansion tank if used.
Ensure that cooling lines are properly clamped and tight. Check for leaks
Grease fan drive bearing
Inspect the water pumps for coolant leaks
Check the radiator cap rubber is in good condition and makes good sealing. i.e. cooling system is pressurized.
This is for higher boiling point of water and to prevent cavitation.

Op Seq Num 40 Department Mechanic

Long Description Pillow Block
Stop the engine; Check the level of wear in the bearings; horizontally / vertically.
Make sure there are no cracks or fractures in the pillow blocks
In order to perform these checks it might be necessary to remove fan guards and fan belts.
Make sure all parts are back in place and correct adjusted before the engine is being operated.
Op Seq Num 50 Department Mechanic
Long Description Air Inlet and exhaust system
Check air receiver service indicator
Clean air cleaners and precleaner as required. (Sand storms
Change the air intake filters elements
Op Seq Num 60 Department Mechanic
Long Description Fuel System
Drain fuel oil or day tank for water and sediment
Inspect the fuel system for leaks. Look for loose fuel line clamps
Observe the fuel filter differential pressure frequently during engine operation.

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 EDC Work Instruction Report

Asset Activity CDE.WEK.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / WEEKLY

Last Update Date 07-08-2023

Op Seq Num 70 Department Mechanic

Long Description Electrical and Starting System

Ensure that the fuel supply to the engine is closed (off)

Inspect alternator and fan belt for wear and for cracking
Adjust the drive belt tension in order to minimize belt slippage
Ensure a full charge for batteries in order to help prevent it from freezing
Check the condition of the electrolyte with the coolant/battery tester
Op Seq Num 80 Department Electric
Long Description Operator Station
Inspect the instrument panel for good condition
Check the condition of the gauges. Replace any gauge that is damaged or can not be calibrated.
Check engine alarm system
This also includes the seawater low-pressure system. (Offshore only)
Test the over speed device: Refer to Service Manual for Max.RPM
Operate all remote shutdown controls, reset controls after test
Note:
Test of the over speed device and remote shutdown controls, shall only be performed with engine and
Generator off line
Verify the engines temperature gauge readings with infrared device.

Ensure that electrical cables connected to batteries and starter motor are protected from short circuit
Op Seq Num 90 Department Mechanic
Long Description Enclosures, guards and bases
The guards must be in the proper place. Repair damaged guards or replace missing guards.
Inspect the wiring and the wiring harnesses for loose connections and for worn or frayed wires.
Inspect the ground strap for a good connection and for good condition
Op Seq Num 100 Department Mechanic
Long Description Test run the engine and checks the following default settings values :

Lube oil pressure Min. 45 psi Max. 70 psi (310-480 kPa)

Lube oil temperature Min. 60 degC Max. 110 degC
Cooling fluid temperature Min. 77 degC Max. 95 degC
Op Seq Num 110 Department Mechanic
Long Description Clean the fuel coolers weekly (if equipped on the engine)

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 EDC Work Instruction Report

Asset Activity CDE.WEK.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / WEEKLY

Last Update Date 07-08-2023

Op Seq Num 120 Department Mechanic

Long Description Procedure for Cleaning Oil Contaminated Cooling System
1. Drain the cooling system.

2. Fill the cooling system with acceptable quality water.

Note:
Refer to the "Caterpillar Minimum Acceptable Water Quality Requirements" in this Special Publication.

3. Start the engine and run the engine until the thermostat opens.

4. Add 0.473 L (0.5 qt) of269-1948 non-foaming detergent.

If the cooling system capacity exceeds 113.6 L (30 US gal),
Add enough detergent to equal approximately 2-3% cooling system
Capacity:
Note:
Pre-dissolve the detergent in approximately 19 L (5 US gallons) of acceptable quality water. Add this mixture directly to the cooling system and top off the cooling
system with water.

5. Run the engine for at least 30 minutes. Drain the Cooling system.

6. Remove a small sample of the detergent solution from the cooling system. Allow the solution to sit for at least 30 minutes and check for signs of a visible oil layer on
top. If oil is still present, repeat the procedure.

Note:
Corrosion of the metal can occur if the detergent solution is in the cooling system for longer than one hour.

7. Flush the cooling system, if there is no visible oil layer in the solution. Fill the cooling system with acceptable quality water. Run the engine for 20 minutes and then
drain the water.

8. Perform the cleaning procedure found in this Special Publication for "Cat Cooling System
Cleaner - Quick flush", if additional removal of scale, rust, and inhibitor deposits from the previous coolant is needed.

9. If additional cleaning is not needed, refill the cooling

System with new coolant.
Op Seq Num 130 Department Mechanic
Long Description Procedure for using Cat Cooling System Cleaner - Quick Flush

Table 7
Cat Cooling System Cleaner for use with Quick Flush Method

Cleaner part number Size of Container

4C-4609 0.5 L (0.125 US gal)
4C-4610 1 L (0.25 US gal)

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 EDC Work Instruction Report

Asset Activity CDE.WEK.1.00000 Description DIESEL ENGINE / CATERPILLAR / 3400 SERIES / WEEKLY

Last Update Date 07-08-2023

Op Seq Num 130 Department Mechanic

Long Description 4C-4611 3.8 L (1 US gal)
4C-4612 19 L (5 US gal)
4C-4613 208 L (55 US gal)

1-Drain the cooling system

2-Refill the cooling system to 90-94% capacity with acceptable quality water

Note
Refer to the "Caterpillar Minimum Acceptable Water Quality Requirements" as found in this Special publication.

3-Top off the cooling system with Cat Cooling System Cleaner - Quick Flush cleaner so that
The solution is 6-10% cleaner

4-Run the engine for 1.5 hours

5. After allowing adequate time for the system to cool, drain the cooling system. Note:
Corrosion of the metals can occur if the Quick Flush cleaning solution is in the cooling system for longer than 2 hours.

6. Flush the cooling system.

a-Fill the cooling system with acceptable quality water.
b. Run the engine for 20 minutes.
c. Drain the water.

7. Refill the cooling system with new coolant

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 EDC Work Instruction Report

Asset Activity MDE.HRS.20000.00000 Description DIESEL ENGINE / CATERPILLAR / 20000 HRS

Last Update Date 10-09-2020

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 8000 hours maintenance.
Arrange with EDC Roving Team ad Rig Superintendent to perform a top overhaul.
Op Seq Num 20 Department Mechanic
Long Description Top end overhaul
May very well be extended up to, or past 16000 running hours, provided that the following vital conditions are observed. of the engine

That the oil samples analysis still indicates normal wear pattern
No significant overpressure in crankcase originating from piston blow-by and/or excessive valve guide wears.
Lube oil consumption is normal.
Exhaust temperatures are normal.
That the exhaust fumes appear to be normal (not injector wear signs)
Op Seq Num 30 Department Mechanic
Long Description Top Overhaul
Complete overhaul of the cylinder heads and intake and exhaust valves
Parts to be renewed if wear limits have been reached. See Caterpillar's service manual.
Valve lash is measured between the rocker arm and the bridge for the valves
The camshaft must be correctly timed with the crankshaft before an adjustment of the fuel timing is made. Visual check of pistons and cylinder liners.
If deemed necessary, pistons are to be pulled for extended examination, in addition check the piston-cooling tubes for correct alignment and position. Overhaul Jacket
Water Cooling Pump.
Dismantle the Oil Pump for inspection of abnormal wear or damage, replace parts as necessary.
Op Seq Num 40 Department Mechanic
Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity MDE.HRS.40000.00000 Description DIESEL ENGINE / CATERPILLAR / 40000 HRS

Last Update Date 10-09-2020

Op Seq Num 10 Department Mechanic

Long Description Issue work permit and record its number at comment.
Carry out 8000 hours maintenance.
Arrange with EDC Roving Team ad Rig Superintendent to perform a major overhaul.
Op Seq Num 20 Department Mechanic
Long Description IInterval between Major Overhauls is normally set to 30.000 running hours; it can be higher, all depending on the engine performance. Following vital conditions should
be observed:
That the oil samples analysis still indicates normal wear pattern.
No significant overpressure in crankcase originating from piston blow-by and/or excessive valve guide wears.
Lube oil consumption is normal.
Exhaust temperatures are normal.
That the exhaust fumes appear to be normal (not injector wear signs)
Op Seq Num 30 Department Mechanic
Long Description Major Overhaul should comprise the following basic elements :
-Complete overhaul of the cylinder heads.
-Renewal of all fuel injectors/pumps, return the used ones for reconditioning.
-Renewal of pistons, piston rings, pins, bearings, cylinder liners and connecting rod bearings.
-Renewal off all main bearings, thruster plates and seals.
-Check of the camshaft bearings.
-Overhaul of the fuel transfer pump.
-Overhaul of the Turbo Chargers.
-Overhaul of the Lube Oil Pump, Cooling Water Pump and Shutoffs system.
-Check the Actuator Drive Gear Assembly, Linkages and ball Joints for wear.
Note : Replace the Actuator with a new or reconditioned tested one.
-Ensure thoroughly cleaning of all parts before assembly and filling of new oil.
-Ensure correct alignment of engine and generator.
Op Seq Num 40 Department Mechanic
Long Description "Make sure before sending Engines to Cairo W/S for overhaul that it is:
* in clean condition from dust and grease.
* drained from all oils."
Op Seq Num 50 Department Mechanic
Long Description On completion of the maintenance, fill in the work order Report and send it to EDC Cairo Office.

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 EDC Work Instruction Report

Asset Activity MSA.HRS.250.00004 Description LUBRICATION / OIL SAMPLE / ENGINE / 250 HRS

Last Update Date 03-09-2018

Op Seq Num 10 Department Mechanic

Long Description Take oil sample.

Op Seq Num 20 Department Mechanic

Long Description Oil Sampling Steps:
1. Use protective gear such as gloves and goggles.
2. Use a new sample bottle; remove the cap and screw into the pump body.
3. Using a new length of hose for each sample.
4. Push the tube through the top of the pump until it appears half way down the sample bottle.
5. Make sure to tighten the thumbscrew to secure the tube.
6. Place the end of the tube into the sampling point. (Filling gap, Dipsticks or Pre-defined sampling point)
7. A sample should be drawn from 5-10 cm above the lowest part of gearbox/tank.
8. Ensure that the sample bottle is vertical throughout the sampling operation and that it is not overfilled.
9. Push and pull the oil pump plunger in the bottle by a few pump strokes to start the suction.
10. Fill the bottle by oil then loosen bottle from pump to stop oil flow.
11. Immediately tighten the bottle cap to avoid any contamination.
Op Seq Num 30 Department Mechanic
Long Description Oil Sampling Behavior
1. Always sample well-mixed oil after running at least 15 minutes.
2. Always sample oil at normal operating temperatures.
3. Do not allow external dirt to enter sample before or after sampling.
4. When taking oil samples do not take samples from used oil filters.
5. Do not take the oil sample from the drain.
6. Drain stream or a waste oil container.
7. Always use a new hose for each sample to avoid cross contamination.
8. Ensuring that the pump hose does not touch the bottom of the reservoir.
9. Do not overfill sample bottles.
10. Discard the hose correctly on completion of sampling. Do not re use.
11. To avoid contaminating the pump do not operate it on its side,
12. Be sure that the oil is completely drained form the pump hose.
13. Make sure the pump is clean after each sample is taken.
Op Seq Num 40 Department Mechanic
Long Description Full complete the sample table.

Op Seq Num 50 Department Mechanic

Long Description Send the oil sample bottle to the lubrication team Cairo office.

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 EDC Work Instruction Report

Asset Activity MSL.HRS.500.00004 Description LUBRICATION / OIL CHANGE / ENGINE / 500 HRS

Last Update Date 03-09-2018

Op Seq Num 10 Department Mechanic

Long Description Change oil as per OEM recommendation.

Op Seq Num 20 Department Mechanic

Long Description Oil changing procedure:

1. Use protective gear such as gloves and goggles.

2. If the equipment is cold, start it and let it run for five minutes to warm the oil. If it?s hot, wait at least 30 minutes to avoid getting burned.
3. To remove the drain plug, which is underneath the gearbox, use only correct properly fitting tool for the plug so that you do not damage the plug. The plug may be
the same size as the filler plug.
4. Clean the area before you remove the plug, so that grit does not fall through the hole. Many plugs unscrew with an Allen key.
5. Put a container under the drain hole - large enough to take all the oil. or use one of the special containers that can be sealed afterwards for carrying the oil for
disposal.
6. Loosen the filler plug to make sure it has not seized and that you will be able to refill. Have some rag handy to soak up any splashes.
7. Take out the drain plug.
8. When the oil flow has slowed to a drip, clean the drain hole and hook out any metal particles or other debris. Any significant amount of metal debris indicates trouble
inside the gearbox, and you should consult a garage.
9. If the drain plug has a washer, fit a new one. Replace the plug firmly, but do not overtighten it.
10. Fill to the correct level with the new oil and refit the filler plug. Use the oil specified by the equipment OEM.
Op Seq Num 30 Department Mechanic
Long Description Full complete the changing oil table.

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