FILM-IDENTIFICATION 2015563 - Caterpillar

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with this maintenance interval, perform all previous maintenance interval requirements.Top End (Optional)
One maintenance interval for some engines or customers is labeled Top End Overhaul, because it involves removal, inspection and rework of the cylinder head components. This interval is dependent on load-sensitive items/total amount of fuel consumed.A top end overhaul is generally indicated by increased fuel consumption and reduced power. This option consists of completely reconditioning your cylinder head, but the cylinder components are not worn enough to need repair.Your Caterpillar dealer may be offering a variety of options regarding overhaul programs. Caterpillar recommends that a Top End Overhaul be performed at this maintenance interval. Top end overhaul options may be available by:* Your Caterpillar Engine parts and service dealer does the work of removing, installing and reconditioning components.* You bring your components to your dealer for reconditioning.* An exchange basis where your dealer stocks exchange or Cat Remanufactured Products for your engine.* Do-it-yourself Kits consisting of exchange cylinder head, gaskets, etc.Overhaul
Overhaul is defined as the interval at which the major wear items in the engine should be replaced. The overhaul interval represents overhaul of a non-failed engine. In other words, the engine is being rebuilt with certain new parts replacing worn parts. The major wear items include piston rings, engine rod and main bearings, valves, and valve seats, etc.Incidental to the replacement of these relatively few parts is the complete inspection of all other parts that are visible during the opening up of the engine. The disassembly required to perform an overhaul means that disturbed seals and gaskets, etc., will be replaced and the internal passages of the engine and block be cleaned.The maintenance schedules give intervals in hours and calendar time for overhaul. These intervals are average values and there will be engines that may require overhauling at shorter intervals and many which could go longer.The real measure of when to overhaul an engine is performance as measured by output, compression, fuel consumption and oil consumption. If an engine meets, and is still performing in accordance to all of the above parameters at acceptable levels, then it should not be overhauled even though it has reached the hourly interval.The overhaul interval in the Maintenance Schedule gives Caterpillar's recommendation for performing an overhaul. The interval is expressed in total fuel consumption as well as Service Hours. The best figure to use is total fuel consumption, even if this figure is estimated. Fuel consumption more closely follows the load upon the engine because consumption increases, as the load upon the engine increases.The hours figure is an average value for a reasonable load factor. The hours figure will be too high if the engine is run at high load and too low if the engine is lightly loaded.Use the fuel consumption or Service Hour figure only as a guideline. Other factors, such as