Professional Documents
Culture Documents
Introductions:
Name:
Address:
College: ITM, Per
Dealer Name: Ferreyros S.A.
Agenda
Engine Families
Engine Works & Wears
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lube System
Fuel System
Air System
Electronics
Parts Differentiation
REMAN
Resources
Engine Families
C-15/C18/3400
C-9/C-11/C-13 (186 - 1044 kW)
(227 - 492 kW)
3116/3126/C-7
(86 - 313 kW)
3500 Family
(507 - 2500 kW)
3000 Series
400 Series
(3.7 - 45 kW)
4000 Series
(322 - 1886 kW)
800 Series
(39 - 60 kW)
1100 Series
(49 - 186 kW)
M43
(5400 16200 kW)
3200 Family
(93 - 336kW)
3300 Family
(63 - 300 kW)
M20
(1020 1710 kW)
M25
(1800 2700 kW)
M32
(2880 8000 kW)
3600 Family
(1350 - 7200 kW)
Bore
Stroke
Compression Ratio
Displacement
Horsepower
Bore Size
The diameter of the
cylinder
Measured in inches
or millimeters
Stroke
How far the piston
moves from TDC to
BDC
Equal to twice the
crank radius
Compression Ratio
Ratio between the cylinder
volume with the piston at
BDC and the volume with
the piston at TDC
Compression ratio of our
engines are approximately
a 16:1 (non-ACERT) and
18:1 (ACERT)
Displacement
Engine size is
expressed in liters
or cubic inches
2
(3.14
X
B
) X Stroke X No. of Cyls.
Displacement =
4
Horsepower
Horsepower is the rate of doing work (how quickly a force is
applied through a distance)
Horsepower can be expressed in pound feet per second
1 horsepower = 550 lb/ft per second
= 33,000 lb/ft per minute
3054
3126B
Rebuild Strategy
3003 - 3034, expected engine life equals machine life
3046 - 3066, limited rebuild opportunity
3003
3013
3024
3034
C6.6
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
Rebuild Strategy
Cost effective rebuild for all
models
Reman components and
limited short blocks, bare
blocks, and piston packs
available
3100
3400 HEUI
C9 Series Features
using ACERT Technology
C9 Replaces the 3300
ADEM A4 Electronic Control Module
8.8 liter (537 cu in)
HEUI fuel system
Cross Flow heads ( 4 valves per cylinder)
Turbocharged and Air to Air aftercooling
Improved block and head material strength
Mid-supported liner
Integral oil cooler
Reduced weight, leaks and engine width
C9
C11
C13
C15
Rebuild Strategy
Cost effective rebuild for all
models
Reman components, short
blocks, long blocks and
engines available
3406
3500B
Rebuild Strategy
Cost effective rebuild for all models
Reman components, short blocks,
long blocks and engines available
3500 Machine
WL
906 - 939C
924 - 938
924F - 962G
950, 962
966F - 980F
966
972
980G - 990 II
980H
988H
992G - 994D
3011
3013
Sagami, Japan
3044
3046
3064
3066
Gosselies, Belgium
3116
3126
C7
C9
3126
C7
C9
Griffen, Georgia
3408
3412
C27
C30
C32
Mossville, Illinois
3406
3456
C-10
C11
C-12
Lafayette, Indiana
3508
3512
3516
3520
3524
Keil, Germany
CM20
CM25
CM32
CM43 GCM34
3024
3034
3054
Engine Models
3056
C1.5
3304
3306
C13
C15
C2.2
C6.6
C-16
C18
M25
M32
3606
M43
3608
3612
3616
Agenda
Engine Families
Engine Works & Wears
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lube System
Fuel System
Air System
Electronics
Parts Differentiation
REMAN
Resources
Engine Wear
Definition of Wear
Contact
Pressure
Relative Motion
Cylinder liners
Seals & gaskets
Piston rings
Turbo bearings and seals
Valves, guides, and seats
Main and rod bearings
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Intake
Compression
Power
Exhaust
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Internal Components
3126B/C7
Valve Train
1.
2.
3.
4.
5.
6.
7.
8.
Cam lobe
Lifter
Pushrods
Rocker arms
Bridge (intake)
Valve spring
Exhaust valve
Intake valves
4
6
7
8
2
1
Cylinder liner
O-ring seals
Piston
Piston rings
Piston pin and
retainer
Connecting Rod
A connecting rod
connects the
piston to the
crankshaft
C15
Intake Valve
Actuation is part of the
Caterpillar compression
brake.
Crankshaft
Rod Bearing Journals
Front
Rear
Web
Main Bearing Journals
Counterweights
There are 2 rotations of the crankshaft for each 4 stroke cycle!
Cylinder Block
The cylinder block is the
central component of
any engine
It houses the
components that make
up the Serious Nucleus
of the engine
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Turbocharger
Wastegate
Boost
Small turbo,
No wastegate
Wastegate Actuator
Spins up quicker for good engine response
Regulates turbo speed & prevents over-speeding
Small turbo,
with wastegate
Large turbo
No wastegate
Engine Load
Aftercooling
Water Pump
Flow of the coolant begins at the
water pump
Pump impeller creates the flow
Water pumps are gear or belt
driven
Water pump seals
Separates engine oil from coolant
Oil Cooler
Engine coolant flows from the
water pump directly into the oil
cooler
Oil carries heat away from critical
engine parts
Heat is transferred from the oil to
the engine coolant
Oil Cooler
Coolant flows through copper
tubes in the oil cooler housing
Oil flows around the outside of
the tubes
Scale build-up caused by
improper cooling system
maintenance can be cleaned out
of tubes
Engine components
Air compressor
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Cooling Systems
Coolant flows around
cylinder liners
Absorbs heat from the
combustion chamber
Prevents breakdown of
oil film between pistons
and liners
Cooling Systems
Coolant flows through
passages in the cylinder block
into the cylinder head
Water seals between the head
and block prevent coolant
leaks
Some engines have water
ferrules to direct coolant to
critical areas
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Cools
Seals & Lubricates
Support
Separate
Oil Pump
Relief Valve
Oil Cooler
Oil Filter
Bypass Valves
Oil Level Gauge
(Dipstick)
7 Oil Pressure Gauge
8 Oil Pan
Soot particles
agglomerating together
Barrier Filter
Centrifugal Filter
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Single Fuel System
1973
CSFS
1981
MUI
1975
1983
NSFS
1980
1988E
UI
1985
1990
Unit Injection
1994
HEUI
1995
MUI
EUI
HEUI
Common
Rail
(Single Fuel)
2000
2005
Timeline
1974
SMFS
1987
PEEC
2004
Rail
Pre-Combustion (PC)
Direct Injection (DI)
Fuel Line
Fuel Line
Fuel Injector
Electrical Wire
Fuel Injector
Glow Plug
Pre-Combustion
Fuel Injector
Housing
Nozzle
Assembly
Piston
Piston
Heat Plug
Pre-Combustion
Mechanically
Controlled
Unit Injector
Direct Injection
Pencil Style
Direct Injection
Unit Injector
Barrel
Fill Port
Plunger
Sleeve
Spill Port
Filling
Begin
Injection
Continue
Injection
End
Injection
MUI System
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 - Injection
On a signal from the
ECM, the solenoid
closes the fuel valve
Pressure elevates at
the tip to the 5,500 psi
needed to unseat the
valve
Injection begins
EUI - Injection
Fuel continues to inject
until the ECM signals the
solenoid to open the valve
Injection timing and
duration is controlled by the
ECM
HEUI System
A unit injector is positioned
above each cylinder
An Electronic Control Module
(ECM) controls fuel rate,
timing, and injection pressure
The injector is hydraulically
actuated
Fuel Manifold
Pump
C6.6
Injector
Dust
Temperature/Climate
Hours of continuous operation
Terrain
System Improvement
Reduce system damage caused by fuel
Water Separator
Primary Fuel Filter
Bypass Flow
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Exhaust out
Air manifold
From exhaust ports
at cylinder heads
Provide adequate
quantities of clean
filtered intake air
Compresses the
intake air into the
cylinders in order to
product more power
Air System
Flow
1.
2.
3.
4.
Precleaner
Air Filters
Turbocharger
Intake Manifold &
Cylinder Head(s)
5. Combustion
Chamber
6. Exhaust Manifold
Wear
Turbocharger
Bearings
Seals
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lubrication System
Fuel System
Air System
Electronics
Information Management
Accurate Tracking
Stored Results
Engine Monitoring
Fluid Level
Fluid Pressure
Fluid Temperature
Benefits
Improved Emissions
Increased Performance &
Reliability
Improved Diagnostics
Meet customer needs for
New Features / Advanced
Technology
Generations of Experience
1987
8-bit
PEEC II
1991
1993
Advanced
8-bit
PEEC III
Two 8-bit
ADEM II
1998 32-bit
ADEM III
2004 32-bit
ADEM 4
Proven Reliability
PEHJ0145
Agenda
Engine Families
Engine Works & Wears
Engine Wear
Combustion Process
Internal Components
External Components
Cooling System
Lube System
Fuel System
Air System
Electronics
Parts Differentiation
REMAN
Resources
Cylinder Heads
Competition
Caterpillar
Rigid tolerances
Design updates
Cylinder Heads
Competition
Oversized, unthreaded,
missing water holes
Caterpillar
Properly machined
Cylinder Heads
Competition
Caterpillar
Blocked passages
Cylinder Heads
Features
Advantages
Optimal cooling
Less likelihood of leaks developing and so less chance of
problems related to leaking and/or overheating
More durable
Longer life
More reliable operation
Less downtime so ultimately lower cost
Valves
Competition
Caterpillar
Turning marks
Precisely ground
Exhaust Valves
Competition
Caterpillar
Inadequate facing
material
Features
Precisely ground
High strength material
More facing material than
industry standard
Advantages
Estimate
Repairs
Cylinder Liners
Competition
Caterpillar
Roll burnished
Controlled flange head thickness
Chamfered O-Ring seal grooves
Heat treated
Cylinder Liners
Competition
Caterpillar
Cylinder Liners
Competition
Caterpillar
Features
Cylinder Liners
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
Piston Rings
Competition
Caterpillar
Thin chrome or
plasma plating
Correct chrome or
plasma plating
Piston Rings
Features
Barrel-faced top ring
Correct chrome or plasma plating
High-strength ductile iron
Heat treated
Advantages
Reduced oil consumption
Increased cylinder liner / ring
life
Less susceptible to breakage
Less downtime
Lower operating costs
C7 Piston
Competition
Caterpillar
Features
Pistons
Nickel-band ring
Specially ground, tapered
Controlled casting process
Precise fit
Advantages
Better sealing
Proper bonding
Less blow-by
Less carbon deposit
Delivers more power
Longer wear
Reusable
C7 Piston
Lowered chance of seizure
Less downtime caused by part
failure
Lower operating costs
213-3193
C7
C11 223-9133
C13 223-9150
160-8199
C9
IRM PELJ0174
Crankshafts
Caterpillar
Proprietary hardening
process-tough core
Excellent reusability
Polished surface finish
to <5 microns
Precise journal grinding
Competition
Not Reusable
Rough surface finish
Oversized journals
Increased bearing friction
Integral Seals
Benefits
Virtually eliminates gasket leaks.
Improved bolt torque retention vs. flat gaskets
Ease of assembly vs. flat gasket
Availability in gasket & seal kits
Radial PTFE
Dirt Lip
Hydro-threads
Wear Sleeve
Bonded Elastomeric
Substrate
Hydro-threads
Valve Covers
Composite
Less noise
Aluminum
Two piece composite/aluminum
Fully isolated
Reduces noise up to 1dBA
NewLipSeal
Piston
Guide
Features
Advantages
Prevents contamination
from infiltrating into
sensitive area
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
What is Remanufacturing?
Differences between RepairRebuildRemanufacture
Repair
Usually simple
Fixes only a specific
problem
May not use genuine CAT
parts depending on labor
source.
Rebuild
Usually retains the component identity
More than a simple repair
Usually done by dealer, customer or
re-builder
Restores to near original condition
May not use genuine Cat parts
Re-builder assumes the warranty
liability
Requires investments in tools, equip.,
training, etc
Rebuild and return or exchange
turnaround time involved
Remanufacture
Consistent factory environment
Process and quality control
Upgrades to latest engineering
changes
Harvest components (looses its
original identity)
Uses 100% genuine Cat parts
Cat Reman carries standard parts
warranty
Requires cores exchange only
Cat
Product Support
Strategy
Do It Myself
Work With Me
Do It For Me
Reman Parts
OPTIONS
(One Voice)
Dealer Exchange
Classic Parts
Used Parts
Crankshafts
Water pumps
Cylinder Packs
Complete Engines
Connecting Rods
Fuel
Injection