1985/09/01 Caterpillar

Caterpillar's "framework" for maintenance and repair options shows the cost saving choices at a glance.

A constant concern of fleet managers and owner/operators is that loads get where they're going on time without equipment failure. If an engine quits in the middle of the desert, drivers and owners are in serious trouble. What can be done to prevent this from happening? Caterpillar has established a logical sequence of maintenance and repair procedures to help ensure dependable engine operation.

Three procedures will help you meet your engine's needs from the day it enters service to the date it is retired. They are: periodic maintenance and service; before-failure repairs; and, after-failure repairs.

A kit can help keep the cooling system clean. Periodic cleaning is essential for good engine health.

Caterpillar Engine parts and service Dealers support this approach with a variety of options, including dealer-performed flat-rated repairs, convenient do-it-yourself repair kits, and a full line of exchange components including Caterpillar factory Remanufactured Products. If you incorporate this management method, you can establish a repair-before-failure program. This program will significantly reduce your cost-per-mile expenses and ensure you will not incur downtime. If you are to survive, you must have a plan. It can be your best route to success in a business that demands every advantage your can give it.

PM kits insure you have everything you need-filters and cooling system conditioner, plus oil sample bottle and mailer (optional).

Preventive Maintenance

To keep your engine running, you need to service it on a regular basis. Changing oil and filters, adding cooling system conditioner, and taking regularly scheduled oil samples for analysis are all necessary functions if you are to make each trip without any unexpected failures. This PM can be performed by you or your local engine dealer. If you choose to do it yourself, Caterpillar has "kits" which contain everything you need, except the oil, including step instructions.

Tune up kits are available for all Caterpillar mid-range and heavy-duty diesel engines. Kits include exchange nozzles and instructions.

Repair Indicators

Let's assume your engine is receiving regular PM, but something doesn't seem right. Who is better equipped to realize this than the person who lives with his truck day in and day out? An indicator can be one of two types-planned or problem.

A planned indicator can be the number of hours or miles on the engine. At certain points, you know that the engine is going to need service, overhauling, or exchanging. Rather than let it run to failure, you PLAN for the repair.

A problem indicator might occur on the road and all of a sudden you notice a loss of power or, more realistically, your fuel pressure begins to drop and you have to shift down one more gear to make the same grade you took last week in direct drive. Another problem indicator could be your oil sampling report. if you are enrolled in Caterpillar's Scheduled Oil Sampling (S *O*S) Program, your Caterpillar Dealer will be analyzing your oil, interpreting the results, and sending you reports. For example, if the iron, aluminum, chrome and silicon readings all increase, it normally indicates dirt entry which results in cylinder liner, ring, and piston wear. Often this can be corrected, before serious damage is done, by finding and fixing an air inlet leak.

When one of these repair indicators has surfaced, you will want to take action. The first step is to talk it over with your mechanic or dealer service manager. Between the two of you, you will identify the problem and what fix will solve it. It may be that your engine simply needs a tune-up and some adjustments. Or, it may be that your dealer will recommend a "Power Analysis Report" (PAR) to make a further diagnosis of the problem. PAR is generally recommended if you have a power complaint and want to verify the engine's output throughout its entire operating range. Another choice might be an external maintenance inspection and repair. During this inspection, it may be found that an external component needs repair such as a turbocharger, water pump, fuel pump, or starter. It can usually be quickly exchanged, and you will be on your way.

Repair Determination Inspection

If the external inspection does not reveal the source of the problem, more information will be needed to recommend the most economical repair options. An inexpensive repair determination inspection can provide this information and help you select the best repair option to fit your needs and pocketbook. This inspection is very similar to exploratory surgery; it opens up the engine to find out what the problem is.

Now, once the exploration or repair determination inspection is made, you should have the information necessary to make the best repair choice. The Caterpillar Engine parts and service dealer breaks these choices down into two major categories: before-failure repairs and after-failure repairs. The before-failure repair is always less expensive because you can reuse the most parts- generally things are just worn, not broken. You should always try for making before-failure repairs to keep expenses as low as possible.

Before-failure Repairs

If a repair determination inspection reveals that your engine has not suffered crankshaft or block damage, the repair can normally be made in-frame without removing the engine from the truck. In this category, you have three options.

1. Lower End Overhaul

A lower end overhaul, or what is commonly called "bearing roll-in", consists of rolling in main and rod bearings with the engine still in the truck. It is done when the engine is not using oil, and the cylinder bores are in good condition but the bearings are worn out due to normal wear. This will be especially important to you if your engine has the older style of nickel-bonded bearings. If copper-bonded bearings are used, they will probably not need replacement between major overhauls. The cost of a bearing roll-in is minimal - between 3% and 5% of new engine cost. It is especially economical when compared to the cost of a new crankshaft or block. Your Caterpillar Dealer offers lower end overhaul flat rates or kits, with step-by-step instructions available, if you want to do it yourself.

2. In-Frame Overhaul

If your engine has both cylinder bore and bearing wear, consider an frame overhaul. If you have practiced good engine maintenance but your engine has just worn out in normal use, you can save money with an in-frame overhaul. The cost will be 20 to 25% of new engine cost. If you can do it yourself, Caterpillar parts and service dealers have in-frame kits that include all the parts, exchange components, gaskets, and instructions needed to do the job. In some cases, even the special tools maybe provided for a modest fee.

Whether or not you should attempt to do an in-frame overhaul is another matter. If you build hot rods, race stock cars, or rebuild motorcycles, you can probably do your own in-frame overhaul. On the other hand, if you have never done more than change oil and filters and check the radiator, chances are you will want to leave the in-frame overhaul to your dealer. He can also help if your shop is full or too busy to get the job done on time.

3. Reassemble "As Is"

After the repair determination inspection, you may decide not to make repairs. You can trade it as is, use it as a back-up unit, or continue to run it. In any event, you make the decision; but you make it from a position of knowledge, not just chance and a good guess.

After-failure Repairs

If for some reason your engine should fail, you still have many economical repair options. These will depend on the type and degree of damage. In some cases, the engine does not require removal. Let's review these options by type of damage.

1. Cylinder Block "Only" Damage

Normally, cylinder block damage occurs in the upper end of the engine. It can be pitting, liner seal erosion, etc. These repairs will not usually require engine removal. The options are:

a. Remove and install a new liner (linered engines.)

b. Boring and installing an oversized piston in unlinered engines.

c. Boring and sleeving the damaged cylinder (unlinered engines).

d. Installing a new cylinder block (all less-expensive options should be considered first.)

2. Crankshaft Only Damage

This damage generally occurs when a rod or main bearing fails. Crankshaft replacement usually requires engine removal. Options include:

a. Caterpillar factory Remanufactured Crankshaft.

b. New crankshaft-your old crankshaft may be a valuable trade-in.

c. Regrind your crankshaft.

3. Cylinder Block and Crankshaft Damage

Occasionally this damage occurs. It happens when a main bearing spins and requires engine removal. Options are:

a. Recondition block and regrind crankshaft.

b. Recondition block and install a replacement crankshaft.

c. Install a Caterpillar Remanufactured Short Block

d. Install a new short block.

e. Install a new block and crankshaft.

4. Complete Engine Replacement

If you have extensive damage and downtime is critical, complete engine replacement may be the only practical repair. Here are the options:

a. Install a Caterpillar factory Remanufactured Engine for about 50 to 60 % of the cost of a new engine.

b. Install a new Caterpillar Engine.

Through proper maintenance management, you can be in complete control of every situation. You will be managing your repairs, they will not be managing you. It is the smart way to go in a business that challenges you to carefully consider every option available.