ROLLER GP-TRACK 5363549 - Caterpillar

Table 1
Overhaul Schedule
First Occurrence Following Intermediate Overhaul
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 reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, "Index of Publications on Reusability or Salvage of Used Parts".
Aftertreatment dosing cabinet
Aftertreatment CEM
Camshaft
Coolant (SCA) temperature regulator (ESTAT)
Crankshaft
Driven equipment (Alignment)
Engine cylinder block
Flywheel
High-pressure fuel lines
Rear gear train
Oil suction screenReconditioning or Exchanging of Components
Inspect the following components according to the instructions that are in Cat 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 Cat dealer can provide these services and components.
Aftertreatment DEF injector
Aftertreatment DEF pump
Camshaft followers
Connecting rods
Coolant (SCA) temperature regulator (ESTAT)
Cooling system including, tubes, brackets, clips, housings, and elbows
Crankshaft vibration damper
Cylinder head assembly
Cylinder liners
Engine mounts
Exhaust manifolds
Fuel pressure regulating valve
Fuel transfer pump
Jacket water pump
Oil cooler bypass valve
Oil cooler core
Oil lubrication system including tubes, brackets, clips, housings, and elbows
Oil pressure regulating valve
Oil Prelube pump
Oil pump
Piston pins
Rocker arms
SCAC water pump
Software update
Starter motorReplacement of Components
Replace the following components during the major overhaul:
Aftercooler core
Aftercooler gaskets and air inlet bolts
Aftertreatment air regulator
Aftertreatment air strainer
Aftertreatment catalysts
Aftertreatment CEM sensors and harnesses
Aftertreatment DEF strainer
Aftertreatment dosing cabinet sensors, harnesses, and solenoid valves
Aftertreatment sensors including temperature, DEF level, and pressure
Air inlet compression bellows
Air inlet manifold gaskets and seals
Camshaft bearings
Camshaft thrust washers
Connecting rod bearings
Coolant (SCA) temperature regulator (ESTAT)
Crankshaft seals
Crankshaft thrust washers
Engine control module
Engine sensors - level, pressure, speed, and temperature
Engine wiring harness
Exhaust bellow shields
Exhaust manifold bellows, clamps, and bolts
Exhaust manifold (Turbine inlet) supports and hardware
Exhaust manifold seals
Flexible pipe bellow, turbine outlet elbows, and clamps
Flexible pipe heat shielding
Flywheel ring gear
Front gear train
Fuel accumulator
Fuel