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Engine Works & Wears•   Engine Wear•   Combustion Process•   Internal Components•   External Components•   Cooling System•...
Electronic Control Module (ECM)Caterpillar’s Electronic Control Module (ECM)  and sensors control and monitor key  engine ...
Features & Benefits of ElectronicsFeatures                             Benefits•Electronic Engine Control           •Impro...
ADEM 4 Electronic Engine Control  Generations of Experience 1987      1991       1993       1998 32-bit   2004 32-bit 8-bi...
Electronic Control ModuleWhat if an ECM Fails?• Troubleshooting guides help identify a component  or harness problem• “Lim...
Electronic Control ModuleWhat if a Sensor or Wiring Harness Fails?• Decision to repair or replace depends on the problem• ...
PEHJ0145
Agenda• Engine Families• Engine Works & Wears      Engine Wear      Combustion Process      Internal Components      E...
Engine Parts Quality            •   Total System Design            •   "Same as Caterpillar"            •   Motives       ...
Cylinder HeadsCompetition                    Caterpillar• Cut corners to lower costs   • Rigid tolerances• Dont meet Cat s...
Cylinder Heads Competition                Caterpillar• Oversized, unthreaded,   • Properly machined  missing water holes
Cylinder HeadsCompetition            Caterpillar• Blocked passages     • Rigid cleaning process
Cylinder HeadsFeatures•   Properly machined parts•   Rigid Cleaning Process•   Rigid Tolerances•   Design Updates•   Right...
ValvesCompetition            Caterpillar• Turning marks        • Precisely ground
Exhaust ValvesCompetition                Caterpillar• Inadequate facing        • More facing material  material           ...
Valves, Solution – AdvantageFeatures•   Precisely ground•   High strength material•   More facing material than    industr...
Cylinder LinersCompetition•   Not roll burnished•   Flange thickness out of spec•   O-Ring grooves not chamfered•   Increa...
Cylinder LinersCompetition                Caterpillar• Random cross hatch       • Uniform cross hatch pattern  pattern
Cylinder LinersCompetition                  Caterpillar• Not machined to hone off   • Pre-honed to preserve life  “saw-too...
Cylinder LinersFeatures•   Uniform cross hatch pattern•   Roll burnished•   Controlled flange head thickness•   Chamfered ...
Cylinder Liners    Advantages    • Proper oil distribution    • Longer liner life    • Increased strength; reduced      su...
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Engine systems diesel engine analyst - parte 3

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Engine systems diesel engine analyst - parte 3

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Engine systems diesel engine analyst - parte 3

  1. 1. Engine Works & Wears• Engine Wear• Combustion Process• Internal Components• External Components• Cooling System• Lubrication System• Fuel System• Air System• Electronics
  2. 2. Electronic Control Module (ECM)Caterpillar’s Electronic Control Module (ECM) and sensors control and monitor key engine function, including:• Fuel temperature.• Engine oil temperature.• Oil pressure.• Atmospheric pressure.• Coolant temperature.• Injection actuation pressure• Throttle position• Injection timing & duration• Logged faults
  3. 3. Features & Benefits of ElectronicsFeatures Benefits•Electronic Engine Control •Improved Emissions Engine Speed Governing •Increased Performance & Torque Shaping Reliability Fuel-air Ratio Control •Improved Diagnostics Cold Mode Strategies •Meet customer needs for Altitude Derating New Features / Advanced Fuel Temperature Compensation Technology•Information Management Accurate Tracking Stored Results•Engine Monitoring Fluid Level Fluid Pressure Fluid Temperature
  4. 4. ADEM 4 Electronic Engine Control Generations of Experience 1987 1991 1993 1998 32-bit 2004 32-bit 8-bit Advanced Two 8-bit ADEM III 8-bit ADEM II ADEM 4PEEC II PEEC III Proven Reliability
  5. 5. Electronic Control ModuleWhat if an ECM Fails?• Troubleshooting guides help identify a component or harness problem• “Limp home” modes• Ability to flash files at repair siteECM Replacement Options?• No serviceable piece parts• Some Reman offerings exist
  6. 6. Electronic Control ModuleWhat if a Sensor or Wiring Harness Fails?• Decision to repair or replace depends on the problem• Sensors and harness segments are serviceable• Replacing an entire harness is a last resort
  7. 7. PEHJ0145
  8. 8. Agenda• Engine Families• Engine Works & Wears  Engine Wear  Combustion Process  Internal Components  External Components  Cooling System  Lube System  Fuel System  Air System  Electronics• Parts Differentiation• REMAN• Resources
  9. 9. Engine Parts Quality • Total System Design • "Same as Caterpillar" • Motives • Parts Availability • Design Modifications • Quality • Reusability • Repair Solutions  New, Reman, Classic, Kits
  10. 10. Cylinder HeadsCompetition Caterpillar• Cut corners to lower costs • Rigid tolerances• Dont meet Cat specs • Design updates
  11. 11. Cylinder Heads Competition Caterpillar• Oversized, unthreaded, • Properly machined missing water holes
  12. 12. Cylinder HeadsCompetition Caterpillar• Blocked passages • Rigid cleaning process
  13. 13. Cylinder HeadsFeatures• Properly machined parts• Rigid Cleaning Process• Rigid Tolerances• Design Updates• Right design for the systemAdvantages• Optimal cooling• Less likelihood of leaks developing and so less chance of problems related to leaking and/or overheating• More durable• Longer life• More reliable operation• Less downtime so ultimately lower cost
  14. 14. ValvesCompetition Caterpillar• Turning marks • Precisely ground
  15. 15. Exhaust ValvesCompetition Caterpillar• Inadequate facing • More facing material material than industry standard
  16. 16. Valves, Solution – AdvantageFeatures• Precisely ground• High strength material• More facing material than industry standardAdvantages Estimate Repairs• Increased protection against valve lip cracking and stem breakage• Increased strength that allows for reusability through 1 or 2 overhauls• Greater fatigue strength• Longer wear life• More durable• More reliable operation• Less downtime so ultimately lower cost Discussion
  17. 17. Cylinder LinersCompetition• Not roll burnished• Flange thickness out of spec• O-Ring grooves not chamfered• Increased chance of crackingCaterpillar• Roll burnished• Controlled flange head thickness• Chamfered O-Ring seal grooves• Heat treated
  18. 18. Cylinder LinersCompetition Caterpillar• Random cross hatch • Uniform cross hatch pattern pattern
  19. 19. Cylinder LinersCompetition Caterpillar• Not machined to hone off • Pre-honed to preserve life “saw-tooth” peaks and disperse oil better
  20. 20. Cylinder LinersFeatures• Uniform cross hatch pattern• Roll burnished• Controlled flange head thickness• Chamfered O-Ring seal grooves• Heat treated• High-grade gray iron• Perfect fit
  21. 21. Cylinder Liners Advantages • Proper oil distribution • Longer liner life • Increased strength; reduced susceptibility to cracking • Leakage prevention • Reusable at first overhaul • Lower repair / maintenance costs over time • Higher productivity • Less downtime

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