New Cylinder Head and Head Gasket Leak Test Procedure Available for 3500 Engines {0701,
1100, 1124, 1223} (REHS7138-08)
SMCS - 0701, 1100, 1124, 1223 i09930557
Caterpillar Products
PPW
3500 Family Generator Sets and Power Modules
3500 Family Pumpers
202 -000
3500C Engines
4
16: 04/1 084D
/ 2
All 3500 Diesel
All 3500 Engines 2
RE 9:36- 6
All 3500 Machine Diesel Engines
H
© 2 713 5:00
S
Caterpillar Products Machine Engines
0
All 3500 Series
024 8
Engine Commercial
Cat
3500 and 3500B
erp
Engine Generator Set
illa
3500 and 3500B
r In
Engine Machine
3500 and 3500B
c.
Engine Commercial
3500 Series
Engine Generator Set
3500 Series
Engine Machine
3500 Series
Engine Commercial
3500B Series
Engine Generator Set
3500B Series
Engine Machine
3500B Series
Off-Highway Truck/Tractor
773 (S/N: FKT1-UP)
Wheel Tractor-Scraper
621 (S/N: WYD1-UP; WYJ1-UP; WYX1-UP; WYY1-UP)
623 (S/N: WYF1-UP; WYK1-UP)
627 (S/N: WYG1-UP; WYL1-UP)
Revision History:
Table 1
Revision Summary of Changes
08 Added serial numbers.
07 Added warnings and updated the procedure.
06 Updated effectivity.
05 Added effectivity.
Introduction
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 pressure testing tool
and describes the test procedure.
Safety
The engine crankshaft and connected components may rotate
when pressurizing the engine cylinder. The rotating components
could cause personal injury. Ensure that extremities stay clear
of the moving components’ path.
Do not work in a position that is in line with the broken
component. Pressurized fluids discharged from the component
orifice can cause injury or death. Follow the procedure listed
below.
Ensure that all fluid is removed from any cylinders with an open
port. Engine rotation can cause pressurized fluid to be expelled
from those cylinders which may also cause personal injury or
death.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, PERJ1017, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and
mandates.
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.
1. Disconnect electrical power from the engine by removing ground connection or by using battery
shut off switch.
2. Remove the rocker arm assembly.
3. Remove the fuel injector for a diesel engine.
4. Ensure that all fuel is out of the cylinder head.
5. Install 370-2284 Injector Plug Tool or 512-0538 Dummy Injector Plug tool and secure the tool
using the injector hold down clamp.
6. Ensure that the ball valve is closed.
7. Connect the pressure test tool to supply of compressed air or nitrogen.
8. Open the ball valve until the gauge stabilizes at 690 kPa (100 psi).
9. Close the ball valve.
erp
il lar
10. When 100 psi of air is put into the cylinder with the ball valve closed and the piston stroke is at
Inc
the bottom dead center position, watch gauge for a slow and steady pressure release to zero.
.
11. If the gauge drops to zero in less than 2 seconds, the cylinder is suspect and further
investigation is needed.
12. Reinstall the injector from the cylinder that was pressure test. Then repeat Steps 2 through 11
for each cylinder.
PPW-0002084D
2024/04/16
16:25:48-05:00
i05793690
© 2024 Caterpillar Inc.
