Unit 1 Lesson 1 Caterpillar Diagnostic Tools

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, LED’s, 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MODULAR DESIGN CONCEPT • Allows tools to be "updated"' not outdated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The new line of tools are designed with the future in mind, allowing them to be "UPDATED" rather than "OUTDATED."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, let’s 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 -7°C to +62°C (40°F to + 150°F). The new tool cases are considerably less expensive and are available through Caterpillar’s 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 Caterpillar’s 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 150°C (32 to 300°F). The thermistors are designed to be used with Caterpillar’s 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 -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 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 -50°C to +850°C (-58F to +1562°F) with a maximum error of ±1.1°C (±2°F).

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 -20°C to +870°C (0°F to +1600°F), 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 Caterpillar’s 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 engine’s 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.

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