REBUILD
CASE STUDIES

SYMPTOMS

• •Excessive blow-by and oil consumption (1 quart per 500 miles)
• •Loss of power under load
• •Blue smoke on acceleration
• •Low compression on cylinders 3 and 5

ROOT CAUSE

Worn piston rings and cylinder wall glazing. High-hour engine with deferred maintenance.

SOLUTION

Complete out-of-frame rebuild with cylinder boring, new pistons and rings, crankshaft polish, new bearings, complete gasket set, and injector service.

OUTCOME

Engine restored to like-new performance. Customer reports improved fuel economy and no oil consumption. Equipment returned to full service.

SYMPTOMS

• •White smoke and coolant loss
• •Overheating under load
• •Rough idle and misfires
• •Coolant in oil (milky appearance)

ROOT CAUSE

Failed head gaskets and warped cylinder heads due to overheating event.

SOLUTION

In-frame rebuild with cylinder head removal, resurfacing, new head gaskets, ARP head studs, new injectors, EGR cooler replacement, and cooling system flush.

OUTCOME

No more coolant loss or smoke. Engine runs smooth with full power restored. Customer using truck for daily farm operations.

SYMPTOMS

• •Hard starting when cold
• •Rough running and low power
• •Excessive black smoke
• •High fuel consumption

ROOT CAUSE

Worn injectors and low compression due to carbon buildup and ring wear.

SOLUTION

Complete rebuild with bore and hone, new pistons, rings, bearings, timing components, new injectors, high-pressure fuel pump, and turbocharger inspection.

OUTCOME

Starts instantly, runs smooth, full power restored. Customer reports noticeably improved fuel economy. Extended service life ahead.

SYMPTOMS

• •Catastrophic failure - thrown rod
• •Knocking noise before failure
• •Metal shavings in oil
• •Engine seized

ROOT CAUSE

Bearing failure due to oil starvation from clogged oil passages. Lack of regular oil changes.

SOLUTION

Complete overhaul with new block (original cracked), reground crankshaft, all new internal components, EGR system overhaul, and oil cooler replacement.

OUTCOME

Engine completely rebuilt with upgraded oil filtration system. Customer implemented strict maintenance schedule. Running strong after 150,000 miles.

SYMPTOMS

• •Loss of power during field operations
• •Excessive oil consumption (1 qt per 8 hours)
• •Overheating under load
• •Hard starting and rough idle

ROOT CAUSE

High-hour wear on cylinder walls, piston rings, and valve seals. Coolant passages partially blocked from mineral deposits.

SOLUTION

Complete engine rebuild with bore, hone, new pistons, rings, bearings, valve job, cooling system flush, and injector service.

OUTCOME

Full operating power restored with normal oil consumption. Equipment returned to full agricultural production schedule. Owner reports improved fuel economy.

SYMPTOMS

• •Low power and slow hydraulics
• •Excessive smoke (blue and black)
• •High oil consumption
• •Difficult starting

ROOT CAUSE

High-hour wear on rings, bearings, and valve seals. Turbocharger oil seal failure.

SOLUTION

Complete rebuild with bore, hone, new pistons, rings, bearings, valve job, turbocharger rebuild, and fuel system service.

OUTCOME

Machine operating at full power with normal hydraulic speed. Customer using for heavy excavation work. No smoke or oil consumption.