4/21/2018 G3520C Generator Set GZN00001-UP(SEBP3868 - 38) - Documentation

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Product: GENERATOR SET
Model: G3520C GENERATOR SET GZN00479
Configuration: G3520C Generator Set GZN00001-UP

Special Instruction
New Cylinder Head and Head Gasket Leak Test Procedure Available for 3500 Engines{1100,
1223}
Media Number -REHS7138-02 Publication Date -01/05/2014 Date Updated -01/05/2014

i05793690

New Cylinder Head and Head Gasket Leak Test Procedure

Available for 3500 Engines{1100, 1223}
SMCS - 1100; 1223

Caterpillar Products:Machine Engines All 3500 Series

Caterpillar Products: 3500 Family Generator Sets and Power Modules 3500 Family Pumpers 3500C
Engines
Engine:Commercial 3500 and 3500B G3500 Family
Engine:Generator Set 3500 Series
Engine:Machine 3500B Series
Engine: All 3500 Engines

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 compression testing tool and
describes the test procedure.

Assemble the Pressure Test Tool

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4/21/2018 G3520C Generator Set GZN00001-UP(SEBP3868 - 38) - Documentation

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

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4/21/2018 G3520C Generator Set GZN00001-UP(SEBP3868 - 38) - Documentation

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. Remove the spark plug adapter for a gas engine.

4. Ensure that all fuel is out of the cylinder head.

5. Install the 370-2284 Injector Plug Tool and secure the tool using the injector hold down clamp.

a. 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

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.

10. 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. Repeat steps 2 through 11 for each cylinder.

Copyright 1993 - 2018 Caterpillar Inc. Sat Apr 21 2018 13:47:18 GMT+0100 (W. Central Africa Standard Time)
All Rights Reserved.
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