GLOBAL MANPOWER DEVELOPMENT

Participant Guide

Engine Repair ILT

Course Number: 29658

4/7/2008
 Course 29658
Engine Repair ILT

Length: Two Days

Prerequisites: Electrical/Electronics WBT

Basic Electricity
Electrical Circuit Components
Electrical/Electronic Components
Batteries, Charging, and Starting
Engine Repair Part 1 WBT
Engine Repair Part 2 WBT
Engine Repair Diagnostic Exercise 16
Engine Repair Diagnostic Exercise 17
Knowledge of SIS

Description: This course consists of a WBT and Hands-On component. Intended for
Caterpillar service technicians, this course will familiarize the learner with
specific engine repair techniques to supplement information covered in the
WBT component of this training. Topics include diagnosing engine
concerns, demonstrating diagnostic procedures, and inspection
techniques.

Classification: This program is intended for Caterpillar Service Technicians who have
completed the WBT prerequisite components of this course. This Hands-
On component allows Caterpillar Service Technicians to practice and
demonstrate lessons learned throughout the course. This component
focuses on the inspection, service, and equipment required to perform
engine repairs.

Class Size: 8 participants

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 Course Goal
Upon successful completion of this course, the technician will be able to inspect, service, and
troubleshoot Caterpillar engines.

Course Objectives
Upon successful completion of this course, the technician will be able to demonstrate their
ability to:

1.0 Inspect a cylinder bore using a borescope

2.0 Measure the cylinder liner projection

3.0 Diagnose cylinder bore concerns using a dial bore gauge and identify a liner that is
correctly honed

4.0 Service a cylinder head using a head bolt torque procedure

5.0 Service a valve train using a valve lash adjustment procedure

6.0 Inspect a cylinder head and block deck using a flatness procedure

7.0 Inspect valves and valve guides using a micrometer, hole gauge, and/or no-go gauge

8.0 Visually inspect crankshaft journals and bearings for wear and defects

9.0 Service crankshaft thrust bearings using a remove and replace procedure and
measuring crankshaft endplay

10.0 Inspect cylinder valve springs using a valve spring tester and square

11.0 Inspect a camshaft lobe using a micrometer

12.0 Diagnose water temperature regulator using an opening test procedure

13.0 Diagnose Jacket Water Aftercooler (JWAC) concerns using ΔP and ΔT tests and
comparing the maximum inlet air temperature and inlet manifold temperature to
specifications/Testing and Adjusting

14.0 Diagnose oil pump concerns using the gauge group

15.0 Service a cooling system using a flush procedure

16.0 Diagnose engine mechanical concerns by interpreting S.O.S results

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 Cat 7 Step Diagnostics Process

Notes:

♦ The 7 Step Diagnostics Process will be applied within each Workstation

♦ Where you are in the 7 Step Diagnostics Process with each Objective

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Investigation Phase:

Step 1: Verify the Customer Concern

1. Make sure the problem exists:

♦ Is the machine being used in the right application?
♦ Is the machine being operated correctly?
♦ Does the customer perceive a problem that is really normal
operation?
♦ Verify active fault exists (i.e. error codes on the instrument panels)
♦ Ask the operator to duplicate the concern
♦ Ask the operator:
o When
o How often
o Under what conditions

2. Document pertinent information

♦ Serial number and machine type

3. Intermittent concerns: TBD

Notes:

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Investigation Phase:

Step 2: Conduct an Initial Inspection

1. Conduct a walk-around inspection. Use all your senses to find obvious signs of damaged
components inside the cab and throughout the machine:
♦ Sight: leaks, broken, bent, or worn parts; smoke, fluid level checks, over-heated parts
♦ Sound: knocking, grinding, hissing
♦ Smell: burned fluid and over-worn parts
♦ Touch: vibration, excessive clearances (caution about heat)

2. Check the machine monitor. Make note of active service codes (be careful not to
prematurely investigate codes that are not related to the customer's original concern - don't
jump to conclusions)

3. Perform operational tests (dynamic tests) to verify customer concern:

♦ Evaluate condition of controls
♦ Evaluate operating ranges
♦ Perform cycle time test

4. Review machine history folder for recent repairs, technician comments, and preventative
maintenance practices.

5. Summarize your factual findings and compare to customer's original concern.

Notes:

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Isolate Phase:

Step 3: List Possible Causes of Concern

1. Use the factual findings that relate to original concern from step 2 to generate your list of
possible causes and potential diagnostic tests.

2. Use your understanding of the normal operation of the system, subsystems, components and
related systems to help you identify all possible components that may be the cause of concern.

Notes:

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Isolate Phase:

Step 4: Analyze possible Causes and Determine Root Cause.

1. Use Service resources including service bulletins, SIS, PIPS, Service magazines, technical
information bulletins, etc.

2. Conduct operational tests.

3. Conduct functional tests.

4. Check pertinent data in machine monitoring system to see if data supports the concern and
use data to refine the isolation of probable causes.

5. Perform troubleshooting procedures from Caterpillar Service Information System (SIS) to

assist with correct process.

6. Perform test and adjust procedures per SIS, Service Magazines, etc. Confirm if the
component or system is within specification:
♦ If it is within specification, eliminate it as a possibility of the concern and continue
analysis
♦ If it is not within specifications, make adjustment
♦ If the adjustment does not bring component within specification, continue analysis within
that component or system

7. Refine your test and adjust procedures given previous results (if required).

NOTE: Remember while inspecting, you need to determine:

♦ Is the component in question the root cause of the concern?

OR

♦ Is the component failure resultant damage from another source?

Improper maintenance
Improper service
Improper operation
Overheated or contaminated hydraulic oil
Debris from previous concerns
Debris from another source

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Repair Phase:

Step 5: Repair Root Cause

1. Use current service information as needed to complete the repair.

Step 6: Verify the Repair

1. Recreate the circumstances of the original concern to verify customer concern is resolved.

2. Ensure that the symptoms do not re-occur.

Step 7: Document the concern, analysis, and repair in the Service Report

1. Write customer concerns, tests performed, parts replaced, suggestions to customer, root
cause, and repairs made on service report for future reference.

Notes:

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 Morning/Afternoon Activities Overview
I Course Introduction

A Course Length – Two days

B Required Student Skills – Review the “Skills Required for Mastery” list

C Course Activities – On bench/desk workstations with a morning and an afternoon rotation

There will also be a morning and an afternoon debrief

D Course Evaluation – This is a competency-based course

II Session Introduction

A Briefly describe each workstation

B Each student must demonstrate key skills at each workstation

C Each workstation requires students to document their actions and in some instances
answer questions on an accompanying worksheet

D Student participation during the debriefing is essential. In addition to the remediation value
associated with the review of the exercises, it helps confirm the students’ understanding

III Workstation Rotation(s)

A Students rotate between workstations from morning through afternoon.

B Monitor the performance of all students

C Use the Required Student Skills form to document student achievement

IV Debrief Session(s)

Review the main steps of the exercise. Ask leading questions that engage dialogue. Compare
similarities or contrasts between methods and results of different student groups. Use
accompanying worksheets as an instrument to facilitate reviews.

V Lunch / Prepare for Afternoon Rotation

VI Afternoon Rotation/Debrief Session(s)

VII Dismissal

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 Course Agenda
Day One Morning AND Afternoon

♦ Class is divided into 2 groups of 4 and will rotate between workstations

♦ Students will be required to complete Handouts (Work Orders), according to the procedures
identified during completing workstation exercises

Workstation 1:
♦ Students will be required to work as a group to:
o Inspect a cylinder bore using a borescope (Objective 1)
o Diagnose cylinder bore concerns using a dial bore gauge and identify a liner that is
correctly honed (Objective 3)
o Service cylinder head using a head bolt torque procedure (Objective 4)
o Service a valve train using a valve lash adjustment procedure (Objective 5)

Workstation 2 / 3:
♦ Students will be required to work as a group to:
o Measure the cylinder liner protection (WS 2 – Objective 2)
o Inspect a cylinder head and block deck using a flatness procedure (WS 2 – Objective 6)
o Inspect valves and valve guides using a micrometer, hole gauge, and/or no-go gauge
(WS 2 – Objective 7)
o Service crankshaft thrust bearings using a remove and replace procedure and measuring
crankshaft endplay (WS 2 – Objective 9)
o Visually inspect crankshaft journals and bearings for wear and defects (WS 3– Objective 8)
o Inspect cylinder valve springs using a valve spring tester and square (WS 3– Objective 10)
o Inspect a camshaft lobe using a micrometer (WS 3– Objective11)
o Diagnose water temperature regulator using an opening test procedure
(WS 3– Objective 12)

Day Two Morning

♦ Continuation of Day One

♦ Each group will finish Day One’s activities

Day Two Afternoon

♦ Entire class comes together for briefings covering Workstations 4 and 5

Workstation 4:
♦ Students will be required to work as a group to:
o Diagnose a Jacket Water Aftercooler (JWAC) using ΔP and ΔT tests and compare the
maximum inlet air temperature and inlet manifold temperature to specifications/Testing and
Adjusting (Objective 13)
o Diagnose oil pump concerns using the gauge group (Objective 14)

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Workstation 5:
♦ Students will be required to work as a group to:
o Service a cooling system using a flush procedure (Objective 15)
o Diagnose engine mechanical concerns by interpreting S.O.S results (Objective 16)

4/7/2008 11
 Safety

Safety is YOUR responsibility and should always be YOUR top priority. Therefore, it is your
responsibility to know about, read, understand, and practice ALL safety related guidelines listed in
ALL relevant information (i.e. Caterpillar Operations and Maintenance Manual, Product Safety
Bulletins, local / state / federal codes, life capacity charts, implement joystick pattern charts, etc.). It is
in everyone’s best interest that you both keep and communicate this attitude.

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 Symptom Probable Cause Next Step(s)
Low Oil Low crankcase oil level Fill oil to specifications, then look for leaks,
Pressure smoke, or obvious damage
Wrong or improperly Replace with a dipstick with correct part
marked dipstick number
Improperly operating Inspect the oil pressure gauge and replace
oil pressure gauge if needed
Plugged oil filter Replace oil filter according to specifications
Low oil viscosity Test oil according to SOS to verify the
viscosity
Fuel diluted engine oil Isolate internal fuel leakage in engine.
Refer to SEBD0717 for details.
Low oil pump speed Inspect the oil pump gears and replace if
needed
Restricted oil pump Inspect and clean the screen, replace if
suction line needed
Air leakage at the Check for source of leak and replace parts
supply side of pump as needed according to specifications
A stuck open oil pump Inspect the open relief valve and replace if
relief valve needed
Worn main and rod Replace if needed
Bearings
Loose main and rod
caps
Loose or missing spray Inspect the jet, tighten or replace according
jet to specifications
A stuck closed relief Check for a restriction in the oil passages of
valve the oil cooler, replace if needed
High Oil Improperly operating Inspect the oil pressure gauge and replace
Pressure oil pressure gauge if needed
A stuck closed oil Inspect the relief valve and replace if needed
pump relief valve
Excessive Oil Low oil viscosity Test oil according to SOS to verify the
Consumption viscosity
Overloaded engine Verify that the load is correct for the engine
(hot, thin oil)
Worn valve guides Inspect valve guides, if needed replace
Missing or damaged according to specifications
valve guide seals
Worn piston rings and Inspect rings and liners, replace if needed
cylinder liners according to specifications
Leaking turbo seals Replace turbo seals according to
(blue smoke) specifications
Overfilled crankcase Check crankcase to verify that it is not
overfilled

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WEAR ELEMENT SOURCES
COPPER:
• Oil cooler tubes
• Piston wrist pin bushings
• Governor bushings
• Turbocharger sleeve bearing
• Timing gear thrust washers
• Timing gear bearings
• Rocker arm bushings
• (Anti-seize compounds)
• (Oil additives)

CHROMIUM
• Piston rings

ALUMINIUM
• Main and rod bearings
• Timing gear bushings
• Oil pump bushing
• Pistons
• Dirty entry (clay)
• Water pump/timing gear housing

IRON
• Crankshaft
• Camshaft
• Valves (seats, guides)
• Cylinder walls
• Timing gears
• Oil pump

LEAD
• Overlay on main and rod bearings
• Camshaft bearings

SILICON
• Dirty entry
• (Silicon grease)
• (Silicon additives)

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