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
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
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

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

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

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

4
6

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.

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

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)

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 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

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

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

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

NewLipSeal

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

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

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 (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