SPRING 2M3469 - Caterpillar

Caterpillar Products 3500 Family Generator Sets and Power Modules 3500 Family Pumpers 3500C EnginesCaterpillar Products Machine Engines All 3500 SeriesEngine 3500 and G3500 EnginesEngine Commercial 3500 and 3500B G3500 FamilyEngine Commercial 3500 and 3500B G3500 FamilyEngine Generator Set 3500 and 3500B G3500 FamilyEngine Machine 3500 and 3500B G3500 FamilyEngine Commercial 3500 SeriesEngine Commercial 3500 SeriesEngine Generator Set 3500 SeriesEngine Machine 3500 SeriesEngine Commercial 3500B SeriesEngine Commercial 3500B SeriesEngine Generator Set 3500B SeriesEngine Machine 3500B SeriesIntroduction
Do not perform any procedure that is outlined in this Special Instruction until the entire instruction has been read and understood.This Special Instruction illustrates the assembly process for creating a cylinder compression testing tool and describes the test procedure.Assemble the Pressure Test Tool
Illustration 1 g03671818
Assembled pressure test tool
(1) 212-7043 Pressure Gauge
(2) 4S-6399 Connector
(3) 1/4" ball valve with 1/4" - 18 NPTF female connections
(4) 5P-8998 Fitting
(5) 3B-7762 Tee
(6) 4S-6399 Connector
(7) 7V-0916 Hose As
(8) 245-4908 O-Ring Seal
(9) 370-2284 Injector Plug Tool
Illustration 2 g06352909
(10) 512-0538 Dummy Injector Plug tool (3500 Tier 4 Engines)Acquire and assemble parts as shown in Illustration 1. Use Teflon thread sealant on each threaded connection. Tighten all fittings until leak-free.Cylinder Pressure Leak Test Procedure
Note: Pressurizing the engine cylinder may cause the crankshaft to rotate.Note: Do not exceed 690 kPa (100 psi) when using this tool.
Disconnect electrical power from the engine by removing ground connection or by using battery shut off switch.
Remove the rocker arm assembly.
Remove the fuel injector for a diesel engine. Remove the spark plug adapter for a gas engine.
Ensure that all fuel is out of the cylinder head.
Install 370-2284 Injector Plug Tool or 512-0538 Dummy Injector Plug tool and secure the tool using the injector hold down clamp.
For a gas engine, use 1 each of the following parts to hold down the injector plug tool:
7E-2580 Injector Clamp
7F-8698 Bolt
7N-5487 Washer
Ensure that the ball valve is closed.
Connect the pressure test tool to supply of compressed air or nitrogen.
Open the ball valve until the gauge stabilizes at 690 kPa (100 psi).
Close the ball valve.
Watch gauge for a slow and steady pressure release to zero.
If the gauge drops to zero in less than 2 seconds, the cylinder is suspect and further investigation is needed.
Repeat steps 2 through 11 for each cylinder.