Engine systems diesel engine analyst - parte 4
- 1. Piston Rings Competition Caterpillar • Flat-faced top ring • Barrel-faced top ring
- 2. Piston Rings Competition Caterpillar • Thin chrome or • Correct chrome or plasma plating plasma plating
- 3. Piston Rings Features Advantages •Barrel-faced top ring • Reduced oil consumption •Correct chrome or plasma plating • Increased cylinder liner / ring life •High-strength ductile iron • Less susceptible to breakage •Heat treated • Less downtime • Lower operating costs
- 4. Nickel Ring Band Pistons C7 Piston Competition Caterpillar • Ring bands disbonded • Controlled casting process • Grooves do not meet flatness, • Ultrasonic inspection size, or location specifications • Improved reusability
- 5. Features Pistons • Nickel-band ring • Specially ground, tapered • Controlled casting process • Precise fit Advantages • Better sealing • Proper bonding C7 Piston • Less blow-by • Less carbon deposit • Lowered chance of seizure • Delivers more power • Less downtime caused by part failure • Longer wear • Lower operating costs • Reusable
- 6. One Piece Steel Piston Used on 3408, 3412, 3500 & all ACERT engines • Increased structural capability • Machined from a single steel forging • Eliminates need for a separate aluminum skirt & possible breakage • Eliminates possible debond of ring groove • Reduced thermal expansion allows piston fit to be tighter for a reduction in liner cavitation • Reduction in surface area provides less friction and helps fuel consumption • Higher Oil Flow • Bigger piston oil gallery & new oil jets • Runs cooler thus reducing piston carbon deposit and oil consumption • New ring pack • 25% reduction in blow-by • No bushings to replace in 3408 & 3412
- 7. Fractured Split Rod Technology Models 3114, 3116, 3126, C7, C9, C11 and C13 Features • Forged for high strength 213-3193 • Rod able to accept higher loads C7 • Eliminates fretting on joint face • Eliminates locating dowel C11 – 223-9133 C13 – 223-9150 160-8199 C9 IRM – PELJ0174
- 8. Crankshafts • Caterpillar • Competition Proprietary hardening Not Reusable process-tough core Rough surface finish Excellent reusability Oversized journals Polished surface finish Increased bearing friction to <5 microns Precise journal grinding
- 9. Integral Seals Edge Bonded (Metal Carrier) Void-Volume (Plastic Carrier) Benefits • Virtually eliminates gasket leaks. • Improved bolt torque retention vs. flat gaskets • Ease of assembly vs. flat gasket • Availability in gasket & seal kits
- 10. Unitized Design Crankshaft Seal For 3400 Series & C15 Engines Old Style Clamped PTFE New Style Elements Bonded Elastomeric Flanged Wear Sleeve Substrate PTFE Radial PTFE Oil Lip Dirt Lip PTFE Oil Lip Wear Sleeve Flange Wear Sleeve Axial Dirt Lip Hydro-threads Hydro-threads • Reduced potential for leakage • Significantly longer seal life • Easier installation Up to 2X improvement in on-highway truck • Reduced installation damage Up to 3X improvement in earth-moving • Minimized contamination • Increased reliability
- 11. Valve Covers Composite Less noise Aluminum • Two piece composite/aluminum • Used on all ACERT engines • Fully isolated • C7 thru C32 • Reduces noise up to 1dBA
- 12. Cylinder Head Gaskets Steel spacer core sandwiched between two layers of spring steel Improved sealing head/block • Multi layered steel Improved durability • Sealing • Crush strength • Creep resistance • Joint stability Used on all ACERT
- 13. Features Advantages Heavy Duty Water Temperature Regulators Prevents contamination Lip Seal at the top of the from infiltrating into Guide For Various Engine sensitive area Applications Piston Regulator is not stuck in Help retain grease which one position due to is used to reduce friction contamination or loss of in the guide area grease within guide area 247-7133 Open Temp Engine does not run cold or hot due to a stuck 87-90 deg C regulator 248-5513 Open Temp 81-84 deg C Lower maintenance costs New Lip Seal Guide Improved engine life
- 14. Agenda • Engine Families • Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics • Differentiation • REMAN • Resources
- 16. What is Remanufacturing? Differences between RepairRebuildRemanufacture
- 17. Repair • Usually simple • Fixes only a specific problem • May not use genuine CAT parts depending on labor source.
- 18. Rebuild • Usually retains the component identity • More than a simple repair • Usually done by dealer, customer or re-builder • Restores to near original condition • May not use genuine Cat parts • Re-builder assumes the warranty liability • Requires investments in tools, equip., training, etc • Rebuild and return or exchange – turnaround time involved
- 19. Remanufacture • Consistent factory environment • Process and quality control • Upgrades to latest engineering changes • Harvest components (looses its original identity) • Uses 100% genuine Cat parts • Cat Reman carries standard parts warranty • Requires cores – exchange only
- 20. Reman Is An Exchange Business Reman Sale $40 $60 Core Deposit Core Deposit $60 Returned Price of New $100 Customer returns core Dealer sells Reman water pump = $100 No Core = No Reman Product
- 21. Cat Product Support Strategy – Reman’s Role New Cat Parts Cat Do It Myself Reman Parts Product Support Work With Me OPTIONS Dealer Exchange Strategy Do It For Me Classic Parts (One Voice) Used Parts • Support Cat Dealer repair option & exchange programs • Lower repair costs • Prime path for On-Highway Truck & lower volume dealers • Peak shaving for dealers with component rebuild centers (CRC’s) • Help Cat Dealers manage MARC & CSA contracts profitability • Expand product coverage through accelerated NPI • Expand global access to Reman products • Help alleviate technician shortages (Technician-in-a-Box)
- 22. Reman Engine Product Coverage On-Highway Truck Engines Long Blocks Short Blocks Cylinder Heads Crankshafts Camshafts & Kits Short and Long Blocks Cylinder Kits Complete Engines Fuel Nozzles & Injectors Fuel Injection Pumps Fuel Air Ratio Controls Turbochargers Cylinder Heads Crankshafts Water Pumps Oil Pumps Starters Connecting Rods Alternators Oil Coolers Camshafts Air Compressors Rocker Arms Kits Water pumps Lifters Rocker Arms Fuel Cylinder Packs Pistons Packs Injection
Editor's Notes
- #2: February 4, 2013 Flat-faced top rings can scrape too much oil off the cylinder wall, increasing liner and ring wear. The barrel faced ring used by Caterpillar reduces oil consumption and liner damage by maintaining the proper oil film on the cylinder liner.
- #3: February 4, 2013 The thick chrome or plasma plating on the Cat piston rings ensures longer wear life than the thin plating found on many will-fit rings. Correct chrome plating or plasma plating allows the ring to withstand the oscillating forces within an engine.
- #4: February 4, 2013 HAVE TEAM ASSIGNED TO PISTON RINGS PRESENT THE ADVANTAGES THEY COMPILED. COMPARE TO LIST ON SLIDE. ADDITIONAL POINTS TO MAKE IF NOT INCLUDED IN PARTICIPANT LISTS: Caterpillar designs and develops for exacting needs in engine model, family and application to ensure maximum productivity and life. Feature related to high-strength ductile iron use, rather than gray iron as used in competitive products, is true for all Caterpillar castings .
- #5: February 4, 2013 Will-fit manufacturers' ring bands can be partially disbonded. And, their individual ring grooves don't meet Cat flatness, size or location specs. That means they have the potential for blowby and damage to the cylinders. Caterpillar uses cast-in nickel ring bands for greater piston strength, longer wearing grooves, better sealing and piston reusability. Quality control differs between Cat and the competition. Cat uses a controlled casting process and 100% ultrasonic inspection to ensure proper bonding. Competitors' pistons show poor bonds between piston body and ring band, which can lead to piston failure. The nickel ring band pistons are used on older 3400 series engines on the top 2 rings. This 3406 IPD Piston (2W0865) was used in a 980C. It failed at 3400 hours due to the obvious ring band bond separation. The nickel band insert is used only for the top ring on the C7 engine and 3126 engines used in low HP applications. The pistons used in this applications are 1 piece aluminum. This design gets rid of a lot of the stresses of the previous designs and practically eliminates debonding failures. Older 3406, 3408 and 3412 engines still use the nickel ring bands on the top 2 rings. Engines using these pistons are still being built today.
- #6: February 4, 2013 HAVE TEAM ASSIGNED TO PISTONS PRESENT THE FEATURES AND ADVANTAGES THEY COMPILED. COMPARE TO LIST ON SLIDE. ADDITIONAL POINTS TO MAKE IF NOT INCLUDED IN PARTICIPANT LISTS: Pistons and liners need to mate precisely. Because of Caterpillar’s unique oval construction, will-fits cannot fit perfectly so result in less efficient operation and higher costs. COMPARE TO ADVANTAGES LISTED ON SLIDE. The nickel band insert is used only for the top ring on the C7 engine. 3400 series engines use the nickel band on the top 2 rings.
- #7: February 4, 2013 Here are a few more Features and Advantages related to Caterpillar pistons. A recent design improvement in Caterpillar pistons is a result of new technology. This is a one-piece piston for the 3408, 3412, 3500 and all ACERT engines. This new 1 piece piston is made from Forged Steel , it is much more durable and reliable than the previous aluminum 2 piece piston . There is no separate aluminum skirt, this eliminates the potential for a broken skirt and the possibility of debond on the ring groove . There are no bushings to replace or to fail – only for the 3408 and 3412 engines A new oil jet means higher, more control of oil flow. Have to get new oil jets; don’t reuse old jets, won’t get enough oil A bigger piston gallery means you will run cooler and consume less oil And a new ring pack means a 25% reduction in blowby or the amount of oil that is just blowing by the piston RING. Typical questions include: Does this piston have the same reciprocating mass as the old ones? Yes, can mix and match old vs. new during rebuild but dealers hesitate to do this. Do rings change? 3408 and 3412 engines have all new rings. All ACERT engines have new top rings only. The black coating on the One Piece Steel ACERT pistons is for 2 reasons. If the piston is bushingless, then the overall black coating (manganese phosphate) is for the pin bore seizure resistance and is a good binding agent for the graphite coating which is on the skirts. The graphite coating on the skirts is to help prevent skirt scuffing/seizure while the parts are wearing together. On bushed pin bore pistons, we have kept the black phosphate coating on to help the graphite to stick to the piston. As a side benefit, the black phosphate coating helps keep the piston from rusting before it is assembled. On the skirts, the graphite will wear in relation to the contact pattern between the skirt and the liner. In some places it will wear off. The reuse guidelines has pictures of what is acceptable and what is not acceptable on the loss of graphite.
- #8: February 4, 2013 Still another advancement in technology brought us is this new Fractured Split Rod for the 3114, 3116, 3126, C9, C11 & C13 engines. The new fractured split rod is forged for high strength and durability , which means the rod can accept higher loads . There has been a virtual elimination of fretting on the joint face which means perfectly matched surfaces. These rods are running about 25% less to manufacture because of reduced and controlled machining steps. In addition, the machining process Caterpillar uses ensures the cap and rod will stay together because the bearing fits correctly. The offset bearing cap design on the C9 allows the use of a 2 bolt rod design with a bigger pin journal. The alternate design would be a 4-bolt (smaller bolt diameter) non-angled split because of the small cross section that would be available at the joint.
- #9: February 4, 2013
- #10: February 4, 2013 As part of Caterpillar’s continuing development of leak free engines and drive train components, Caterpillar is changing from flat gaskets to ‘Integral seals’ for our tougher engine, hydraulic and drive train sealing applications. Integral seals provide a more robust fluid seal than flat gaskets, which are cut out of flat sheets of gasket material. Integral seals are controlled compression seals, with O-Ring technology applied to gasket-type carriers. Integral seals are comprised of a rubber sealing element, or bead, bonded to a carrier. The carrier can be plastic or metal. The carrier transfers the load through the bolted joint. The rubber bead material is chosen based on the fluids, temperatures and pressures to be sealed. Integral seal gaskets have rubber beads made from Cat formulas of Nitrile, HNBR, EPDM, FKM and Silicone rubber. Two types of Integral Seals are now being used: an Edge-Bonded (metal carrier) seal and a Void-Volume (plastic carrier) seal with integrated metal load limiters. Today these seals are used in many applications across our product line. For example, the edge bonded seal is used as the front cover seal for the 3406E engine. The void volume seal is used on a lot of oil pan applications. 2 questions typically: 1. Reuse? No from engineering (extremely low hours and some will reuse) Not a direct replacement for old gaskets since stack up tolerances could cause some interference. Additional advantage is that these seals come off in one piece; no scrapping required and no chance of getting foreign material into the engine.
- #11: February 4, 2013 Caterpillar has also developed a new crankshaft seal that features a: Unitized Seal Flange Shaped Wear Sleeve Bonded Design Superior Dirt Exclusion ASK What might some Advantages be of this new design? Probe for responses Reduced Potential for Leakage Easier Installation Reduced Installation Damage Minimized Contamination Significantly Longer Seal Life Click to bring up Advantages box. In addition, the unitized seal group provides improved and more reliable performance: Up to two times improvement in on-highway truck application in field tests Up to three times improvement in earth-moving application in field tests
- #12: February 4, 2013 Used on all ACERT Engines from C7 thru C32
- #13: February 4, 2013 Used on all ACERT Engines from C7 thru C32
- #14: February 4, 2013 The new design is a drop-in replacement for the current regulator and is designed to have longer life improvement than the current design, which will lower operating costs and reduce unscheduled engine down-time. Two different temperature regulators have been cancelled and replaced by the new regulators with internal seals: 7C-3095 has been cancelled and replaced by 247-7133. The opening temperature is 87-90 deg C and fully open temperature is 98 deg C. 4W-4794 has been cancelled and replaced by 248-5513. The opening temperature is 81-84 deg C and fully open temperature is 92 deg C. The new regulators are identified by a part number that is stamped on the regulator. There is a “+” sign stamped before and after the part number which indicates the presence of the internal seal in the regulator. Retrofits The improved temperature regulator can be utilized into existing engines in applications on the field. No additional part or service is required to utilize the new regulators. 3126B (S/N: 8YL1-UP), 3196 (S/N: 2XR1-UP), 3406B (S/N: 4TB1-UP), 3406C (S/N: 3ER1-UP), 3406E (S/N: 6TS1-UP), C-10 (S/N: MBJ1-UP; Z2B1-UP; CFA1-UP; BCX1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP), C-11 (S/N: KCA0-UP; GLD0-UP; WCE0-UP; G2C0-UP), C-12 (S/N: CPD1-UP; 9SM1-UP; TME1-UP; GEP1-UP; 9HP1-UP; BEL1-UP; CEF1-UP; MBL1-UP; 1YN1-UP; 2KS1-UP; 9NS1-UP) C-13 (S/N: KCB0-UP; LGK0-UP; WCE0-UP; PRP0-UP; JAM0-UP), C-15 (S/N: 6NZ1-UP), C-16 (S/N: 7CZ1-UP)
- #15: February 4, 2013 Next we will discuss the offerings of Cat Reman Products. Reman is just one out of many repair options when it comes to the repair of engines.
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