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Overhaul Intervals Which are Based on Fuel Consumption and Engine Ratings
Experience has shown that the interval for an overhaul is most accurately based on fuel consumption. Fuel consumption corresponds more accurately to the engine load.
Table 1
"B" and "C" Rated Engine Overhaul Intervals
Overhaul Interval "B" Rated Interval "C" Rated Interval
Major Overhaul 1400600 L (370000 US gal) 757100 L (200000 US gal)
Table 2
"E" Rated Engine Overhaul Intervals
Overhaul Interval "E" Rated Interval
Top End 454250 L (120000 US gal)
Major Overhaul 757100 L (200000 US gal) Overhaul Intervals Which are Based on Oil Consumption
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Cat engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.The oil consumption rate (brake-specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake-specific oil consumption (BSOC) depends on the engine load. Consult your Cat dealer for assistance in determining the typical oil consumption rate for your engine.When engine oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase in blowby and a slight increase in fuel consumption.Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best value for the following reasons:
Costly unplanned downtime can be avoided.
Many original parts can be reused according to the standards for reusable parts.
The engine service life can be extended without the risk of a major catastrophe due to engine failure.
The best cost/value relationship per hour of extended life can be attained.After Failure Overhaul
If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired.If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 and 50 percent of the cost of a new engine with a similar exchange core.This lower cost can be attributed to three aspects:
Specially designed Cat engine features
Cat dealer exchange components
Caterpillar remanufactured exchange componentsCoolant Analysis
The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S O S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled.A coolant analysis can be conducted to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis.Caterpillar recommends an S O S Coolant Analysis (Level 2).S O S Coolant Analysis (Level 2)
An S O S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An S O S Coolant Analysis (Level 2) provides the following information:
Complete S O S Coolant Analysis (Level 2)
Visual inspection of properties
Identification of metal corrosion
Identification of contaminants
Identification of built up impurities (corrosion and scale)S O S Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations.For more information, refer to Special Publication, SEBU6251, "Cat Commercial Diesel Engine Fluids Recommendations" or contact your Cat dealer.Engine Components
Refer to this Operation and Maintenance Manual, "Overhaul (Top End)" for a list of components which are affected by a top end overhaul. Refer to this Operation and Maintenance Manual, "Overhaul (Major)" for a list of components which are affected by a major overhaul.Severe Service Application
Severe service operation can accelerate component wear. An engine which operates in a severe service application may need more frequent maintenance intervals for the following reasons:
Maximum reliability
Retention of full service lifeA severe service application is an application which exceeds the current published standards for that engine. Caterpillar maintains standards for the following engine parameters:
Horsepower
Range of rpm
Fuel consumption
Fuel quality
Altitude
Maintenance intervals
Selection of oil
Selection of coolant
Environmental qualities
InstallationRefer to the standards for your engine or consult your Cat dealer to determine if your engine is operating within the defined parameters.Because of individual applications, identifying all the factors which can contribute to severe operation is impossible. Consult your Cat dealer about the maintenance that is needed for your specific engine.The following factors can contribute to severe operation: environment, improper operating procedures, and improper maintenance practices.Extreme Ambient Temperatures
Extended operation in environments that are cold or hot can damage components. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in cold temperatures. Hot inlet air reduces the performance capabilities of the engine.Note: See this Operation and Maintenance Manual, "Cold-Weather Operation" topic (Operation Section), or see Supplement, SEBU5898, "Cold-Weather Recommenda