engine systems diesel engine analyst - parte 3

Engine Works & Wears Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Electronic Control Module (ECM) Caterpillar’s Electronic Control Module (ECM)

and sensors control and monitor key engine function, including:

Fuel temperature. Engine oil temperature. Oil pressure. Atmospheric pressure. Coolant temperature. Injection actuation pressure Throttle position Injection timing & duration Logged faults

Features & Benefits of ElectronicsFeaturesElectronic Engine Control

Engine Speed GoverningTorque ShapingFuel-air Ratio ControlCold Mode StrategiesAltitude DeratingFuel Temperature Compensation

Information ManagementAccurate TrackingStored Results

Engine MonitoringFluid LevelFluid PressureFluid Temperature

BenefitsImproved EmissionsIncreased Performance & Reliability Improved DiagnosticsMeet customer needs for New Features / Advanced Technology

ADEM 4 Electronic Engine Control

19878-bit

PEEC II

1991Advanced

8-bitPEEC III

1993Two 8-bitADEM II

1998 32-bitADEM III

2004 32-bit

ADEM 4

Generations of Experience

Proven Reliability

Electronic Control Module

What if an ECM Fails? Troubleshooting guides help identify a component

or harness problem “Limp home” modes Ability to flash files at repair site

ECM Replacement Options? No serviceable piece parts Some Reman offerings exist

Electronic Control Module

What if a Sensor or Wiring Harness Fails? Decision to repair or replace depends on the problem Sensors and harness segments are serviceable Replacing an entire harness is a last resort

PEHJ0145

Agenda Engine Families Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lube System Fuel System Air System Electronics

Parts Differentiation REMAN Resources

Total System Design "Same as Caterpillar" Motives Parts Availability Design Modifications Quality Reusability Repair Solutions

New, Reman, Classic, Kits

Engine Parts Quality

Cut corners to lower costs Don't meet Cat specs

Competition Rigid tolerances Design updates

Caterpillar

Cylinder Heads

Cylinder Heads

Oversized, unthreaded,missing water holes

Competition

Properly machined

Caterpillar

Blocked passages

Competition Rigid cleaning process

Caterpillar

Cylinder Heads

Cylinder HeadsFeatures Properly machined parts Rigid Cleaning Process Rigid Tolerances Design Updates Right design for the system

Advantages Optimal cooling Less likelihood of leaks developing and so less chance of

problems related to leaking and/or overheating More durable• Longer life• More reliable operation• Less downtime so ultimately lower cost

Turning marks

Competition

Precisely ground

Caterpillar

Valves

Inadequate facingmaterial

Competition More facing material

than industry standard

Caterpillar

Exhaust Valves

Features• Precisely ground• High strength material• More facing material than

industry standard

Advantages• Increased protection against valve lip cracking and stem

breakage• Increased strength that allows for reusability through 1 or 2

overhauls• Greater fatigue strength• Longer wear life• More durable• More reliable operation• Less downtime so ultimately lower cost

Estimate Repairs

DiscussionDiscussion

Valves, Solution – Advantage

Not roll burnished Flange thickness out of spec O-Ring grooves not chamfered Increased chance of cracking

Competition

Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated

Caterpillar

Cylinder Liners

Random cross hatch pattern

Competition Uniform cross hatch pattern

Caterpillar

Cylinder Liners

Competition Not machined to hone off

“saw-tooth” peaks

Caterpillar Pre-honed to preserve life

and disperse oil better

Cylinder Liners

Cylinder LinersFeatures Uniform cross hatch pattern Roll burnished Controlled flange head thickness Chamfered O-Ring seal grooves Heat treated High-grade gray iron Perfect fit

Advantages Proper oil distribution Longer liner life Increased strength; reduced

susceptibility to cracking Leakage prevention Reusable at first overhaul Lower repair / maintenance

costs over time Higher productivity Less downtime

Cylinder Liners