PAD AS 7G2703 - Caterpillar

Refer to this Operation and Maintenance Manual, "Maintenance Recommendations" to determine the maintenance interval for a major overhaul.The need for a major overhaul is determined by several factors.
An increase of oil consumption
An increase of crankcase blowby
The total amount of fuel consumption
The service hours of the engine
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 surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service.Note: Oil analysis can also 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 Caterpillar 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.A major overhaul includes all the work that is done for the top end overhaul. A major overhaul includes more parts and labor. Extra parts and labor are required to rebuild the engine completely.For the major overhaul, all the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and inspected. If necessary, the parts are replaced. The crankshaft is measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced with a Caterpillar replacement part.Your Caterpillar dealer can provide these services and components. Your Caterpillar dealer can ensure that the components are operating within the appropriate specifications.Replacement of Components
Replace the following components during the major overhaul:
Aftercooler core
Camshaft bearings
Connecting rod bearings
Crankshaft seals
Crankshaft thrust washers
Crankshaft vibration damper
Electronic unit injectors
Gear train bushings
Gear train bearings
Main bearings
Piston ringsInspection, 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.
Camshaft followers
Camshaft thrust washers
Connecting rods
Cylinder head assembly
Cylinder liners
Engine mounts
Scavenge oil pump
Engine wiring harness
Exhaust manifold seals
Exhaust manifold bellows
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
Pushrods
Rocker arms
Spacer plate
Software update
TurbochargerInspection 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".
Aftercooler core
Camshaft
Crankshaft
Driven equipment (alignment)
Engine cylinder block
Engine control module
Exhaust bellow shields
Flywheel
Front gear train (gears)
Oil suction screen
Rear gear trainInspect the camshaft for damage to the journals and the lobes.Inspect 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