Toromont Cat Power Systems Power Systems Home Consultants Corner Contact Us
Electric Power - Customer Support - Preventative Maintenance - Total Maintenance & Repair - Extended Service Coverage - Power Protections Plans - Overhaul Program - Overhaul Protection - Extended Life Coolant - S·O·S Fluid Analysis - Fuel Contamination Control - Filters Technical Analysis Industrial Marine Scheduled Maintenance Product Support Locator
Customer Support // Electric Power // Overhaul Program //
 
OVERHAUL PROGRAM
Being in a business that's dependent on your equipment's performance, you know the value your engine brings to the equation. It's truly the lifeblood of your business. And when it's down, you're down. So you recognize the value of proper maintenance and timely, before-failure engine overhauls.

You have many choices when it comes to who will perform your overhauls.

You could do them yourself, but you aren't in that business and probably don't want to administer your own warranty anyway. And, with the technical advances of today's electronic engines, it can be a lot like working on your own car... changing the oil is one thing, but intricate work like an engine overhaul is usually left to the professionals at the dealership.

You could call the local engine shop, but they can't offer the 24 hour, seven day emergency field service, the 80-plus percent off-the-shelf parts availability or the comprehensive warranty you need to stay ahead. And, chances are, your overhaul will take longer - and your business can be down longer - waiting for parts and paying to help a general technician become a specialist on your engine.

You need to call us.

Because we are in the engine business, we've made significant investments in tooling, field service trucks and diagnostic equipment that will help us do the job better and faster. These are investments you don't need to make, just like those made on your behalf at the dealership where you take your car to be serviced.

And we have some of the best trained, most experienced technicians around; the best training program to help keep them up-to-date and superior processes in place - like our parts shuttle system and stringent parts reusability guidelines - that help us offer the best engine overhaul program available.

THE TOROMONT POWER SYSTEM OVERHAUL PROGRAM HAS FOUR LEVELS:

Lower End Overhaul
A Lower End Overhaul is available when your engine has specific wear to the parts that are made to wear - your main and rod bearings - but little or no ring or liner wear exists.		 Top End Overhaul
A Top End Overhaul is available for engines in applications when cylinder head components - the valve assemblies, thermostat & turbocharger - wear faster than liners, rings or bearings.

Level I Overhaul
Level I Overhaul is available for engines that have reached a point in their service life where there is both cylinder bore and bearing wear.
Level II Overhaul
A Level II Overhaul is designed for engines with extensive wear and for units approaching a second overhaul.




» CLICK HERE TO VIEW OVERHAUL LEVELS

LOWER END OVERHAUL INCLUDES:

Install new:
Thrust and main crankshaft
Connecting rod bearings
Oil, oil filters and fuel filters
Air filters
Required gaskets and seals

Inspect:
Crankshaft and vibration damper
Main oil pump
Operational test of engine

Clean and test:
Primary fuel filter
Clean engine

TOP END OVERHAUL INCLUDES:

Install new:
Temperature regulators
Oil, oil filters and fuel filters
Air filters
Required gaskets and seals
Exhaust studs

Recondition or install Cat remanufactured:
Cylinder heads: Install new valve guides, exhaust valves, valve rotators and any needed seats and intake valves. Grind valves and seats. Resurface cylinder head as needed. Reseal prechambers (part of Caterpillar remanufactured cylinder heads)
Turbocharger(s): Install Caterpillar remanufactured cartridges (rebearing and reseal cartridges when remanufactured cartridges are not available) Clean both housings. Install new gaskets, seals and bolts
Fuel injectors (Cat remanufactured)
Air fuel ratio control
Set high and low idle and static timing

Inspect:
Spacer plate and liner projection
Camshaft, camshaft rollers and followers
Rocker arm assembly
Intake and exhaust manifolds
Operational test of engine

Clean and test:
Primary fuel filter
Clean engine

LEVEL I OVERHAUL INCLUDES:

Install new:
Piston rings and cylinder liners (part of Cat remanufactured cylinder liner pack)
Thrust bearings and crankshaft main bearings
Connecting rod bearings
Temperature regulators
Oil, oil filters, fuel filters
Air filters
Camshaft lifter clips
Exhaust studs
Required gaskets and seals

Front and rear crankshaft seals Recondition or install Cat remanufactured:
Connecting rods and pistons (part of Cat remanufactured cylinder liner packs)
Cylinder heads: Install new valve guides, exhaust valves, valve rotators and any needed seats and intake valves. Grind valve and seats. Resurface cylinder head as needed. Reseal prechambers (part of Caterpillar remanufactured cylinder heads)
Turbocharger(s): Install Caterpillar remanufactured cartridges (rebearing and reseal cartridges when remanufactured cartridges are not available) clean both housings. Install new gaskets, seals and bolts
Fuel injectors (Cat remanufactured)
Air fuel ratio control
Reset fuel settings
Set high and low idle and static timing
Water pump
Fan drive: install seals, bearings and belts

Inspect
Space plate and liner projection
Camshaft, camshaft rollers and followers
Crankshaft end clearance
Vibration damper
Rocker arm assembly
Main oil pump
Operational test of engine

Clean and test:
Primary fuel filter
Aftercooler core: clean and pressure check. Install new gaskets and seals for aftercooler, air lines and coolant lines
Clean engine

LEVEL II OVERHAUL INCLUDES:

Install new:
Piston rings and cylinder liners (part of Cat remanufactured cylinder liner pack)
Thrust bearings and crankshaft main bearings
Connecting rod bearings
Temperature regulators
Oil, oil filters, fuel filters
Air filters
Required gaskets and seals
Camshaft bearings and lifter clips
Front and rear crankshaft seals
Fan belt set
Exhaust studs
Fuel hand priming pump

Recondition or install Cat remanufactured:
Connecting rods and pistons (part of Cat remanufactured cylinder liner packs)
Cylinder heads: Install new valve guides, exhaust valves, valve rotators and any needed seats and intake valves. Grind valve and seats. Resurface cylinder head as needed. Reseal prechambers (part of Caterpillar remanufactured cylinder heads)
Turbocharger(s): Install Caterpillar remanufactured cartridges (rebearing and reseal cartridges when remanufactured cartridges are not available) clean both housings. Install new gaskets, seals and bolts
Fuel injectors (Cat remanufactured)
Air fuel ratio control
Reset fuel settings
Set high and low idle and static timing
Water pump
Main oil pump
Fuel injection pump: Disassemble pump and clean all parts. Install new: Rack, bearings, governor bearings, camshaft bearings, governor oil pump gears and cover, servo, governor weights, piston assembly, rack bars and crossover link, gaskets and seals. Calibrate fuel injection pump housing and governor
Fan drive: install seals, bearings and belts
Oil filters base: Install new relief springs, gaskets, seals and filters
Timing advance: Install new springs and calibrate

Inspect:
Space plate and liner projection
Camshaft, camshaft rollers and followers
Crankshaft end clearance
Vibration damper
Rocker arm assembly
Gear train
Piston cooling jets

Clean and test:
Oil cooler:Clean and pressure check. Install new gaskets and seals for oil cooler, oil liner and coolant lines
Aftercooler core: clean and pressure check. Install new gaskets and seals for aftercooler, air lines and coolant lines
Dynamometer test the rebuilt engine at 100% horsepower rating (loadbank test if unit is a generator set)
Primary fuel filter
Steam clean and paint engine


CONTACT INFORMATION
Telephone:   (416) 667-5758 or 1-877 Cat Power
MaK Marine:   1-877 MaK Power
Rental Hotline:   1-866-667-5544
Fax: (416) 667-5514
Email: info@toromontpowersystems.com
  Main Office:   Concord - Power Division
P.O. Box 5511
3131 Highway 7 West - Bldg. A,
Concord, Ontario, L4K1B7
 

2008 © Toromont Cat Power Systems All Rights Reserved. Copyright Information & Legal Notice Website Privacy Statement BCI Logo