3819996 Volvo.Penta Intermediate lever

Top End (Optional)
One maintenance interval for some engines or customers is labeled Top End Overhaul, 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.A top end overhaul is generally indicated by increased fuel consumption and reduced power. This option consists of completely reconditioning your cylinder head, but the cylinder components are not worn enough to need repair.Your Caterpillar dealer may be offering a variety of options regarding overhaul programs. Caterpillar recommends that a Top End Overhaul be performed at this maintenance interval. Top end overhaul options may be available by:* Your Caterpillar Engine parts and service dealer does the work of removing, installing and reconditioning components.* You bring your components to your dealer for reconditioning.* An exchange basis where your dealer stocks exchange or Cat Remanufactured Products for your engine.* Do-it-yourself Kits consisting of exchange cylinder head, gaskets, etc.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. The major wear items include 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 opening up of the engine. The disassembly required to perform an overhaul means that disturbed seals and gaskets, etc., will be replaced and the internal passages of the engine and block be cleaned.The maintenance schedules give intervals in hours and calendar time for overhaul. These intervals are average values and there will be engines that may require overhauling at shorter intervals and many which could go longer.The real measure of when to overhaul an engine is performance as measured by output, compression, fuel consumption and oil consumption. If an engine meets, and is still performing in accordance to all of the above parameters at acceptable levels, then it should not be overhauled even though it has reached the hourly interval.The overhaul interval in the Maintenance Schedule gives Caterpillar's recommendation for performing an overhaul. The interval is expressed in total fuel consumption as well as Service Hours. The best figure to use is total fuel consumption, even if this figure is estimated. Fuel consumption more closely follows the load upon the engine because consumption increases, as the load upon the engine increases.The hours figure is an average value for a reasonable load factor. The hours figure will be too high if the engine is run at high load and too low if the engine is lightly loaded.Use the fuel consumption or Service Hour figure only as a guideline. Other factors, such as how conscientiously preventive maintenance has been performed, fuel quality, operating conditions, S O S results, etc., are important in deciding when to perform an overhaul as well as some important economic points to keep in mind.Caterpillar has chosen the recommended overhaul periods with total operating costs in mind. The choice to continue running, or to overhaul the engine at the recommended service interval is yours. Maybe there won't be a failure within a reasonable amount of time, but more parts will require replacement and you will have to do the overhaul sooner or later anyway.By not performing an overhaul, the risk of seizing a piston, breaking a rod, fatiguing a bearing or causing other severe damage to the engine increases.Most users will save money by overhauling at the intervals recommended in the charts. It is virtually NEVER cheaper to wait for the engine to show signs of excessive wear or failure; "REPAIR-BEFORE-FAILURE" is the least expensive alternative for most components and engines, when all costs are accounted for.Overhaul Programs
Your Caterpillar dealer may be offering a variety of options regarding overhaul programs and Caterpillar recommends that an Overhaul be performed at this maintenance interval.Overhaul Before Failure
A planned overhaul may be your best value, because the program can:* Avoid costly unplanned downtime* Reuse as many original parts as standards permit* Extend your engine's service life without the risk of a major catastrophe had you continued to operate to component failure* Get the best cost/value relationship per hour of extended lifeThe cost of a scheduled, before failure overhaul is usually 20 to 25 percent of the cost of a new engine.Flat Rate Overhaul
To further control overhaul costs, Caterpillar recommends that you contact your dealer for information regarding the availability of a Flat Rate Overhaul.A Flat Rate Overhaul is not really a type of overhaul but a program that guarantees the maximum price you will pay for an overhaul. Flat Rate Overhauls will help control costs.Flat rate prices on preventive maintenance programs or major repair options are available from many servicing dealers for all Caterpillar engine models.Overhaul Options
Caterpillar Dealer - Contact your Caterpillar dealer to schedule a Before Failure Overhaul. Overhaul Kit - This useful kit was developed for those users that prefer to perform their own overhaul. This kit includes a combination of new, reused and Remanufactured parts. Also included is a step-by-step instruction regarding how to perform an overhaul. An Overhaul Kit simplifies parts ordering, helps speed repairs and reduces parts costs.Contact your local Caterpillar dealer for information regarding the Overhaul Kit.Overhaul Recommendation
To minimize downtime and provide the lowest cost and highest value, Caterpillar recommends that the engine be Overhauled Before Failure by scheduling an overhaul with your Caterpillar dealer. Overhaul programs vary with engine application and from dealer to dealer. Therefore, Caterpillar recommends that you confer with your dealer to obtain specific information regarding the types of programs offered and overhaul services provided for extending the life of your engine.Overhaul Instructions
If you elect to perform an overhaul yourself, without having a Caterpillar dealer perform the overhaul for you, or without using an overhaul kit, then you should be aware of the following: Rebuild or Exchange Cylinder Head, Connecting Rods, Cylinder Liners, Pistons, Turbochargers, Oil Pump, Water