R

TOOL
OPERATING
MANUAL
Using the 193-5859 Cylinder Pressure Tool Kit
(All Gas Engines)
SMCS: 1000

NEHS0798
June 2000

Introduction
The 193-5859 Cylinder Pressure Tool Kit is
designed to check cylinder compression on
G3300, G3400, G3500, and G3600 Engines.
A low compression reading can be an
indication of valve guttering, broken valves,
broken or worn piston rings, or worn cylinder
liners. Using this tool is a quick way to check
for potential engine wear.

To avoid personal injury or death

follow all warnings.

To avoid personal injury or death,

carefully read and understand all
instructions before attempting to
operate this equipment. Do not operate or work
on a machine unless you read and understand
the instructions and warnings in the Operation
and Maintenance manuals. Contact your
Caterpillar dealer for replacement manuals.
Proper care is your responsibility. Always
follow all State and Federal health and safety
laws and/or local regulations.

300

400
0

8T0855
4000

3000

20

1000

kPa
psi

2000

Always consult the Material Safety

Data Sheet for chemical hazards and
first aid instructions. These sheets
should be available from the manufacturer/
supplier of the fluid.

10

0798-04

Illustration 1. 193-5858 Cylinder Pressure Group.

Always wear protective

clothing while operating any
machinery.
Keep loose
clothing and fingers away from moving parts to
prevent pinching and crushing.

Safety

To avoid eye injury, always

wear protective glasses or
face shield when using any
equipment, a hammer, or similar tool. Chips or
other debris can fly off objects when struck.
Make sure no one can be injured by flying
debris before striking any object.
Personal injury can result
from pressure air. Maximum
air pressure at the nozzle
must
be
below
205
kPa
(30
psi)
for
cleaning
purposes.
When using
pressure air, wear protective
clothing, a protective face shield, and
protective glasses.

Test Procedure
Do not smoke while working
on or near any fuel system.
Personal injury or death can
occur as a result of a spark.

Failure to turn off the natural

gas supply to the engine
during testing will cause a
dangerous situation. It could
lead to an explosion, causing engine damage,
personal injury, or even death.

To prevent personal injury,

clean up any spilled fluids
immediately.
To
avoid
tripping, do not leave tools or
components laying around in the work area.

NOTE: Obtain the correct compression ratio

for the engine being tested prior to the
test procedure.

Nomenclature

1. Turn OFF the natural gas fuel supply.

2

2. Remove all spark plugs.

3. Lock the choke (G3600 Engines) or throttle

plate (G3300 - G3500 Engines) in the open
position.

12

SM

CS:

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O OO
MA PER L
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Jun S07
e 200 98
0

Us
(All ing
Ga the
s En 19
100
gine3-5858
0
s)
Cy

linde

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mpr

4. Snap the upper and lower portion of the

compression gauge together using the
quick disconnect fitting.

essio

n Ga

ug

NOTICE

3000

2000
200

8T0855
4000

kPa
psi

1000

Do not install both O-rings on the end of the

adapter group at the same time. The O-ring not
being used to seal the adapter group could fall
into the engine, causing damage at the time of
engine startup.

50
0

100

300

400

10
11 13

7 8

C80091

Illustration 2. 193-5859 Cylinder Pressure Tool Kit.

5. Install an O-ring seal on the end of the

adapter group (black rod).

Chart A.
193-5859 Cylinder Pressure Tool Kit (Gas Engines)
Item

Part No.

Description

6V-3072

Case

6V-6126

Holder Block (foam)

8L-2786

O-ring Seal (brown)

8M-5127

O-ring Seal (yellow)

192-7130

Adapter Group

5P-8998

Pipe Nipple

6V-4144

Coupler Assembly

8T-0855

Pressure Gauge

10

4M-5317

Pipe Reducing Bushing

11

9U-6387

12

NEHS0798

NEEG2911

b. The 8L-2786 O-ring Seal (brown) is

used on the M18 thread on G3500 and
G3600 Engines.

Cylinder Pressure Group

13

a. The 8M-5127 O-ring Seal (yellow) is

used on the M14 thread on G3300 and
G3400 Engines.

6. Thread the compression gauge into the

spark plug hole.
7. Crank the engine for 3 to 5 compression
strokes or until the gauge reaches the
maximum available pressure. Use the
same number of compression strokes for
each cylinder being measured to ensure
accuracy.

Bleed Valve
Tool Operating Manual
Check Valve (CCC-CAT001)
Decal (case lid, not shown)

NOTE: The compression gauge group is

designed with a built-in check valve. This
valve will hold the pressure in the gauge, until
an accurate gauge reading has been
obtained.

11. Compare the actual pressure readings to

the Compression Ratio Chart. If the
pressure is one or more compression
ratios higher than normal, the engine may
need a top end overhaul. If the pressure
is one or more compression ratios lower
than normal, the engine may have valve
guttering, broken valves, broken or worn
piston rings, or worn cylinder liners.

8. Record the cylinder pressure.

9. Release the pressure using the pressure
release valve just under the pressure
gauge.

12. If the pressure reading is not in the charts

acceptable range, make the appropriate
repairs as per the Engines Service
Manual.

10. Remove the compression gauge and

check all the other cylinders.

2275 (330)
2205 (320)
2136 (310)
2067 (300)
1998 (290)

Pressure kPa (psi)

1929 (280)
1850 (270)
1791 (260)
1723 (250)
1654 (240)
1585 (230)
1516 (220)
1447 (210)
1378 (200)
1309 (190)
1240 (180)
1171 (170)
1102 (160)
1034 (150)
965 (140)
7:1
0798-03

8:1

9:1

10:1

11:1

12:1

13:1

Compression Ratio

Illustration 3. Compression Ratio Chart.

2000 Caterpillar Inc.

All Rights Reserved

NEHS0798
Printed in U.S.A.