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Special Instruction
Using the 1U-8860 Large Engine Blowby Pickup Group{0781, 0785}
Media Number -SEHS8984-01 Publication Date -09/02/1996 Date Updated -30/01/2002

SEHS89840001

Using the 1U-8860 Large Engine Blowby Pickup Group{0781,

0785}
SMCS - 0781; 0785
3508, 3508B, G3508, 3512, 3512B, G3512, 3516, 3516B, G3516, 3606, G3606, 3608, G3608,
3612, G3612, 3616, and G3616 Engines.

Introduction
The 1U-8860 Large Engine Blowby Pickup Group is an optional pickup for use with the 8T-2701
Blowby/Air Flow Indicator.

It contains a large 38 mm (1.5 in) I.D. pickup which allows it to be used on large engines without
increasing the crankcase pressure.

It is designed to monitor the blowby volume on Caterpillar 3500 and 3600 series engines and the
larger D300 series engines as well as competitive large engines.

The range of this pickup is 94 to 1888 Liters Per Min. (L/min), (200 to 4000 Cubic Feet Per Hour
[cfh]).

Due to its all metal construction and large size, it is suitable for permanent installation on engines
so blowby can be continuously monitored, making it useful for dynamometer rooms or marine or
gen set installations.

The pickup group can also be used to measure air velocity such as radiator cooling air flow. When
connected to the 8T-2701 Blowby/Air Flow Indicator, it provides a digital display of the blowby
value (the volume of exhaust gas escaping to the crankcase). This blowby value can be used as an
indication of engine condition.

However, it should not be used as a stand alone "good/bad" indicator for engine overhaul. It can
be used as a signal that other engine condition indicators such as oil consumption, low power, hard
starting, and excessive fuel consumption should be checked to determine if an engine is in need of
maintenance.

The large blowby meter has no moving parts. An ultrasonic sound vortex shedding principle is
used to measure the air flow. This principle makes the pickup reliable and virtually maintenance
free.

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This unit will be used to replace the smaller 8T-2685 Pickup for the measurement of 3500 series
engine blowby. The 8T-2685 Pickup can be used on these engines, but only for a short duration
test since the 50.8 mm (2 in) engine breather tube is reduced to 15.7 mm (.63 in) during the test.
The 8T-2701 Blowby/Air Flow Indicator will be used with the larger probe, however a 1U-8863
Conversion Group must be installed to make it accurate. Refer to Installation of the 1U-8863
Conversion Group.

Refer to Special Instruction SEHS8712 for additional information on the Blowby/Air Flow
Indicator.

Adaptability

When used with the 8T-2701 Indicator, the 1U-8860 Pickup can be used to measure the blowby
on any engine within the blowby range of 94 to 1888 L/min (200 to 4000 cfh). This includes the
larger Caterpillar D300 Engines, the 3500 and 3600 series engines.

Smaller D300 and 3500 engines may not have enough blowby at idle or partial load to give a
reading when they are in good condition. Therefore, the indicator display will read zero until the
engine is loaded.

1U-8860 Large Engine Blowby Pickup Group

(1) 6V-7145 Case NEEG2332 Decal (1U-8860 Group)

(2) 1U-8861 Pickup - Large Engine Blowby NEEG2331 Decal (1U-8861)

(3) 1U-8863 Conversion Group - Large Pickup

(4) 9M-0164 Hose Clamp - Worm Drive 12.7 mm × 63.5 mm Dia. (.50 in × 2.50 in Dia.) 2
Required.

(5) 1U-8868 Hose, Rubber - 57 mm ID. × 305 mm (2.3 in ID. × 12.0 in) (Goodyear Part No.
56036).

(6) SEHS8984 Special Instruction (not shown).

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Optional Items

(1) 8T-2701 Blowby / Airflow Indicator

(2) 8T-5297 Cable - Blowby Pickup 915 mm (3.0 ft)

(3) 6V-2198 Cable - Blowby Pickup 5486 mm (18.0 ft)

(4) 5P-7366 Cable - Indicator Power 5486 mm (18.0 ft)

(5) 8T-5268 Converter, 110/220 Volts AC, 50/60 Hz for powering 8T-2701 Indicator. Supplies 11
to 20 Volts DC at 0.3 Amp. (Max. Current).

(6) 8T-2700 Blowby / Airflow Indicator Group for Small Engines, Complete (not shown).

Specifications (When used with the 8T-2701 Indicator)

Blowby Measuring Range:

Liters Per Minute (L/min) ... 94 to 1888

Cubic Feet Per Hour (cfh) ... 200 to 4000

Air Flow Measuring Range: (With Blowby V1.20 PROGRAM installed in 8T-2700
Indicator:

Meters Per Minute (M/min) ... 83 to 1656

Feet Per Minute (f/m) ... 272 to 5436

Accuracy:

The system accuracy is ± 10% of reading.

Resolution:

Blowby: 1 L/min (1 ft3/m)

Airflow: 1 M/min (1 ft/m)

Operating Temperature:

Pickup: -18 to 121°C (0 to 250°F)

Storage Temperature:

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Pickup: -40 to 232°C (-40 to 450°F)

Probe Size:

Length: 382 mm (15.0 in)

Outside Dia.: 50.8 mm (2.00 in)

Inside Dia.: 38.1 mm (1.50 in)

Width: 113 mm (4.5 in)

Height: 130 mm (5.2 in)

1U-8860 Group Case Size:

432 × 330 × 114 mm (17.0 × 13.0 × 4.5 in)

Weight:

1U-8860 Group: 6.1 kg (13.50 lb)

1U-8861 Pickup only: 3.0 kg (6.60 lb)

Power:

Provided by the PICKUP connector on the 8T-2701

Blowby/Air Flow Indicator.

Installation of the 1U-8863 Conversion Group

A 1U-8863 Blowby V1.20 Conversion Group integrated circuit (1) is packaged with the 1U-8860
Large Engine Blowby Pickup Group. This integrated circuit contains the program which makes
the large pickup readings accurate.

The integrated circuit must be installed in the 8T-2701 Blowby/Air Flow indicator you will be
using. Once this is completed, the 8T-2701 indicator will be accurate for both the Large Blowby
Pickup and the Small Blowby Pickup.

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The 1U-8863 Conversion Group (1) is the small plastic box packed in the front storage area of the
large pickup case. Open the small plastic case to identify the conversion group integrated circuit
memory, but DO NOT remove it at this time. It should be marked "1U-8863 Blowby Gp. V1.20".

Use the following instructions to install the integrated circuit in the 8T-2701 Indicator which will
be used with the large blowby probe.

NOTICE

The 1U-8863 conversion group integrated circuit memory may be

damaged by static electricity discharge. DO NOT handle in a carpeted,
dry, area where static electricity may be present.

Installation Instructions

1. Remove six screws (2) from the rear cover and remove cover (3).

2. Remove battery (4) from the holder. Use a small screwdriver to pry the old Blowby V1.19
integrated circuit memory from its socket and remove.

NOTE: This part is to be replaced and is no longer needed.

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3. Remove the 1U-8863 Blowby Group V1.20 integrated circuit (1) from its protective plastic case
and very carefully install it into the socket next to the battery holder (5) as shown above.

NOTE: The notch in the end of item (1) must be at the battery holder end of the socket.

NOTE: Check to make sure all of the pins are in the socket and are not bent over or under.

NOTE: The integrated circuit may not have as many pins as the socket has holes. When this
occurs, install the integrated circuit as far as it will go towards the edge of the printed circuit board
so the empty socket holes are on the battery holder end of the socket.

4. Install a new 9 Volt battery in the battery holder.

NOTE: Be sure that the + (positive) terminal on the battery is on the + (positive) red terminal on
the holder.

5. Install rear cover (2) and six screws(3).

6. Check the operation of the 8T-2701 Indicator with the large blowby probe as described later. If
a small 8T-2685 Pickup is available, also check the indicator with it by using the procedure in
Special Instruction SEHS8712, "Using the 8T-2700 Blowby/Air Flow Indicator Group".

7. If the indicator works properly it is ready for use.

Blowby Test Procedure

1. Locate the crankcase breather(s) (1) on the engine. The engine may have more than one
crankcase breather. If there is more than one, the blowby coming from all of them must be
measured at the same time.

Most engine installations will already have the breathers connected together with tubing (2). The
pickup can then be installed after the point where they come together (3). If they are not already
connected together, they may be connected with hoses or by temporarily plugging all but one
breather for a short period during a temporary test.

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If the pickup installation is to be permanent, the breathers must be connected together with
adequate sized tubing to prevent excessive crankcase pressure.

2. The 1U-8861 Large Engine Blowby Pickup (4) can be installed directly into the breather
flexible fitting (5) used on some Caterpillar engines, provided the fitting is the correct size. This
installation is suitable for a temporary check of blowby.

Be sure to install the pickup with the arrow pointing away from the engine in the direction of
blowby air flow. Secure the pickup with a hose clamp. Since the pickup is heavy, it may be
necessary to secure the pickup to keep it from moving during the operation.

3. For installation to the end of a metal blowby tube, a rubber hose (6) is included in the group. It
will fit most tubes which have close to a 50 mm (2.0 in) diameter. Secure the hose with clamps
(7).

4. Attach an 8T-5297 Cable or a 6V2198 Cable to the connector on the pickup and the other end to
the pickup connector on the 8T-2701 Indicator. This completes the installation.

Measuring Blowby
NOTE: The large blowby pickup is sensitive to excessive high frequency noise and air currents
entering the open end of the pickup. To prevent inaccurate readings, keep the pickup outlet as far
away from the engine turbocharger as possible, and away from the fan or any wind blowing past
the open end of the pickup.

If the pickup must be placed close to the engine or in the air stream, use a length of rubber hose to
extend the outlet away from the source of high frequency noise or air stream.

1. Refer to Special Instruction SEHS8712 for instructions on how to operate the 8T-2701
Indicator.

2. Start and run the engine until normal operating temperature is reached.

3. Blowby readings should be taken with the engine at full rpm. Readings may be taken at no load
or full load, but the engine must be loaded to measure the maximum blowby output of the engine

On smaller 3500 engines the indicator may show zero until the engine is loaded since the blowby
is below the minimum rating of the pickup.

Analyzing Results
NOTE: Blowby should be used as a guide only to indicate engine condition and not as an absolute
good/bad indicator. DO NOT use the blowby data alone to determine if the engine should be

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rebuilt. If the blowby value is high, check the other indicators, such as oil consumption, low
power, etc.

Approximate blowby rates for Caterpillar large engines are shown in the chart. The values listed
are the typical maximum rates for an engine in new condition. These values are typical ONLY and
not absolute.

NOTE: Additional valves can be found in the Technical Marketing Information.

It is recommended to always check the blowby by the same method for better comparison of
future tests. Record the blowby rate and the load on the engine during the test for later reference.

It is suggested that new engines initially be checked for blowby and thereafter during all
maintenance checks.

As the engine rings and cylinder walls wear, the blowby will gradually increase. The blowby on a
worn engine will be considerably higher than for a new engine. By keeping a record of the results,
a gradual increase in the amount of blowby will be noted until the amount of blowby has become
excessive.

Usually, high oil consumption and other problems associated with high blowby will not be
experienced until the blowby is considerably higher than the values shown in the chart.
(Approximately two times or more.)

After a new engine is used for a short time, the blowby can decrease as the rings are seated. Also,
a newly rebuilt engine can have a high blowby rate due to the rings not being properly seated, or
worn parts which were not changed, ie. valve guides.

Checking the Operation of the Large Blowby Pickup

Obtain the 8T-2700 Blowby/Air Flow Group which will be used with the large probe. Perform the
check out instructions per Special Instruction SEHS8712, to be sure the probe is working properly
before proceeding.

If the 8T-2685 Pickup is not available, only perform the following tests.

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The components required for the following test are the 8T-2701 Indicator, the 8T-5297 or 6V-
2198 Cable and the 1U-8861 Pickup.

1. Connect the 1U-8861 Pickup to the indicator with the cable.

2. Press the ON switch, then the FT/MIN, ACTUAL, and the NORM RATE switches. An arrow
should appear on the display and point to the same name as the switch pressed. The display should
read zero.

3. Blow into the pickup in the direction of the arrow on the side. Observe the reading on the
indicator display. It should read approximately 862 to 1439 FT/MIN, depending on how hard you
blow.

4. Press the M/MIN switch and the arrow should point to M/MIN. Blow into the pickup again and
the indicator should read approximately 262 to 438 M/MIN, depending on how hard you blow.

5. Press the FT3/HR switch and the arrow should point to the FT3/HR. Blow into the pickup again
and the indicator should read approximately 635 to 1059 FT3/HR, depending on how hard you
blow.

6. Press the L/MIN switch and the arrow should point to L/MIN. Blow into the pickup again and
the indicator should read approximately 300 to 500 L/MIN depending on how hard you blow.

7. Press the OFF switch and the display should be blank.

This completes the test for the 1U-8863 pickup.

Checking Airflow with the Large Blowby Pickup

The 1U-8861 Pickup can be used to check air flow through the radiator core in the same manner
as the 8T-2685 Pickup, however, the range of air flows it will measure is not as broad.

The large pickup will not read a low air flow. When checking a radiator with the large pickup, it
will often read zero in areas which have low air flows.

This makes it harder to check for plugging.

Refer to Special Instruction SEHS8712, "Checking Air Flow", for details.

Repair Information
If the large blowby probe does not operate correctly, use the procedure, "Checking Operations of
the Pickup", to determine if the problem is in the pickup or the indicator.

If the pickup is found to be faulty, contact Caterpillar Service Technology Group for service or
warranty information.

Units less than one year old will be repaired under warranty (except for abuse). Cost of out of
warranty repairs will be charged to the owner.

Phone - Toll Free Numbers

Outside Illinois ... 1-800-542-8665

Inside Illinois ... 1-800-541-8665

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Canada ... 1-800-523-8665

U.S. Mail only:

Caterpillar Inc.
Service Technology Group LD180
600 W. Washington Street
East Peoria, Illinois 61630

UPS or Emery only:

Caterpillar Inc.
Service Technology Group LD180
330 S.W. Adams Street
Peoria, Illinois 61602

Copyright 1993 - 2011 Caterpillar Inc. Sat Dec 31 14:20:54 UTC+0330 2011
All Rights Reserved.
Private Network For SIS Licensees.

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