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Introduction
This Special Instruction outlines acceptable appearance differences between Cat ® Reman and new production parts. Occasionally there is a Cat Reman process change, which will alter the appearance of parts without affecting function or usability.
For additional information, refer to Technical Marketing Information (TMI) compare consist or submit a Parts Technical request using the PSCRM system providing an image of the packaging label for the Reman product.
Cat Reman Short Blocks
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| Illustration 1 | g03671470 |
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Short block on the left that has been sprayed and remilled Short block on the right with staining (1) Stains | |
Cat Reman will often employ advanced salvage technologies to mill a cylinder block deck to remove minor nicks, dents, or pitting. Where the deck height no longer meets print specs, the blocks are sprayed and remilled as needed to return the block to within specifications. These Cat Reman blocks are shipped with the appearance seen in the left image of Illustration 1. The right image of Illustration 1 shows a block, which has undergone advanced cleaning processes, but did not require spraying and remilling to meet specifications. In this case, there may remain some evidence of prior use, such as staining. This staining will not affect the performance of the block. The block assembly meets all of the reusability and salvage specifications as outlined in Reuse And Salvage Guidelines , SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks".
To date, blocks with staining have been used in Cat Reman long block and engine products. Where needed to support short block requirements, the staining has been milled off, often requiring spray processes to bring the surfaces back to specification. Cat Reman is announcing that customers may begin to receive short blocks that have this staining. Short blocks with this staining do not affect performance, meet all the salvage and reuse guidelines and new part specifications and are acceptable for use in any engine application.
Camshaft Lobe Size Change for Cat Reman Camshafts
Exhaust and intake camshaft lobe profiles for C27 and C32 machines were modified by increasing the lobe widths. This change provides a more uniform surface profile across width of the lobe, which addresses spalling issues on cam lobes and rocker rollers. The new camshafts feature lobes of the same width for both valves and injector rocker. Previously, the valve lobes were narrower than the injector lobe, causing the grinding wheel to wear unevenly. This uneven wear could produce a step in the lobe profile, which was linked to part failures. New cams are now processed differently, using the same width grinding wheel for each lobe. Cat Reman cams are processed with independent grinding wheels for each lobe width. This different process allows the wheels to wear evenly and does not create any steps. The Cat Reman process continues to repair and remove steps on first issue cams as the cams are salvaged to become Cat Reman cams. New cams featuring wide lobes will not contain steps in the lobe profile. Cat Reman cams with either wide or narrow lobes will not contain steps in the lobe profile. There are no functional differences between Cat Reman cams with wide or narrow valve lobes.
Cat Reman Electronic Fuel Injectors with a Steel Ring Around the Stator on the Solenoid
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| Illustration 2 | g03672815 |
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(A) Stator with steel ring
(B) Stator without steel ring | |
In order to improve the salvage of injector components, Cat Reman reuses solenoids with a steel ring around the stator on selected electronic unit injectors. This improvement will alter the appearance of the injectors having stators with the steel ring around the solenoid and the injectors without the steel ring. This change will not alter fit or performance in any way. Refer to Illustration 2 for acceptable injector appearances.
New Location for Laser Markings on Certain Electronic Unit Injectors
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| Illustration 3 | g03673138 |
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| Illustration 4 | g03673145 |
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View A A "New laser marking location" (1) Trim code (2) Serial number (3) Part number | |
Certain Cat Reman electronic unit injectors may have the trim code, serial number, and part number laser marking located on the side of the solenoid. All identifying information for a Cat Reman injector such as trim code, serial number and part number will appear together in one laser marking. Refer to Illustrations 3 and 4. The laser marking shown allows the information to be read without removing the injector from the cylinder head. 3500 electronic injectors will continue to have this information etched on the tappet. Validation tests confirm the location change will not alter quality, reliability, fit, or performance.
Additional Grinding Process to Stator Sleeve
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| Illustration 5 | g03673510 |
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(1) Sleeved stator
(2) Ground stator | |
Certain Reman 3406 and 3500 electronic unit injectors may have a ground stator sleeve. These injectors may be produced with stators, which have been ground slightly around the outside to remove potentially obsolete identification information. Previously, these injectors were processed with a metal sleeve around the outside of the stator to cover the potentially obsolete information. Dealers will see both sleeved and ground stators. These differences will not affect quality, performance, form, fit, or function. The figures in Illustration 5 show the acceptable appearances of the affected electronic unit injectors.
Reman Remanufactured HEUI Injectors - Coating Applied
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| Illustration 6 | g03869392 |
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(1) Original process
(2) Remanufactured injector with black oxide coating | |
A coating is being applied to the nozzle cases on remanufactured HEUI injectors. The black oxide coating has been applied to reduce friction during component assembly and assist in the prevention of rust of the nozzle case. The figures in Illustration 6 show the addition of the black oxide coating.
Color Difference of Remanufactured Solenoids
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| Illustration 7 | g03869394 |
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(1) Discoloration on remanufactured solenoids
(2) New solenoid | |
The electric control solenoid on all remanufactured HEUI injectors undergoes extensive testing to meet reuse criteria. If a solenoid meets this reuse criteria, the solenoid will be used on remanufactured injectors. These solenoids will have a different color when compared to new solenoids due to aging and oil staining from use in the engine. This color change in the solenoid does not affect the performance of the injector. The figures in Illustration 7 show the change in color of the remanufactured solenoids.
Cat Reman Mechanical Fuel Injectors - Discoloration of Remanufactured Cones
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| Illustration 8 | g03673615 |
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(1) Discoloration area
(2) New process (3) Original process | |
Remanufactured Mechanical Unit Injectors (MUI) are now shipped with the rack in the fuel "OFF" position in order to eliminate the need to move the fuel rack before installation into the cylinder head. The fuel rack on the MUIs should not be moved without compressing the tappet spring.
The issue of the dragging of the fuel rack was caused by the process of remanufacturing the cones for the fuel injectors. The remanufactured cones were causing the rack to drag. The cones are now remanufactured in order to eliminate the fuel rack from dragging.
The change in the remanufacturing process of the cones for the injectors causes the cones to have some discoloration. The change in the appearance of the remanufactured cones is normal and will not affect the performance of the fuel injectors. Illustration 8 shows the area of discoloration on the injector cones.
Metal Deposition Process Around Bracket
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| Illustration 9 | g03673701 |
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(1) Side view of metal deposit
(2) Top view of same metal deposit | |
Certain mechanical unit injectors undergo a metal deposition process around the bracket. This process will alter the appearance of the remanufactured mechanical unit injectors. Validation tests confirm that the metal deposition does not alter quality, reliability, fit, or performance. Illustration 9 shows acceptable appearances with this new metal deposition process.
Cat Reman Cylinder Packs
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| Illustration 10 | g03868860 |
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Technical Marketing Information (TMI) search | |
Different cylinder rod part numbers are accepted as core and used to assemble certain cylinder packs. Reman processes ensure that the rod weight used for a given cylinder pack part number is the same. Dealers can enter the Reman part number of the cylinder pack into the Technical Marketing Information (tmiwebclassic.cat.com) system's base part number compare consist to view a list of acceptable rods for a given cylinder pack.
Refer to Illustration 10 for how TMI is used to determine that five separate connecting rods are acceptable for the 0R-0916 Cylinder Pack.
Cat Reman Pistons - Dull Finish of Blast Cleaned Pistons
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| Illustration 11 | g03868875 |
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(1) Shiny surface finish
(2) Dull surface finish (A) New process (B) Original process | |
The blast cleaning process used for Reman pistons creates a dull surface finish when compared to the shiny machined surface of a new piston. This finish does not reduce performance, and a combination of new pistons and Reman cleaned pistons may be used.
Reman Cylinder Head - Valves with Various Part Numbers
Reman heads contain valves with various part numbers. Using the TMI part consist shows the various acceptable valve part numbers used for a given Reman cylinder head. During the salvage processes, valves are updated to the latest specifications. The old (pre-Reman) part number stamped onto the valves will not be removed during remanufacturing.
Cat Reman Camshaft Gears
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| Illustration 12 | g03877422 |
The Reman cleaning processes may discolor camshaft gears. This discoloration does not affect performance, core credit, or the metallurgical properties of the gears. In Illustration 12, the camshaft gear appears darker in color when compared to the crank gears.