Engine Systems

DIESEL ENGINE ANALYST

Introductions:
Name: Address: College: ITM, Per 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
3116/3126/C-7 (86 - 313 kW) C-15/C18/3400 C-9/C-11/C-13 (186 - 1044 kW) (227 - 492 kW) M43 (5400 16200 kW)

3000 Series
400 Series (3.7 - 45 kW)

3500 Family (507 - 2500 kW) 4000 Series (322 - 1886 kW) 3200 Family (93 - 336kW) 3300 Family (63 - 300 kW) M20 (1020 1710 kW)

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

M25 (1800 2700 kW)

M32 (2880 8000 kW)

3600 Family (1350 - 7200 kW)

This represents only a fraction of the engine offerings Caterpillar produces

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 Displacement = X Stroke X No. of Cyls. 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

C9

Integral oil cooler Reduced weight, leaks and engine width

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 ADEMA4 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 ADEMA4 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 Sagami, Japan Gosselies, Belgium Greenville, South Carolina Griffen, Georgia Mossville, Illinois Lafayette, Indiana Keil, Germany 3011 3044 3116 3126 3408 3406 3508 CM20 3013 3046 3126 C7 3412 3456 3512 CM25 3024 3064 C7 C9 C27 C-10 3516 CM32 C30 C11 3520 C32 C-12 3524 C13 C15 C-16 C18 3606 M43 3608 3612 3616 3034 3066 C9 3054 3304 Engine Models 3056 C1.5 3306 C2.2 C6.6

C175-12 C175-16 C175-20 M20 M25 M32

CM43 GCM34

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

Intake

Compression

The Combustion Process 4 Stroke Cycle

Power

Exhaust

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. 2. 3. 4. 5. 6. 7. 8. Cam lobe Lifter Pushrods Rocker arms Bridge (intake) Valve spring Exhaust valve Intake valves
4 6

3126B/C7
5 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 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

Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

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.
Small turbo, No wastegate

Wastegate

Boost

Small turbo, with wastegate Large turbo No wastegate

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

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

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 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 Cats 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.

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 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

Types of Fuel Systems

Pump & Line
Current Scroll Fuel System New Scroll Fuel System Sleeve Metering Fuel System (SMFS) Program Electronic Engine Controls (PEEC) 1981 MUI 1983 NSFS 1988 EUI 1994 HEUI

Unit Injection
MUI EUI HEUI Common Rail (Single Fuel)

1973 CSFS

Pre 1970 1970

1975

1980

1985

1990

1995

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 Glow Plug Pre-Combustion

Fuel Injector
Fuel Injector Housing Nozzle Assembly Mechanically Controlled Unit Injector

Heat Plug

Piston

Piston

Pre-Combustion

Direct Injection Pencil Style

Direct Injection Unit Injector

Sleeve Metering Fuel System

Barrel

Plunger

Fill Port

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 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

Inlet air from air cleaners

Boost air at 300 - 400

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

Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Electronic Control Module (ECM)

Caterpillars 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

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

Engine Monitoring
Fluid Level Fluid Pressure Fluid Temperature

ADEM 4 Electronic Engine Control

Generations of Experience

1987
8-bit PEEC II

1991
Advanced 8-bit PEEC III

1993
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

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 Parts Quality

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

Cylinder Heads

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

Caterpillar
Rigid tolerances Design updates

Cylinder Heads

Competition
Oversized, unthreaded, missing water holes

Caterpillar
Properly machined

Cylinder Heads

Competition
Blocked passages

Caterpillar
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
Turning marks

Caterpillar
Precisely ground

Exhaust Valves

Competition
Inadequate facing material

Caterpillar
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 Less downtime so ultimately lower cost
Discussion

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
Random cross hatch pattern

Caterpillar
Uniform cross hatch pattern

Cylinder Liners

Competition
Not machined to hone off saw-tooth peaks

Caterpillar
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
Flat-faced top ring

Caterpillar
Barrel-faced top ring

Piston Rings

Competition
Thin chrome or plasma plating

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

Caterpillar
Controlled casting process Ultrasonic inspection Improved reusability

Features
Nickel-band ring Specially ground, tapered Controlled casting process Precise fit Better sealing Proper bonding Less blow-by Less carbon deposit Delivers more power Longer wear Reusable

Pistons

Advantages

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
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

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
Radial PTFE Dirt Lip

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

Bonded Elastomeric Substrate

PTFE Oil Lip Wear Sleeve Flange

Hydro-threads

Wear Sleeve

Axial Dirt Lip

Hydro-threads

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

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 Piston

Features

Advantages
Prevents contamination from infiltrating into sensitive area

Lip Seal at the top of the Guide

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 248-5513 Open Temp 81-84 deg C

Engine does not run cold or hot due to a stuck regulator

Lower maintenance costs

New Lip Seal

Guide

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

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 Remans Role

New Cat Parts

Cat Product Support Strategy (One Voice)

Do It Myself Work With Me Do It For Me

Reman Parts

OPTIONS

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 (CRCs)

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