Caterpillar Diesel Engine Sytems Basics

Engine Systems

DIESEL ENGINE ANALYST

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 C-15/C18/3400 C-9/C-11/C-13 (186 - 1044 kW) (227 - 492 kW)

3116/3126/C-7 (86 - 313 kW)

3500 Family (507 - 2500 kW)

3000 Series 400 Series (3.7 - 45 kW)

4000 Series (322 - 1886 kW)

800 Series (39 - 60 kW) 1100 Series (49 - 186 kW)

M43 (5400 16200 kW)

3200 Family (93 - 336kW) 3300 Family (63 - 300 kW)

This represents only a fraction of the engine offerings Caterpillar produces

M20 (1020 1710 kW)

M25 (1800 2700 kW)

M32 (2880 8000 kW)

3600 Family (1350 - 7200 kW)

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

2 (3.14 X B ) X Stroke X No. of Cyls. Displacement = 4

Horsepower  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

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

Engine Model Numbers  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

3000/3100 Series Features  Dry Sleeve/Parent Bore  Parent Bore – 3116/26, C7,3208  Dry Sleeve - 3054

3054

 One piece block assembly  Light weight with high horsepower to weight ratios

3126B

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

3003

3013

3024

3034

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 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

C7

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

3100

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

C11

• ADEM A4 Electronic Control Module • MEUI fuel system • Cross Flow heads • Turbocharged and Air to Air aftercooling

C13

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 Series Features using ACERT™ Technology    

   

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/turns to improve airflow Proven MEUI fuel system ADEM™A4 Controller Engine oil & filter changes increased to 500 hours under most operating conditions

Used on D10T, 773F, 775F

C32 Series Features using ACERT™ Technology  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 under most operating conditions

Used on 777F & D11T (fall 07)

3300/3400 C7- C32 Series - Service Strategy  Current Serviceability  Piece parts and subcomponents 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 3000 D3C III - D5C III -301.5 - 320B C6.6 D5N 953, 963 3100 D5M - D6M -322B - 345B C7 D6N 322, 325 3300 D6R - D7R -330B - 350 L C9 D6R 973 330D C11 725, 730 C13 345 3400 D8R - D10R 769 - 775 375 - 5080 C15 D8T 735,740 C18 D9T 771 385C C27 D10T 3500 D11R 777 - 797 5130 - 5230

WL 906 - 939C 924 - 938 924F - 962G 950, 962 966F - 980F 966 972 980G - 990 II 980H 988H 992G - 994D

Engine Build Locations Build Location Peterborough, England

3011

3013

Sagami, Japan

3044

3046

3064

3066

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

Lafayette, Indiana

3508

3512

3516

3520

3524

Keil, Germany

CM20

CM25

CM32

CM43 GCM34

3024

3034

3054

Engine Models 3056 C1.5

3304

3306

C13

C15

C2.2

C6.6

C-16

C18

C175-12 C175-16 C175-20 M20

M25

M32

All Gas engines Produced in Lafayette Indiana Electric Power Modules Packaged @ FG Wilson or Griffen Georgia

3606 M43

3608

3612

3616




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

Intake

Compression


Power

Exhaust


Reciprocation & Rotation

Oil Consumption and Blow-by



Internal Components

3126B/C7

Valve Train 1. 2. 3. 4. 5. 6. 7. 8.

Cam lobe Lifter Pushrods Rocker arms Bridge (intake) Valve spring Exhaust valve Intake valves

5

4 6

3

7 8 2 1

Pistons, Rings, & Liners     

Cylinder liner O-ring seals Piston Piston rings Piston pin and retainer

C15 Piston Assembly

Piston is one piece design

Connecting Rod  A connecting rod connects the piston to the crankshaft

Cylinder Head & Cam Shaft  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

C15

Cat Compression Brake

Intake Valve Actuation is part of the Caterpillar compression brake.

Crankshaft Rod Bearing Journals

Front

Rear

Web Main Bearing Journals Counterweights There are 2 rotations of the crankshaft for each 4 stroke cycle!

Cylinder Block  The cylinder block is the central component of any engine  It houses the components that make up the “Serious Nucleus” of the engine



Turbocharger    

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

Waste Gate 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

Boost

Small turbo, No wastegate

Wastegate Actuator  Spins up quicker for good engine response  Regulates turbo speed & prevents over-speeding

Small turbo, with wastegate Large turbo No wastegate

Engine Load

Aftercooling

 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)

Causes of Premature Wearout & Failure of Aftercoolers  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

Water Pump  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

Oil Cooler  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

Engine components

Air compressor



Importance of Cooling System 40-60% Of All Engine Downtime Is Associated With Cooling 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 Pump 2 Oil Cooler 3 Passages through block and head 4 Temp. Regulator & Regulator Housing 5 Radiator 6 Pressure Cap 7 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



Importance Lubrication System 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 2 3 4 5 6

Oil Pump Relief Valve Oil Cooler Oil Filter Bypass Valves Oil Level Gauge (Dipstick) 7 Oil Pressure Gauge 8 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

Methods to control soot levels in engine oil:  

 

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)

Soot particles agglomerating together

Barrier Filter

Centrifugal Filter


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

Types of Fuel Systems  Pump & Line    

Current Scroll Fuel System New Scroll Fuel System Sleeve Metering Fuel System (SMFS) Program Electronic Engine Controls (PEEC)

1973 CSFS

Pre 1970 1970

1981 MUI

1975

1983 NSFS

1980

1988E UI

1985

1990

 Unit Injection     1994 HEUI

1995

MUI EUI HEUI Common Rail (Single Fuel)

2000

2005

Timeline 1974 SMFS

1987 PEEC

2004 Rail

Fuel Delivery - History  

Pre-Combustion (PC) Direct Injection (DI) Fuel Line

Fuel Line Fuel Injector

Electrical Wire

Fuel Injector

Glow Plug Pre-Combustion

Fuel Injector Housing

Nozzle Assembly

Piston

Piston

Heat Plug

Pre-Combustion

Mechanically Controlled Unit Injector

Direct Injection Pencil Style

Direct Injection Unit Injector

Sleeve Metering Fuel System

Barrel Fill Port

Plunger

Sleeve Spill Port

Filling

Begin Injection

Continue Injection

End Injection

Scroll Metering Fuel System  Pump & line governor  Few moving parts  Simple mechanical governor  Easy starting & service  More tolerant of dirt  Economical

MUI System 





A unit injector is positioned above each cylinder A mechanically actuated governor controls fuel rate (scroll metered) with flyweights and springs Timing is fixed

EUI 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 - 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

HEUI System  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

Cat Fuel System – Single Fuel

Fuel Manifold

Pump

C6.6

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 Inlet air from air cleaners

Boost air at 300 º- 400º Inlet air from air cleaners

Exhaust out Air manifold From exhaust ports at cylinder heads



Provide adequate quantities of clean filtered intake air 



Removes exhaust gases from the cylinders and reduces exhaust noise

Compresses the intake air into the cylinders in order to product more power

Air System

Air System Components  Precleaner  Air Filters  Filter Service Indicator  Turbochargers  Aftercooler  Intake & Exhaust Manifolds  Muffler

Air System Operation 

Flow 1. 2. 3. 4.

Precleaner Air Filters Turbocharger Intake Manifold & Cylinder Head(s) 5. Combustion Chamber 6. 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 Electronics Features Electronic Engine Control Engine Speed Governing Torque Shaping Fuel-air Ratio Control Cold Mode Strategies Altitude Derating Fuel Temperature Compensation

Information Management Accurate Tracking Stored Results

Engine Monitoring Fluid Level Fluid Pressure Fluid Temperature

Benefits Improved Emissions Increased Performance & Reliability Improved Diagnostics Meet customer needs for New Features / Advanced Technology

ADEM 4 Electronic Engine Control

Generations of Experience

1987 8-bit PEEC II

1991

1993

Advanced 8-bit PEEC III

Two 8-bit ADEM II

1998 32-bit ADEM III

2004 32-bit ADEM 4

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




Engine Parts Quality        

Total System Design "Same as Caterpillar" Motives Parts Availability Design Modifications Quality Reusability Repair Solutions  New, Reman, Classic, Kits

Cylinder Heads

Competition

Caterpillar

 Cut corners to lower costs  Don't meet Cat specs

 Rigid tolerances  Design updates

Cylinder Heads

Competition  Oversized, unthreaded, missing water holes

Caterpillar  Properly machined

Cylinder Heads

Competition

Caterpillar

 Blocked passages

 Rigid cleaning process

Cylinder Heads Features     

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

Valves

Competition

Caterpillar

 Turning marks

 Precisely ground

Exhaust Valves

Competition

Caterpillar

 Inadequate facing material

 More facing material than industry standard

Valves, Solution – Advantage

Features

• Precisely ground • High strength material • More facing material than industry standard

Advantages

Estimate Repairs

• 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 Discussion • Less downtime so ultimately lower cost

Cylinder Liners Competition    

Not roll burnished Flange thickness out of spec O-Ring grooves not chamfered Increased chance of cracking

Caterpillar    

Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated

Cylinder Liners

Competition

Caterpillar

 Random cross hatch pattern

 Uniform cross hatch pattern

Cylinder Liners

Competition

Caterpillar

 Not machined to hone off “saw-tooth” peaks

 Pre-honed to preserve life and disperse oil better

Features       

Cylinder Liners

Uniform cross hatch pattern Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated High-grade gray iron Perfect fit

Cylinder Liners 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

Piston Rings

Competition

Caterpillar

 Flat-faced top ring

 Barrel-faced top ring

Piston Rings

Competition

Caterpillar

 Thin chrome or plasma plating

 Correct chrome or plasma plating

Piston Rings

Features Barrel-faced top ring Correct chrome or plasma plating High-strength ductile iron Heat treated

Advantages  Reduced oil consumption  Increased cylinder liner / ring life  Less susceptible to breakage  Less downtime  Lower operating costs

Nickel Ring Band Pistons

C7 Piston

Competition

Caterpillar

 Ring bands disbonded  Grooves do not meet flatness, size, or location specifications

 Controlled casting process  Ultrasonic inspection  Improved reusability

Features • • • •

Pistons

Nickel-band ring Specially ground, tapered Controlled casting process Precise fit

Advantages • • • • • • •

Better sealing Proper bonding Less blow-by Less carbon deposit Delivers more power Longer wear Reusable

C7 Piston • Lowered chance of seizure • Less downtime caused by part failure • Lower operating costs

One Piece Steel Piston Used on 3408, 3412, 3500 & all ACERT engines • Increased structural capability • Machined from a single steel forging • •

• • •

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 • •

• •

Eliminates need for a separate aluminum skirt & possible breakage Eliminates possible debond of ring groove

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

Fractured Split Rod Technology Models 3114, 3116, 3126, C7, C9, C11 and C13 Features    

213-3193 C7

Forged for high strength Rod able to accept higher loads Eliminates fretting on joint face Eliminates locating dowel

C11 – 223-9133 C13 – 223-9150

160-8199 C9

IRM – PELJ0174

Crankshafts



Caterpillar  Proprietary hardening process-tough core  Excellent reusability  Polished surface finish to <5 microns  Precise journal grinding



Competition    

Not Reusable Rough surface finish Oversized journals Increased bearing friction

Integral Seals

Edge Bonded (Metal Carrier)

Void-Volume (Plastic Carrier)

Benefits • Virtually eliminates gasket leaks. • Improved bolt torque retention vs. flat gaskets • Ease of assembly vs. flat gasket • Availability in gasket & seal kits

Unitized Design Crankshaft Seal Old Style

For 3400 Series & C15 Engines Clamped PTFE New Style Elements PTFE Oil Lip

Radial PTFE Dirt Lip

Flanged Wear Sleeve

Wear Sleeve Flange

Hydro-threads

    

Wear Sleeve

Reduced potential for leakage Easier installation Reduced installation damage Minimized contamination Increased reliability

Axial Dirt Lip

Bonded Elastomeric Substrate

PTFE Oil Lip

Hydro-threads

 Significantly longer seal life  Up to 2X improvement in on-highway truck  Up to 3X improvement in earth-moving

Valve Covers

Composite

Less noise

Aluminum  Two piece composite/aluminum  Fully isolated  Reduces noise up to 1dBA

 Used on all ACERT engines  C7 thru C32

Cylinder Head Gaskets Steel spacer core sandwiched between two layers of spring steel

Improved sealing head/block

 Multi layered steel  Improved durability  Sealing  Crush strength  Creep resistance  Joint stability  Used on all ACERT

Heavy Duty Water Temperature Regulators For Various Engine Applications

New Lip Seal

Piston

Guide

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 RepairRebuildRemanufacture

Repair  Usually simple  Fixes only a specific problem  May not use genuine CAT parts depending on labor source.

Rebuild  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

Remanufacture  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

Reman Is An Exchange Business Reman Sale $40 Core Deposit $60 Price of New $100

$60 Core Deposit Returned

Customer returns core

Dealer sells Reman water pump = $100

No Core = No Reman Product

Cat Product Support Strategy – Reman’s Role New Cat Parts

Cat Product Support Strategy

Do It Myself Work With Me Do It For Me

Reman Parts

OPTIONS

(One Voice) •

Dealer Exchange Classic Parts Used Parts

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)

Reman Engine Product Coverage     

Short and Long Blocks

     

Crankshafts

      

Water pumps

 

Cylinder Packs



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 Cylinder Heads Turbochargers Water Pumps Oil Pumps Starters Alternators Camshafts Oil Coolers Air Compressors Rocker Arms Kits Lifters Rocker Arms Pistons Packs

Complete Engines

Connecting Rods

Fuel Injection

Caterpillar Diesel Engine Sytems Basics

Recommend Documents