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Maintenance Intervals
The Maintenance Schedule requires all previous interval maintenance items to be performed first. For instance, if the Every Three Month maintenance is being done, then the Every Week and Daily maintenance items must be completed BEFORE performing the Every Three Month maintenance.Engines may be equipped with various optional components and the charts may recommend maintenance for items not installed on your engine. Simply disregard reference to any extraneous items. If unsure of any item, consult your Caterpillar dealer.Top End Interval
This interval is labeled TOP END because it involves removal, inspection and rework of the cylinder head components. This interval is dependent on load-sensitive items/total amount of fuel consumed.Overhaul Interval
The last interval in each chart lists the components inspected, rebuilt, exchanged or replaced at overhaul. OVERHAUL is defined as the interval at which the major wear items in the engine should be replaced. The Overhaul interval represents overhaul of a non-failed engine. In other words, the engine is being rebuilt with certain new parts replacing worn parts such as piston rings, engine rod and main bearings, valves and valve seats., etc.Incidental to the replacement of these relatively few parts is the complete inspection of all other parts that are visible during the overhaul of the engine. The disassembly required to do an overhaul means that disturbed seals and gaskets, etc., will be replaced, and the internal passages of the engine and block be cleaned.* The TOP END and OVERHAUL intervals assume that regular maintenance recommendations in the rest of the chart have been carefully followed.* Some users may obtain significantly longer or shorter life than the chart recommends between overhauls, but if the recommended intervals are followed, OVERHAULS will occur BEFORE actual FAILURE, and the total COST of operation will be minimized.Although most users will obtain more life between overhauls than the chart recommends, Caterpillar has determined that these limits are the best (least cost) for the vast majority of our engine users. Extend the intervals to overhaul ONLY if your experience shows strong evidence that the intervals are too short for your application and maintenance practices.Interval Terminology
Engine components can generally be grouped into speed sensitive and load sensitive categories. Therefore, the maintenance interval for each item listed in the Maintenance Schedule is primarily based on the item and its relationship to either engine speed or load. Speed sensitive items such as water pumps, air compressors, etc., are not primarily affected by the load on your engine during operation. The load on an engine will not significantly accelerate the repair or replacement cycle for speed sensitive items. Therefore, the maintenance intervals established for speed sensitive items are based on calendar time. Load sensitive items such as piston rings, cylinder liners, etc., are affected by the load on your engine during operation. Generally speaking, the lower the load, the longer the engine life and conversely, the higher the load, the shorter the engine life. A heavy load on an engine will accelerate the repair or replacement cycle for load sensitive items.Load sensitive items are normally internal engine components. The amount of fuel consumed is directly related to the load on your engine. The amount of fuel consumed is a better indicator of when to perform maintenance than time or distance, however Caterpillar recognizes that fuel consumption is difficult to document in some applications. An estimated fuel consumption figure can be used to determine some intervals.Maintenance Options
Rebuild with New PartsGenuine Caterpillar parts are constantly tested and modified to incorporate the latest design advancements. Your Caterpillar dealer can rebuild or provide the parts needed for overhauling your engine. Your benefit; long lasting replacement parts at competitive prices. New ComponentsReplace worn or failing components with new components. Repair KitsThese useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair the components, in either the owner's maintenance shop or at a Caterpillar servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. ExchangeThis cost-cutting service permits you to exchange worn engine components for quality Caterpillar Remanufactured or Caterpillar dealer rebuilt components on an over-the-counter basis. When you need them, these parts are ready for a substantial savings in both time and money. Caterpillar Factory Remanufactured ComponentsThe latest remanufacturing techniques and procedures are used to restore components to like-new performance capability and to Caterpillar's original functional specifications.Usually Caterpillar Remanufactured Components have a warranty identical to that of a new part. Remanufactured parts may not be available in your area. Contact your Caterpillar dealer for information. If there is a component you need, contact your Caterpillar dealer to see if it is offered under his Dealer Exchange Component Program. The Maintenance Schedules follow in this manual. Ensure that the recommendations are adhered to.