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The purpose of this instruction is to aid in the proper use of the 4C3502 Engine Repair Indicator Kit designed for dealer Product Support Sales Representatives (PSSR).The kit enables a few simple tests to be made which will assist the PSSR in evaluating a machine's condition and in many cases determine if a before failure overhaul is recommended for the engine. When a determination cannot be made from the following procedure the dealers Service Department should be consulted for further machine evaluation.The tests described in this instruction are not intended to be a substitute for any type of inspection which might be performed by a qualified Caterpillar service mechanic.Before making a call on a customer, inspect each item in the kit to ensure it is included and in good working order. The test should be first performed on a machine in the dealership to become more familiar with the tooling.
PEEP8211 Engine Evaluation WorksheetThe Engine Evaluation Worksheet, form PEEP8211, included with the kit should be used to record the data obtained from the test. The worksheet aids in the completion of the machine condition evaluation and determination for a before failure overhaul.This instruction covers each separate section of the evaluation worksheet and the use of tooling, tests and procedures for each section.Necessary Parts
The following chart lists the items in each 4C3502 Engine Repair Indicator Kit. Replacement parts/forms can be ordered from the Parts Department except for the items with alternate sources indicated.
The kit contains only a sampling of Lubrication and Maintenance Interval Decals. A complete listing of available decals is published quarterly in the Service Magazine.
Customer And Machine Information
It is essential that this section of the worksheet be completed in full for proper documentation of the inspection. This information will allow you to begin a history file, by machine, that may be referenced later. It also contains key information to assist your Service Department should they be required to further inspect the machine or conduct repairs.Machine Working Conditions
The questions in this section are related to the machine application and its operating environment. These questions are required for the Engine Overhaul Estimator Guide calculations.The question regarding load factor assigns a rating to the amount of time the engine is fully loaded and therefore burning a maximum amount of fuel. The following descriptions will assist in rating the particular machine application being evaluated.
The load factor descriptions may also be found in the Performance Handbook and on the Overhaul Estimator.
Track-Type Tractors
High: Steady ripping, shuttle pushloading, agricultural drawbar work at full throttle, little or no idle or travel in reverse. Medium: Production dozing, pulling scrapers, most pushloading. Low: Considerable idle or travel with no load.Motor Graders
High: Ditching, fill spreading, spreading base material, ripping, heavy road maintenance, snow plowing. Medium: Average road maintenance, road mix work, scarifying, snow plowing. Low: Finish grading, light maintenance, road travel.Skidders
High: Skidding large loads [6810 kg (15000 lb) for the 518; 11350 kg (25000 lb) for the 528] in steep terrain (over 10%) with high skidding resistance. Medium: Skidding medium size loads [4540-6810 kg (10000-15000 lb) for the 518; 6810-11350 kg (15,000-25,000 lb for the 528] in moderate terrains (5-10%) with average skidding resistance. Low: Skidding small loads in flat terrain with low skidding resistance.Feller Bunchers, Delimbers And Loaders
High: Steady felling and bunching with little idle time. Medium: Steady cycling with frequent periods of idle. Low: Light easy work. Considerable idling.Backhoe Loaders
High: Production work with long cycles and/or constant flow implements. Medium: General work with regular cycles in medium applications. Low: Utility work with intermittent cycles in light to medium applications.Pipelayers
High: Steady cycling, little or no idle time. Medium: Normal cycling, less than 50% idle time. Low: Light duty utility with 50% or more idle time.Wheel Tractor-Scrapers
High: Continuous high total resistance conditions with steady cycling. Medium: Typical road building use. Low: Average use but with considerable idling, favorable grades, low rolling resistance and easy loading material.Off-Highway Trucks And Tractors
High: Long haul times with frequent unfavorable grades. Steady cycling with little or no idle time. Haul roads are poorly maintained with high rolling resistance. Medium: Normal load and hull times. Some adverse grades. Varying load and haul road resistance. Low: Considerable idle time. Short to medium hauls on well maintained roads. Minimum total resistance.Articulated Dump Trucks
High: Long haul times with frequent unfavorable grades. Steady cycling with little or no idle time. Haul roads are poorly maintained with high rolling resistance. Medium: Normal load and haul times. Some adverse grades. Varying load and haul road resistance. Low: Considerable idle time. Short to medium hauls on well maintained roads. Minimum total resistance.Wheel Tractors And Compactors
High: Heavy dozing, compacting heavy material. Medium: Production dozing, most pushloading, shovel cleanup, normal compaction. Low: Considerable idle or travel with no load.Wheel Loaders
High: Steady cycling on the basic loader cycle. Medium: Steady cycling but over haul distances or work on basic loader cycle with frequent periods of idle. Low: Light utility work. Considerable idle.Track-Type Loaders
High: Continuous loading from bank on basic loader cycle. Medium: Bank loading on basic loader cycle with idle periods or stockpile work including travel. Low: Large amounts of idle in any application.Hydraulic Excavators
High: Most pipeline applications in hard, rocky material. Digging 90-95% of the daily work schedule. Medium: Most residential sewer applications in natural bed clay. Digging 60-85% of the daily work schedule. Most log loading applications. Low: Most utility, urban applications in sandy loam. Digging less than 50% of the daily work schedule. Scrap handling applications.Front Shovels
High: Steady cycling in hard to dig material. Medium: Steady cycling with frequent periods of idle. Low: Light easy work, considerable idle.Visual Engine Inspection
Walk around the machine and inspect those items listed on the worksheet. Any problems found should be noted on the worksheet, brought to the attention of the customer and either corrected by him or your Service Department.