unit 1 lesson 1 caterpillar diagnostic tools

UNIT 1Caterpillar Diagnostic Tools

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Unit Objectives:

At the completion of this unit, each student will be able to:

• Explain the uses and capabilities of Caterpillar diagnostic tools.

Unit References:

None Required

Tooling:

None Required

Lesson 1: Caterpillar Diagnostic Tools

Introduction

Caterpillar diagnostic tools are marketed by the Caterpillar ServiceTechnology Group, which is an internal venture of Caterpillar Inc. Itis organized and run like a separate business. This allows them toquickly respond to dealer needs.

Until the last few years, diagnostic test equipment had been costlyand easily damaged. Also, even the best equipment had lacked theaccuracy needed to make precise engine adjustments andmeasurements. New, less expensive, more durable, and moreaccurate diagnostic tools that employ LCD readouts, LED’s, andother solid-state devices are now available. Caterpillar equipmenthas become much more sophisticated. These advancements,therefore, require more advanced diagnostic tools.

Fig. 1.1.1 Diagnostic Tooling

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Objective

At the completion of this lesson, the student will be able to explainthe uses and capabilities of Caterpillar diagnostic tools, with at least70% accuracy on a multiple choice quiz.

Unit 1 1-1-3 Engine Diagnostics and RepairLesson 1

Fig. 1.1.2 Older diagnostic tools

The older tool groups were built with analog meters, large and heavymetal cases, and mechanical switches and selectors. These toolswere susceptible to damage from vibration and sudden shocks, suchas from dropping the tool.

Advantages ofNew Diagnostic Tools

• More cost effective• Increased durability and accuracy• More reliable• Light and compact• Easy to use

Fig. 1.1.3 Advantages of Newer Diagnostic Tools

The new tools have these advantages:

• More cost effective

• Increased durability and accuracy

• More reliable

• Lighter and more compact

• Easier to use

By enabling problem diagnosis to be done more rapidly andaccurately, these new tools reduce repair costs.


MODULAR DESIGN CONCEPT

• Allows tools to be "updated"' not outdated

Fig. 1.1.4

New Tools• Factory tested• sealed to prevent damage• Drop tested

Fig. 1.1.5

Another example of the improvements offered by the modular designconcept is perfected standardized circuitry. This has greatly improvedtool reliability.

The new line of tools are designed with the future in mind, allowingthem to be "UPDATED" rather than "OUTDATED."


Fig. 1.1.6

Fig. 1.1.7

Blow-molded polyethylene cases replace the original heavy metalcases. These cases come in seven standard sizes and weigh less thanone pound each. All hinges and latches have been tested for at least4,000 openings and closings at -7°C to +62°C (40°F to + 150°F).The new tool cases are considerably less expensive and are availablethrough Caterpillar’s parts system.

A special instruction booklet is provided for each tool, which includesall the information and specifications that a local repair shop willneed to repair the tool. Caterpillar, of course, will service thoseproprietary items which malfunction. As another example of howthese tools have been improved, let’s look at one of the most basicitems in the new tool line — the package itself.


Fig. 1.1.8

Fig. 1.1.9

Here we see an example of the typical solid state electronics, with themicroprocessor chip (in the large socket), and the re-programmablememory (in the smaller socket).

This is the line of hand-held tools. The cases are of rugged plastic,have digital displays, and are versatile. The solid state electronics areused to improve reliability. The cost of existing and future tools havebeen reduced since the same basic case, digital display, andmicroprocessor board has been used.


Fig. 1.1.10

Fig. 1.1.11

The 6V9450 Engine Pressure Group is used to check the performanceof diesel and natural gas engines, and to make operating adjustmentsto natural gas engines. It can be used to measure engine manifoldpressure, fuel pressure, cooling system pressure, exhaust backpressure, inlet air restriction and other pressures. The gauges are allscaled in English and Metric units. This group includes four 2.5"pressure gauges, one 4" high resolution pressure gauge and onedifferential pressure gauge. Also shown is the optional 1U5554 PanelAssembly with an optional 4" high resolution gauge. This panelassembly can be used to add an additional pressure gauge to thePressure Group.

The 6V4060 Setpoint Indicator and the 6V2100 Multitach are shownin the convenient storage space provided in the 1U5470 enginePressure Group container.

This grouping of tools all relate to engine diagnostics. Each tool willbe shown again and discussed in more detail.


Fig. 1.1.12

The multitach is a digital tachometer that contains a microprocessor.It can be programmed by the operator to directly convert variousinput signals into an rpm speed that is displayed on the digitalreadout. The multitach can handle a wide variety of inputtransducers.

It can be used to correctly set speed on excavators, hydrostatic drivemachines, and truck engines — all of which require a speedadjustment accuracy of ± 10 rpm. Previous tachometers were onlyaccurate to ± 40 rpm.

It can be programmed from .5 to 256 pulses per revolution and isaccurate to ± 1 rpm over the full range of 40 to 9999 rpm. Designedalong the modular concept, this tool replaces all the differenttachometers used in Caterpillar service tools with a single unit.

The 6V4060 Set Point Indicator is used for determining the set point(formerly called balance point) of Caterpillar diesel engines. LEDsindicate when the engine is in a LUG or OVERRUN condition orwhen the setpoint has been reached. The setpoint rpm is read on the6V2100 Multitach which is installed on the set point indicator.


Fig. 1.1.13

The various multitach pickups are shown clockwise from top left:

• The 6V3136 Photo Pickup, which uses reflective tape for thepulses per revolution input, is used when it is not convenientto get the speed of the rotating member by using either of themagnetic pickups.

• The 8L4171 Magnetic Pickup is used when access to theflywheel teeth is available.

• The 6V4950 Fuel Line Speed Pickup Group can be used withall applications except double walled fuel lines.

• The 6V2197 Magnetic Pickup uses the timing hole in theflywheel to generate a signal.

• Finally, the 5P7360 Tachometer Generator can be used if atach drive is available on the engine.


Fig. 1.1.14

The timing Indicator is a test tool that can be used to check thedynamic timing of Caterpillar’s diesel engines and 3500 spark ignitedengines. The timing advance unit can be checked on those enginesthat are so equipped

A Diesel Timing Adapter or a Spark Timing Adapter must be usedwith the Timing Indicator. The Diesel Timing Adapter (shown at thebottom) consists of a fuel line pressure pickup, a connecting cable,and the adapters necessary to install the pickup in the No. 1 orcompanion cylinder fuel line bonnet.

Also required is a TDC pickup, which is not shown here. The6V2197 Magnetic Pickup, which uses the timing hole in the flywheelto generate a signal, is used for this purpose.


Fig. 1.1.15

The Fuel Flow Monitor Group is a versatile fuel flow measurementsystem designed to help evaluate engine performance. It uses twometers and a hand held monitor to provide fuel flow and fueltemperature measurements for both the supply and return lines. Inaddition, it provides burn rate, average rate, and total fuelconsumption.

The system can also be used to measure fuel flow on engines withouta return line. The small monitor group measures flow rates of4-80 gph and the large monitor group measures flow rates of40-1000 gph. A Combination Fuel Flow Group is available that willdo either of the above (4-1000 gph).


Fig. 1.1.16

Fig. 1.1.17

The Electronic Position Indicator is a microprocessor based, digitalreadout, precision linear measuring gage capable of displaying eitherinch or millimeter displacement. The indicator is capable ofdynamic, static, maximum or minimum measurements. The indicatorcan be zeroed anywhere within its 1 inch range. The indicator wasdesigned to be used for measuring the rack displacement of anoperating engine.

The Blowby/Air Flow Indicator is a hand-held, microprocessor baseddigital indicator capable of displaying either volume or airflowvelocity in both Metric or English units. The group can measure thevolume of blowby gases coming out of the crankcase breather or theair velocity through the radiator. Adapters are provided to connect tothe crankcase breather on engines.


Fig. 1.1.18

Fig. 1.1.19

The 6V9130 Temperature Adapter Group will plug into the DigitalMultimeter and will measure surface temperatures from-50°C to + 900°C (-58°F to 1652°F) within about 1 percent accuracy.The 8T5334 Surface Probe is a fast response probe that is designedfor surface measurements. The 6V9055 is a 1/4" thermocouple probedesigned for use in measuring exhaust temperatures.

The Thermistor Thermometer is a diagnostic tool capable ofmonitoring up to six temperatures by use of the selector switch. Thethermistors can be installed to monitor engine and cooling systemtemperatures. The Thermistor Thermometer has a range of0 to 150°C (32 to 300°F). The thermistors are designed to be usedwith Caterpillar’s Self-sealing Probe Adapters.


Fig. 1.1.20

Fig. 1.1.21

These self-sealing probe adapters provide a method of checkingpressure or temperature in fluid-filled compartments without coolingthe machine down and draining the fluid. The pressure probe has anorifice in the tip. The temperature probe has no orifice.

DO NOT over torque the connectors. Check the Special Instruction.

A plug is used as a protective cover in the connectors when no probeis in use. Always reinstall the plug after removing a probe.

The Multichannel Temperature Selector is designed to be used withthe 6V7070 or 6V7800 digital multimeter and the 6V9129Temperature Adapter. The user may measure 16 individualtemperatures. The unit is supplied with an 8 channel cable pack andan output cable; both are stored in the lid. Should 12 or 16temperatures need to be measured, an optional 8 channel cable packis available.

Fig. 1.1.22

Fig. 1.1.23

The infrared thermometer is a portable non-contact temperaturemeasuring instrument. It will measure surface temperature as long asthe trigger is depressed. The unit will display the current temperatureas well as the highest recorded temperature. This instrument has arange of -20°C to +870°C (0°F to +1600°F), and has a resolution of1 degree, with an accuracy of ± 1 percent of the reading.

The 4C6500 Digital Thermometer Group provides a fast and accuratemethod of measuring temperature. It is capable of measuring fiveindividual temperatures, recording the minimum and maximumtemperature for each of the five channels and calculating onedifferential temperature from any two of the five inputs. Theinstrument is battery powered, and uses probes that are designed to beused with Caterpillar Probe Seal Adapters. The thermometer has aliquid crystal display that can be illuminated for use in low lightconditions. Its measuring range is -50°C to +850°C (-58F to+1562°F) with a maximum error of ±1.1°C (±2°F).

Unit 1 1-1-15 Diagnostics and RepairLesson 1


Fig. 1.1.24

Fig. 1.1.25

This borescope group is designed to see into inaccessible areas suchas combustion chambers. It will fit into bores as small as8 mm (0.31") and reach 240 mm (9.5") into the cavity underinspection. This unit has the bulb at the end of its tube and is batterypowered.

The Coolant Conditioner Test Kit is a quick and accurate method fordetermining if the coolant contains an acceptable concentration ofcoolant conditioner and the approximately correct mix of anti-freeze.

Fig. 1.1.26

Fig. 1.1.27

This is a valve, as seen through a borescope. This picture was takenusing the borescope shown in Figure 2.1.26.

NOTE: Soot in the cylinder absorbs light, so be careful with yourobservations.

This is the larger size borescope group. It will fit into bores as smallas 6.5 mm (0.256") and has a reach of 580 mm (23").

The light source for this borescope can either be 115/220 volts ACpowered, or 12 volts DC if the 6V9459 fiber optic light cable is used.

There is also an option for using a camera to take pictures.



Fig. 1.1.28

Fig. 1.1.29

The heavy-duty multimeter (yellow, on the right) is a completelyportable, extra rugged, sealed, 3 1/2 digit multimeter equipped withseven functions and 29 ranges. All inputs are protected againstcontinuous overload conditions.

The regular-duty multimeter (white, on the left) is a lower costalternative to the heavy-duty multimeter.

This is an example of cylinder wall cross-hatching as seen through aborescope.


Fig. 1.1.30

Fig. 1.1.31

The Electronic Control Analyzer Programmer (ECAP) is a flexibletool with the capability to service a variety of electronic controls.Once considered the full service tool for electronically controlledengines, it has limited usage and support today. The main limitationis that it cannot FLASH software files into the engine’s ECM.

The Digital Diagnostic Tool (DDT) is a hand-held tool that providesbasic diagnostic, vehicle and engine status, and calibration displaysfor Caterpillar’s electronically controlled engines.

This is an older tool, with limited use today. It is still used on gasengines, and for Challenger Tractor engines.


Fig. 1.1.32

Fig. 1.1.33

The Vibration Analyzer Group provides quick and completeidentification of all vibration frequencies and amplitudes present in aconstant speed test. With this capability, dealer personnel cantroubleshoot a customer vibration complaint for various purposes.

The portable printer is a versatile printer that will work with the8T8697 ECAP, 4C0303 Vibration Analyzer and the Datalogger. Theprinter will provide printouts of the data recorded. It has both serialand parallel ports, allowing for connection to many differentcomputers or instruments. It can operate from the internalrechargeable batteries or from a 115 volt AC line.


New Diagnostic Tools• Cost effective• Durable, reliable• Accurate• Less bulky• Easy to use

Fig. 1.1.34

In summary, CSTG Tooling carries a one year warranty, and is

• Cost effective,• Durable, reliable• Accurate• Less bulky• Easy to use

Always use the proper tool for the application.

unit 1 lesson 1 caterpillar diagnostic tools

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