DIESEL ENGINE ANALYST
Engine Systems
Introductions:
Name: Address: College: ITM, Perú Dealer Name: Ferreyros S.A.
Agenda Engine Families Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics
Parts Differentiation REMAN Resources
Engine Families
This represents only a fraction of the engine offerings Caterpillar produces
3116/3126/C-7(86 - 313 kW)
3200 Family(93 - 336kW)
3300 Family(63 - 300 kW)
C-9/C-11/C-13(227 - 492 kW)
C-15/C18/3400 (186 - 1044 kW)
3500 Family(507 - 2500 kW)
3600 Family(1350 - 7200 kW)
M20(1020 -1710 kW)
M25(1800 -2700 kW)
M32(2880 -8000 kW)
M43 (5400 -16200 kW)
800 Series(39 - 60 kW)
1100 Series(49 - 186 kW)
400 Series(3.7 - 45 kW)
4000 Series(322 - 1886 kW)
3000 Series
Common Engine Terms
Bore Stroke Compression Ratio Displacement Horsepower
Bore Size
The diameter of the cylinder
Measured in inches or millimeters
Stroke
How far the piston moves from TDC to BDC
Equal to twice the crank radius
Compression Ratio
Ratio between the cylinder volume with the piston at BDC and the volume with the piston at TDC
Compression ratio of our engines are approximately a 16:1 (non-ACERT) and 18:1 (ACERT)
Displacement
Engine size is expressed in liters or cubic inches
Displacement = X Stroke X No. of Cyls. (3.14 X B 2 )
4
Horsepower is the rate of doing work (how quickly a force is applied through a distance)
Horsepower can be expressed in pound feet per second
1 horsepower = 550 lb/ft per second
= 33,000 lb/ft per minute
Horsepower
Engine Model Numbers
3208 Engine: 3200 = Engine Family & Relative Size
(3000, 3200, 3300, 3400, 3500, 3600)
08 = number of Cylinders
Depending on engine family, could
be 04, 06, 08, 12, 16, 18, or 24
3116 Engine 3100 = Engine Family
11 = 1.1 liters per cylinder, so:
3126 has 1.2 liters per cylinder
3176 has 1.7 liters per cylinder
6 = number of cylinders (4 or 6)
Engine Model Numbers
C-10, 10 liter truck engine 3176C is used in all other applications
C-12, 12 liter truck engine 3196C is used in all other applications
C7 replaced the 3126 engine C-9 replaced the 3306 engine
On-Highway & D6
Engine Model Numbers
3406 Engine
3406E was a 14.6 liter engine until 1998 In 1998, 3406E was 14.6 or 15.8 liter for truck 3456 was the 15.8 liter in any non-truck application In 2000, 14.6 liter and 15.8 liter became C-15 and
C-16 for truck, industrial applications In 2003, 15.2 liter truck is ACERT C15
Engine Model Numbers
3000/3100 Series Features
Dry Sleeve/Parent Bore Parent Bore – 3116/26, C7,3208 Dry Sleeve - 3054
One piece block assembly
Light weight with high horsepower to weight ratios
3126B
3054
3000 Series - Service Strategy Current Serviceability
Components only - 3003, 3013, 3024, 3034 Piece Parts - 3046, 3054, 3056, 3066 Reman as volume/need dictates
Rebuild Strategy 3003 - 3034, expected engine life equals machine life 3046 - 3066, limited rebuild opportunity
3013 3024 3034 3003
C6.6 Series Features using ACERT™ Technology
C6.6 Replaces the 3056E
• 1.1 Liter per Cylinder, Inline 6
• 4 valves per cylinder
• Cross Flow heads
• Fully Electronically Controlled
• Common Rail Fuel system
• Sculpted Block design reduced noise C6.6
Cross Flow Cylinder Heads
Cross flow design and refined port geometry
Improved breathing
Reduced pumping loss
Better combustion
C7 Series Features using ACERT™ Technology
C7
C7 Replaces the 3116, 3126
• ADEM A4 Electronic Control Module
• Cylinder block – increased tensile strength
• HEUI fuel system
• Cross Flow heads
• Turbocharged and Air to Air aftercooling
3100
3100 & C7 Series - Service Strategy
Current Serviceability Piece Parts For All
Rebuild Strategy Cost effective rebuild for all
models Reman components and
limited short blocks, bare blocks, and piston packs available
3300/3400 Series Features
One piece block One piece cylinder head Replaceable valve guides and seats Caterpillar fuel system Replaceable wet cylinder liners Roller cam followers and steel camshaft Totally hardened forged steel crankshaft
3400 HEUI
C9 Series Features using ACERT™ Technology
C9 Replaces the 3300
• ADEM A4 Electronic Control Module
• 8.8 liter (537 cu in)
• HEUI fuel system
• Cross Flow heads ( 4 valves per cylinder)
• Turbocharged and Air to Air aftercooling
• Improved block and head material strength
• Mid-supported liner
• Integral oil cooler • Reduced weight, leaks and engine width
C9
C11/C13 Series Features using ACERT™ Technology
C11 Replaces the 3176, C-10
C13 Replaces the 3196, C-12
• ADEM A4 Electronic Control Module
• MEUI fuel system
• Cross Flow heads
• Turbocharged and Air to Air aftercooling C13
C11
C15/C18 Series Features using ACERT™ Technology
C15 Replaces the 3406E, C-15
• ADEM A4 Electronic Control Module
•Variable injection timing•Controls quantity of fuel•Optimizes fuel pressure •Transient control for both speeds and loads
• MEUI fuel system
• Cross Flow heads
• Turbocharged and Air to Air aftercooling
C15
C27 replaces 3412 Two single overhead cams Gear-train for cams moved to back
Reduces noise & vibration Tight system tolerances - pistons & liners
More complete fuel combustion Reduced blow-by Fewer emissions
New block eliminates bends/turnsto improve airflow
Proven MEUI fuel system ADEM™A4 Controller Engine oil & filter changes
increased to 500 hours undermost operating conditions
C27 Series Features using ACERT™ Technology
Used on D10T, 773F, 775F
C32 Series Features using ACERT™ Technology
Used on 777F & D11T (fall 07)
C32 replaces 3508B Newly designed block adds
structural strength Cross flow cylinder head delivers
improved air flow Increased compression ratio
of 16.5:1 Proven MEUI fuel system ADEM™A4 Controller Engine oil & filter changes
increased to 500 hours undermost operating conditions
3300/3400 C7- C32 Series - Service Strategy
Current Serviceability Piece parts and sub-
components for all models.
Rebuild Strategy Cost effective rebuild for all
models Reman components, short
blocks, long blocks and engines available 3406
3500 Series Features One piece high strength cast engine block
Individual cylinder heads
Four valves per cylinder.
Self aligning roller cam followers.
Oil cooled pistons
Unit injectors at 20,000 psi
Caterpillar fuel system 3500B
3500 Series - Service Strategy
Current Serviceability Piece parts for all
Rebuild Strategy Cost effective rebuild for all models Reman components, short blocks,
long blocks and engines available
3500 Machine
Engine/Machine Usage Chart Series TTT TTL OHT HEX WL3000 D3C III - D5C III -- 301.5 - 320B 906 - 939CC6.6 D5N 953, 963 924 - 9383100 D5M - D6M -- 322B - 345B 924F - 962GC7 D6N 322, 325 950, 962
3300 D6R - D7R -- 330B - 350 L 966F - 980FC9 D6R 973 330DC11 725, 730 966C13 345 9723400 D8R - D10R 769 - 775 375 - 5080 980G - 990 IIC15 D8T 735,740 980HC18 D9T 771 385C 988HC27 D10T3500 D11R 777 - 797 5130 - 5230 992G - 994D
Engine Build Locations Build Location
Peterborough, England 3011 3013 3024 3034 3054 3056 C1.5 C2.2 C6.6
Sagami, Japan 3044 3046 3064 3066 3304 3306
Gosselies, Belgium 3116 3126 C7 C9
Greenville, South Carolina 3126 C7 C9
Griffen, Georgia 3408 3412 C27 C30 C32
Mossville, Illinois 3406 3456 C-10 C11 C-12 C13 C15 C-16 C18
Lafayette, Indiana 3508 3512 3516 3520 3524 C175-12 C175-16 C175-20 3606 3608 3612 3616
Keil, Germany CM20 CM25 CM32 CM43 GCM34 M20 M25 M32 M43
Engine Models
All Gas engines Produced in Lafayette Indiana
Electric Power Modules Packaged @ FG Wilson or Griffen Georgia
Agenda Engine Families Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics
Parts Differentiation REMAN Resources
Engine Wear
Definition of Wear Contact Pressure Relative Motion
Normal & Abnormal wear Major wear items
Cylinder liners Seals & gaskets Piston rings Turbo bearings and seals Valves, guides, and seats Main and rod bearings
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
The Combustion Process – 4 Stroke Cycle
Compression Intake
The Combustion Process – 4 Stroke Cycle
Exhaust Power
The Combustion Process – 4 Stroke Cycle
Reciprocation & Rotation
Oil Consumption and Blow-by
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Internal Components
Valve Train
1. Cam lobe
2. Lifter
3. Pushrods
4. Rocker arms
5. Bridge (intake)
6. Valve spring
7. Exhaust valve
8. Intake valves
1
8
7
6
54
3
2
3126B/C7
Cylinder liner O-ring seals Piston Piston rings Piston pin and
retainer
Pistons, Rings, & Liners
Piston is one piece design
C15 Piston Assembly
Connecting Rod
A connecting rod connects the piston to the crankshaft
A cylinder head is installed on top of the block
The camshaft turns at ½ the speed of the crankshaft to control intake & exhaust operation
Cylinder Head & Cam Shaft
C15
Cat Compression Brake
Intake ValveActuation is part of the Caterpillar compression brake.
Crankshaft
Front Rear
Counterweights
Main Bearing Journals
Rod Bearing Journals
Web
There are 2 rotations of the crankshaft for each 4 stroke cycle!
The cylinder block is the central component of any engine
It houses the components that make up the “Serious Nucleus” of the engine
Cylinder Block
Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
An exhaust driven air compressor Impeller on the left Turbine on the right Connecting shaft, free floating bearings, oil lubricated center housing
Causes of Premature Wear or Failure Poor oil quality Dirt ingestion Hot engine shut down
Turbocharger
• The wastegate is opened by the high pressure boost in the compressor side of the turbo.
• Some of the exhaust gas then bypasses the turbine and escapes or ‘wastes’ to the exhaust stack.
Wastegate Actuator
Wastegate
Large turboNo wastegate
Small turbo, with wastegate
Engine Load
Bo
os
t
Small turbo, No wastegate
Waste Gate Turbocharger
Spins up quicker for good engine response Regulates turbo speed & prevents over-speeding
Heat exchanger for inlet air
Series of metal tubes through which hot inlet air flows
Heat from the air flowing from the tubes is absorbed through the tube walls and carried away
2 types Air to air (ATAAC) Jacket water (JWAC)
Aftercooling
Most common cause -- failure of the turbocharger compressor wheel
Damages aftercooler tubes Coolant leakage into inlet air stream
Poor coolant maintenance may cause pitting/corrosion of the aftercooler tubes
Results in water to air leakage Hydraulic lock on the engine
Causes of Premature Wearout & Failure of Aftercoolers
Flow of the coolant begins at the water pump
Pump impeller creates the flow
Water pumps are gear or belt driven
Water pump seals
Separates engine oil from coolant
Water Pump
Engine coolant flows from the water pump directly into the oil cooler
Oil carries heat away from critical engine parts
Heat is transferred from the oil to the engine coolant
Oil Cooler
Coolant flows through copper tubes in the oil cooler housing
Oil flows around the outside of the tubes
Scale build-up caused by improper cooling system maintenance can be cleaned out of tubes
Oil Cooler
Engine components
Air compressor
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Importance of Cooling System
40-60% Of All Engine Downtime Is Associated With 40-60% Of All Engine Downtime Is Associated With Cooling System ProblemsCooling System Problems
Important Customer Reminders:
Use proper start up procedures
Clean debris from the radiator and fan
Check radiator cap seal
Inspect the water pump for leaks
Select the right coolant
Function of Cooling System Maintain proper engine temperature
for optimum performance Dissipates excess heat from other
machine systems: Engine Transmission Hydraulic
Cools compressed inlet air to optimize combustion
Cooling System Components
1 Water Pump2 Oil Cooler3 Passages through
block and head4 Temp. Regulator &
Regulator Housing5 Radiator6 Pressure Cap7 Hoses & Pipes
Causes of Cooling System Wear & Failure Single most common problem – poor coolant quality
Due to… Not maintaining adequate levels of coolant additives Using coolant that does not meet Cat’s specifications Not keeping the cooling system topped off Using coolant past its useful life
Other problems include: Coolant to air leaks in the aftercooler
Causes hydraulic lock Radiator or hose failures
From reusing old radiators and hosing Failure to service the coolant relief valve
… most cooling system problems can be avoided with proper maintenance practices!
Cooling Systems
Coolant flows around cylinder liners
Absorbs heat from the combustion chamber
Prevents breakdown of oil film between pistons and liners
Cooling Systems
Coolant flows through passages in the cylinder block into the cylinder head
Water seals between the head and block prevent coolant leaks
Some engines have water ferrules to direct coolant to critical areas
Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Importance Lubrication System
70-80% crank failures are due to oil contamination. 70-80% crank failures are due to oil contamination.
Function of Lubrication System
Cleans Parts Cylinder Walls
Cools Seals & Lubricates
Support Separate
Lubrication System Components
1 Oil Pump2 Relief Valve3 Oil Cooler4 Oil Filter5 Bypass Valves6 Oil Level Gauge
(Dipstick)7 Oil Pressure Gauge8 Oil Pan
Engine Lube System
Causes of Lube System Wear & Failure Single largest problem is short engine life due to
excessive soot in the oil Poor quality/low performance engine oil Extended oil change intervals Poor maintenance practices Fuel dilution Wear (Lube System Caused)
Seals/Bearings Turbo Crank - Main/Rod Valve, Guide
High quality engine oils contain effective soot dispersant additives
High performance, full flow, lube filter options Standard, Advanced, & Ultra High
Bypass filtration devices: centrifugal or barrier filters
Oil renewal systems (for large mining machines)
Methods to control soot levels in engine oil:
Soot particles agglomerating together
Barrier Filter
Centrifugal Filter
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Single Fuel System
Function of Fuel System
Meters the amount of fuel to achieve desired power
Regulates engine speed and timing sequence
Helps control emissions
Fuel System Operation
Pump & Line Current Scroll Fuel System New Scroll Fuel System Sleeve Metering Fuel System (SMFS) Program Electronic Engine Controls (PEEC)
Timeline
1988EUI
1974 SMFS
1975 1980 1985 1990 1995 2000 2005Pre 1970 1970
1994HEUI
1987PEEC
1981MUI
2004 Rail
Types of Fuel Systems Unit Injection
MUI EUI HEUI Common
Rail(Single Fuel)1983
NSFS1973CSFS
Fuel Delivery - History Pre-Combustion (PC) Direct Injection (DI)
Pre-Combustion Direct Injection Pencil Style
Direct Injection Unit Injector
Fuel Line
Fuel Injector
Glow Plug
Heat Plug Piston
Electrical Wire
Fuel Injector Housing
Pre-Combustion
Fuel Line
Fuel Injector
Piston
Nozzle Assembly
Mechanically Controlled Unit Injector
Filling Begin Injection
Continue Injection
End Injection
Barrel
Plunger
Sleeve
Fill Port
Spill Port
Sleeve Metering Fuel System
Scroll Metering Fuel System
Pump & line governor Few moving parts Simple mechanical governor Easy starting & service More tolerant of dirt Economical
A unit injector is positioned above each cylinder
A mechanically actuated governor controls fuel rate (scroll metered) with flyweights and springs
Timing is fixed
MUI System
A unit injector is positioned above each cylinder
An Electronic Control Module (ECM) controls fuel rate and timing
Injectors are mechanically actuated by a camshaft
EUI System
EUI - Injector Fill
Without pressure from the rocker arm, a spring keeps the plunger retracted
Fuel flows into the injector through the fill / spill port, past the solenoid valve and into the barrel
EUI - Injection On a signal from the
ECM, the solenoid closes the fuel valve
Pressure elevates at the tip to the 5,500 psi needed to unseat the valve
Injection begins
EUI - Injection Fuel continues to inject until the ECM signals the solenoid to open the valve
Injection timing and duration is controlled by the ECM
A unit injector is positioned above each cylinder
An Electronic Control Module (ECM) controls fuel rate, timing, and injection pressure
The injector is hydraulically actuated
HEUI System
Cat Fuel System – Single Fuel
C6.6
Fuel Manifold
Pump
Injector
Fuel System Wear & Failure Causes Short unit injector life due to excessive abrasive particles in
the fuel Abrasive particles damage sealing surfaces causing leakage of
high pressure fuel and low engine power Abrasive particles are inherent in most fuels Most particles can be removed by using High Efficiency filters
Injector seizure due to excess water in the fuel Always small amounts of water in fuel, which is harmless Excess water in fuel reduces the lubricating film strength of fuel
and causes seizure of the injector plunger and barrel Maximum amount of allowable water in fuel is 0.1%
Fuel System Wear & Failure Causes Injector sticking or seizure due to fuel overheating
Fuel in the injector “cooks” and produces varnish which causes components to stick or seize
Viscosity of hot fuel is inadequate and the fuel film thickness will not provide adequate protection against scuffing or seizure of the plunger and barrel
Fuel overheating can be caused by operating in extreme ambient temperatures. An auxiliary fuel cooler installed in the fuel supply line to the cylinder heads may be required to limit fuel temperatures
Running fuel tank too low, or running out of fuel causes the fuel to cycle through the engine too frequently and becomes very hot. This can be avoided by keeping the fuel tank levels at ¼ full or above
Fuel System Wear & Failure Causes Poor quality oil
Fuel may be low in viscosity or lubricity. Fuel which is old or oxidized often contains excessive gums or resins which promotes injector sticking or seizure.
Effect of Work Environment Dust Temperature/Climate Hours of continuous operation Terrain
System Improvement
Reduce system damage caused by fuel Water Separator Primary Fuel Filter Bypass Flow
Minimize tip failure caused by aeration Maintain fuel supply pressure
Stripping Out Water
Water Separator Second line of defense
All free water 87% emulsified water
Injector damage
Removing Larger Debris
Primary Fuel Filter 10+ micron particle retention
prevents premature secondary fuel filter plugging
protects fuel transfer pump
Remove Fine Abrasives
Secondary Fuel Filter 2 micron and larger
98% efficient Reduces wear on fuel injectors and pumps
Essential for higher pressure systems Extends life of older systems as well
Double Filter/Double Life
Series filtration Second filter “safety net”
Second filtering pass Filter failure
- Double injector wear life
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Air Intake & Exhaust System Functions
Compresses the intake air into the cylinders in order to product more power Removes exhaust gases from the
cylinders and reduces exhaust noise
Provide adequate quantities of clean filtered intake air
Inlet air from air cleaners
Exhaust out
Boost air at 300 º- 400º
Air manifold
Inlet air from air cleaners
From exhaust ports at cylinder heads
Air System
Precleaner Air Filters Filter Service
Indicator Turbochargers Aftercooler Intake & Exhaust
Manifolds Muffler
Air System Components
Air System Operation Flow
1. Precleaner2. Air Filters3. Turbocharger4. Intake Manifold &
Cylinder Head(s)5. Combustion
Chamber6. Exhaust Manifold
Wear Turbocharger
Bearings Seals
Air System Wear & Failure Causes
Single most common problem – dust ingestion Causes accelerated abrasive wear of piston rings & liners Most often caused by inlet leaks around flexible joints in
air inlet piping May also be caused by defective/damaged air filters, or
poor maintenance practices
Plugged air filters Turbo failures Coolant to air leaks in the aftercooler Hydraulic lock
Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Electronic Control Module (ECM) Caterpillar’s Electronic Control Module (ECM)
and sensors control and monitor key engine function, including:
Fuel temperature. Engine oil temperature. Oil pressure. Atmospheric pressure. Coolant temperature. Injection actuation pressure Throttle position Injection timing & duration Logged faults
Features & Benefits of ElectronicsFeaturesElectronic Engine Control
Engine Speed GoverningTorque ShapingFuel-air Ratio ControlCold Mode StrategiesAltitude DeratingFuel Temperature Compensation
Information ManagementAccurate TrackingStored Results
Engine MonitoringFluid LevelFluid PressureFluid Temperature
BenefitsImproved EmissionsIncreased Performance & Reliability Improved DiagnosticsMeet customer needs for New Features / Advanced Technology
ADEM 4 Electronic Engine Control
19878-bit
PEEC II
1991Advanced
8-bitPEEC III
1993Two 8-bitADEM II
1998 32-bitADEM III
2004 32-bit
ADEM 4
Generations of Experience
Proven Reliability
Electronic Control Module
What if an ECM Fails? Troubleshooting guides help identify a component
or harness problem “Limp home” modes Ability to flash files at repair site
ECM Replacement Options? No serviceable piece parts Some Reman offerings exist
Electronic Control Module
What if a Sensor or Wiring Harness Fails? Decision to repair or replace depends on the problem Sensors and harness segments are serviceable Replacing an entire harness is a last resort
PEHJ0145
Agenda Engine Families Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics
Parts Differentiation REMAN Resources
Total System Design "Same as Caterpillar" Motives Parts Availability Design Modifications Quality Reusability Repair Solutions
New, Reman, Classic, Kits
Engine Parts Quality
Cut corners to lower costs Don't meet Cat specs
Competition Rigid tolerances Design updates
Caterpillar
Cylinder Heads
Cylinder Heads
Oversized, unthreaded,missing water holes
Competition
Properly machined
Caterpillar
Blocked passages
Competition Rigid cleaning process
Caterpillar
Cylinder Heads
Cylinder HeadsFeatures Properly machined parts Rigid Cleaning Process Rigid Tolerances Design Updates Right design for the system
Advantages Optimal cooling Less likelihood of leaks developing and so less chance of
problems related to leaking and/or overheating More durable• Longer life• More reliable operation• Less downtime so ultimately lower cost
Turning marks
Competition
Precisely ground
Caterpillar
Valves
Inadequate facingmaterial
Competition More facing material
than industry standard
Caterpillar
Exhaust Valves
Features• Precisely ground• High strength material• More facing material than
industry standard
Advantages• Increased protection against valve lip cracking and stem
breakage• Increased strength that allows for reusability through 1 or 2
overhauls• Greater fatigue strength• Longer wear life• More durable• More reliable operation• Less downtime so ultimately lower cost
Estimate Repairs
DiscussionDiscussion
Valves, Solution – Advantage
Not roll burnished Flange thickness out of spec O-Ring grooves not chamfered Increased chance of cracking
Competition
Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated
Caterpillar
Cylinder Liners
Random cross hatch pattern
Competition Uniform cross hatch pattern
Caterpillar
Cylinder Liners
Competition Not machined to hone off
“saw-tooth” peaks
Caterpillar Pre-honed to preserve life
and disperse oil better
Cylinder Liners
Cylinder LinersFeatures Uniform cross hatch pattern Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated High-grade gray iron Perfect fit
Advantages Proper oil distribution Longer liner life Increased strength; reduced
susceptibility to cracking Leakage prevention Reusable at first overhaul Lower repair / maintenance
costs over time Higher productivity Less downtime
Cylinder Liners
Flat-faced top ring
Competition Barrel-faced top ring
Caterpillar
Piston Rings
Thin chrome orplasma plating
Competition Correct chrome or
plasma plating
Caterpillar
Piston Rings
Piston Rings
Advantages Reduced oil consumption Increased cylinder liner / ring
life Less susceptible to breakage Less downtime Lower operating costs
FeaturesBarrel-faced top ringCorrect chrome or plasma platingHigh-strength ductile ironHeat treated
Ring bands disbonded Grooves do not meet flatness,
size, or location specifications
Competition Controlled casting process Ultrasonic inspection Improved reusability
Caterpillar
C7 Piston
Nickel Ring Band Pistons
PistonsFeatures• Nickel-band ring• Specially ground, tapered• Controlled casting process• Precise fit
• Lowered chance of seizure • Less downtime caused by part
failure• Lower operating costs
Advantages• Better sealing • Proper bonding• Less blow-by • Less carbon deposit • Delivers more power• Longer wear• Reusable
C7 Piston
One Piece Steel Piston
• Increased structural capability• Machined from a single steel forging
• Eliminates need for a separate aluminum skirt & possible breakage
• Eliminates possible debond of ring groove• Reduced thermal expansion allows piston fit
to be tighter for a reduction in liner cavitation• Reduction in surface area provides less
friction and helps fuel consumption • Higher Oil Flow
• Bigger piston oil gallery & new oil jets• Runs cooler thus reducing piston carbon deposit
and oil consumption• New ring pack
• 25% reduction in blow-by • No bushings to replace in 3408 & 3412
Used on 3408, 3412, 3500 & all ACERT engines
Fractured Split Rod Technology
Features Forged for high strength Rod able to accept higher loads Eliminates fretting on joint face Eliminates locating dowel
C11 – 223-9133
C13 – 223-9150
Models 3114, 3116, 3126, C7, C9, C11 and C13
213-3193
C7
160-8199
C9 IRM – PELJ0174
Not Reusable Rough surface finish Oversized journals Increased bearing friction
Competition Caterpillar Proprietary hardening
process-tough core Excellent reusability Polished surface finish
to <5 microns Precise journal grinding
Crankshafts
Benefits• Virtually eliminates gasket leaks.
• Improved bolt torque retention vs. flat gaskets
• Ease of assembly vs. flat gasket
• Availability in gasket & seal kits
Void-Volume (Plastic Carrier) Edge Bonded (Metal Carrier)
Integral Seals
Unitized Design Crankshaft Seal
Reduced potential for leakage Easier installation Reduced installation damage Minimized contamination Increased reliability
For 3400 Series & C15 Engines
Radial PTFEDirt Lip
Clamped PTFEElements
Hydro-threads Wear Sleeve
PTFEOil Lip
Old Style
Wear Sleeve Flange PTFE Oil Lip
Hydro-threads
Flanged Wear Sleeve
Bonded Elastomeric
Substrate
Axial Dirt Lip
New Style
Significantly longer seal life Up to 2X improvement in on-highway truck Up to 3X improvement in earth-moving
Two piece composite/aluminum Fully isolated Reduces noise up to 1dBA
Composite
Aluminum
Less noise
Valve Covers
Used on all ACERT engines C7 thru C32
Multi layered steel Improved durability
Sealing Crush strength Creep resistance Joint stability
Used on all ACERT
Steel spacer core sandwiched between two layers of spring steel
Improved sealing head/block
Cylinder Head Gaskets
For Various Engine Applications Piston
New Lip Seal Guide
Heavy Duty Water
Temperature Regulators Features Advantages
Lip Seal at the top of the Guide
Prevents contamination from infiltrating into sensitive area
Regulator is not stuck in one position due to contamination or loss of grease within guide area
Help retain grease which is used to reduce friction in the guide area
247-7133 Open Temp
87-90 deg C
Engine does not run cold or hot due to a stuck regulator
248-5513 Open Temp
81-84 deg C Lower maintenance costs
Improved engine life
Agenda Engine Families Engine Works & Wears
Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics
Differentiation REMAN Resources
Cat Remanufactured Products
What is Remanufacturing?
Differences between RepairRebuildRemanufacture
Usually simple Fixes only a specific
problem May not use genuine CAT
parts depending on labor source.
Repair
Usually retains the component identity More than a simple repair Usually done by dealer, customer or
re-builder Restores to near original condition May not use genuine Cat parts Re-builder assumes the warranty
liability Requires investments in tools, equip.,
training, etc Rebuild and return or exchange –
turnaround time involved
Rebuild
Consistent factory environment Process and quality control Upgrades to latest engineering
changes Harvest components (looses its
original identity) Uses 100% genuine Cat parts Cat Reman carries standard parts
warranty Requires cores – exchange only
Remanufacture
Dealer sells Reman water pump = $100
Customer returns core
No Core = No Reman Product
$60 Core Deposit Returned
Reman Sale $40
Core Deposit $60
Price of New $100
Reman Is An Exchange Business
New Cat Parts
Reman Parts
Dealer Exchange
Classic Parts
Used Parts
Do It MyselfDo It Myself
Work With MeWork With Me
Do It For MeDo It For Me
OPTIONSOPTIONS
CatCatProduct SupportProduct Support
StrategyStrategy
(One Voice)(One Voice)
• Support Cat Dealer repair option & exchange programs• Lower repair costs
• Prime path for On-Highway Truck & lower volume dealers
• Peak shaving for dealers with component rebuild centers (CRC’s)
• Help Cat Dealers manage MARC & CSA contracts profitability
• Expand product coverage through accelerated NPI
• Expand global access to Reman products
• Help alleviate technician shortages (Technician-in-a-Box)
Cat Product Support Strategy – Reman’s Role
On-Highway Truck Engines Long Blocks Short Blocks Cylinder Heads Crankshafts Camshafts & Kits Cylinder Kits Fuel Nozzles & Injectors Fuel Injection Pumps Fuel Air Ratio Controls Turbochargers Water Pumps Oil Pumps Starters Alternators Oil Coolers Air Compressors Rocker Arms Kits Lifters Rocker Arms Pistons Packs
Crankshafts
Cylinder Heads
Complete Engines
Camshafts
Cylinder Packs
Water pumps
Connecting Rods
Short and Long Blocks
Fuel Injection
Reman Engine Product Coverage