This document provides an overview of diesel engine systems. It begins with an introduction and agenda, then discusses various engine families and the locations where they are built. It provides information on common engine components and systems, including the combustion process, cylinder head, crankshaft, piston assembly, and turbocharger. It also outlines expected engine wear items and different service strategies for rebuilding engines. The document aims to familiarize the reader with diesel engine workings and components.

1. Engine Systems
DIESEL ENGINE ANALYST

2. Introductions:
• Name:
• Address:
• College: ITM, Perú
• Dealer Name: Ferreyros S.A.

3. 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

4. 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)
3000 Series 3500 Family
(507 - 2500 kW)
400 Series
(3.7 - 45 kW)
4000 Series
(322 - 1886 kW)
M25 M32
3200 Family (1800 -
800 Series M20 (2880 -
(93 - 336kW) 2700 kW)
(39 - 60 kW) (1020 - 8000 kW)
3300 Family 1710 kW)
3600 Family
1100 Series (63 - 300 kW)
(49 - 186 kW) (1350 - 7200 kW)
This represents only a fraction of the engine offerings Caterpillar produces

5. Common Engine Terms
• Bore
• Stroke
• Compression Ratio
• Displacement
• Horsepower

6. Bore Size
• The diameter of the
cylinder
• Measured in inches
or millimeters

7. Stroke
• How far the piston
moves from TDC to
BDC
• Equal to twice the
crank radius

8. 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)

9. Displacement
• Engine size is
expressed in liters
or cubic inches
Displacement = (3.14 X B 2 ) X Stroke X No. of Cyls.
4

10. 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

11. 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

12. 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)

13. 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

14. 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

15. 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

16. 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

17. 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
C6.6
• Sculpted Block design reduced noise

18. Cross Flow Cylinder Heads
• Cross flow design and
refined port geometry
 Improved breathing
 Reduced pumping loss
 Better combustion

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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 C15
• MEUI fuel system
• Cross Flow heads
• Turbocharged and Air to Air aftercooling

25. C27 Series Features using ACERT™ Technology
• C27 replaces 3412
• Two single overhead cams
• Gear-train for cams moved to back
 Reduces noise & vibration
• Tight system tolerances - pistons & liners
 More complete fuel combustion
 Reduced blow-by
 Fewer emissions
• New block eliminates bends/turns
to improve airflow
• Proven MEUI fuel system
• ADEM™A4 Controller
• Engine oil & filter changes
increased to 500 hours under
most operating conditions
Used on D10T, 773F, 775F

26. C32 Series Features using ACERT™ Technology
• C32 replaces 3508B
• Newly designed block adds
structural strength
• Cross flow cylinder head delivers
improved air flow
• Increased compression ratio
of 16.5:1
• Proven MEUI fuel system
• ADEM™A4 Controller
• Engine oil & filter changes
increased to 500 hours under Used on 777F & D11T (fall 07)
most operating conditions

27. 3300/3400 C7- C32 Series - Service
Strategy
• Current Serviceability
 Piece parts and sub-
components for all models.
• Rebuild Strategy
 Cost effective rebuild for all
models
 Reman components, short
blocks, long blocks and
engines available
3406

28. 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
3500B
• Caterpillar fuel system

29. 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

30. 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

31. Engine Build Locations
Build Location Engine Models
Peterborough, England 3011 3013 3024 3034 3054 3056 C1.5 C2.2 C6.6
Sagami, Japan 3044 3046 3064 3066 3304 3306
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 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
All Gas engines Produced in Lafayette Indiana
Electric Power Modules Packaged @ FG Wilson or Griffen Georgia

32. 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

33. 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

34. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

35. The Combustion Process – 4 Stroke Cycle
Intake Compression

36. The Combustion Process – 4 Stroke Cycle
Power Exhaust

37. The Combustion Process – 4 Stroke Cycle

38. Reciprocation & Rotation

39. Oil Consumption and Blow-by

40. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

41. Internal Components

42. 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

43. Pistons, Rings, & Liners
• Cylinder liner
• O-ring seals
• Piston
• Piston rings
• Piston pin and
retainer

44. C15 Piston Assembly
•Piston is one piece design

45. Connecting Rod
• A connecting rod
connects the
piston to the
crankshaft

46. Cylinder Head & Cam Shaft
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

47. Cat Compression Brake
•Intake Valve
•Actuation is part of the
Caterpillar compression
brake.

48. Crankshaft
Rod Bearing Journals
Front Rear
Web
Main Bearing Journals
Counterweights
There are 2 rotations of the crankshaft for each 4 stroke cycle!

49. 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

50. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

51. 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

52. 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
Wastegate bypasses the turbine and escapes or
‘wastes’ to the exhaust stack.
Small turbo,
No wastegate
Boost
Small turbo,
with wastegate
Wastegate Actuator Large turbo
No wastegate
• Spins up quicker for good engine response
• Regulates turbo speed & prevents over-speeding Engine Load

53. • Heat exchanger for inlet air
Aftercooling
• 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)

54. 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

55. 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

56. 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

57. 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

58. Engine components
Air compressor

59. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

60. 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

61. 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

62. 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

63. 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!

64. Cooling Systems
 Coolant flows around
cylinder liners
 Absorbs heat from the
combustion chamber
 Prevents breakdown of
oil film between pistons
and liners

65. 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

66. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

67. Importance Lubrication System
70-80% crank failures are due to oil contamination.

68. Function of Lubrication System
• Cleans
 Parts
 Cylinder Walls
• Cools
• Seals & Lubricates
 Support
 Separate

69. 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

70. Engine Lube System

71. 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

72. 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

73. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics
Single Fuel System

74. Function of Fuel System
• Meters the amount
of fuel to achieve
desired power
• Regulates engine
speed and timing
sequence
• Helps control
emissions

75. Fuel System Operation

76. 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

77. 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
Pre-Combustion Direct Injection Direct Injection
Pencil Style Unit Injector

78. Sleeve Metering Fuel System
Barrel
Fill Port
Plunger
Sleeve
Spill Port
Filling Begin Continue End
Injection Injection Injection

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

80. 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

81. 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

82. 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

83. 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

84. 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

85. 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

86. Cat Fuel System – Single Fuel
Fuel Manifold
Pump
C6.6 Injector

87. 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%

88. Fuel System Wear & Failure Causes
• Injector sticking or seizure due to fuel overheating
 Fuel in the injector “cooks” and produces varnish which
causes components to stick or seize
 Viscosity of hot fuel is inadequate and the fuel film
thickness will not provide adequate protection against
scuffing or seizure of the plunger and barrel
 Fuel overheating can be caused by operating in extreme
ambient temperatures. An auxiliary fuel cooler installed in
the fuel supply line to the cylinder heads may be required
to limit fuel temperatures
 Running fuel tank too low, or running out of fuel causes
the fuel to cycle through the engine too frequently and
becomes very hot. This can be avoided by keeping the
fuel tank levels at ¼ full or above

89. 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.

91. Effect of Work Environment
• Dust
• Temperature/Climate
• Hours of continuous operation
• Terrain

92. 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

93. Stripping Out Water
• Water Separator
 Second line of defense
• All free water
• 87% emulsified water
 Injector damage

94. Removing Larger Debris
• Primary Fuel Filter
 10+ micron particle retention
• prevents premature secondary
fuel filter plugging
• protects fuel transfer pump

95. 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

96. Double Filter/Double Life
• Series filtration
 Second filter “safety net”
• Second filtering pass
• Filter failure
- Double injector wear life

97. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

98. Air Intake & Exhaust System Functions
Boost air at 300
Inlet air from air º- 400º
cleaners Inlet air from air
cleaners
Exhaust out
Air manifold
From exhaust ports
at cylinder heads
• 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

99. Air System

100. Air System Components
• Precleaner
• Air Filters
• Filter Service
Indicator
• Turbochargers
• Aftercooler
• Intake & Exhaust
Manifolds
• Muffler

101. 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

102. 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

103. Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

104. 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

105. 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

106. ADEM 4 Electronic Engine Control
Generations of Experience
1987 1991 1993 1998 32-bit 2004 32-bit
8-bit Advanced Two 8-bit ADEM III
8-bit ADEM II ADEM 4
PEEC II
PEEC III
Proven Reliability

107. 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

108. 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

109. PEHJ0145

110. 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

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

112. Cylinder Heads
Competition Caterpillar
• Cut corners to lower costs • Rigid tolerances
• Don't meet Cat specs • Design updates

113. Cylinder Heads
Competition Caterpillar
• Oversized, unthreaded, • Properly machined
missing water holes

114. Cylinder Heads
Competition Caterpillar
• Blocked passages • Rigid cleaning process

115. 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

116. Valves
Competition Caterpillar
• Turning marks • Precisely ground

117. Exhaust Valves
Competition Caterpillar
• Inadequate facing • More facing material
material than industry standard

118. 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

119. 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

120. Cylinder Liners
Competition Caterpillar
• Random cross hatch • Uniform cross hatch pattern
pattern

121. Cylinder Liners
Competition Caterpillar
• Not machined to hone off • Pre-honed to preserve life
“saw-tooth” peaks and disperse oil better

122. 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

123. 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

124. Piston Rings
Competition Caterpillar
• Flat-faced top ring • Barrel-faced top ring

125. Piston Rings
Competition Caterpillar
• Thin chrome or • Correct chrome or
plasma plating plasma plating

126. 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

127. 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

128. 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

129. 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

130. 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

131. 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

132. 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

133. Unitized Design Crankshaft Seal
For 3400 Series & C15 Engines
Old Style Clamped PTFE
New Style
Elements Bonded Elastomeric
Flanged Wear Sleeve Substrate
PTFE
Radial PTFE Oil Lip
Dirt Lip
PTFE Oil Lip
Wear Sleeve Flange
Wear Sleeve Axial Dirt Lip
Hydro-threads Hydro-threads
• Reduced potential for leakage • Significantly longer seal life
• Easier installation  Up to 2X improvement in on-highway truck
• Reduced installation damage  Up to 3X improvement in earth-moving
• Minimized contamination
• Increased reliability

134. Valve Covers
Composite
Less noise
Aluminum
• Two piece composite/aluminum • Used on all ACERT engines
• Fully isolated • C7 thru C32
• Reduces noise up to 1dBA

135. 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

136. Features Advantages
Heavy Duty Water
Temperature Regulators Prevents contamination
Lip Seal at the top of the
from infiltrating into
Guide
For Various Engine sensitive area
Applications Piston
Regulator is not stuck in
Help retain grease which
one position due to
is used to reduce friction
contamination or loss of
in the guide area
grease within guide area
247-7133 Open Temp Engine does not run cold
or hot due to a stuck
87-90 deg C regulator
248-5513 Open Temp
81-84 deg C Lower maintenance costs
New Lip Seal Guide Improved engine life

137. 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

138. Cat Remanufactured Products

139. What is Remanufacturing?
Differences between
RepairRebuildRemanufacture

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

141. 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

142. 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

143. Reman Is An Exchange Business
Reman Sale $40 $60 Core Deposit
Core Deposit $60 Returned
Price of New $100
Customer returns core
Dealer sells Reman water pump = $100
No Core = No Reman Product

144. Cat Product Support Strategy – Reman’s Role
New Cat Parts
Cat
Do It Myself Reman Parts
Product Support
Work With Me OPTIONS Dealer Exchange
Strategy
Do It For Me Classic Parts
(One Voice)
Used Parts
• Support Cat Dealer repair option & exchange programs
• Lower repair costs
• Prime path for On-Highway Truck & lower volume dealers
• Peak shaving for dealers with component rebuild centers (CRC’s)
• Help Cat Dealers manage MARC & CSA contracts profitability
• Expand product coverage through accelerated NPI
• Expand global access to Reman products
• Help alleviate technician shortages (Technician-in-a-Box)

145. Reman Engine Product Coverage
 On-Highway Truck Engines
 Long Blocks
 Short Blocks
 Cylinder Heads
 Crankshafts
 Camshafts & Kits
Short and Long Blocks  Cylinder Kits
Complete Engines
 Fuel Nozzles & Injectors
 Fuel Injection Pumps
 Fuel Air Ratio Controls
 Turbochargers Cylinder Heads
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