CATERPILLAR

CERTIFIED
REBUILD

CUSTOMER ______________________ MODEL ______________________ SERIAL NO.

________________________

Condition
Appraisal
Report
Commercial Diesel Engines
PEYD ©2005 Caterpillar Inc. PRINTED IN U.S.A.

CERTIFIED REBUILD APPRAISAL PROCEDURE

1. Before the formal inspection is started, complete the following Start Engine.
research: Check operator’s panel while waiting for warm up.
Determine the engine’s serial number and request a SIMS II Observe gauges.
report. Check engine operation (including unusual noises, vibrations,
Determine the complete history of the engine – as much as and excessive smoke)
possible. Inspect Vibration Damper
Familiarize yourself with this form and the Time and Material Inspect belts, tensioners, and pulleys
Pricing Worksheet.
Check for oil, coolant, and fuel leaks
Familiarize yourself with the Product Update List and Product
Inspect engine mounts
Update Record.
Check engine wiring, harnesses, connectors and seals for
2. Inspector should take the following tools and information to
damage and proper routing Check coolant for evidence of gas
perform condition appraisal:
bubbles.
Filter Cutter; extension magnet; flashlight; oil sample kit;
replacement filters; wrenches; Parts Books; Updates and Engine Shut engine down. Take
News References; Product Update Record; 1U9800 Ultrasonic oil samples.
Wear Indicator Group and Special Instruction SEHS9089 4. Complete the pages of the Condition Appraisal Report form
3. Inspect the Engine using the following order: pertaining to components and provide an overall condition rating
for each component.
Walk around the engine and make mental notes of overall
condition. 5. Return this inspection report to the Certified Rebuild Coordinator
for pricing.
Check fluid levels, i.e., antifreeze, engine oil and fuel. Look for
conditions such as color, water, and new oil.

2
 TOTAL OVERALL ENGINE – BASIC ENGINE
CONDITION IDICATORS YES NO YES NO
ABNORMAL REPAIR HISTORY? ABNORMAL SMOKE COLOR?
WON’T START/OPERATE? BLOCK REQUIRES REPLACEMENT?
ABNORMAL NOISES? SOS HISTORY & CHECK ABNORMAL?
METAL IN FILTER NON-CAT FILTER?

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION M N R S NR COMPONENT CONDITION REMARKS

Block
Heads
Spacer Plate
Turbocharger
Aftercooler
Manifolds
Inlet
Exhaust
Manifold Shields
Flywheel Ring Gear
Flywheel Housing
Oil Pumps:
Main Oil Pump
Scavenge Oil Pump
Sump Pump
Oil Filter Housing
Oil Filter
Engine Mounts
Engine Covers
Trunnion Group
Drive Belts
Fan
Alternator

OTHER
4
 RADIATOR & GUARD
CONDITION IDICATORS YES NO YES NO
ABNORMAL REPAIR HISTORY? CRACKS?

LEAKS? BENT?

LOW COOLANT LEVEL? EXCESSIVE RADIATOR GUARD MOVEMENT?

NON-CATERPILLAR RADIATOR? OIL IN COOLANT

WELDED?

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION M N R S NR COMPONENT CONDITION REMARKS

Radiator:
Standard
Folded Core
Radiator Shields
Radiator Baffles
Radiator Core
Radiator Bottom Guard
Fan
Top Tank
Bottom Tank
Fan Guard
Fan Baffles
Radiator Mounts
ADDITIONAL NOTES

5
 CYLINDER HEAD
OPERATION YES NO CONDITION INDICATORS YES NO
CLEANED (HOT TANK) VISIBLE CRACKS?
INSPECTED DAMAGED?
PRESSURE TESTED LEAKS?
REUSED RESURFACED?
REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION QTY M N R S NR COMPONENT CONDITION REMARKS

Cylinder Head
Valve Keepers*
Rotocoils
Inner Valve Springs*
Outer Valve Springs*
Spring Seats
Cup Plugs (Freeze Plugs)*
Inlet Valve Seat Inserts
Exhaust Valve Seat Inserts
Dowels*
O-Rings*
Valve Guides
Oil Sleeves
Exhaust Valves
Inlet Valves
Cylinder Head Bolts*
Head Gaskets*
Coolant Passage Seals*
Oil Passage Seals*
* Required Parts Replacement
COMPONENTS: INDICATE COMPONENT DEFECTS:
A. Valve Keeper

B. Rotocoil
C. Inner Valve Spring
D. Outer Valve Spring
E. Spring Seat (Washer)
F. Cup Plug (Freeze Plug)
G. Cup Plug (Freeze Plug)
H. Valve Seat Insert
J. Dowel
K. O-Ring
L. Valve Guide
M. Oil Sleeve
N. Cup Plug (Freeze Plug)
P. Valve Seat Insert
Q. Valve (Inlet and Exhaust)

6
 CYLINDER BLOCK

A. Cylinder Block

B. O-Ring Seal*
C. Cylinder Liner
D. Spacer Plate
E. Spacer Plate Gasket*
F. Dowel*
G. Main Bearing Cap Bolt*
H. Main Bearing Cap
J. Pipe Plug
K. Cover
L. Bolt and Washer
M. Washer
N. Bolt
P. Bolt
Q. Bolt
R. Retainer
S. Piston Cooling Jet
T. O-Ring Seal**
U. Dowel*

LINER PROJECTION
Left Side
Right Side
BORE DIMENSIONS
Liner (L/S)
Liner (R/S)
Main Bearing

7
Cam Bearing (L/S)
Cam Bearing (R/S)

VALVE and INJECTOR MECHANISM

A. Adjustment Screw **

B. Socket Arm **

C. Ring Retaining **

D. Button **

E. Sleeve Bearing **

F. Bridge*

G. Gasket*

H. Hollow Dowel*

J. O-Ring Seal*

K. Lifter Assembly

L. Lifter Spring Guide*

M. Push Rod

N. Bolt and Washer

P. Rocker Shaft

Q. Bolt

8
9
 FRONT CAMSHAFT GEAR, RELATED IDLER and DRIVE GEARS
OPERATION YES NO CONDITION INDICATORS YES NO
CLEANED VISIBLE CRACKS?
INSPECTED DAMAGED?
REUSED ABNORMAL WEAR PATTERNS?
REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION QTY M N R S NR COMPONENT CONDITION REMARKS

O-Ring Seals*
Sleeve Bearings*
Water Pump Drive Gear
Idler Gear Assembly
Socket Head Setscrew
Pump Drive Shaft Assembly
Oil Pump Adapter Assembly
Thrust Washer*
Water Pump Adapter Assembly
Sealing Washers*
Crankshaft Gear
Dowel*
* Required Parts Replacement COMPONENTS: INDICATE COMPONENT DEFECTS
A. O-Ring Seal*

B. Sleeve Bearing*
C. Water Pump Drive Gear
D. Idler Gear Assembly
E. Socket Head Setscrew
F. Pump Drive Shaft Assembly
G. O-Ring Seal*
H. O-Ring Seal*
J. Sleeve Bearing*
K. Oil Pump Adapter Assembly
L. Thrust Washer*
M. Water Pump Adapter Assembly
N. Sealing Washer*
P. O-Ring Seal*
Q. Sealing Washer*
R. Shaft

10
 S. Sleeve Bearing*
T. Crankshaft Gear
U. Thrust Washer Assembly*
V. Dowel*

A. Camshaft Drive Gear

B. Idler Gear Assembly

C. Thrust Washer*

D. Idler Gear Assembly

E. Cluster Gear Shaft

F. Plate

G. Bearing Sleeve*

H. Idler Shaft

J. Sleeve Bearing*

K. Thrust Plate*

L. Crankshaft Gear

REAR CAMSHAFT GEAR, RELATED IDLER and DRIVE GEARS

OPERATION YES NO CONDITION INDICATORS YES NO
CLEANED VISIBLE CRACKS?
INSPECTED DAMAGED?
REUSED ABNORMAL WEAR PATTERNS?
REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION QTY M N R S NR COMPONENT CONDITION REMARKS

Camshaft Drive Gear
Idler Gear Assembly
Thrust Washer*
Idler Gear Assembly
Cluster Gear Shaft
Plate
Sleeve Bearings*
Idler Shaft
Sleeve Bearings*
Thrust Plate

11
Crankshaft Gear
* Required Parts Replacement COMPONENTS: INDICATE COMPONENT DEFECTS

12
 PISTON and CONNECTING ROD ASSEMBLY
OPERATION YES NO CONDITION INDICATORS YES NO
CLEANED VISIBLE WEAR?
INSPECTED BENT OR DAMAGED?
MAGNAFLUXED (Connecting Rods)
REUSED
REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION QTY M N R S NR COMPONENT CONDITION REMARKS

Sleeve Bearing*
Connecting Rod Assembly
Top Piston Ring*
Piston Body Assembly
Dowel*
Connecting Rod Bearing*
Intermediate Piston Ring*
Oil Ring*
Piston Pin*
Pin Retainer*
* Required Parts Replacement COMPONENTS: INDICATE COMPONENT DEFECTS
A. Sleeve Bearing*

B. Connecting Rod Assembly

C. Top Piston Ring*
D. Piston Body Assembly

E. Dowel*

F. Connecting Rod Bearing*

G. Intermediate Piston Ring*

H. Oil Ring*

J. Piston Pin*

K. Pin Retainer*

CONNECTING ROD BEARING MEASUREMENTS

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

13
 CRANKSHAFT

A. Crankshaft Assembly

B. Plug

C. Main Bearings*

D. Bolt and Dowel*

E. Thrust Bearing*

Crankshaft Journal Measurements

Main Bearing

1 2 3 4 5 6 7 8 9 10 11

Connecting Rod

1 2 3 4 5 6 7 8 9 10

OIL COOLER

14
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

OPERAT ION Y S NO CONDITION INDICATORS YES N

E O
CLEANED LEAKS?

INSPECTED VISIBLE DAMAGE?

PRESSURE TESTED CORROSION?

REUSED

REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTI ON QTY M N R S N COMPONENT CONDITION REMARKS

R
Oil Cooler*

Mounting Flange

O-Ring Mating
Surface
End Sheet

Tubes

Shell

* Required Parts Replacement

COMPONENTS: INDICATE COMPONENT DEFECTS

15
 A. Mounting Flange

B. O-Ring Mating Surface

C. End Sheet

D. Tubes

E. Shell

WATER PUMP

A. Ring Seal*

B. Water Pump Seal*

C. Water Pump Seal Group*

D. Pump Impeller

16
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

E. Retainer

F. Locknut*

G. Lip Type Seal*

H. Pump Drive Shaft Assembly

J. Dowel*

K. Thrust Washer*

L. Water Filter*

M. Pipe Plug
N. Adapter
P. O-Ring Seal*
Q. Pump Housing Assembly

MAIN OIL PUMP

OPERATION Y S NO CONDITION INDICATORS YES NO
E
CLEANED LEAKS?

INSPECTED VISIBLE DAMAGE?

REUSED ABNORMAL WEAR PATTERNS

REJECTED

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M – MISSING N – NON-CAT R - REPLACE S- SALVAGE NR – NORMAL RECONDITION

DESCRIPTION QTY M N R S NR COMPONENT CONDITION REMARKS

Cover

Sleeve Bearing*

17
Pump Shaft Assembly

Sleeve Bearing*

Oil Pump Body Assembly

Pump Cover Assembly

Dowel*

Hollow Dowel*

Relief Valve Cover

Pump Drive Shaft Assembly

Spring*

Pressure Relief Spool

* Required Parts Replacement

COMPONENTS: INDICATE COMPONENT DEFECTS
A. Bolt

B. Washer
C. Gasket*
D. Cover
E. Sleeve Bearing *
F. Pump Shaft Assembly
G. Bearing Sleeve*
H. Oil Pump Body As.l
J. Pump Cover Assembly
K. Dowel*
L. Bolt
M. Bolt
N. Hollow Dowel*
P. Relief Valve Cover
Q. Gasket*
R. Pump Drive Shaft As.
S. Spring*
T. Pressure Relief Spool

18
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED
REUSED
REJECTED

SCAVENGE OIL PUMP

COMPONENTS: INDICATE COMPONENT DEFECTS

A. Drive Gear

B. Sleeve Bearing*

C. Pump Body Assembly

D. Pump Shaft Assembly

E. Sleeve Bearing*

F. Pump Shaft Assembly

G. Pump Cover Assembly

H. Hollow Dowel*

19
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED
REUSED
REJECTED

TURBOCHARGER

COMPONENTS: INDICATE COMPONENT DEFECTS

A. Compressor Housing

B. Compressor Clamp Assembly*

C. Turbocharger Cartridge

D. High Temperature Bolt*

E. Cup Plug*

F. Turbine Housing Assembly

G. Pipe Plug

H. Cup Plug*

J. Turbine Clamp*

20
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED
REUSED
REJECTED

FUEL INJECTION PUMPS

A. O-Ring Seal*

B. O-Ring Seal*

C. Fuel Injector
Group*

D. Injector Clamp

21
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED
REUSED
REJECTED

E. Plug

Injector Size

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

22
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

GOVERNOR

COMPONENTS: INDICATE COMPONENT DEFECTS

Governor Control Group

Flyweight Group
Governor Gear Pump Group

ADDITIONAL NOTES (Record any adjustments performed)

23
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

24
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

INLET MANIFOLD

A. Exhaust Elbow

B. Exhaust Gasket*

C. LH Pipe

D. Bracket

E. O-Ring Seal*

F. O-Ring Seal*

G. Inlet Manifold

H. O-Ring Seal*

J. Cover

K. Manifold Gasket*

L. Gasket*

M. Elbow

25
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

N. Gasket*

P. RH Pipe

Q. Bracket

R. O-Ring Seal*

26
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

EXHAUST MANIFOLD

A. High Temperature Bolt*

B. Locknut*
Bracket
Bracket
E. RH Rear Exh. Manifold
F. High Temperature Bolt*
G. LH Rear Exh. Manifold
H. Bracket
J. Exhaust Seal
K. Spacer
RH Front Exh. Manifold
Bellows*
N. RH Intermediate Exh.
Manifold
P. High Temperature Bolt*
Q. Spiral Wound Seal*
R. LH Front Exh. Manifold
S. LH Intermediate Exh.
Manifold

27
 OPERATION CONDITION INDICATORS YES NO
CLEANED
INSPECTED

COMPONENTS: INDICATE COMPONENT DEFECTS

28
Engine Condition Summary

29
Additional Comments

30
31