BRACKET 3109529 - Caterpillar

Fuel Consumption Before A Major Overhaul
The overhaul interval that is listed in this Operation and Maintenance Manual, "Maintenance Interval Schedule" is expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load.Table 1 lists an average range of fuel consumption for a reasonable load factor before a major overhaul. Use the range of fuel consumption only as a guideline.
Table 1
Approximate Fuel Consumption Before A Major Overhaul    
Engine Model     Fuel Consumption    
3606     11 370 000 L (3,000,000 US gal)    
3608    
15 160 000 L (4,000,000 US gal)    
3612    
22 740 000 L (6,000,000 US gal)    
3616    
30 320 000 L (8,000,000 US gal)    Remanufacturing or Rebuilding of Components
Rework the following components.
Air shutoff valve
Centrifugal oil filter bearings
Cylinder heads
Starting motorReplacement of Components
Replace the following components.
Accessory group bearings
Connecting rod bearings
Cylinder head gaskets
Cylinder head valves and valve guides
Cylinder head valve spring guides
Exhaust manifold gaskets
Exhaust manifold seals and bellows
Exhaust shields
Front gear train bearings
Inlet air line seals
Oil temperature regulators and seals
Unit injectors
Water pump bearings and seals
Water temperature regulators and sealsInspection and/or Replacement of Components
Inspect the following components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts". Replace the components, if necessary.
Aftercooler core
Alarm and shutoff controls
Camshafts
Camshaft bearings
Connecting rods
Crankshaft
Cylinder liners
Cylinder sleeves
Exhaust manifolds
Front gear group
Fuel transfer pump seals
Main bearings
Oil cooler seals
Oil pump bushings and seals
O-Ring seals and plugs
Pistons and piston rings
Priority valve
Rear gear group
Rear gear train bearings and seals
Rocker arm bearings
Thermocouples
Thrust bearings
Turbocharger bearings, bushings, and seals
Valve lubricator pump, gaskets, and seals
Valve mechanism group
Water pump bearing and sealsInspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of scuffing:
camshaft bearings
camshaft followersInspect the crankshaft for any of the following conditions:
deflection
damage to the journals
bearing material that has seized to the journalsCheck the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:
rod bearing
main bearingsNote: If the crankshaft or the camshaft are removed for any reason, use the magnetic particle inspection process to check for cracks.Replace the crankshaft vibration damper if any of the following conditions occur:
Engine failure due to a broken crankshaft
Excessive wear of the front bearing for the crankshaft
Excessive wear of the gear train that is not caused by a lack of lubricationInspect the gears of the gear train and inspect the gear train bushings for the following conditions:
Worn gear teeth
Unusual fit
Unusual wearCleaning and Inspection of Components
Clean the following components. Inspect the components for good condition. Replace the components, if necessary.Replace the gaskets and seals for the components.
Air inlet lines
Camshaft front covers
Camshaft drive gear covers
Central structure covers
Crankcase side covers
Crankshaft
Crankshaft vibration damper
Front housing group
Fuel lines
Fuel transfer pump
Gear inspection group
Oil cooler core
Oil lines
Oil suction screen
Piston undercrown
Power take-off covers
Priority valve group
Rear housing group
Rear structure covers
Valve covers
Water lines