TURBOCHARGER GP 2104742 - Caterpillar

Scheduling a Major Overhaul
Generally, a major overhaul is performed for every other minor overhaul. The need for a major overhaul is determined by several factors. The following are some of those factors:
An increase in power end vibration
Excessive fluctuation in power end lube pressure
The presence of metallic or bearing debris in the lube tank or power end sumpAlso, the following factors must be considered for determining a major overhaul:
The service hours of the power end
The wear metal analysis of the lube oil
Individual subsystem component wearAn 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 may indicate a decrease of wear metals in the lube oil.Monitor the power end as the power end accumulates service hours. Consult your Cat dealer about scheduling a major overhaul.Note: Refer to the literature that is provided by the OEM of the driving equipment.Major Overhaul Information
A major overhaul includes all the work that is done for a minor overhaul, but also includes more parts and labor.Extra parts and labor are required to rebuild the power end completely. Usually, the Power End is relocated for disassembly.For the major overhaul, all the bearings, seals, gaskets, and components that wear are disassembled. The parts are cleaned and the parts are inspected. If necessary, the parts are replaced.Your Cat dealer can provide these services and components. Your Cat dealer can ensure that the components are operating within the appropriate specifications.The following definitions explain the terminology for the services that are performed during an overhaul:Inspect - Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to the following Guidelines for Reusable Parts and Salvage Operations and special instructions:
M0067968 , "Reusability Inspection of Well Stimulation Pump Drivetrain Components"
, M0069554 , "Reusability Inspection of Well Stimulation Pump Crankshaft"The guidelines were developed to help Cat dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired. If the components are not in the reusability guidelines, refer to the SpecificationsService Manual, “Specifications” module.Rebuild - The component can be reconditioned to comply with reusability guidelines.Replace - The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, or a used part. Consult your Cat dealer about repair options.If you elect to perform an overhaul without the services of a Cat dealer, be aware of the recommendations in Table 1. Your Cat dealer can provide these services and components
Table 1
Major Overhaul
Clean Frame
Lube Lines
Internal Frame Sump
Internal Components
Inspect Bull Gears
Connecting Rods
Crankshaft
Crossheads
Crosshead Liners
Frame
Hardware
Pinion
Pony Rods
Rod journal Bearings
Seal Housings
Stay Rods
Replace Breather
Connecting Rod Nyloc Nuts
Crankshaft Seal
Crosshead Wrist Pin Bushings
Gaskets
Pinion Seal
Pony Rod Seals
Roller Bearings
Thrust Bearings