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Re: More Caterpillar Mayhem [Re: 360view] #3078610
09/18/22 11:58 PM
09/18/22 11:58 PM
Joined: May 2003
Posts: 6,560
Downtown Roebuck Ont
Twostick Offline OP
Still wishing...
Twostick  Offline OP
Still wishing...

Joined: May 2003
Posts: 6,560
Downtown Roebuck Ont
Originally Posted by 360view
That fracture looks like a “fatigue crack” that started at a “stress concentration edge” that the original part designers never should allowed to stay in the final design.

The “improved part” from the ebay ad does look superior.

If you absolutely had to repair that - braze it - not weld it or JB Weld Epoxy.
Prior to brazing add steel stiffeners above and below as clearance allows.

Instead of throwing the broken part away,
package it up and mail it to:

Department of Mechanical Engineering
Duke University
Durham NC
attn: Failure Analysis Class

Add a short note saying that you suggest
a 4th year engineering student take on what caused this part to fail for their end of class project,
and that many hundreds of these parts are/were in service around the USA.
( Students are always looking for a worthwhile failure to investigate)

Both CAT and Cummins hire 2-3 Duke students per year,
although the majority of Duke mechanical engineering students are Navy ROTC
(and us taxpayers pay their +$75,000 year tuition)


I'm planning to have a lamp made out of it and some other assorted failures from this engine.

Kevin

3505.jpeg3506.jpeg
Re: More Caterpillar Mayhem [Re: Twostick] #3078666
09/19/22 10:14 AM
09/19/22 10:14 AM
Joined: Jan 2006
Posts: 8,162
USA
3
360view Offline
Moparts resident spammer
360view  Offline
Moparts resident spammer
3

Joined: Jan 2006
Posts: 8,162
USA
How many hours/miles on that 3406E ?

In the 1980s it was the repeated failures of $27,000 CAT turbochargers on 992 front end loaders that gave me heartburn.
$27K back then would be $90K today.

Years later when reading WW-II history I learned that turbochargers were a huge headache on aviation engines.

Re: More Caterpillar Mayhem [Re: 360view] #3078770
09/19/22 03:39 PM
09/19/22 03:39 PM
Joined: Jan 2003
Posts: 2,724
541 slobovia
A990 Offline
master
A990  Offline
master

Joined: Jan 2003
Posts: 2,724
541 slobovia
My 3208 fun was in the 90s. The Air Force sent their Oshkosh snow removal trucks back to be reengined and zero timed. They even got new registration numbers assigned.
Oshkosh even cut a smoking deal on the program. Only thing was the 3208s had been discontinued a year or two prior.
Sourcing parts was a lot harder than it should be.

Re: More Caterpillar Mayhem [Re: 360view] #3079200
09/21/22 01:51 AM
09/21/22 01:51 AM
Joined: May 2003
Posts: 6,560
Downtown Roebuck Ont
Twostick Offline OP
Still wishing...
Twostick  Offline OP
Still wishing...

Joined: May 2003
Posts: 6,560
Downtown Roebuck Ont
Originally Posted by 360view
How many hours/miles on that 3406E ?

In the 1980s it was the repeated failures of $27,000 CAT turbochargers on 992 front end loaders that gave me heartburn.
$27K back then would be $90K today.

Years later when reading WW-II history I learned that turbochargers were a huge headache on aviation engines.


The first time it croaked was Jan 2018 at 750k, dropped a liner. Cut a corner I should have went around on the inframe when I only replaced 2 injectors. 8 months later it split an injector tip and smoked #2 piston and liner. June 2020 it broke the crank.

Currently has 1.1 million on it.

My buddy has a 5EK series that lost an injector tip at 1.1 million. That overhaul has 1.6 million and counting.

Kevin

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