PISTON G 6N6642 - Caterpillar

Refer to this Operation and Maintenance Manual, "Maintenance Recommendations" to determine the maintenance interval for an overhaul.The need for an intermediate 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 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 an 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.Your Cat dealer can provide these services and components. Your Cat dealer can ensure that the components are operating within the appropriate specifications.
Table 1
Overhaul Schedule
First Occurrence
Fuel Consumption 4542492 L (1200000 US gal) 4542492 L (1200000 US gal) 4542492 L (1200000 US gal) 4542492 L (1200000 US gal)
Load Factor < 25 Per Cent 25 - 30 Per Cent 30 - 50 Per Cent > 40 Per Cent
Service Hours 24000 21000 18500 16000
Load Cycles(1)(2) 192000 192000 192000 192000
(1) To illustrate engine capability, a load cycle has been defined as an increase of at least an 80 per cent rated power followed by a decrease of at least 80 per cent rated power. Load cycles of less than 80 per cent rated power may also impact the engine overhaul interval, requiring your specific operating profile to determine your appropriate interval.
(2) Determining the appropriate overhaul interval will require understanding of the locomotive operating profile including total operating hours, amount of fuel burned, load factor, load cycles, and total number of engine starts. Caterpillar requires the use of data recorders to help determine the operating profile and to set appropriate intervals for a fleet on a given route. Changes in operating profiles (a different deployment or change in the operating profile for the existing route) may require adjustment of overhaul intervals to ensure reliable performance. Failure to follow the overhaul intervals may result in unplanned repairs. For assistance with calculating load cycles, installing data recording equipment and/or confirming overhaul intervals, contact your Cat dealer.Inspection of Components
Inspect the following components according to the instructions that are in Cat