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    Unit 1 Lesson 1 Caterpillar Diagnostic Tools

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    Bruno Mariano
    The document discusses Caterpillar diagnostic tools, explaining how newer tools have advantages over older tools like increased durability, accuracy, and reliability due to using solid-state electronics. It provides details on several diagnostic tools including pressure gauges, tachometers, timing indicators, and thermometers.

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    © All Rights Reserved
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    Unit 1 Lesson 1 Caterpillar Diagnostic Tools

    Uploaded by

    Bruno Mariano
    650 views24 pages
    The document discusses Caterpillar diagnostic tools, explaining how newer tools have advantages over older tools like increased durability, accuracy, and reliability due to using solid-state electronics. It provides details on several diagnostic tools including pressure gauges, tachometers, timing indicators, and thermometers.

    Original Description:

    Unit 1 Lesson 1 Caterpillar Diagnostic Tools

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    The document discusses Caterpillar diagnostic tools, explaining how newer tools have advantages over older tools like increased durability, accuracy, and reliability due to using solid-state electronics. It provides details on several diagnostic tools including pressure gauges, tachometers, timing indicators, and thermometers.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    650 views24 pages

    Unit 1 Lesson 1 Caterpillar Diagnostic Tools

    Uploaded by

    Bruno Mariano
    The document discusses Caterpillar diagnostic tools, explaining how newer tools have advantages over older tools like increased durability, accuracy, and reliability due to using solid-state electronics. It provides details on several diagnostic tools including pressure gauges, tachometers, timing indicators, and thermometers.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    You are on page 1of 24

    Caterpillar Diagnostic Tools

    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

    Unit 1: Caterpillar Diagnostic Tools

    UNIT 1

    NOTES

    Introduction
    Caterpillar diagnostic tools are marketed by the Caterpillar Service
    Technology Group, which is an internal venture of Caterpillar Inc. It
    is organized and run like a separate business. This allows them to
    quickly respond to dealer needs.
    Until the last few years, diagnostic test equipment had been costly
    and easily damaged. Also, even the best equipment had lacked the
    accuracy needed to make precise engine adjustments and
    measurements. New, less expensive, more durable, and more
    accurate diagnostic tools that employ LCD readouts, LEDs, and
    other solid-state devices are now available. Caterpillar equipment
    has become much more sophisticated. These advancements,
    therefore, require more advanced diagnostic tools.

    Fig. 1.1.1 Diagnostic Tooling

    Objective
    At the completion of this lesson, the student will be able to explain
    the uses and capabilities of Caterpillar diagnostic tools, with at least
    70% accuracy on a multiple choice quiz.

    Lesson 1: Caterpillar Diagnostic Tools

    Lesson 1: Caterpillar Diagnostic Tools

    Unit 1
    Lesson 1

    1-1-3

    Engine Diagnostics and Repair

    Fig. 1.1.2 Older diagnostic tools

    The older tool groups were built with analog meters, large and heavy
    metal cases, and mechanical switches and selectors. These tools
    were susceptible to damage from vibration and sudden shocks, such
    as from dropping the tool.

    Advantages of
    New 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 and
    accurately, these new tools reduce repair costs.

    Unit 1
    Lesson 1

    1-1-4

    Engine Diagnostics and Repair

    MODULAR DESIGN CONCEPT


    Allows tools to be "updated"' not outdated

    Fig. 1.1.4

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

    New Tools
    Factory tested
    sealed to prevent damage
    Drop tested

    Fig. 1.1.5

    Another example of the improvements offered by the modular design


    concept is perfected standardized circuitry. This has greatly improved
    tool reliability.

    Unit 1
    Lesson 1

    1-1-5

    Engine Diagnostics and Repair

    Fig. 1.1.6

    A special instruction booklet is provided for each tool, which includes


    all the information and specifications that a local repair shop will
    need to repair the tool. Caterpillar, of course, will service those
    proprietary items which malfunction. As another example of how
    these tools have been improved, lets look at one of the most basic
    items in the new tool line the package itself.

    Fig. 1.1.7

    Blow-molded polyethylene cases replace the original heavy metal


    cases. These cases come in seven standard sizes and weigh less than
    one pound each. All hinges and latches have been tested for at least
    4,000 openings and closings at -7C to +62C (40F to + 150F).
    The new tool cases are considerably less expensive and are available
    through Caterpillars parts system.

    Unit 1
    Lesson 1

    1-1-6

    Engine Diagnostics and Repair

    Fig. 1.1.8

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

    Fig. 1.1.9

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

    Unit 1
    Lesson 1

    1-1-7

    Engine Diagnostics and Repair

    Fig. 1.1.10

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

    Fig. 1.1.11

    The 6V9450 Engine Pressure Group is used to check the performance


    of diesel and natural gas engines, and to make operating adjustments
    to natural gas engines. It can be used to measure engine manifold
    pressure, fuel pressure, cooling system pressure, exhaust back
    pressure, inlet air restriction and other pressures. The gauges are all
    scaled in English and Metric units. This group includes four 2.5"
    pressure gauges, one 4" high resolution pressure gauge and one
    differential pressure gauge. Also shown is the optional 1U5554 Panel
    Assembly with an optional 4" high resolution gauge. This panel
    assembly can be used to add an additional pressure gauge to the
    Pressure Group.
    The 6V4060 Setpoint Indicator and the 6V2100 Multitach are shown
    in the convenient storage space provided in the 1U5470 engine
    Pressure Group container.

    Unit 1
    Lesson 1

    1-1-8

    Engine Diagnostics and Repair

    Fig. 1.1.12

    The multitach is a digital tachometer that contains a microprocessor.


    It can be programmed by the operator to directly convert various
    input signals into an rpm speed that is displayed on the digital
    readout. The multitach can handle a wide variety of input
    transducers.
    It can be used to correctly set speed on excavators, hydrostatic drive
    machines, and truck engines all of which require a speed
    adjustment accuracy of 10 rpm. Previous tachometers were only
    accurate to 40 rpm.
    It can be programmed from .5 to 256 pulses per revolution and is
    accurate to 1 rpm over the full range of 40 to 9999 rpm. Designed
    along the modular concept, this tool replaces all the different
    tachometers 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. LEDs
    indicate when the engine is in a LUG or OVERRUN condition or
    when the setpoint has been reached. The setpoint rpm is read on the
    6V2100 Multitach which is installed on the set point indicator.

    Unit 1
    Lesson 1

    1-1-9

    Engine Diagnostics and Repair

    Fig. 1.1.13

    The various multitach pickups are shown clockwise from top left:
    The 6V3136 Photo Pickup, which uses reflective tape for the
    pulses per revolution input, is used when it is not convenient
    to get the speed of the rotating member by using either of the
    magnetic pickups.
    The 8L4171 Magnetic Pickup is used when access to the
    flywheel teeth is available.
    The 6V4950 Fuel Line Speed Pickup Group can be used with
    all applications except double walled fuel lines.
    The 6V2197 Magnetic Pickup uses the timing hole in the
    flywheel to generate a signal.
    Finally, the 5P7360 Tachometer Generator can be used if a
    tach drive is available on the engine.

    Unit 1
    Lesson 1

    1-1-10

    Engine Diagnostics and Repair

    Fig. 1.1.14

    The timing Indicator is a test tool that can be used to check the
    dynamic timing of Caterpillars diesel engines and 3500 spark ignited
    engines. The timing advance unit can be checked on those engines
    that are so equipped
    A Diesel Timing Adapter or a Spark Timing Adapter must be used
    with the Timing Indicator. The Diesel Timing Adapter (shown at the
    bottom) consists of a fuel line pressure pickup, a connecting cable,
    and the adapters necessary to install the pickup in the No. 1 or
    companion cylinder fuel line bonnet.
    Also required is a TDC pickup, which is not shown here. The
    6V2197 Magnetic Pickup, which uses the timing hole in the flywheel
    to generate a signal, is used for this purpose.

    Unit 1
    Lesson 1

    1-1-11

    Engine Diagnostics and Repair

    Fig. 1.1.15

    The Fuel Flow Monitor Group is a versatile fuel flow measurement


    system designed to help evaluate engine performance. It uses two
    meters and a hand held monitor to provide fuel flow and fuel
    temperature measurements for both the supply and return lines. In
    addition, it provides burn rate, average rate, and total fuel
    consumption.
    The system can also be used to measure fuel flow on engines without
    a return line. The small monitor group measures flow rates of
    4-80 gph and the large monitor group measures flow rates of
    40-1000 gph. A Combination Fuel Flow Group is available that will
    do either of the above (4-1000 gph).

    Unit 1
    Lesson 1

    1-1-12

    Engine Diagnostics and Repair

    Fig. 1.1.16

    The Blowby/Air Flow Indicator is a hand-held, microprocessor based


    digital indicator capable of displaying either volume or airflow
    velocity in both Metric or English units. The group can measure the
    volume of blowby gases coming out of the crankcase breather or the
    air velocity through the radiator. Adapters are provided to connect to
    the crankcase breather on engines.

    Fig. 1.1.17

    The Electronic Position Indicator is a microprocessor based, digital


    readout, precision linear measuring gage capable of displaying either
    inch or millimeter displacement. The indicator is capable of
    dynamic, static, maximum or minimum measurements. The indicator
    can be zeroed anywhere within its 1 inch range. The indicator was
    designed to be used for measuring the rack displacement of an
    operating engine.

    Unit 1
    Lesson 1

    1-1-13

    Engine Diagnostics and Repair

    Fig. 1.1.18

    The Thermistor Thermometer is a diagnostic tool capable of


    monitoring up to six temperatures by use of the selector switch. The
    thermistors can be installed to monitor engine and cooling system
    temperatures. The Thermistor Thermometer has a range of
    0 to 150C (32 to 300F). The thermistors are designed to be used
    with Caterpillars Self-sealing Probe Adapters.

    Fig. 1.1.19

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

    Unit 1
    Lesson 1

    1-1-14

    Engine Diagnostics and Repair

    Fig. 1.1.20

    The Multichannel Temperature Selector is designed to be used with


    the 6V7070 or 6V7800 digital multimeter and the 6V9129
    Temperature Adapter. The user may measure 16 individual
    temperatures. The unit is supplied with an 8 channel cable pack and
    an output cable; both are stored in the lid. Should 12 or 16
    temperatures need to be measured, an optional 8 channel cable pack
    is available.

    Fig. 1.1.21

    These self-sealing probe adapters provide a method of checking


    pressure or temperature in fluid-filled compartments without cooling
    the machine down and draining the fluid. The pressure probe has an
    orifice 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 probe
    is in use. Always reinstall the plug after removing a probe.

    Unit 1
    Lesson 1

    1-1-15

    Diagnostics and Repair

    Fig. 1.1.22

    The 4C6500 Digital Thermometer Group provides a fast and accurate


    method of measuring temperature. It is capable of measuring five
    individual temperatures, recording the minimum and maximum
    temperature for each of the five channels and calculating one
    differential temperature from any two of the five inputs. The
    instrument is battery powered, and uses probes that are designed to be
    used with Caterpillar Probe Seal Adapters. The thermometer has a
    liquid crystal display that can be illuminated for use in low light
    conditions. Its measuring range is -50C to +850C (-58F to
    +1562F) with a maximum error of 1.1C (2F).

    Fig. 1.1.23

    The infrared thermometer is a portable non-contact temperature


    measuring instrument. It will measure surface temperature as long as
    the trigger is depressed. The unit will display the current temperature
    as well as the highest recorded temperature. This instrument has a
    range of -20C to +870C (0F to +1600F), and has a resolution of
    1 degree, with an accuracy of 1 percent of the reading.

    Unit 1
    Lesson 1

    1-1-16

    Engine Diagnostics and Repair

    Fig. 1.1.24

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

    Fig. 1.1.25

    This borescope group is designed to see into inaccessible areas such


    as combustion chambers. It will fit into bores as small as
    8 mm (0.31") and reach 240 mm (9.5") into the cavity under
    inspection. This unit has the bulb at the end of its tube and is battery
    powered.

    Unit 1
    Lesson 1

    1-1-17

    Engine Diagnostics and Repair

    Fig. 1.1.26

    This is the larger size borescope group. It will fit into bores as small
    as 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 AC
    powered, 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. 1.1.27

    This is a valve, as seen through a borescope. This picture was taken


    using the borescope shown in Figure 2.1.26.
    NOTE: Soot in the cylinder absorbs light, so be careful with your
    observations.

    Unit 1
    Lesson 1

    1-1-18

    Engine Diagnostics and Repair

    Fig. 1.1.28

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


    borescope.

    Fig. 1.1.29

    The heavy-duty multimeter (yellow, on the right) is a completely


    portable, extra rugged, sealed, 3 1/2 digit multimeter equipped with
    seven functions and 29 ranges. All inputs are protected against
    continuous overload conditions.
    The regular-duty multimeter (white, on the left) is a lower cost
    alternative to the heavy-duty multimeter.

    Unit 1
    Lesson 1

    1-1-19

    Engine Diagnostics and Repair

    Fig. 1.1.30

    The Digital Diagnostic Tool (DDT) is a hand-held tool that provides


    basic diagnostic, vehicle and engine status, and calibration displays
    for Caterpillars electronically controlled engines.
    This is an older tool, with limited use today. It is still used on gas
    engines, and for Challenger Tractor engines.

    Fig. 1.1.31

    The Electronic Control Analyzer Programmer (ECAP) is a flexible


    tool with the capability to service a variety of electronic controls.
    Once considered the full service tool for electronically controlled
    engines, it has limited usage and support today. The main limitation
    is that it cannot FLASH software files into the engines ECM.

    Unit 1
    Lesson 1

    1-1-20

    Engine Diagnostics and Repair

    Fig. 1.1.32

    The portable printer is a versatile printer that will work with the
    8T8697 ECAP, 4C0303 Vibration Analyzer and the Datalogger. The
    printer will provide printouts of the data recorded. It has both serial
    and parallel ports, allowing for connection to many different
    computers or instruments. It can operate from the internal
    rechargeable batteries or from a 115 volt AC line.

    Fig. 1.1.33

    The Vibration Analyzer Group provides quick and complete


    identification of all vibration frequencies and amplitudes present in a
    constant speed test. With this capability, dealer personnel can
    troubleshoot a customer vibration complaint for various purposes.

    Unit 1
    Lesson 1

    1-1-21

    Engine Diagnostics and Repair

    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.

    NOTES

    NOTES

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