CORE AS 3606986 - Caterpillar

Overhaul Recommendation
Caterpillar recommends a scheduled overhaul to minimize downtime. A scheduled overhaul will provide the lowest cost and the greatest value. Schedule an overhaul with your Cat dealer.Overhaul programs vary between dealers. To obtain specific information about the types of overhaul programs and services, consult your Cat dealer.Overhaul Intervals
Some factors that are important for determining the overhaul intervals include the following considerations:
Performance of preventive maintenance
Use of recommended lubricants
Use of recommended coolants
Use of recommended fuels
Proper installation
Operating conditions
Operation within acceptable limits
Engine load
Engine speedGenerally, engines that are operated at a reduced load and/or speed achieve more service life before an overhaul. This statement is for engines that are properly operated and maintained.Other factors must also be considered for determining a major overhaul:
The total amount of fuel consumption
The service hours of the engine
An increase of oil consumption
An increase of crankcase blowby
The wear metal analysis of the lube oil
An increase in the levels of noise and vibrationAn increase of wear metals in the lube oil indicates that the bearings and the wear surfaces may require service. An increase in the levels of noise and vibration indicates that rotating parts require service.Note: Oil analysis may indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals.Monitor the engine as the engine accumulates service hours. Consult your Cat dealer about scheduling a major overhaul.Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.Use whichever criteria occurs first to determine the correct interval for the maintenance procedures in table 1: fuel burned, service hours, Megawatt-hours, and years.
Table 1
Maintenance Interval Schedule(1)(2)
Interval Fuel Burned Service Hours(3) Megawatt -hours Years Maintenance Procedures
Intermediate (Midlife) Overhaul 1 2200000 L (600000 US gal) 16000 9000 5 Refer to this Operation and Maintenance Manual, "Overhaul (Intermediate)".
Major Overhaul 1 4400000 L (1200000 US gal) 32000 17000 10 Refer to this Operation and Maintenance Manual, "Overhaul (Major Overhaul)"
Intermediate (Midlife) Overhaul 2 6600000 L (1800000 US gal) 48000 25500 15 Refer to this Operation and Maintenance Manual, "Overhaul (Intermediate)"
Major Overhaul 2 8800000 L (2324960 US gal) 64000 34000 20 Refer to this Operation and Maintenance Manual, "Overhaul (Major Overhaul)"
(1) Engines rated at 1800 rpm
(2) Assumption based on cycle weighted fuel efficiency of 218
(3) Service hours are calculated based on 25% load factor and gallons per hour of 149.7Oil Consumption as an Overhaul Indicator
Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Cat engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals.Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases.The oil consumption rate (brake-specific oil consumption) is