Engine systems diesel engine analyst - full

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)


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


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


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


• 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 Replaces the 3300


• 8.8 liter (537 cu in)

• HEUI fuel system

• Cross Flow heads ( 4 valves per cylinder)


• 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


• MEUI fuel system


• Turbocharged and Air to Air aftercooling C13

C11

C15/C18 Series Features using ACERT™ Technology

C15 Replaces the 3406E, C-15


•Variable injection timing•Controls quantity of fuel•Optimizes fuel pressure •Transient control for both speeds and loads

• MEUI fuel system



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


Used on D10T, 773F, 775F


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




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


Exhaust Power


Reciprocation & Rotation

Oil Consumption and Blow-by


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


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


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


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


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


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


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




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



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

Education

Engine systems diesel engine analyst - full