Engine

Repair Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Connecting Rods / Engine Block . . . . . . . . . . . . . . . . . 46
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Turbos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Promotional Literature . . . . . . . . . . . . . . . . . . . . . . . . 59
Related Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Engine Maintenance and
Repair Options Flowchart . . . . . . . . . . . . . . . . . . . . . 63
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
 Engine
Repair Indicators
REPAIR INDICATORS FOR ENGINES
Engine Warning Signs Possible Causes Cat Dealer Option
1. Excess black smoke at Dirty primary/secondary air cleaner Technical Analysis
full load (hot, unburned fuel) Overloading Overfueling Customer/Dealer Discussion
Operating in too high a gear
Faulty turbocharger
2. Blue smoke Hours on engine S O S Results

(oil consumption) Worn rings/liners Component Inspection/Repair

3. White smoke
(steam: water in combustion
chamber)
(on start-up: unburned fuel)
4. Increased oil consumption/
Worn turbocharger seals Repair Determination Inspection
Worn valve products Customer/Dealer Discussion
Leaking head gasket Cracked head Technical Analysis
and/or liners Tune-Up
Faulty injector Customer/Dealer Discussion
Incorrect starting procedure
Incorrect fuel injection timing
Low quality fuel
Hours on engine S O S Results

excess blow-by Worn or broken rings/liners Component Inspection/Repair

Worn turbocharger seals Repair Determination Inspection
Worn valve guides Technical Analysis
Customer/Dealer Discussion
5. Unusual noises Malfunctioning fuel nozzles/injectors Tune-Up
Worn piston pin bushings Technical Analysis
Worn rod/main bearings Repair Determination Inspection
Malfunctioning turbocharger Component Inspection/Repair
Too much valve lash Customer/Dealer Discussion
6. Lack of power Dirty air cleaner Dirty fuel filter Technical Analysis
Incorrect adjustment of governor linkage Tune-Up
Malfunctioning fuel nozzles/injectors Customer/Dealer Discussion
Slipping torque converter
Improper set point
Low quality fuel
7. Increased fuel consumption Fuel leak Dirty air cleaner Technical Analysis
Malfunctioning turbocharger Tune-Up
Malfunctioning fuel nozzles/injectors Customer/Dealer Discussion
Improper set point
Incorrect machine operation
8. Overheating Plugged radiator core (external and internal) Technical Analysis
Incorrect adjustment or worn belts/pulleys Customer/Dealer Discussion
Low coolant level
Malfunctioning temperature regulators
Dirty air cleaner
Incorrect operator technique
Slipping torque converter
9. Hard starting Worn fuel injector pump Tune-Up
(engine missing) Improper starting technique Customer/Dealer Discussion
Low quality fuel low octane rating
or water in fuel
Malfunctioning fuel nozzles/injectors
Low cranking speed
10. Oil level over full Coolant/fuel leak into crankcase S O S Results

Improper oil fill Customer/Dealer Discussion

11. Debris in oil filter Dirt entry Damaged bearings S O S Results

Coolant/fuel leakage into crankcase Customer/Dealer Discussion

Extended oil change period
Incorrect oil used
12. Scheduled Oil Sampling Scheduled Oil Sampling (S O S) is probably

S O S Results

Results the single best indicator of internal Customer/Dealer Discussion

engine wear and potential failure.
13. Engine service meter hours Service meter hours are a good S O S Results

indicator of when certain repairs are needed. Customer/Dealer Discussion

42
 Engine
Liners
CYLINDER LINERS
Flange
Cat cylinder liner features:
Induction hardened molybdenum alloy to extend life and offer
reusability.
Water-cooled over their full length for excellent heat dissipation and
long life. Cross Hatch
Liner flange roll burnished to resist fatigue cracking. Pattern

Manufactured with precise cross-hatch honing to maintain oil control.

Caterpillar Mid-Range Dry Cylinder Sleeve
For details see Engine Block.

Details make the difference

Keep it Cat
CUSTOMER SERVICE TIP

Cat cylinder liners are designed for long life and can often be reused.

When reusing Cat heat treated liners, it is recommended they be flex-

honed to restore the proper pattern. See Piston and Liner Reusability
Guidelines for procedures:

Pistons SEBF8049
Liners SEBF8068

43
 Engine
Pistons
PISTONS
Special features of Cat Aluminum Pistons
Pistons are profiled and tapered and conform to the bores perfectly at
operating temperatures (Figure 1).
Silicon alloy aluminum pistons are designed for long life.
Cast-in nickel iron ring band provides long-wearing grooves for better
ring support, piston strength, better sealing, and reusability (Figure 2).
Cat pistons have two or three rings depending on engine model.
All Cat pistons are 100% ultrasonically inspected to ensure integrity
between the ring carrier and piston bond.

Figure 1
Caterpillar Piston Types

Teepee Design
Teepee piston design is used on all current production engines (Figure 3).
Cast-in
The design features more material in the pin boss load area of the piston, Nickel Iron
distributing stress in the pin bore over a greater area, enabling the piston to Ring Band
withstand high peak cylinder pressures.
The combined weight of the piston and rod is exactly the same weight as
the older group (which is still serviced). Therefore, the improved piston, Figure 2
rod, and pin can be installed together in one cylinder and the engine will
be balanced. (Complete replacement of all pistons and rods is usually not
necessary always refer to NPR).

Two Piece Articulated Pistons

The 3116, 3126, 3176, some 3406, 3412, 3500, C-10 and C-12 Engines
utilize a two piece articulated design piston (Figure 4). This design
consists of an aluminum piston skirt and a steel piston crown. The two are
joined by the piston pin which also connects to the connecting rod.
Benefits of this design include:
Increased cylinder pressure capability
Higher combustion temperature capability Figure 3
Reduced piston slap
Piston
Better combustion and reduced smoke due to the rings located closer to Ring
(Top)
the top of the piston
Higher piston crown reusability due to steel construction.
Piston Ring
CUSTOMER SERVICE TIPS (Intermediate)
Piston
Before your customer replaces a piston, liner, etc., be sure the failure Ring (Oil)
has been analyzed. Your dealer servicemen are trained in failure Piston
Crown
diagnosis. Assembly
Evaluate reuse vs. replacement to help your customer save money. See Sleeve Sleeve
reusability guideline SEBF8049. Bearing Bearing

For more information, order Questions and Answers About Cat

Pistons PEDP8022.PISTON RINGSPISTON RINGS
Piston
Skirt

Figure 4

44
 Engine
Piston Rings
PISTON RINGS
Cat piston rings are made of a strong yet flexible ductile iron or steel and
are heat treated for additional strength. In addition, the chrome or plasma
thickness of the wear material on Cat piston rings is greater than the
industry standard and will provide exceptionally long wear life. All Cat
rings are 100% inspected for roundness, unlike at some ring manufacturers.

Caterpillar uses various shapes and types of rings, depending on the

model, application, rating and market. Caterpillar chooses the perfect ring
for the specific engine application. Some of the terms used to describe Cat
rings are discussed below.

PISTON RING DESCRIPTIONS

Top and Intermediate Rings
Rectangular versus Keystone
* Rectangular used for oil control and emissions improvement on Keystone Ring
some engines.
* Keystone rings the keystone design is used in the top two rings
of many Cat engines. This design improves engine life by reducing Chrome or Plasma Coating
chance of rings sticking by keeping carbon deposits from trapping
the ring.

Barrel Faced or Tapered Profile

Rectangular Ring
* Barrel faced the barrel face profile provides superior sealing to with Barrel Profile
reduce blowby when compared to straight profile.
* Tapered profile the tapered face second ring is used to provide a
scraping action for good oil control.

Chrome or Plasma Coating

Ring with
* Chrome chrome is used in most piston rings Tapered Profile

* Plasma plasma hard coating is used in higher rated and hotter

applications.

Oil Rings
* Cat has chromed double rails which trap and remove excess oil from Double Rail Oil
cylinder walls. Control Ring

Rails
Spring

45
 Engine
Connecting Rods / Engine Block
CONNECTING RODS
Cat connecting rods are forged for high strength and toughness. They are
hardened and machined to close tolerances to ensure straightness, correct
weight and alignment.

During engine assembly a number is etched on the crankshaft rod end and
rod cap. This shows that these two parts are a pair and were machined
together. During engine overhaul these parts must always be used together
as a pair.
High Quality Steel
Tapered Design
All current production Cat engines use rods with more pin bearing surface
at the lower (loaded) side of the pin bore. The tapered rod supplements the
increased metal content in the pin boss area of the piston, providing more
strength to withstand increased peak cylinder pressures.

PISTON PINS
Piston pin strength is extremely important. High quality steel is required
with no flaws or impurities. Caterpillar inspects 100% of all piston pins
for material flaws and puts a much finer surface finish on the pins than is
typical in the industry.

ENGINE BLOCK
The block or main frame of the engine system must be strong, yet
compact and lightweight. It must maintain accurate internal rigidity under
all operating conditions. Features of Cat blocks include:
Cast in Caterpillars modern, state of the art foundries, for consistent
high quality.
Cast of the finest alloys with higher tensile strength than most other
engine manufacturers.
Deep skirted block construction . . . extends well below crankshaft
centerline . . . adds block strength and rigidity.
Designed to be rebuilt. All Caterpillar blocks are designed for more
than one life. Many Caterpillar engine short blocks are available on an
exchange basis. Check your dealerships inventory.
Various cylinder block repair parts are available, such as inserts for the
top and lower bores. Oversize main bearings are also available.

Caterpillar Mid-Range Dry Cylinder Sleeve

Dry cylinder sleeves are available for field repair of 3114, 3116 and 3200
family of engines. The dry sleeve is designed to eliminate block
replacement in mid-range engine overhauls when honing or boring
oversize is not possible.

Benefits of dry sleeving include:

Substantial cost savings due to not having to replace the block after
cylinder bore damage.
Increased total engine life because of additional overhaul capability.
Depending on the number of cylinders which are badly damaged, dry
sleeving may not be cost effective. Be sure to make a thorough inspection
of the cylinder block to determine if it is usable. For installation details see
Special Instruction SMHS7638 (3200) or SEHS9047 (3114/3116).
46
 Engine
Crankshaft
CRANKSHAFT
Every moving part of an engine is somehow affected by the performance
of the crankshaft. Because crankshafts are a high cost replacement item, it
is tempting to look for a less expensive reground substitute, or source
salvage work from a local repair shop.

Here are some of the reasons for insisting on genuine Cat new and
remanufactured crankshafts:
Forged and precision machined from premium, high strength steel.
Heat treated by a patented hardening process for high strength and
outstanding wear characteristics. The hardening processes give Cat
crankshafts a very hard, high carbon surface structure, while the center
remains tough for shock absorption.
Journals are finish-ground and polished assuring ultimate smoothness
for less internal friction and long bearing life.
All crankshafts are precision balanced, both statically and dynamically
to provide long life.
Front and rear crankshaft seals have wear sleeves to provide increased
crank reusability.
Because of the quality built into Caterpillar crankshafts, often a crank can
be reused rather than replaced. Refer to the following for salvage/repair
guidelines:

SEBF8054 Procedure to measure and straighten bent crankshafts

SEBF8039 Inspection of crankshafts for cracks
SEBF8041 Crankshaft measurement
SEBF8042 Procedure to polish crankshafts
SEBF8043 Visual inspection of crankshafts

When replacement is necessary, or when uptime is critical, exchange may

be the best option. Caterpillar has a complete line of value-priced remanu-
factured crankshafts available.

47
 Engine
Bearings
BEARINGS
Bearings are relatively inexpensive wear items designed to protect the expen-
sive crankshaft, connecting rod and block. They do this by:
Providing a soft, smooth surface with a high load carrying capability. This
protects crankshaft journal surfaces during engine start-ups and heavy
loads.
Trapping or embedding small pieces of metal and debris in the soft bear-
ing surface to prevent damage to the journal surfaces.
Maintaining correct oil flow and pressure between parts.
All Caterpillar bearings have a consistent construction that allows them to
deliver maximum performance and life and offer greater protection of the
other more expensive engine components. Two areas where bearing con-
struction is vital to performance are: wall thickness and crush height.
Consistent wall thickness: When the main or rod cap is bolted in place, Precise crush height
the bearing and crankshaft journal are in close proximity. A film of oil
exists between the two components during engine operation to protect
them from damage. The consistent wall thickness of Cat bearings ensures
that the film of oil is the proper thickness, helping prevent the friction and
metal-to-metal contact that can cause excessive wear and premature failure.
Precise crush height: Cat bearings feature precise crush height, which
helps ensure proper clearance, oil flow and keeps the bearing from con-
tacting the crankshaft for longer life. Precise control of the crush height
is also critical to create the correct level contact pressure between the bear-
ing and housing. If the contact pressure is too low the bearing could move Consistent wall thickness
in the housing and cause fretting damage.
Caterpillar bearings are made of several layers of material. The type of metal
used for each layer depends on the application in which the bearing will be
used. As your engine performance demands increase, Caterpillar is constantly
looking for new and improved engine bearing material and designs. Cater-
pillar offers three bearing designs to match the unique variables of each
engine system. System matched genuine Caterpillar bearings increase dura-
bility, improve reliability, and optimize performance of each engine.

All Cat bearings described below have a steel back that makes up 90% of
the thickness. The steel back provides the strength for the bearings. Cater-
pillar carefully controls the steel for yield strength and surface finish. The
design and materials selected in addition to the steel back is what differen-
tiates the three bearings.

Aluminum Alloy Bearing (Bi-Metal) Aluminum alloy bearing

Bi-metal bearings feature an advanced aluminum alloy and no overlay, pro- (bi-metal)
viding more consistent bearing clearance and little wear. The advanced alu-
minum alloy is soft giving it the ability to embed debris, without having the
overlay. Yet it is harder than standard bearing overlay enabling it to have a
more consistent bearing clearance and greater wear resistance.
Aluminum alloy

Steel back

48
 Engine
Bearings
Aluminum Alloy Bearings (With Overlay) Aluminum alloy bearing
(with overlay)
Aluminum Alloy bearings feature aluminum bearing material, copper
bonding, and a lead-tin overlay material in addition to the steel back. Each
of these materials provide valuable features to optimize performance.

The high strength Aluminum Alloy material is scuff and corrosion

resistant. Bearing scuffing occurs when the crankshaft journal comes in Copper
Steel back
bonding
contact with the bearing surface instead of being separated by a film of oil. material
This happens at the time of engine start-up and during engine operation Aluminum
with too thin an oil film. As an engine operates, acids build up in the alloy
lubrication oil. Caterpillars aluminum alloy bearings are less susceptible Lead/tin/copper
overlay
to corrosion.

Caterpillar Aluminum Alloy bearings have a Copper Bonding layer that

provides a strong bond between the layers while also reducing the
coefficient of friction. The copper bonding layer offers protection during
marginal lubrication conditions. Additionally, copper bonding on an
Aluminum alloy is more tolerant to situations when bearings are subjected
to dirt, excessive heat, or lack of oil.

The Lead-Tin Overlay and Tin Flashing protects the aluminum layer of the
bearing by embedding small particles and by providing a slippery surface
during marginal lubrication and engine start-up.
Copper/lead bearing
Copper-Lead Bearings
Copper-lead bearings feature high fatigue strength, increasing durability
and reliability. The copper-lead bearings share some of the features as the
Aluminum alloy bearings. Similar to the Aluminum Alloy bearings, they
have a Lead/Tin/ Copper overlay, and a steel back. However, there are
important differences that enable them to optimize performance based on Nickel
Steel
variables unique to each engine system. dam
back
Copper/lead
Instead of using a copper bonding material, a Nickel Dam material is used alloy
to prevent the tin in the overlay from diffusing into the alloy copper/lead Lead/tin/copper
alloy. Without this type of nickel dam material the bearing would be overlay
susceptive to corrosion.

49
 Engine
Bearings
Packaging
Bearings cannot do the job they are designed to do if they are scratched,
chipped or gouged prior to putting them into an engine. For that reason,
Caterpillar has established the highest packaging standards of the bearing
industry. These standards provide careful and complete protection of the
bearings. Open a box of Caterpillar bearings and a box of competitive
bearings and you will see the difference.

Bearing Failure Analysis

Before any failed bearings are replaced, a bearing failure analysis should
be performed by your dealerships service department. Many times
failures are blamed on the bearings when bearing damage is only the result
of another problem such as lack of oil, improper oil change intervals, a
damaged oil pump, wrong oil viscosity, fuel dilution of the oil, improper
oil filter by-pass valve operation, electrical discharge damage to the crank-
shaft, etc. If a thorough failure analysis is not performed, the user may not
fix the cause of the first failure and a repeat second failure could occur.

Non-standard Size Bearings

Caterpillar provides a number of undersize and oversize bearings. This
allows users to lower repair costs by using undersize crankshafts and/or
oversize connecting rod bores and cylinder block main journal bores.
Consult parts books for specific part numbers.

CUSTOMER SERVICE TIPS

Users may also be interested in these publications for additional bearing

information:
Questions and Answers About Engine Bearings, PEDP0002
Engine Bearings and Crankshafts, SEBD0531
Guideline for Reusable Parts Main and Connecting Rod Bearings,
SEBF8009
Bearing Performance and Failure Analysis for 3208 Truck Engine,
SEBD0528
3400 Engine Major Component Performance Guide SEBD0794
Caterpillar Bearing Kits (Counter Card) LEWT9346
Engine Bearings Data Sheet PEHP8042

50
 Engine
Valves
VALVES
Valves must resist wear, warping, friction, and constant beating against the
valve seat, plus provide an effective seal to keep gases inside the cylinder
during combustion. Caterpillar matches the metallurgy and construction of
its valves to the specific applications of each. These vary from light-duty, Keeper
one piece intake valves to heavy-duty exhaust valves made of two or three
Area
different materials. Cat valve materials exceed industry standards. Many Thru
aftermarket valve manufacturers offer will-fit valves which do not meet Hardened
Caterpillar material specifications.
StemHigh
Carbon
The type of valve used is determined by whether the engine is direct Steel
injection, precombustion chamber, turbocharged or naturally aspirated,
and whether it runs on natural gas, LP or diesel fuel. Engines with greater
horsepower and engines that operate on gas run hotter than lower rated or
diesel fueled engines.
Weld
Some Cat valves have up to 1-1/2 times more facing material than industry Forged
standard on the critical face area. Exhaust valves are more robust than Face
Head
Fillet Area
intake valves because they operate in higher temperatures. With proper
engine maintenance Cat intake valves can be reused several times, an Wear-
Resistant
important customer benefit that lowers engine owning and operating costs. Hard Facing

Typical Caterpillar Two-Piece Valve

VALVE GUIDES
Replaceable Cat valve guides are made of low friction, graphitic iron and
are precision bored. Most Cat valve guides are threaded to allow a tight fit
between the valve and guide, while still allowing an oil path for lubrication.

VALVE SEATS
Cat valve seats are made of premium materials to resist high temperatures and
wear. Insert material is matched to the valve face material to optimize life.
Various insert alloys used include materials such as: chrome, tungsten, nickel
and cobalt.

CUSTOMER SERVICE TIP

Save your customer money. Before replacing valves, recommend he look
at reusing present valves. See Parts Reusability Guideline SEBF8002.
For more information, refer to Questions and Answers About Valves,
PEDP0001.

51
 Engine
Fuel System
The fuel system components control the amount and timing of the fuel
injected into the cylinders. Both functions are critical to efficient
combustion, which translate into performance and economy.

Fuel
Fuel lines
Injector

Piston

Fuel
Injection
Pump
Housing
Fuel Transfer
Pump
Fuel Filter

Precombustion (PC)
On precombustion engines fuel is pumped from the fuel injection pump hous-
ing where individual fuel pumps direct fuel to injectors in each cylinder.
There is one fuel injector located in the precombustion chamber above each
cylinder. The precision drilled holes in the end of the fuel injector direct fuel
into the precombustion chamber where the fuel begins to ignite. The par-
tially ignited fuel is then injected into the cylinder.

Fuel line

Electrical Wire

Fuel injector
Glow plug
Fuel injector housing
Precombustion
on chamber

Heat plug Piston

Direct Injection (DI)

The direct injection fuel (DI) system differs from the precombustion
system in that there is no precombustion chamber and fuel is injected
directly into the combustion chamber. The fuel injectors are located above
the combustion chamber and inject atomized fuel directly on top of the
piston.

Fuel line

Injector housing
Fuel injector

Piston

52
 Engine
Fuel Injectors
NOZZLES
Capsule nozzles are used in all precombustion chamber (PC) Cat Diesels
and early DI Heavy Duty Engines.

Direct injection pencil-style or 7000 series nozzles are used in all pump
and line fuel systems (3000, 3200, 3300 and 3400 engines).

Line
Assembly
Nut

Retainer

Bleed
Screw

Body

Seat
Compression
Seal Washer
Nozzle
Tip Assembly

Capsule Nozzle Pencil Style Nozzle

Carbon
dam (seal)

7000 Series Nozzle (current production)

Hydraulic Electronic Unit Injector

The HEUI uses hydraulic energy, instead of mechanical energy, from the
pressurized oil for injection. The pressure of the incoming oil controls the rate
of injection by controlling the speed of the intensifier piston and plunger
movement. The amount of the fuel injected is determined by the duration of
the pulse from the Electronic Control Module. Only Caterpillar HEUI fuel
systems can control injection pressure, injection timing, and injection rate
electronically.

53
 Engine
Fuel Injectors
Unit Injectors
Unit injectors are used on 3406E, 3408E, 3412E, 3500, and 3600 Series, and
1.1 and 1.7 liter engines. Here, the fuel pump and injector for each cylinder
are combined into a single unit, the unit injector. There is one unit injector
for each cylinder.

In PC and DI systems the fuel injection pumps are grouped together in the
fuel injection pump housing, on the side of the engine. In a unit injector sys-
tem, fuel is delivered from the fuel transfer pump to the unit injector which
injects fuel diretly into each cylinder. Unit injectors eliminate the need for
high pressure fuel lines that connect the fuel pump housing to the nozzles.
This allows for higher fuel system injection pressures which result in better fuel
atomization and more complete burning of the fuel.

Fuel pump

Fuel
Injector

Nozzle
assembly
Threaded Piston
cone
Electronically Controlled Unit Injector (EUI)
Mechanically Controlled Unit Injector (MUI)
(3176)
(3114, 3116, 3500, 3600)

Unit Injectors

NOTE: Environmental Protection Agency (EPA) certification is required

in the U.S.A. for Cat on-highway vehicle engines. Cat engines are certi-
fied with Cat nozzles. To ensure the engine continues to meet EPA require-
ments, use genuine Cat new or remanufactured replacement nozzles and
injectors.

54
 Engine
Turbos
Turbochargers
Turbochargers are optional components used to force more air into the combustion
cylinder. This results in more fuel being burned, yielding a higher horsepower out-
put.

Caterpillar pioneered diesel turbocharging in the earthmoving industry in the 1940s,

after turbocharging had been developed for aircraft. Cat turbochargers are matched
to the engine. Too little boost can cause excessive exhaust temperature, reduce power,
waste fuel, crack exhaust manifolds, etc. Too much boost will temporarily increase
engine performance, but will rapidly increase wear and destroy pistons, valves,
cylinder heads, head gaskets and bearings.

Design Differences
Improved Design Turbine Seal Ring
Many turbochargers have an ordinary cast iron seal ring on the hot end. If this ring fails it can do two things:
1. When the engine is running at high speed, exhaust gases can get past the ring and into the oil system. This con-
taminates the oil and causes excessive crankcase pressure.
2. When the engine is idling, the oil can leak past the seal ring and escape into the exhaust, causing excessive oil con-
sumption. Caterpillar engineers insist on chrome alloy seal rings to maintain tension and give longer wear life.
Step Bore
On most Cat turbos, the turbine seal ring is set in a step bore which holds the seal ring in place. Before step boring was
introduced, exhaust gas pressure could cause the seal ring to gradually wear its way along the shaft. This not only wore
out the seal ring, but damaged the shaft beyond repair. Its something you may not find on competitive turbochargers.

55
 Engine
Turbos
Repair Options
There are a variety of repair options available for turbocharger repair. For
example:
Dealer repair
Planned component replacement
Reman/Exchange turbo group or cartridge
New turbo
A Cat dealer always performs a turbocharger failure analysis before
making a repair.

Turbocharger Failure Analysis

Turbocharger failure analysis is a step-by-step method to determine why the
turbocharger failed. Failure may result from lack of lubricant, dirty oil, foreign
material in the exhaust or inlet piping, high back pressure, poor workman-
ship, or faulty material. It is generally caused by something other than the turbo,
which creates a chain reaction eventually damaging the turbo. If the real
cause of the failure is not found and fixed, a repeat failure could occur. See the
booklet Questions and Answers About Turbocharger Repair and Replace-
ment (PEDP8023) for more details.

CUSTOMER SERVICE TIP

Reusability guidelines are available for your customer: SEBF8018 Turbo-

chargers; SEBF8019 Turbocharger Specifications, plus Diagnosing Turbo
Failures FEG45138. For more information and customer handout, order
Questions and Answers About Turbocharger Repair and Replacement
PEDP8023.

Details make the difference Keep it Cat

56
 Engine
Radiators
Currently, four types of radiator cores are available on Cat Equipment:
ADVANCED MODULAR COOLING SYSTEM (AMOCS)
The advanced modular cooling system is the latest proprietary cooling sys-
tem from Caterpillar. It features durable, low fin density modular core design
like the IMRM but also has no top tank for much faster removal and assem-
bly. Just remove 2 bolts at the top of each module to remove. The modules
are 2-pass flow (hot coolant up, cool down).

IMPROVED MULTI-ROW MODULE RADIATORS (IMRM)

The improved multi-row module radiator is a durable, low fin density, mod-
ular core design, to be used when plugging is a problem with the higher fin
density design of the folded core. The lower fin density design minimizes
plugging, while retaining the modular replacement/low repair cost benefits
of the folded core. Check with service engineering to determine which core
is available to best match application requirements.

FOLDED CORE RADIATORS

The folded core radiator is a modular design heat exchanger, consisting of
individually replaceable core assemblies. Individual modules can be replaced
when damage or failures occur. Normal field replacement time for folded
core radiators is estimated to be one hour less than for conventional radia-
tors assuming all parts of the folded core and a new or rebuilt conventional
core are at the job site. Salvage procedures for folded core modules have
been introduced in guidelines for reusable parts SEBF8130.
The folded core design provides increased reliability by using rubber seals.
These seals, which join the modules to the radiator tanks, tend to isolate the
modules from vibration and permit thermal expansion to occur without intro-
ducing high stresses in the modules.

CONVENTIONAL CORE
The conventional core radiator is a single unit, low fin density core, manu-
factured to rigid Caterpillar specifications. Caterpillar cores are designed
with the engine application in mind, to provide optimal engine cooling .
Check with service engineering to determine which core is available to best
match application requirements.
Caterpillar radiator cores are well built:
Copper Fins high heat transfer
hemmed (extra bracing) for strength
Steel Fins used where abrasion and added strength are needed.
Solder Coated prior to assembly, Caterpillar cores parts are coated with
solder to insure good solder joints and better heat transfer. This step takes more
time in manufacturing which many competitive manufacturers avoid.
Brass Tubes non-corrosive, strong, superior life, 50,000 psi (344,740 kPa)
tensile strength.
Air Tested all cores are air tested at 15 psi.
Radiator core protector
Honeycombed steel grid protects radiator core against abrasion in extremely
sandy conditions. It mounts between radiator core and blower type fan to
absorb impact force of particles propelled by fan.

Fanblast deflectors
Fit on the front of radiator housing. Louvers direct blower fan blast upward.
In tandem pushing it protects operator from heat and fan-blown dust.

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V-Belts
Caterpillar offers individual V-belts or matched sets. If a belt fails, all belts
should be replaced with a matched set, thus avoiding additional downtime
and preventing excessive wear due to uneven loading of belts, pulleys,
bearings and shafts.

V-BELT SIZING KEY

Pulley
Belt Groove
Belt Top Width Width
Size A B
Inch mm Inch mm Inch mm
3/8 10A .422 10.72 .380 9.65
1/2 13A .547 13.89 .500 12.70
11/16 15A .688 17.48 .625 15.88
3/4 17A .750 19.05 .690 17.53
15/16 .938 23.83 .878 22.30
1-1/16 1.062 26.97 1.003 25.48
1-1/4 1.297 32.94 1.253 31.83

Belt Size
Belt size refers to SAE nominal top width of belt for belts 11/16" and
larger. Belt size is pulley groove width for 3/8" and 1/2" belts. SAE
Effective Length equals:
Outer circumference minus .38" (9.65 mm) for 3/8" and 1/2" belt size.
Outer circumference minus .57" (14.48 mm) for 11/16" and up belt size.
For detailed information at the part number level, refer to the One Safe
Source Catalog.

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Promotional Literature
For a complete list of Promotional Literature for all parts products, use the Parts & Service Marketing Communica-
tion Materials catalog PEGP9800-09.

Direct Mail
How to Reduce Your Engine Costs PEDP0050 English
Maintenance and Repair Options 3208 PEDP4109 English
Maintenance and Repair Options 3304 PEDP6114 English
Maintenance and Repair Options 3406 LEDQ4199 English
A Guide for Managing Engine Performance and Life PEDP7101 English
PSDP7101 Spanish
(There Is a Difference) Cat Engine Parts Quality PEDP7102 English
Cat Engine Parts Quality Post Card PEDP9118 English
Six Ways to Keep Your Cooling System Working Right PEDP9113 English
Sales Aids
Your Engine Management Guide PEDP7028 English
Engine Repair Options Posters PEWP6717 English
PEWP8703 English
PEWP8704 English
Engine Systems and Support PEDP6028 English
Slide/Scripts and Videos
Straight Talk on Cooling System Maintenance Video PEVN1670 English
Profitable Game Plan Repair Bearing Failure PEVN2556 English
Competitive Test Report Videos:
Radiators PEVN1847 English
Product Training Bulletins
Introduction to Diesel Engine TECB6005 English
How Diesel Engines Work and Wear TECB6006 English
Electronic PSK JERD2143 English
Customer Meeting Package PEKP6026 English
Data Sheets
Cylinder Heads and Valves PEHP6041 English
Radiators PEHP8041 English
Graphite Head Gaskets Data Sheet PEHP3125 English
Starters and Alternators PEHP6027 English
Cooling System Maintenance Tips PEDP9113 English
Engine Bearings PEHP8042 English
Article Reprint
Repair Before Failure (article reprint from Equipment Mgt.) PEDP1136 English
Videos
Gasket Video PEVN2764 English

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Promotional Literature
PARTS COMPETITIVE BULLETINS
Provide Parts & Service Sales force with results of laboratory competitive
tests on various components. The Bulletins include a list of Caterpillar and
Competitive Parts tested, a brief comparison of specifications, and the results
of the metallurgical and/or other tests performed. PSSRs can use Parts
Competitive Bulletins to show customers the key critical test areas and what
the test results can mean to them in component performance. Bulletins are
not intended for broad distribution. They are designed to be used in face-to-
face selling situations where the customer is using, or considering using, the
competitive product.
Parts Competitive Bulletins now available are:
Engine
Caterpillar vs. Ghinassi Cylinder Heads LEKQ6257 English
LSKQ6257 Spanish
Caterpillar vs. (Glacier) A.E. Engine Parts LEKQ7134 English
LSKQ7134 Spanish
Caterpillar vs. IPD and A.E. Engine Parts Inc. Valves LEKQ7258 English
Caterpillar vs. IPD and Pulve Fuel Nozzles LEWT9423 English
Caterpillar vs. Smagon Main Bearings LEWT9339 English
Caterpillar vs. Michigan/Clevite Piston, Rings & Liner LEWT9435 English
Caterpillar vs. Clevite and IPD Piston, Rings & Liner LEWT9439 English
Caterpillar vs. Perfect Circle Piston, Rings & Liner LEWT9438 English
Caterpillar vs. Sirt Crankshaft LEWT9436 English
Caterpillar vs. ESP (Italy) Engine Parts LEKQ9128 English
Caterpillar Pistons, Rings vs. Perfect Circle PEWP9728 English
Caterpillar Liners vs. Vandervell PEWP9730 English
Caterpillar 3406 Pistons vs. IPD LEWT1074 English
Caterpillar vs. IPD 3400 & 6.25 Bore Nozzles LEXQ3065 English
Caterpillar vs. IPD 6.25 Bore Liners LEXQ3047 English
Caterpillar vs. IPD 6.25 Pistons & Piston Rings LEXQ2317 English
Caterpillar vs. IPD 3400 Rings, Liners & Valves LEXQ2318 English
Caterpillar vs. Sealed Power 3300/3400 Liners, Pistons & Rings LEXQ2316 English
Caterpillar 3306 Engine Parts vs. FP Diesel PEWP5032 English
PSWP5032 Spanish
Caterpillar 3306 Engine Parts vs. Industrial Parts Depot PEWP5029 English
Caterpillar 3208 Engine Parts vs. Industrial Parts Depot PEWP5030 English
Caterpillar 3406 Engine Parts vs. Industrial Parts Depot PEWP5031 English
Caterpillar 3306 Engine Parts vs. Industrial Parts Depot PEWP5034 English
Engine Parts (Pistons, Liners) vs. Berrick Industries PEWP2000 English
PSWP2000 Spanish
Pistons & Rings vs. Perfect Circle PEWP9728 English
PSWP9728 Spanish
Radiator vs. Various PEWP0022 English
Piston Rings and Liners vs. Perfect Circle PEWP3003 English
Cylinder Liner vs. Equitrade PEWP3004 English
Fuel Injection Parts vs. Interstate Diesel/McBee Supply PEWP3125 English
Cylinder Kit vs. AE Clevite PEWP3126 English
Valves vs. KARVALVES PEWP3129 English
Intake Valve vs. AE Clevite PEWP3134 English
3306 and 3406 vs. Michigan 77 (Clevite) LEWT1147 English
3406B Rod Bearings vs. IPD LEXQ4341 English
3208 & 3406 Nozzle Kits vs. Dipaco LEXQ4344 English
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 Engine
Promotional Literature
Parts Competitive Bulletin Index PEWP8752-08 English
Remanufactured 3208 Engine vs. Springfield Manufacturing PEJP7027 English
D348 Engine Cylinder Kit vs. FP Diesel PEJP7026 English
D398 Fuel Injection Pump vs. IPD PEWP4127 English
PSWP4127 Spanish
3306 Chamber Assembly vs. IPD PEWP4125 English
PSWP4125 Spanish
3306 Water Pump Shaft vs. IPD PEWP4126 English
PSWP4126 Spanish
Engine Overall Kit vs. No. 1 PEWP4129 English
Cat 3406 Cylinder Head vs. Ghinassi PEWP6030 English
Cat 3300 Exhaust & Intake Valves vs. ESP PEWP6037 English
Cat 3500 Engine Parts vs. Clevite LEXQ6177 English
Cat 3406 Valve Lifter vs. Industrial Parts Depot LEXQ6631 English
Cat 6.25" Bore Gas Engine Parts vs. FP Diesel LEXQ6774 English
Cat 6.25" Bore Diesel Engine Parts vs. FP Diesel LEXQ6775 English
Cat Pistons vs. Industrial Parts Depot LSKQ6294 Spanish
Cat Pistons vs. AE Engine Parts Inc. LSKQ6295 Spanish
Cat vs. Equipment Spare Parts PEWP5028 English

61
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Related Services
ENGINE-RELATED SERVICES

Exchange
Caterpillar and your dealership have an extensive inventory of exchange engine components, including complete
engines. Be sure you know what is available. Exchange components reduce downtime and lower owning and
operating costs.

Scheduled Oil Sampling

Your Caterpillar dealership can build up a record of wear analysis through oil sampling for each Cat engine. Repair
costs and unscheduled downtime can be minimized by using Scheduled Oil Sampling.

ERIK
The Engine Repair Indicator Kit 4C3502 (ERIK) is available for dealer PSSRs to evaluate planned and problem
repair indicators for your customers machines. The easy-to-use tooling, inspection form and instructions allow
maintenance/repair recommendations to be made quickly and confidently.

Overhaul Management Guide

Overhaul Management Guide JERC4400 (OMG) is a computer analysis service that provides a quick and easy way to
calculate the estimated life remaining in your engines and transmissions, and determine the best time to perform a
before-failure overhaul. It can significantly reduce owning and operating costs.

Specialized Tools/Qualified Servicemen

Your dealerships service department has special tools and specialization areas designed to make engine repair fast
and efficient. Cat dealer servicemen attend training schools on a regular basis and have easy access to Caterpillar
service literature. Specialized tooling and trained servicemen take the guesswork out of repairs.

Parts Reusability
Take advantage of the extra life built into each Cat part. Reusability guidelines are published by Caterpillar to show
how to determine which engine parts are okay to reuse. Some of the guidelines are listed below. For a complete list,
order SEBF8029.

SEBF8002 Valves and valve springs

SEBF8009 Main and connecting rod bearings
SEBF8018 Turbochargers
SEBF8019 Turbocharger specifications
SEBF8034 Valve and valve spring specifications
SEBF8049 Pistons
SEBF8068 Cylinder liners

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Engine Maintenance and Repair Options Flowchart

ENGINE
MAINTENANCE AND REPAIR OPTIONS FLOWCHART
1. MAINTENANCE & SERVICE
PREVENTIVE
MAINTENANCE

REPAIR
INDICATORS
TUNE-UP TECHNICAL
ANALYSIS
CUSTOMER/DEALER
DISCUSSION
COOLING COMPONENT
SYSTEM INSPECTION/REPAIR
REPAIR DETERMINATION
INSPECTION
2. BEFORE FAILURE 3. AFTER FAILURE
LOWER END CYLINDER BLOCK
OVERHAUL ONLY DAMAGE

TOP END CRANKSHAFT

OVERHAUL ONLY DAMAGE

LEVEL I CYLINDER BLOCK &

OVERHAUL CRANKSHAFT DAMAGE

LEVEL II COMPLETE ENGINE

OVERHAUL REPLACEMENT

REASSEMBLE
AS IS

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Engine Maintenance and Repair Options Flowchart
ENGINE MAINTENANCE AND REPAIR OPTIONS FLOWCHART
The preceding flowchart summarizes the repair options concept, and can
be very useful when explaining options to customers and employees alike.
For discussion purposes, the chart can be divided into three sections:

1. Maintenance and Service

2. Before Failure
3. After Failure

1. MAINTENANCE AND SERVICE

Preventive Maintenance (PM)

There are a number of PM options available to offer customers to help engines
last longer and reduce engine costs.
Inspection Checklists
Cat Fluids
Caterpillar Filters
SOS
Cat Care Kits
Customer Support Agreements which include PM
Maintenance Control System (MCS)
Overhaul Estimator Guide (OEG) Software

Repair Indicators
Repair indicators warn you something needs attention. There are two
types: planned and problem indicators.
Planned indicators
A. Usage engine service meter hours, gallons of fuel, SOS
analysis, etc.
Problem indicators
A. Performance noise, vibration, lack of power, smoke, increased
oil consumption, increased fuel consumption, etc.
B. Filter Inspection
C. Leaks
D. Operator Discussion

Customer/Dealer Discussion
Once an indicator has surfaced, we can discuss:
What is the problem?
What are the repair options?
Is more diagnosis needed?
All of the options are explored so customers can choose the best repair
option for their needs.

64
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Engine Maintenance and Repair Options Flowchart
Technical Analysis

Technical Analysis is a two-level diagnostic inspection of the engine. It can pinpoint the cause and extent of a prob-
lem. Often this type of inspection shortens repair time and reduces repair costs.
Level I is a general visual examination of the engine condition.
Level II is a more extensive inspection of a specific system that Level 1 identifies as not performing properly.
Engine Repair Indicator Kit (ERIK) Evaluates planned and problem repair indicators utilizing the Engine Over-
haul Estimator Guide and the results of a basic non-technical inspection. For more information on ERIK, refer to
Product Support Insight #28 and/or refer to this section of the Guidebook for the announcement.

Component Inspection/Repair
Inspection may reveal that a component such as a water pump, starter, or turbocharger needs repair or replacement.
Exchange programs include components that meet customer needs with off-the-shelf availability. Dealer Exchange and
Caterpillar Remanufactured Products are available.
Component Repair Kits should be made available to customers so they can make their own repairs.

Tune-up
It may be that a tune-up is all that an engine needs to restore power, performance and fuel efficiency. A normal tune-
up period would be once a year or before a scheduled job to assure machine performance.
Convenient Caterpillar Tune-up Kits let customers do the work themselves. All parts and instructions needed are
included.
Dealers do the work, often flat-rated.

Cooling System Maintenance

Research shows that 40% of all premature engine failures can be attributed to the cooling system deficiencies. Proper
cooling system maintenance significantly reduces the risk of catastrophic engine failures.

Cooling system options include:

Tune-up customer job site (system analysis in machine)
Test in shop
Repair core salvageable
Replace core unsalvageable

Repair Determination Inspection (RDI)

This thorough internal engine inspection will help determine any needed repairs.
This is the key step in helping you decide which repair option is best for your customer.

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Engine Maintenance and Repair Options Flowchart
2. REPAIR BEFORE FAILURE
Before Failure repairs should be done when there is only minimal crankshaft or cylinder block wear. These repairs can
often be made in-frame. The options listed depend on the type and degree of wear. Repair Before Failure is the cus-
tomers best value because Cat parts reuse is maximized and customer downtime is minimized.

Lower End Overhaul

This option consists of rolling in new main and rod bearings. Its an ideal choice when there is little or no ring or liner
wear and the bearings are worn due to normal operation.
It can be done in-frame except on a few machines.
Flat-rated, it is about 3-15% of the cost of a new engine.
Overhaul Kits can help customers make their own repairs. All the parts can be packaged for them according to their
specific engine model. The kits include only genuine Caterpillar parts making them a convenient and safe choice.

Top End Overhaul

A top end overhaul may be all thats needed to restore power and efficiency. It consists of reconditioning or exchanging the
cylinder head assembly for machines where cylinder head components wear faster than liners, rings and bearings.
It can be performed in-frame.
Flat-rated, it is about 12-25% of the cost of a new engine.
Caterpillar Remanufactured cylinder heads are available for most engines.

Level I Engine Overhaul

For engines with both cylinder bore and bearing wear, consider a Level I Engine Overhaul.
Flat-rated, it is about 30-50% of the cost of a new engine.
In-Frame Overhaul Kits can be made available. Include in the kits Exchange cylinder heads, pistons, rods, filters,
tools and instructions everything needed to make the repairs.
The crankshaft and/or cylinder block should not be damaged.

Level II Engine Overhaul

Engines with extensive wear or that are approaching the time for a second overhaul may require a Level II Engine
Overhaul.
Major components are rebuilt or exchanged.
Flat-rated, it is about 40-70% of the cost of a new engine.
Exchange parts are available (see section on Exchange).

Reassemble As Is
Depending on the owning and operating plans, customers may want to consider this option.
Allows customers to delay the repair, use the machine as a backup or trade it.
Consider a Dealer Exchange or a Caterpillar Remanufactured Engine, Long Block, or Short Block where available.

66
 Engine
Engine Maintenance and Repair Options Flowchart
3. AFTER FAILURE REPAIRS
If your engine does fail, you still have several economical repair options. Here are four categories of engine damage
and the repair options for each. We can help you determine which is the best for you.

Cylinder Block Only Damage

Cylinder block damage usually occurs in the top end, such as pitting or liner seat erosion. Here are your options:
Bore and sleeve the block for any or all damaged cylinders on engines without liners. Caterpillar dry sleeves are avail-
able for all 3200 and 3100 Series engines.
Replace/reuse only damaged cylinder liners. Since liners are offered individually for most engines, you buy only
the parts you need. And Caterpillar pistons are also made to be reused.
Trade your damaged pistons, rods and liners for Caterpillar Remanufactured cylinder packs available for 3176, 3300,
3400, and 3500 Series Engines. Each cylinder pack includes a Caterpillar Remanufactured rod, piston, liner and
pin, preassembled with new rings and seals, ready to install in the block.
Install inserts in block for liner seat erosion.
Machine top deck.
Install a new Caterpillar cylinder block.
Metal spray top deck and machine to original height.

Crankshaft Only Damage

When a main or rod bearing fails, crankshaft replacement requires engine removal.
Install a Caterpillar Remanufactured undersize crankshaft. They are priced approximately 20-35% of new and are
available for all current Caterpillar engines.
Exchange for a Caterpillar Upgrade to New crankshaft priced approximately 55-65% of new. They are new Cater-
pillar standard size crankshafts.
Install a new Caterpillar crankshaft.

67
 Engine
Engine Maintenance and Repair Options Flowchart
Cylinder Block and Crankshaft Damage
Damage to both block and crankshaft usually results from a main bearing failure which requires engine removal. Your
repair options include:
Recondition the cylinder block and install a Caterpillar Remanufactured undersize crankshaft. Line bore the block
and install oversize main bearings, undersize crank and undersize rod bearings.
Rebuildability makes this a very popular option.
Recondition the block and install a Caterpillar Upgrade to New crankshaft. Exchange your old crankshaft for a
new one and still use standard size rod bearings.
Install a Caterpillar Remanufactured short block or long block. Remanufactured short blocks, available for some engines,
are priced approximately 30-50% of new. Remanufactured long blocks are available for 3300 and 3400 at 40-50%
of new.
Install a new Caterpillar cylinder block and crankshaft. New bare blocks and crankshafts are available. This option
lets you reuse the camshaft, pistons, rods and other acceptable parts.

Complete Engine Replacement

When downtime is critical and failure extensive, complete engine replacement may be the only practical repair. You
still have options:
Install an engine from your Exchange Program which includes your own rebuilt engines or Caterpillar Remanu-
factured engines, priced approximately 50-60% of new.
Install a new Caterpillar engine.

Related Publications:
How to Reduce Costs and Increase Engine Life (Marine) LEDM4330

68
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Notes

69
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Notes

70