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Overhaul Considerations
Reduced hours of operation at full load and/or operating at reduced settings result in lower average power demand. Lower average power demand should increase the length of operating time before an engine overhaul is required.An overhaul is generally indicated by increased fuel consumption and reduced power. Overhaul includes completely reconditioning the cylinder head(s), but the cylinder components are not worn enough to need repair.Factors such as: conscientious preventive maintenance, fuel quality used, operating conditions, S O S oil analysis results, etc., are important considerations in deciding when to perform an overhaul.Estimating Oil Consumption
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the capacity of a makeup oil system required to accommodate your maintenance intervals.Oil consumption is proportional to the engine operating percent load. The higher the percent load, the higher the amount of oil consumed per hour.The oil consumption rate, or brake specific oil consumption (BSOC) is measured in grams/brake kW-hour (lb/bhp-hour). The BSOC varies depending on the load on your engine. Contact your Caterpillar dealer for assistance in determining typical oil consumption for your engine.Oil Consumption as an Overhaul Indicator
When an engine's oil consumption has risen to three times the initial (new) consumption rate due to normal wear, then the engine should be scheduled for overhaul. There may be a corresponding increase in blowby and a slight increase in fuel consumption.Overhaul Before Failure
A planned Overhaul Before Failure may be your best value, because you 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 failure* Get the best cost/value relationship per hour of extended lifeAfter Failure Overhaul
If you experience a major engine failure which requires removal of the engine from the hull, there are also many After Failure Overhaul options available. An overhaul should be performed if your block or crankshaft needs to be repaired.If the block and/or crankshaft is repairable, overhaul cost should be between 40 and 50 percent of the cost of a new engine (with like exchange core).This lower cost can be attributed to Caterpillar "designed-in" features, Caterpillar dealer and Caterpillar Remanufactured exchange components.Overhaul Recommendation
To minimize downtime and provide you with 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.If you elect to perform an overhaul without Caterpillar dealer overhaul service, you should be aware of the maintenance that follows. Rebuild or ExchangeAlternator, Cylinder Head Assembly, Connecting Rods, Pistons, Turbocharger, Oil Pump, Oil Pump Relief Valve, Fuel Ratio Control and Timing Advance.These components should be inspected according to the instructions found in various Caterpillar reusability publications. In order to determine the reusability publications needed for inspecting your parts, refer to the Index Of Publications On Reusability Or Salvage Of Used Parts section in SEBF8029, Guideline For Reusable Parts and Salvage Operations.The Guideline For Reusable Parts and Salvage Operations is part of an established Caterpillar parts reusability program. The guidelines were developed to assist Caterpillar dealers and customers reduce costs by avoiding unnecessary expenditures for new parts when existing parts can be used as is, or repaired, or salvaged.Parts complying with the specifications outlined in the reusable parts guideline will provide additional service life. If your parts comply with the established visual and dimensional inspection specifications expressed in the reusable parts guideline, the parts should be reused.If your parts are not within the specifications, then the parts should be salvaged, repaired, or replaced. Failure to salvage, repair or replace out-of-spec parts will result in unscheduled downtime and could result in costly repairs caused by potential damage to other engine parts.Furthermore, the use of out-of-spec parts can reduce your engine's efficiency and increase fuel consumption. Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar recommends that you salvage, repair or replace your out-of-spec parts. Install NewCrankshaft Bearings, Crankshaft Seals and Piston Rings.In most probability, your crankshaft bearings and crankshaft seals will not last until your second overhaul. Therefore, Caterpillar recommends the installation of these new components at each overhaul period. InspectCrankshaft, Camshaft, Camshaft Followers and Bearings, Damper and Cylinder BlockThe ideal time for inspecting these items is while your engine is disassembled for overhaul. Inspect each component for potential damage as follows:* Crankshaft - Inspect for deflection, journal damage and bearing material seized to the journal. At the same time, check the taper and profile of the crankshaft journals by interpreting your main and rod bearing wear patterns. If the crankshaft is removed for any reason, use the magnetic particle inspection process to check the crankshaft for cracks.* Camshaft - Inspect the camshaft for journal damage and lobe damage. If the camshaft is removed for any reason, use the magnetic particle inspection process to check the camshaft for cracks.* Camshaft Followers and Bearings - Inspect the cam bearings for fatigue and wear.* Damper - It is our recommendation to replace the damper for any of the reasons that follow.1. The engine has had a failure because of a broken crankshaft.2. The crankshaft front bearing is badly worn.3. There is a large amount of gear train wear that is not caused by a lack of oil.If none of the above conditions is found, dampers can be used again at overhaul, providing the damper is not damaged. TestFuel Injection Nozzles, Fuel Injection Pump, and GovernorHave your Caterpillar dealer check your these components for proper operation and correct settings. Your Caterpillar dealer can rebuild or furnish exchange components.The cost of diesel fuel can be 80 to 85 percent of the total cost to own and operate