Testing For Excessive Cylinder Blowby in 3500 Engines

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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

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Instrucción Especial
Testing for Excessive Cylinder Blowby in 3500 Engines{1000, 1100, 1223}
Número de medio -REHS7857-00 Fecha de publicación -09/11/2012 Fecha de actualización -12/11/2012
i05083590
Testing for Excessive Cylinder Blowby in 3500 Engines{1000, 1100,

1223}
SMCS - 1000; 1100; 1223
Caterpillar Products:Machine Engines All 3500 Series

Caterpillar Products: 3500 Family Generator Sets and Power Modules
Engine: All 3500 Engines
Introduction
Do not perform any procedure in this Special Instruction until you have read and understood the information.
Using these instructions can help detect a single cylinder with excessive pressure blowing past the piston
rings.
The blowby can be due to piston rings that are worn or broken. The blowby can also be due to worn or
damaged cylinder liners.
The common materials that are needed for the testing can be obtained in most shops.
This test uses the crankcase breathers or T-hoses, where all venting locations are fitted with caps or plugs.
One plug is drilled to provide restriction and amplification of the pressure signal.
One is fitted with a 1/8 inch hose barb fitting and a hose that is routed to a manometer.
All other breathers are capped off.
A manometer is used with the cylinder cutout function of Caterpillar Electronic Technician (ET) to
determine crankcase pressure changes associated with individual cylinders.
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A torque converter load is maintained on the engine during the test in order to maintain a small load on the
engine. The load enables all the injectors to have similar injection duration so that failed cylinder can be
found more easily.
Ensure that there are no other leak paths for exhaust gas to escape the crankcase in order to perform the test.
Note: Oil filter differential pressure typically runs between 2 and 4 PSI at coolant temperatures above 77° C
(170° F). Excessive blowby is suspected If oil filter differential pressure alarms are present or the filter
differential pressure exceeds 5 PS.
Do not operate or work on this machine unless you have read and
understand the instructions and warnings in the Operation and
Maintenance Manual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact your Caterpillar
dealer for replacement manuals. Proper care is your responsibility.
Required Test Materials
Illustration 1 g03251500
(1) 1/8 inch hose
(2) Hose clamp
(3) 1/8 inch hose barb fitting in a plug or cap
(4) Plug or cap with drilled hole for restriction and amplification
(5) Manometer
Table 1
Required Materials
Material Comment
3 ABS plastic plugs 1-1/2 inch The plugs or caps are used to seal off the breathers.
inner diameter and 2-1/4 inch
outer diameter Install a threaded fitting into one plug or cap, enabling installation of a
Or 1/8 inch hose barb fitting (3) .
Six similar caps
Drill a 1/2 inch hole into one plug or cap (4). A 1/2 inch hole is a good
starting place.
Having a few different caps with 3/8, 1/2, and 3/4 inch orifices will
allow the restriction to be varied as necessary. Different sizes can help
produce 4 to 10 inches H2O at the beginning of the test.
The holes in the plugs or caps provide restriction and amplify the
signal to the manometer. A smaller hole increases the restriction
(pressure) and therefore increases the amplification. Too little or too
much amplification will make cylinders with more blowby difficult to
find.
A variable sized orifice can be fabricated by inserting a ball valve into

the hole. The ball valve can be set to the desired restriction and
resulting amplification at the beginning of the test. Do not alter the
valve throughout the duration of the testing.
Having different sizes that can reduce the amplification can be helpful
with engines that have higher blowby.
3 to 6 hose clamps Clamps (2) secure the plugs or caps onto the breathers.
1/8 inch rubber hose long
enough to route from the engine
Hose (1) will convey pressure changes to the manometer.
to the engine control. Use hose
that resists kinks.
Digital manometer with a
Manometer (5) will measure pressure changes.
resolution of 0.01 inches H2O
Personal computer with

Caterpillar Electronic Cat ET will be used to perform the cylinder cutout test.
Technician (ET) software
Install the Test Materials
(1) Plug with the orifice hole
Alternative locations for the plugs
(2) Outlet of the breather
(3) Outlet of the tee
1. Install the plug or cap with the 1/2 inch orifice (1) into the outlet of one of the crankcase breathers (2).
The preferred location is nearer to the engine control. Alternatively, install the plug or cap into the tee
hose (3) for a pair of breathers.
The plug provides restriction and amplifies the signal to the manometer.
(4) Plug with fitting for the 1/8 inch hose
2. Install the plug or cap with the 1/8 inch hose barb fitting (4) into another breather or tee hose. The
preferred location is nearer to the engine control.
3. Connect the rubber hose to the fitting. Route the hose to the manometer in the cab. Approximately 15
feet of rubber hose is needed to connect the fitting to the manometer.
(5) Solid plug
4. Block the remaining breathers or tee hoses with solid plugs or caps (5), preferably on the right-hand
side of the engine.
5. Establish communication with Cat ET and the engine ECM.
Perform the Test

1. Operate the engine until a temperature of at least 77° C (170° F) is achieved.
Note: In cold ambient temperatures the radiator may require a tarp to restrict air flow across the
radiator in order to maintain coolant temperatures at or above 77° C (170° F).
2. Maintain a small load on the engine at low idle to help keep the operating temperature above 77° C
(170° F) during the test. For example on a 793D, operate the engine at idle (700 RPM), lock the
brakes, chock the wheels, and put the truck into first gear.
3. Observe the manometer and allow the crankcase pressure to stabilize. Record the pressure reading
from the manometer before each cylinder is cut out.
Note: Under ideal conditions, the crankcase pressure should be between 4 and 10 inches H2O. If the
crankcase pressure is higher or lower than 4 to 10 inches H2O, adjust the orifice size.
4. Perform a single cylinder cutout test for each cylinder. Closely watch for the change in crankcase
pressure. Record the pressure reading from the manometer when a stabilized value is reached.
Note: Make sure to allow the pressure to stabilize for each reading.
5. Repower the injector for each cylinder. Closely watch for the change in crankcase pressure. Record
the pressure reading from the manometer when a stabilized value is reached.
Note: The crankcase pressure should return to approximately the same value taken before the cylinder
was cut out. If the engine changed load during the test due to cycling parasitic load, rerun the test on
that cylinder.
Analyzing the Results
The value for the blowby for each cylinder is obtained by subtracting the stabilized reading taken during
each cut out cylinder from the reference value. The reference value is taken just before each cylinder is cut
out. When repowering the injector the crankcase pressure should return to approximately the same stabilized
value, duplicating the same change in blowby.
Example Analysis
The example in Table 2 only uses four cylinders. For an actual test, values for all of the cylinders are used.
Table 2
Reference Value 8.32 in H2O
Cylinder 1 Measured Value by cutting injector 1 7.52 in H2O
Measured Value when repowering injector 1 8.41 in H2O
Table 3
8.32 - 7.52 = 0.80 in H2O
Cylinder 1 blowby contribution
8.41 - 7.52 = 0.89 in H2O
Cylinder 1 has excessive blowby or a failed top ring.
Table 4
Cylinder 8 blowby contribution 8.52 - 8.63 = -0.11 in H2O
8.46- 8.63 = -0.17 in H2O
Cylinder 8 shows an increase in crankcase pressure. This cylinder is fine. The increase in blowby is caused
by the transfer of load and increased injector duration to other powered cylinders.
Table 5
8.22 - 8.12 = 0.10 in H2O
8.18 - 8.12 = 0.06 in H2O
Cylinder 13 shows only a slight drop in crankcase pressure. This cylinder is fine.
Table 6
8.89 - 7.89 = 1.00 in H2O
8.79 - 7.89 = 0.90 in H2O
Cylinder 16 has excessive blowby or a failed top piston ring.
Recommendations for Inspection
When suspect cylinders are found, perform the leak test in Special Instruction, REHS7138.
(1) Exhaust side plug
(2) Valve cover hole
Alternatively, cylinders can also be inspected with a borescope through the plug on the exhaust side of the
cylinder head. Alternatively, the borescope can also be used through the valve cover hole with the respective
valves open.
If necessary, visually compare the suspect cylinder/s to a cylinder that tested ok.
Evaluation Worksheet
Table 7
Date Unit
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Engine
Serial number hours
Coolant temperature (°C) rpm
Reference value for the whole engine (in - H2O)
Oil Filter Differential Pressure at 1800 Rpm (170°F+ Oil Filter Differential
Yes / No
Coolant) Alarms
Table 8
A. Stabilized B. Stabilized Value C. Stabilized Value Contribution of
Cylinder
Reference in after Cutout in H2O after Repower in Cylinder A-B to B-C in
H2O H2O H2O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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Búsqueda avanzada de texto completo - REHS7857 - Testing for Excessive Cylinder Bl...

Producto: NO SE HA ESCOGIDO NINGUN EQUIPO

Testing for Excessive Cylinder Blowby in 3500 Engines{1000, 1100,

Caterpillar Products:Machine Engines All 3500 Series

All other breathers are capped off.

Required Test Materials

(1) 1/8 inch hose

(2) Hose clamp

(3) 1/8 inch hose barb fitting in a plug or cap

A variable sized orifice can be fabricated by inserting a ball valve into

Personal computer with

Install the Test Materials

(1) Plug with the orifice hole

Alternative locations for the plugs

(2) Outlet of the breather

(3) Outlet of the tee

(4) Plug with fitting for the 1/8 inch hose

(5) Solid plug

5. Establish communication with Cat ET and the engine ECM.

Perform the Test

Analyzing the Results

Cylinder 1 Measured Value by cutting injector 1 7.52 in H2O

Measured Value when repowering injector 1 8.41 in H2O

Reference Value 8.52 in H2O

Cylinder 8 Measured Value by cutting injector 8 8.63 in H2O

Measured Value when repowering injector 8 8.46 in H2O

Reference Value 8.22 in H2O

Cylinder 13 Measured Value by cutting injector 13 8.12 in H2O

Measured Value when repowering injector 13 8.18 in H2O

Reference Value 8.89 in H2O

Cylinder 16 Measured Value by cutting injector 16 7.89 in H2O

Measured Value when repowering injector 16 8.79 in H2O

Cylinder 1 has excessive blowby or a failed top ring.

8.46- 8.63 = -0.17 in H2O

Cylinder 16 has excessive blowby or a failed top piston ring.

Recommendations for Inspection

(1) Exhaust side plug

(2) Valve cover hole

Coolant temperature (°C) rpm

Reference value for the whole engine (in - H2O)

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