Engine, Drive Train, and Hydraulic Repair Indicator Quick Reference Guide

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1 Engine, Drive Train, and Hydraulic Repair Indicator Quick Reference Guide

2 Planned Indicators Planned Indicators SM provide the best insight Service Meter Hours CAT Engine Repair Indicators Description into internal component wear and potential failure. Operating and Maintenance Manual gives general guidelines for servicing based on service meter hours. Experience Talking with your machine s operator can - Observation and Discussion reveal many potential component problems. Service History Fuel Consumption Site Operations Maintenance Advisor (SOMA) Service history indicates how frequently routine maintenance is performed. Indicates when a piece of equipment is operating at less than optimum efficiency. SOMA is a software that assesses customers operating and maintenance practices and provides component life estimates. Excess black smoke Dirty primary/secondary air cleaner Faulty Turbocharger at full load Operating in too high a gear Technical Analysis Inspection (hot, unburned fuel) Overfueling Overloading Increased fuel Malfunctioning fuel nozzles/injectors Technical Analysis Inspection consumption Malfunctioning turbocharger Dirty air cleaner Tune-up Improper set point Fuel leak Blue smoke Worn turbocharger seals S O S Fluid Analysis (oil consumption) Worn rings/liners Component Inspection/Repair Worn valve guides Repair Determination Inspection Hours on engine White smoke Cracked head and/or liners Technical Analysis Inspection (steam: water in Leaking head gasket combustion chamber)

3 CAT Engine Repair Indicators (Continued) White smoke Incorrect starting procedure (on start-up: unburned fuel) Incorrect fuel injection timing Tune-up Faulty injector Increased oil Worn or broken rings/liners S O S Fluid Analysis consumption Worn turbocharger seals Component Inspection/Repair (excess blow-by) Worn valve guides Repair Determination Inspection Hours on engine Technical Analysis Inspection Unusual Noises Malfunctioning fuel nozzles/injectors Technical Analysis Inspection Malfunctioning turbocharger Repair Determination Inspection Worn piston pin bushings Component Inspection/Repair Worn rod/main bearings Too much valve lash Tune-up Lack of power Incorrect adjustment of governor linkage Technical Analysis Inspection Malfunctioning fuel nozzles/injectors Slipping torque converter Tune-up Improper set point Dirty fuel filter Dirty air cleaner Low quality fuel Overheating Malfunctioning temperature regulator Technical Analysis Inspection Incorrect adjustment or worn belts/pulleys Incorrect operator technique Cooling System Maintenance Plugged radiator core (external and internal) Low coolant level Dirty air cleaner Hard starting Malfunctioning fuel nozzles/injectors (engine missing) Improper starting technique Tune-up Worn fuel injector pump Slipping torque converter Low cranking speed Low quality fuel (low cetane rating or water in fuel) Oil level over full Coolant/fuel leak into crankcase S O S Fluid Analysis Improper oil fill Debris in oil filter Coolant/fuel leakage into crankcase S O S Fluid Analysis Extended oil change period Damaged bearings Incorrect oil use Dirt in entryway

4 CAT Final Drive Repair Indicators Brake Slippage Worn plates and disks Technical Analysis Inspection Wrong oil used Linkage out of adjustment Unusual Noises Worn plates and disks Technical Analysis Inspection Dirt in entryway Overheating Wrong oil used Technical Analysis Inspection Worn or damaged seals Debris on Magnetic Plug Dirt in entryway Wrong oil used Extended oil change period Disc disintegration Worn gears or bearings Vibration Gear failure Technical Analysis Inspection Sprocket failure Bearing failure Leaks Worn, hard, cracked seals Sprocket failure Bearing failure

5 CAT Transmission Repair Indicators Hesitation/Slippage Worn plates and disks Technical Analysis Inspection Linkage out of adjustment Linkage not free Incorrect pressure settings Wrong oil used Unusual Noises Worn gears/bearings Technical Analysis Inspection Dirt in entryway Aeration/cavitation s Vibration Bent drive shaft Technical Analysis Inspection Gear failure Bearing failure Overheating Wrong oil used Technical Analysis Inspection Plugged radiator Worn pump/pressure relief valve Worn or damaged seals Worn or dirty control valve Debris in Filter/ Dirt in entryway on Magnetic Screen Wrong oil used Extended oil change period Worn gears/bearings Disk disintegration Leaks Worn, hard, cracked seals

6 CAT Differential Repair Indicators Bent or Damaged Lines External damage Technical Analysis Inspection Unusual Noises Worn gears/bearings Technical Analysis Inspection (when traveling straight) Ring & pinion need adjustment Dirt in entryway Unusual Noises Worn differential case assembly Technical Analysis Inspection (when turning) Worn spiders Worn spider gears Vibration Gear failure Technical Analysis Inspection Spider failure Differential failure Bearing failure Debris on Magnetic Contamination entry (dirt/debris) Plug Extended oil change period Wrong oil used Worn gears/bearings Leaks Worn/damaged seals (pinion/differential) Worn bearings Overheating Wrong oil used Technical Analysis Inspection Worn or damaged seals

7 CAT Hydraulic Repair Indicators Leaks System pressure too high Hose service Scored or bent cylinder rod Thorough visual machine inspection Failed or incorrect seals Maintenance and diagnostic services Improperly torqued hose connection Worn or damaged hoses, tubes & fittings Missing guards Excessive cylinder drift Valve adjustment needed Identification and measurement Scored cylinder Diagnostic services Failed seal or seals Scored valve Contaminated oil Slow cycle times Engine performance Machine measurements Faulty Valve compared to specs Diagnostic services Worn system components Contaminated oil Noisy operation Engine performance Thorough visual machine inspection Restriction in system Aeration Worn system components Faulty relief valve System overheating Faulty oil cooler Thorough visual machine inspection Maintenance and diagnostic services Plugged filter Worn system components Faulty relief valve Wrong viscosity or contaminated oil Restriction in system Poor operator habits Loose cylinder joints Worn rod or cylinder eye/trunnion Component Inspection/Repair Poor lubrication Improper PM schedule Blisters or abrasions Pinhole leaks in liner material Thorough visual machine inspection in hose Poor hose routing Hose service External damage System overheating Excessive hose movement Improper clamping or routing of hose Hose service Aeration/cavitation

8 Commitment of service and support Cat Dealers define world-class product support. We offer you the right parts and service solutions, when and where you need them. The Cat Dealer network of highly trained experts keeps your equipment up and running to maximize your equipment investment. For more information, contact your local Cat Dealer or visit PEGJ Caterpillar All Rights Reserved Printed in U.S.A CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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