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• College: ITM, Perú
• Dealer Name: Ferreyros S.A.
Agenda
• Engine Families
• Engine Works & Wears
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lube System
Fuel System
Air System
Electronics
• Parts Differentiation
• REMAN
• Resources
Engine Families
C-15/C18/3400 M43
C-9/C-11/C-13 (186 - 1044 kW) (5400 -
(227 - 492 kW) 16200 kW)
3116/3126/C-7
(86 - 313 kW)
• Measured in inches
or millimeters
Stroke
Displacement = (3.14 X B 2
) X Stroke X No. of Cyls.
4
Horsepower
• Horsepower is the rate of doing work (how quickly a force is
applied through a distance)
• 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
Improved breathing
Better combustion
C7 Series Features
using ACERT™ Technology
• 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
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 C9
• 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
C11/C13 Series Features
using ACERT™ Technology
• 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
• 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 WL
3000 D3C III - D5C III -- 301.5 - 320B 906 - 939C
C6.6 D5N 953, 963 924 - 938
3100 D5M - D6M -- 322B - 345B 924F - 962G
C7 D6N 322, 325 950, 962
3300 D6R - D7R -- 330B - 350 L 966F - 980F
C9 D6R 973 330D
C11 725, 730 966
C13 345 972
3400 D8R - D10R 769 - 775 375 - 5080 980G - 990 II
C15 D8T 735,740 980H
C18 D9T 771 385C 988H
C27 D10T
3500 D11R 777 - 797 5130 - 5230 992G - 994D
Engine Build Locations
Build Location Engine Models
Peterborough, England 3011 3013 3024 3034 3054 3056 C1.5 C2.2 C6.6
Mossville, Illinois 3406 3456 C-10 C11 C-12 C13 C15 C-16 C18
Lafayette, Indiana 3508 3512 3516 3520 3524 C175-12 C175-16 C175-20 3606 3608 3612 3616
Keil, Germany CM20 CM25 CM32 CM43 GCM34 M20 M25 M32 M43
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
5
4
1. Cam lobe
6 3
2. Lifter
3. Pushrods
4. Rocker arms
7
5. Bridge (intake)
6. Valve spring 8
7. Exhaust valve
2
8. Intake valves
1
Pistons, Rings, & Liners
• Cylinder liner
• O-ring seals
• Piston
• Piston rings
• Piston pin and
retainer
C15 Piston Assembly
C15
• A cylinder head is
installed on top of the
block
• The camshaft turns at ½
the speed of the
crankshaft to control
intake & exhaust
operation
Cat Compression Brake
•Intake Valve
•Actuation is part of the
Caterpillar compression
brake.
Crankshaft
Rod Bearing Journals
Front Rear
Web
Main Bearing Journals
Counterweights
Small turbo,
No wastegate
Boost
Small turbo,
with wastegate
• 2 types
Air to air (ATAAC)
Jacket water (JWAC)
Causes of Premature Wearout &
Failure of Aftercoolers
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
1 Water Pump
2 Oil Cooler
3 Passages through
block and head
4 Temp. Regulator &
Regulator Housing
5 Radiator
6 Pressure Cap
7 Hoses & Pipes
Causes of Cooling System Wear & Failure
• Single most common problem – poor coolant quality
Due to…
Not maintaining adequate levels of coolant additives
Using coolant that does not meet Cat’s specifications
Not keeping the cooling system topped off
Using coolant past its useful life
• Other problems include:
Coolant to air leaks in the aftercooler
• Causes hydraulic lock
Radiator or hose failures
• From reusing old radiators and hosing
• Failure to service the coolant relief valve
… most cooling system problems can be avoided
with proper maintenance practices!
Cooling Systems
Prevents breakdown of
oil film between pistons
and liners
Cooling Systems
Coolant flows through
passages in the cylinder block
into the cylinder head
• Cleans
Parts
Cylinder Walls
• Cools
• Seals & Lubricates
Support
Separate
Lubrication System Components
1 Oil Pump
2 Relief Valve
3 Oil Cooler
4 Oil Filter
5 Bypass Valves
6 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
Soot particles
• Oil renewal systems (for large mining agglomerating together
machines)
Barrier Filter
Centrifugal Filter
Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics
• Regulates engine
speed and timing
sequence
• Helps control
emissions
Fuel System Operation
Types of Fuel Systems
• Pump & Line • Unit Injection
Current Scroll Fuel System MUI
New Scroll Fuel System EUI
Sleeve Metering Fuel System (SMFS) HEUI
Program Electronic Engine Controls (PEEC) Common Rail
(Single Fuel)
1973 1981 1983 1988E 1994
CSFS MUI NSFS UI HEUI
Pre 1970 1970 1975 1980 1985 1990 1995 2000 2005
Timeline
1974 1987 2004
SMFS PEEC Rail
Fuel Delivery - History
• Pre-Combustion (PC)
• Direct Injection (DI)
Fuel Line Fuel Line
Fuel Injector
Electrical Wire Fuel Injector
Mechanically
Glow Plug Nozzle Controlled
Fuel Injector Unit Injector
Housing Assembly
Pre-Combustion
Piston Piston
Heat Plug
Barrel
Fill Port
Plunger
Sleeve
Spill Port
• 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 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
Exhaust out
Air manifold
• Provide adequate
quantities of clean • Compresses the
filtered intake air intake air into the
cylinders in order to
• Removes exhaust gases from the product more power
cylinders and reduces exhaust noise
Air System
Air System Components
• Precleaner
• Air Filters
• Filter Service
Indicator
• Turbochargers
• Aftercooler
• Intake & Exhaust
Manifolds
• Muffler
Air System Operation
• Flow
1. Precleaner
2. Air Filters
3. Turbocharger
4. 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)
Caterpillar’s Electronic Control Module (ECM)
and sensors control and monitor key
engine function, including:
• Fuel temperature.
• Engine oil temperature.
• Oil pressure.
• Atmospheric pressure.
• Coolant temperature.
• Injection actuation pressure
• Throttle position
• Injection timing & duration
• Logged faults
Features & Benefits of Electronics
Features Benefits
•Electronic Engine Control •Improved Emissions
Engine Speed Governing •Increased Performance &
Torque Shaping Reliability
Fuel-air Ratio Control •Improved Diagnostics
Cold Mode Strategies •Meet customer needs for
Altitude Derating New Features / Advanced
Fuel Temperature Compensation Technology
•Information Management
Accurate Tracking
Stored Results
•Engine Monitoring
Fluid Level
Fluid Pressure
Fluid Temperature
ADEM 4 Electronic Engine Control
Generations of Experience
Proven Reliability
Electronic Control Module
Competition Caterpillar
• Cut corners to lower costs • Rigid tolerances
• Don't meet Cat specs • Design updates
Cylinder Heads
Competition Caterpillar
• Oversized, unthreaded, • Properly machined
missing water holes
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 • More facing material
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 Caterpillar
• Random cross hatch • Uniform cross hatch pattern
pattern
Cylinder Liners
Competition Caterpillar
• Not machined to hone off • Pre-honed to preserve life
“saw-tooth” peaks and disperse oil better
Cylinder Liners
Features
• 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 • Correct chrome or
plasma plating plasma plating
Piston Rings
Features Advantages
• Reduced oil consumption
•Barrel-faced top ring
• Increased cylinder liner / ring life
•Correct chrome or plasma plating
• Less susceptible to breakage
•High-strength ductile iron
• Less downtime
•Heat treated
• Lower operating costs
Nickel Ring Band Pistons
C7 Piston
Competition Caterpillar
• Ring bands disbonded • Controlled casting process
• Grooves do not meet flatness, • Ultrasonic inspection
size, or location specifications • Improved reusability
Features Pistons
• Nickel-band ring
• Specially ground, tapered
• Controlled casting process
• Precise fit
Advantages
• Better sealing
• Proper bonding
C7 Piston
• Less blow-by
• Less carbon deposit • Lowered chance of seizure
• Delivers more power • Less downtime caused by part failure
• Longer wear • Lower operating costs
• Reusable
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
• Forged for high strength
213-3193
• Rod able to accept higher loads
C7 • Eliminates fretting on joint face
• Eliminates locating dowel
C11 – 223-9133
C13 – 223-9150
160-8199
C9 IRM – PELJ0174
Crankshafts
• Caterpillar • Competition
Proprietary hardening Not Reusable
process-tough core Rough surface finish
Excellent reusability Oversized journals
Polished surface finish Increased bearing friction
to <5 microns
Precise journal grinding
Integral Seals
Less noise
Aluminum
• Two piece composite/aluminum • Used on all ACERT engines
• Fully isolated • C7 thru C32
• Reduces noise up to 1dBA
Cylinder Head Gaskets
Steel spacer core sandwiched
between two layers of spring steel
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 $60 Core Deposit
Core Deposit $60 Returned
Price of New $100
Crankshafts
Water Pumps
Oil Pumps
Starters Connecting Rods
Alternators
Oil Coolers Camshafts
Air Compressors
Rocker Arms Kits
Water pumps Lifters
Rocker Arms Fuel
Cylinder Packs Pistons Packs Injection