CARRIER A-DIFF 2K5085 - Caterpillar

The maintenance intervals that are listed in this Operation and Maintenance Manual, "Maintenance Interval Schedule" are expressed in service hours. A more accurate figure to use is fuel consumption. Fuel consumption corresponds more accurately to the engine load.Refer to this Operation and Maintenance Manual, "Maintenance Recommendations" to determine the maintenance interval for an in-frame overhaul.Typically, an in-frame overhaul does not require the engine to be removed. Instead, the service is performed with the engine in place. If the customer requires a minimum disruption in the production of power, the engine can be replaced with a rebuilt model of identical specifications.Note: The generator or the driven equipment may also require service when the in-frame overhaul is performed.An in-frame overhaul includes all the work that is done for a top end overhaul. Also, some other components that wear are replaced. Some components are inspected for good condition. Some components are reconditioned or replaced, if necessary.Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.If you elect to perform an in-frame overhaul without the services of a Caterpillar dealer, be aware of the following recommendations.For instructions on removal and installation of components, see the Service Manual, "Disassembly and Assembly" module.Replacement of Components
Replace the following worn components with new components during the in-frame overhaul.
Aftercooler core
Camshaft bearings
Camshaft thrust washers
Connecting rod bearings
Crankshaft thrust washers
Crankshaft vibration damper
Crankshaft seals
Electronic unit injectors
Exhaust system shields
Fuel rails
Gear train bushing and bearings
Main bearings
Piston rings
Pressure sensors
Temperature sensors
Turbocharger cartridgesInspection, Reconditioning, or Exchanging 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".Recondition the worn components or exchange the components, if necessary. Your Caterpillar dealer can provide these services and components.
Auxiliary water pump
Camshaft followers
Connecting rods
Critical fasteners
Cylinder head assembly
Cylinder liners
Engine mounts
Engine wiring harness
Fuel pressure regulating valve
Fuel priming pump
Fuel transfer pump
Inlet manifold gaskets
Inlet manifold seals
Oil cooler core
Oil pump
Pistons
Piston pins
Prelube pump
Push rods
Rocker arms
Software update
Spacer plate
Starter
Turbochargers
Water pumpInspection 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".
Camshaft
Crankshaft vibration damper
Driven equipment (alignment)
Engine control module
Front gear train
Oil screenInspect the camshaft for damage to the journals and the lobes. Inspect the following components for signs of wear and/or for signs of fatigue:
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