Engine Tool Guide_2_2e_12870.pdf

GROUP 2 ENGINE TOOLS

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-502-1205

GROUP 2 ENGINE TOOLS

COMPRESSION GAUGE Purpose : Intended to measure engine piston compression pressure.

! 2-2

2-2 Weight : 14.5 kg

No.

1 1a 1b 1c 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16a 16b 17 17a 17b 18 18a 18b 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Part No.

795-502-1590 795-502-1210 795-502-1220 795-502-1230 795-502-1240 795-502-1250 795-502-1260 795-502-1270 795-502-1283 795-502-1291 795-502-1310 795-502-1320 795-502-1330 795-502-1340 795-502-1350 795-502-1360 795-502-1370 795-502-1380 795-502-1500 795-502-1510 795-502-1520 795-502-1530 795-502-1540 795-502-1550 795-101-1580 795-101-1560 795-101-1571 795-502-1610 795-502-1560 795-502-1570 795-502-1580

Tool description

Gauge ass'y ! Gauge ! Hose ! Valve Adapter Adapter Adapter Adapter Case Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter ass'y ! Adapter ! Plate Adapter ass'y ! Adapter ! Plate Adapter ass'y ! Adapter ! Joint Name plate Packing Packing Packing

All models 3D68E-3 3D72, 75, 84-1 1D75-1, 1D84-1 3D78 84-2, 4D94E-21A 92-1 94-1 2D94-2, 4D94-2, 4D95L, 4D95W, 4D130-1 95-1 102 105-1, 2, 3 105-5, 110 SA6D108 114 120-11, 130-1 125 125E-3 140-1 140E-3 155-4 170-1 (6D, 8V, 12V ) 170-1 (16V) 170E-3 (HPI) Cummins 743 Cummins 855 Cummins KT1150

Component parts

1 ! ! ! 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ! ! 1 ! ! 1 ! ! 1 1 1 1

1 ! ! !

795-111-1110 Adapter 1 790-553-1110 Adapter 1 ! 790-553-1120 ! Adapter ! 790-553-1130 ! Adapter ! 790-553-1140 ! Packing 790-471-1090 Adapter 1 790-471-1110 Plate 1 790-472-1370 Adapter 1 795-502-1390 Adapter 1 795-502-1700 Adapter ass'y 1 795-111-1120 Adapter 1 1 795-471-1410 Adapter 1 6217-71-6110 Gasket 1 795-471-1310 Adapter 1 795-611-1210 Adapter 795-790-3610 Gauge 795-790-3710 Tester No. 23 to No. 39 parts are option

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! ! 1

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

1 ! ! !

Remarks

1 ! 0-7 MPa ! Length 390mm ! With a reset button

1 1 1 1 1 1 1 1 1

6D, 8V, 12V

1 1 1

direct injection type squish chamber type 1 ! !

1 ! ! 1 ! !

1

1

1 1

1 ! ! !

see page 2-2-2

1 1

see page 2-2-3 see page 2-2-3 see page 2-2-3 see page 2-2-3 see page 2-2-4 see page 2-2-4

1 1 1 1 1 1 6 1 1

2-2-1

see page 2-2-4 see page 2-2-4

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

790-553-1110

(Continued from page 2-2-1 )

ADAPTER

How to use: 1) Remove the nozzle holder of the engine cylinder head and attach the adapter (4 — 10) applicable to the machine concerned. 2) Attach the hose (2), valve (3) and gauge (1) to the adapter. 3) Push the reset button for the valve and adjust the gauge pointer to the zero position. 4) While driving the engine from the starting motor, measure the piston compression pressure.

! 2-2

2-2

Weight: 0.14 kg Applicable engine: 2D94-2, 4D94-2, 4D95L, 4D95W, 4D130-1 Component parts: No.

Part No.

Part name

Weight (kg)

1 790-553-1120

Adapter

0.055

2 790-553-1130

Adapter

0.084

3 790-553-1140

Packing

0.001

Purpose: Used to measure engine compression pressure. How to use: Remove the glow plug of engine. Screw the adapter and set a gauge. Then, measure the compression pressure. Necessary tool: 795-502-1590 Gauge ass'y

Example of use:

2-2-2

1 pc.

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

790-471-1090 790-472-1370

GROUP 2 ENGINE TOOLS

ADAPTER

790-471-1110

PLATE

! 2-2

2-2

Weight : 0.7 kg Tool No. and applicable engine: No.

Tool No.

Q'ty Weight (kg)

1 790-472-1370

1

0.2

SA6D108

2

1

1.2

16V170

790-471-1090

Applicable model : 16V170

Applicable engine

Purpose : Used to measure engine compression pressure. Necessary tool: 790-471-1090 795-502-1590

Purpose : Used to measure engine compression pressure.

Adapter Gauge ass'y

1 pc. 1 pc.

Necessary tool : 795-502-1590 790-471-1110

Gauge ass'y Plate (16V170 only)

795-502-1390

1 pc. 1 pc.

ADAPTER

Weight : 0.25 kg Applicable model : 1D75-1, 1D84-1 Purpose : Used when measuring the compression pressure of engine. How to use: To use, see SERVICE TOOL GUIDE 2-2-1 and 2. Necessary tool: 795-502-1590 790-553-1130 790-553-1140

2-2-3

Gauge ass'y Adapter Packing

1 pc. 1 pc. 1 pc.

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-502-1700

GROUP 2 ENGINE TOOLS

ADAPTER ASS'Y

795-111-1120

ADAPTER

! 2-2

2-2

Weight : 0.13 kg

Weight : 0.3 kg Applicable model : 102 engine

Applicable model : 3D68E-3 engine

Purpose : Used to measure engine compression pressure.

Purpose : Used to measure Yanmar engine compression pressure.

Necessary tool : 795-502-1590 Gauge ass'y 795-502-1760 Packing

1 pc.

Necessary tool: 795-502-1590

Gauge ass'y

1 pc.

Component parts: No.

Tool No.

Part name

Q'ty

Weight (kg)

1

795-502-1710

Adapter

1

0.05

2

795-502-1720

Sleeve

1

0.05

3

795-502-1750

Packing

1

0.001

4

795-502-1740

Ring

1

0.001

5

795-502-1730

Joint

1

0.20

795-790-3710

795-790-3610

GAUGE

TESTER

Weight: 0.8 kg

Weight: 1.2 kg Applicable model : 114 engine

Applicable model : 114 engine

Purpose : Used to measure engine compression pressure.

Purpose : Used to measure 114 engine compression pressure.

Necessary tool : 795-790-3610 Gauge

1 pc. 2-2-4

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-201-1504

GROUP 2 ENGINE TOOLS

BLOW-BY CHECKER

795-790-1900 795-790-3300

BLOW-BY TOOL

! 2-2

2-2

Weight: 5 kg Tool No. and applicable engines

Purpose: Used to measure engine blow-by pressure. " For details of how to operate, see the Operation Manual. Specifications: 1) Applicable engines: Komatsu, Cummins engines (VTA1710, IH engine: Used option parts) 2) Pressure gauge: Chamber pressure gauge • Measuring range: 0 — 5 kPa (±0.2%) • Min. scale: 0.2 kPa 3) Silicon tube: ø 5 × ø 6 × 4,000 mm 4) Size: 415 × 300 × 60 mm (Using case)

Applicable engines

No.

Tool No.

1

795-790-1900

102

2

795-790-3300

114

Purpose: Used to measure the engine crankcase pressure. Necessary tool: 795-790-1610

Mano meter

795-790-1610

Manometer

Example of use:

With out mercury. Specifications: • Measuring range: +15” to -15” • Hose inner dia. : 3/16” • Hose outer dia. : 5/16” • Hose length : 48”

2-2-5

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Inter DT817

VT(A)1710

Inter DT268,466,414

Cummins KT1150

KT1150(560)

Cummins NT(A)855

6D140, Cummins NTC743

Cummins N855

1

795-790-3300 Tool (body)

1

2

799-201-1541 Gauge

1

1

1

1

1

1 1

1 1

1 1

1 1 1

1 1

1 5 kPa

3

799-201-1571 Tube

1

1

1

1

1

1 1

1 1

1 1

1 1 1

1 1

1 Cylicon tube 4 m

4

799-201-1530 Nut

1

1

1

5 6

799-201-1521 Adapter 799-201-1581 Case

1 1

1

1

7

799-201-1411 Adapter

1

8

799-201-1460 Plug

3

9

799-201-1450 Adapter

1 1

1 1 1

1

795-790-1950 Tool (body)

1

1 1

1 1

799-201-1511 Tool (body)

11 799-201-1430 Adapter

1 1

Remarks

1

10 799-201-1640 Adapter

1

Cummins N743

1

S(A)6D155,170

1

6D125,S4D130

1

114

3D94,4D94,4D105 (S)6D105,6A6D110,6D108

1

Tool description

102

(S)4,6D85 (marked:{} no turbo)

Part No.

All model

No.

2D94

Component parts:

1

Option for 102 1

Option for 114

Oil filler mounting adapter 1

{3}

1

1 1

Diams. of joints: 14.5 mm, 16 mm Blind plug for N743 vent hole Diams. of joints: 19 mm, 26 mm

1

3 1

1

1 1

1

1

1 1

For I.H engine 1 only

12 799-201-1440 Adapter

1

13 799-201-1630 Joint

1

14 799-201-1470 Hose

1

15 799-201-1421 Hose

1

16 799-201-1480 Hose

1

1 1

1

φ14 xφ20 x 60

17 799-201-1490 Hose

2

2 2

2

φ14 xφ20 x 1000

18

07281-00289 Clamp

2

19

07281-00259 Clamp

1

1 1 1

1

1 1

1

1 1

1 1

φ20 xφ26 x 60

1

φ16 xφ22 x 60

2 1

1

Option 799-201-1590

GAUGE

Applicable engines: V type engine Purpose: Used when measure V type engine blow-by pressure. Specifications: Pressure range: Graduation Min.: Accuracy: Safety device:

0 - 10 kPa 0.2 kPa 1.0 class (JIS) With over pressure preventing unit

Necessary tools: 799-201-1504 Blow-by checker 799-201-1511 Nozzle 799-201-1450 Adapter

Weight: 0.3 kg

2-2-6

1 pc 2 pcs 2 pcs

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Note: If, any abnormal pressure, caused by a defective turbocharger, is detected while measuring the blowby pressure, use the following device.

795-500-1001 795-500-2000

SPECIFIC GRAVITY TESTER

Option 799-201-1400

3-WAY SELECTOR VALVE ASSEMBLY

! 2-2

2-2 Applicable engine S(A)6D155 (D155, D355) Weight: 0.3 kg Purpose 1) Used to measure the specific gravity of the battery liquid and the charging condition of the battery. 2)Used to measure the freezing temperature when anti-freeze is use. Specifications: 795-500-1001 795-500-2000 Gravity of the Reading 1.100 ~ 1.300 1.00 ~ 1.30 battery liquid range Measurement freezing Reading -5 ~ -50 °C - 8 ~ -50 °C temperature range Type of the anti-freeze AF-PT, AF-ACLNON AMINE

How to use Base line adjustment 1) Put 1 — 2 drops of clean water (service water) onto the prism face of the tester. 2) Close the light intake plate and look into the eyepiece with the tip of the tester directed at light. 3) If the boundary line between blue and white deviates from the water line, make them coincide by turning the base line adjusting screw A. Measurement 1) Put 1 — 2 drops of a solution to be measured onto the prism face using a sampler and read the position of the boundary line by looking into the eyepiece. 795-500-2010 Cover plate 795-500-2020 Pin

Component parts: No.

Part No.

Tool description Q't y

20 799-201-1310 Pipe

1

21 799-201-1320 Pipe

2

22 799-201-1330 Valve

1

23 799-201-1340 Hose

2

24 799-201-1350 Hose

1

25 799-201-1360 Hose

2

26 799-201-1370 Hose

2

Remarks

3-way valve Ø20.5 × Ø26 × 60 mm Ø20.5 × Ø26 × 1,000 mm Ø28.5 × Ø36 × 60 mm Ø30.5 × Ø36 × 60 mm

27 07281-00359

Clamp

5

Ø25 × Ø35

28 07281-00419

Clamp

4

Ø27 × Ø45

" 795-500-1000 Old tester can not be measured antifreeze of a super coolant type (AF-ACL) " For the details, refer to the Operation Manual furnished with the tester. 2-2-7

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-202-7002

GROUP 2 ENGINE TOOLS

WATER TESTER Standard combined electrodes: 2120 type. Cell constant, abt. 5cm-1 type; Throw-in type with ø18mm. Lead wire, ø4.9mm and 1.5m. Temperature of the liquid to be measured: 0 — 50°C Power source: Dry cells, 006P, 9V, one piece Measurement accuracy: Conductivity, ±3% (1/100N Kcl solution) Temperature, ±1°C Life, battery: Abt. 50 hours (continuous). Alarm, battery life: B (battery) mark. Hold function: Available. Weight: Abt. 230 g (basic unit), Abt. 130 g (for electrode and 1.5m lead wire.)

! 2-2

How to use

Component parts (1 piece each) No.

Part No.

Tool description

Remarks

1 799-202-7200 Meter assembly Conductivity meter 2 799-202-7600 PH test paper

PH 1 - 11

3 799-202-7610 PH tester paper PH6.6 - 8.2

5 799-202-7800 Reagent

Designated reagent 15 cc polyethylene Standard liquid 500 cc bin

6 799-202-7902 Case

Storage case

7 799-202-8201 Measure cup

Colorimetric tube

8 799-202-8300 Cup

100 cc polyethylene

9 799-202-8400 Bottle

To refill the standard liquid

10 799-202-8451 Filler

To take specimens

Purpose Used to judge the condition of cooling water before put in the radiator and the effectiveness of the corrosion resistor. Specifications Name: Handy type conductivity meter Model: Thick C, TS-51 Characteristics that can be measured: (1) Conductivity . . .0 — 19.99 mS/cm at 25°C 0 — 1.999 mS/cm at 25°C 0 — 199.9 µS/cm at 25°C 0 — 19.99 µS/cm at 25°C Note: 4-range and manual switching. (2) Temperature . . .0 — 50°C Temperature compensation: Automatic compensation for 1/100N Kcl solution (1.9%/°C) Display: LCD and 3½ digits Operating temperature: 0 — 40°C

2-2-8

1 Measuring conductivity (or conductance) # Turn measurement switch ON. $ Set mode switch to COND. % Set range switch to "20 mS/cm". & Put the electrode in the liquid (or solution) to be measured, then shake the electrode up and down two to three times to release the internal air. ' Make the range smaller one after another, then read at the display section for proper range. Note: (1) If the measurement value is more than 20.0 mS/cm, display such as 1. m will be made, indicating that no measurement can be made. (2) For the unit of conductivity, S (Siemens)/ cm is used although unit (mho)/cm was used before. Ω

4 799-202-7700 Reagent

2 Measuring temperature # Turn measurement switch ON. $ Set mode switch to TEMP, then read at the display section 3 Holding display If you cannot read because of measurement position or measurement location, set measurement switch to "HOLD" to hold the display.

2-2

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

4 PH value 1) Dip the PH test paper into sample water. 2) Compare discoloration of the test paper with the standard discoloration chart attached to the test paper. (Two kinds of test paper are provided; use them properly depending on PH value being tested.) 5 NO2 concentration (Refer to below photo) 1) Fill the colorimetry tube (measuring cylinder) 2 with 10 cc or 5 cc of standard solution in the dropping bottle for rebottling 1. 2) Add two or three drops 3 into colorimetry tube 2, plug the tube, and shake up the tube satisfactorily. (Solution in the colorimetry tube will be changed in color to bluish green.) 3) Sample water into beaker 4. Pour little quantity of sample water into the colorimetry tube and shake up the tube satisfactorily. 4) Repeat step until color of solution in the tube changes to red. 5) When discoloration is found, measure the quantity of solution in the colorimetry tube. 6) Calculate NO2 concentration by applying the quantity measurement to the conversion graph below.

Example of use:

2-2-9

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-201-2301

GROUP 2 ENGINE TOOLS

INJECTOR TESTER

! 2-2

2-2

Weight: 26.3 kg

Applicable engine

Cummins engine (With flange type injectors)

Purpose Intended to test injector plungers and cups for tightness. How to use 1) Connect the compressed air source (at 0.55— 0.62 MPa {5.6 — 6.3 kg/cm2}) to the tester. 2) Remove the spring from the injector and insert the plunger only. 3) Set the cap in the counter bore and turn upward the fuel inlet and drain hole, then fill the injector with fuel. 4) Place the handle to the plunger and push in it. 5) Open the air valve and subject the system to a predetermined pressure for about 3 sec., check being made that there is no air escape from the inlet hole and from the drain hole. Example of use:

2-2-10

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-202-9001

GROUP 2 ENGINE TOOLS

RADIATOR CAP TESTER

! 2-2

2-2

Purpose: This tester confirm function of the pressure valve and checks the cooling system for water leakage. Construction: The tester is composed of a electric air pump for pressurizing and an adapter.

Component parts: No.

Part No.

Tool description

* Type of radiator cap

Remarks

1

799-202-9001

Radiator cap tester

-

(1)

799-202-9200

! Pump assembly

-

Battery 12V (DC), Delivery rate = 0.6 MPa

(2)

799-202-9211

! Cap

B

M80, P = 1.5

(3)

799-202-9221

! Cap

B

M80, P = 2 (double thread screw)

(4)

799-202-9231

! Adapter

A

Rubber outer dia. Ø38

(5)

799-202-9240

! Joint

A

Ø41 × Ø41 H =73

(6)

799-202-9250

! Joint

A

Ø50 × Ø41 H=62

(7)

799-202-9260

! Joint

A

Ø54 × Ø41 H=54

(8)

799-202-9271

! Adapter

A

Rubber outer dia. Ø48

(9)

799-202-9281

! Adapter

A

Rubber outer dia. Ø50

(10)

799-202-9311

! Hose

-

L=1m

(11)

799-202-9320

! Cable

-

Power cable

2

799-202-9330

Joint

A

Ø31 × Ø41 H =78

Option

3

799-202-9340

Adapter

A

Rubber outer dia. Ø27.5

Option

4

07041-13633

Plug

C

36 × P1.5, PT 1/8

Option

5

07002-03634

O-ring

C

6

799-202-9360

Nipple

C

* See section "types of caps and types of combinations".

2-2-11

Option CEJN 10 - 220 - 5151 , PT 1/8 Option

!

GROUP 2 ENGINE TOOLS

Specifications of basic unit of pump: • Power source, battery: 12 VDC • Pressure, delivery: 0.6MPa {6kg/cm2}, max. • Pressure gauge: 0 — 0.2MPa {0—2kg/cm2}, containing glycerine • Valve: with regulator valve Types of radiator caps: The cap type in that the radiator cap and water pouring cap are built into a single unit Type A (for automobile use) (Four sizes by diameters are available, i.e., Ø54, Ø50, Ø41 , and Ø31 ) The cap type that has a single unit of pressure valve Type B (Two sizes by the thread pitch of water pouring cap are available) Type C

2-2

The cap type made by WISCO and that has a plug hole in the upper tank

Types of combinations: A type

B type

C type

Checking pressure valve operations

Type Use

Checking for water leak from cooling system

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

How to use: (1) The method of handling type A or B is same as before. For the details, see Operation Manual. (2) To handle type C, remove the plug from the basic unit of the radiator that has a radiator cap, then install plug 4, O-ring 5, nipple 6, and hose 10. Except for above, handle type C in the same manner as type B.

2-2-12

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Reference: List of applicable machine model Machine model

Machine model

Type of radiator cap

D20,21-6

Serial No. 60001 and up

A

PC05

Serial No. 8001 and up

A

D31-18

Serial No. 40001 and up

A

PC07-1

Serial No. 1001 and up

A

D37-2

Serial No. 2501 and up

A

PC10-6

Serial No. 20001 and up

A

D40,41-5

Serial No. 10001 and up

A

PC12UU-1

Serial No. 20001 and up

A

D66S-1

Serial No. 1001 and up

A

PC15

Serial No. 1001 and up

A

PC20-6

Serial No. 24001 and up

A

D50,53-18

Serial No. 83001 and up

B

PC25

Serial No. 1001 and up

A

D57S-1

Serial No. 20001 and up

B

PC28UU-1

Serial No. 1001 and up

A

D60,65-11

Serial No. 50001 and up

B

PC30-6

Serial No. 10001 and up

A

D75S-5

Serial No. 15001 and up

B

PC38UU-1

Serial No. 1001 and up

A

D85-21

Serial No. 35001 and up

B

PC40

Serial No. 18001 and up

A

D95S-2

Serial No. 1279 and up

B

PC45

Serial No. 1001 and up

A

D135-2

Serial No. 10301 and up

B

PC50UU-1

Serial No. 1001 and up

A

D155-2

Serial No. 50001 and up

B

PC60U-5

Serial No. 4501 and up

A

D275-1

Serial No. 10002 and up

B

PC60L

Serial No. 8001 and up

A

D355-3

Serial No. 11728 and up

B

PC60

Serial No. 28001 and up

A

D355-5

Serial No. 12622 and up

B

PC70

Serial No. 34101 and up

A

D375-2

Serial No. 16001 and up

B

PC75UU-1

Serial No. 1001 and up

A

D475-1

Serial No. 10001 and up

B

PC90

Serial No. 1001 and up

A

D475-2

Serial No. 10201 and up

B

PC100L-5C Serial No. 14001 and up

A

D575-2

Serial No. 10001 and up

B

PC100-5C

Serial No. 28001 and up

A

DR450-1

Serial No. 10001 and up

B

PC100-5

Serial No. 30083 and up

A

PC120-5

Serial No. 30001 and up

A

PC150-5

Serial No. 6001 and up

A

Hydraulic Excavator

Bulldozer

! 2-2

Type of radiator cap

2-2-13

PC200,220-5C Serial No. 35001 and up

A

PC200-5

Serial No. 45001 and up

A

PC200LC-5 Serial No. 45001 and up

A

PC300

Serial No. 20001 and up

A

PC400-5

Serial No. 20001 and up

A

2-2

!

GROUP 2 ENGINE TOOLS

Type of radiator cap

Machine model

Type of radiator cap

PW05-1

Serial No. 1001 and up

A

WA20-1

Serial No. 1001 and up

A

PW20-1

Serial No. 1001 and up

A

WA20-2

Serial No. 10001 and up

A

PW30-1

Serial No. 1001 and up

A

WA30-3

Serial No. 9001 and up

A

PW100-3

Serial No. 1862 and up

A

WA30-5

Serial No. 15001 and up

A

PW100N-3

Serial No. 1866 and up

A

WA40-2

Serial No. 3001 and up

A

PF3W-1

Serial No. 10001 and up

A

WA40-3

Serial No. 10001 and up

A

WA50-1

Serial No. 10001 and up

A

PC650-3

Serial No. 10501and up

B

WA70

Serial No. 10001 and up

A

PC1000-1

Serial No. 10001 and up

B

WA100

Serial No. 20001 and up

A

WA150-1

Serial No. 20001 and up

A

WA200-1

Serial No. 20001 and up

A

WA300-1

Serial No. 30001 and up

A

WA320-1C

Serial No. 10001 and up

A

WA350-1

Serial No. 10001 and up

A

WA400-1

Serial No. 10001 and up

A

WA450-1

Serial No. 20001 and up

A

WA470-1

Serial No. 20001 and up

A

HD200D-3

Serial No. 1001 and up

A

HD465-2

Serial No. 4001 and up

A

HD785-3

Serial No. 2001and up

A

Wheel loader

Hydraulic Excavator

Machine model

Dump truck

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

HD200-2

Serial No. 1002and up

B

HD320-2

Serial No. 1005and up

B

WA500-1

Serial No. 10435 and up

A

HD1200M-1

Serial No. 1101 and up

B

WA700-1

Serial No. 10001 and up

A

HD200-2

Serial No. 1215 and up

C

WA600-1

Serial No. 10001 and up

B

HD320-2

Serial No. 2001 and up

C

WA800-1

Serial No. 10001 and up

B

HD320-3

Serial No. 2501 and up

C

HD325-2

Serial No. 1002and up

C

HD325-3

Serial No. 1501 and up

C

HD325-5

Serial No. 2001 and up

C

HD1600M-1

Serial No. 1007 and up

C

2-2-14

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-201-1301

GROUP 2 ENGINE TOOLS

PRESSURE GAUGE

799-201-1201

VACUUM GAUGE

! 2-2

2-2

Weight: 0.5 kg Applicable engine

Cummins engine

Weight: 0.6 kg Applicable engine

Cummins engine

Purpose For measurement of PT pump fuel pressure.

Purpose For measurement of PT pump Vacuum pressure.

Specifications 0 — 2.5 MPa

Specifications 0 — 760 mmHg

How to use Remove the blind plug of PT pump shut off valve and attach the pressure gauge. Then, measure the max. fuel pressure when the engine is changed over from low idle to full throttle.

How to use Attach the vacuum gauge to the PT pump fuel suction side and then measure the vacuum pressure at the max. engine output or at max. revolutions at nonload. Where vacuum pressures exceed the prescribed one, check to see whether the fuel filter or the fuel piping is clogged.

Example of use:

Example of use:

2-2-15

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-1500

GROUP 2 ENGINE TOOLS

VACUUM GAUGE

795-790-1470

PRESSURE GAUGE

! 2-2

2-2

Applicable model: 102, 114 engine

Applicable model: 102, 114 engine

Purpose: Vacuum Gauge Check the fuel filter restriction during the engine performance test. Hose Adapter, Part No. ST-434-2, and vacuum gauge, Part No. ST-434-12, are used to perform the test.

Purpose: Pressure Gauge ( 0 — 75 in. Hg.) Used to measure the intake manifold pressure and exhaust back pressure.

Component parts: Det Description 1 Brazed construction 2 Hose assembly 3 Vacuum gauge

Component parts: Det Description 1 Pressure gauge 2 Pipe coupling 3 Hose (#4) 4 Male connector 5 Male connector

Req'd 1 1 1

2-2-16

Req'd 1 1 1 1 1

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-1700

GROUP 2 ENGINE TOOLS

PRESS TEST KIT

! 2-2

2-2

Applicable model: 102, 114 engine Purpose: Turbocharger Wastegate Pressure Setting Kit Used to set wastegate pressure. Gauge 0 — 60 psi. Component parts: Komatsu tool No.

795-790-1710 795-790-1720

(3823799)Kit, turbo wastegate air pressure test consists of: Det. No. ST. No. Description Specifications Aeroquip #2000-4-5B (1/4-18 NPT Male × 1 Adapter, hose/pipe 1/2-20 THD., #4 Hose) Fitting, socketless Aeroquip #4753-4-4B (1/4-18 NPT Female 2 hose × #4 Hose) Hose, special Aeroquip #2556, #4, 1/4" I.D. (Textile braid 3 Application rubber tube & cover) 18" Long Fitting, socketless Aeroquip #4738-2-4B (1/8-27 NPT Male × 4 hose #4 Hose) Adapter, pipe Aeroquip #2040-2-4S (1/8-27 NPT Male × 5 reducing 1/4-18 NPT Female) 6 ST-990-40 Regulator, pressure Wilkerson, 1/8 NPT Female, #R00-01-000 3823205 Aspcroft #63-1008-AL-02L-60; Ø2 1/2"; 7 Gauge, pressure *REF. 0-60 PSI; 1/4 NPT Lower; 3-2-3% Accuracy 8 Label, warning See drawing

2-2-17

Q't y 1 1 2 2 1 1 1 1

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

! 2-2

2-2

2-2-18

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

799-201-9000

HANDY SMOKE CHECKER

! 2-2

2-2

Weight: 3 kg Applicable engine All models Component parts (each 1 piece) No.

Part No.

TooI description

Remarks

1 799-201-9010

Pump

With a tube

2

799-201-9020

Filter paper

3

799-201-9030

Smoke scale Standard color samples

4

799-201-9040

Case

Containing 300 sheets

Purpose Used to measure the concentration of smoke in the engine exhaust gas. Specifications 1) Range of measurement: 0 to 70% (Degree of contamination) 2) Size of case: 410 × 300 × 65 mm How to use 1) Press the pump handle all the way, loosen the screw on the tip, insert a filter paper into the slit, and tighten the screw. 2) Insert the tip of a sampling tube into the outlet pipe of the muffler. 3) From the condition in step 1), slowly pull the pump handle until it reaches its stroke end. (Time required: 1 to 2 seconds) 4) Loosen the screw, remove the filter paper, and compare the filter paper with concentration samples in the smoke scale to find the scale No. which is most similar to the color of the filter paper.

2-2-19

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-2300

GROUP 2 ENGINE TOOLS

CRACK DETECTOR Applicable model: All engine Purpose: Used to inspect surface cracks, pores, leaks, seams, etc. Used to clean the threads of the pipe plugs and threaded bores. (795-790-2310 Cleaner)

! 2-2

2-2

Component parts: Part No. 795-790-2310

Description

Specification

Size

Q'ty

Cleaner

12 oz. spray can

3" dia. × 5 1/2 ht.

4

Developer

12 oz. spray can

3" dia. × 5 1/2 ht.

2

Penetrant

12 oz. spray can

3" dia. × 5 1/2 ht.

2

Box

Plastic

▲ See det.

1

Instructions

795-790-2400

1

ROD CHECKER Applicable model: 102 engine Purpose: When inspecting connecting rods for center-tocenter distance, deflection and distortion, this rod mandrel serves as a fixing pin. Component parts: Det.

2-2-20

Description

Q't y

1

Body (welded construction)

1

2

Pin

1

3

Locating plunger

1

4

Hand knob

1

5

Lock pin

1

6

Mandrel, piston pin end

1

7

Mandrel, piston pin end

1

8

Sheet, instruction

1

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-2800

GROUP 2 ENGINE TOOLS

MANDREL KIT

! 2-2

2-2

Applicable model: 114 engine Purpose: When inspecting Connecting rod checking fixture, to check length, twist and bore alignment. Necessary tools: ST-561 Rod fixture

2-2-21

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-203-6000

GROUP 2 ENGINE TOOLS

FUEL DRAIN TEST KIT

! 2-2

2-2

Weight: 2.5 kg

Applicable engine

Cummins 743 series engines (with flange type injectors)

Component parts: No.

Part No.

Tool description

Q't y

1

799-203-6100

Adapter assembly

1

2

799-203-6200

Tube assembly

6

3

799-203-6270

Cylinder

1

4

799-203-6290

Case

1

Size of case 370 × 200 × 70 mm Necessary tools 1) Multi-tachometer (799-203-8000) 2) Stopwatch (Commercially available) Purpose Used to check the fuel injectors on 743 series engines for defects. Specifications 1) Application

743 series engines (with flange type injectors) 2) Size of case 370 × 200 × 70 mm

2-2-22

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-201-7101 and others

GROUP 2 ENGINE TOOLS

COOLANT TESTER

! 2-2

2-2

Tool No. and applicable engines Tool No. 799-201-7101 799-201-7200 790-553-1701 799-201-7301 790-553-1601 790-553-1501 799-201-7401 790-553-1800 790-553-1900 790-553-1401 799-201-7501 790-553-1301 790-553-1201 799-201-7601 799-201-7701 799-201-7801

Applicable engines Cummins 855 Series Cummins 743 Series 170 Series 155-4 140 Series 6D125 4D120, 130 6D108 6D105 4D105-5 4D105-1, 2, 3 6D95L 4D95L 4D92, 94 2D94 2D92

Purpose This tester plate is used for checking if there is any water leakage from the cylinder head. How to use 1) Tighten bolt (3) so that centering nut (4) and washer (5) will be fastened to the cylinder head (to an extent not to leave any clearance between the cylinder head and washer). (Depending on the engine model, the mounting position of these parts varies; therefore, refer to the section “Plate mounting position” at a later part.). 2) After setting the O-ring to the plate, mount this plate to the cylinder head.

2-2-23

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

3) Lock plate (1) to the cylinder head, using bolt (3), washer (5), and nut (6).

! 2-2

2-2

4) Mount valve (12) to flange (7) or (8). 5) Fit O-ring (10) (or gasket (9) with Komatsu 2D92 and over) to flange (7) and (8). 6) Mount flanges (7) and (8) to the cooling water ports of the cylinder head, using bolt (11). " Valve (12) is used for purging air from inside the cylinder head at the time of the hydraulic test.

7) Connect the hydrostatic tester to flange (7) to check for water leakage under the application of a hydraulic pressure of 0.25 — 0.59MPa {2.5 — 6.0 kg/cm2} for ten minutes. Or connect the air hose to flange (7) and submerge the cylinder head in the water to check for air leakage. At this time, the cylinder head must be applied with a pneumatic pressure of 0.14 — 0.21 MPa {1.4 — 2.1 kg/cm2} for 30 seconds.

2-2-24

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Weights (kg)

Cummins 855 series 799-201-7100

Cummins 743 series 799-201-7200

799-201-7300

799-201-7400 4D120-11, 130-1

799-201-7500 4D105-1,2,3

799-201-7600 4D92-1, 4D94-1,2

799-201-7700

799-201-7710

Plate

1

1

1

799-201-7810

Plate

1

1

799-201-7720

Plate

1

799-201-7610

Plate

1

1

2.2

799-201-7620

PIate

1

1

1.9

799-201-7510

PIate

1

1

2.7

799-201-7520

Plate

1

1

2.0

799-201-7410

PIate

1

1

3.7

799-201-7420

PIate

1

1

3.7

799-201-7210

Plate

1

799-201-7110

Plate

1

799-201-7310

Plate

1

07000-02016

O-ring

14

07000-02020

O-ring

24

3

799-201-7120

Bolt

8

6

6

8

4

799-201-7130

Centering nut

4

4

4

4

5

799-201-7140

6

01580-01210

Engines

! 2-2

155-4

2D94-1

Tool description

2D92-1

Part No.

All model

No.

799-201-7800

Ass'y Part No.

Component parts and applicable engines

2-2

1.0 0.95

1

0.75

1

1

3.2 1

1 5

4

9

14

8

8

24

8

7

8

4

6

4

4

4

2

2

2

Washer

16 12 12 16 14 16

8

12

8

Nut

8

6

6

8

4

6

4

*799-201-7630 Flange

1

1

1

1

*799-201-7530 Flange

1

7

7 1

2-2-25

8

3.5 5.1

2

Remarks

For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outIet For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outlet For sealing the water outlet To be mounted to No.1 part To be mounted to No.1 part To be mounted to No.1 part To be mounted to No.1 part To be mounted to No 1 part To be mounted to No.1 part For sealing the cooling water port For sealing the cooling water port

!

799-201-7430

Flange

1

799-201-7220

Flange

1

799-201-7150

Flange

1

799-201-7320

Flange

1

799-201-7440

Flange

2

799-201-7230

Flange

1

799-201-7160

Flange

1

799-201-7330

Flange

1

799-201-7640

Gasket

1 1

799-201-7540

Gasket

1

07000-03038

O-ring

3

10 07000-03022

O-ring

2

07002-12434

O-ring

2

01010-30830

Bolt

9 2

01010-30845

Bolt

3

11 02010-00519

Bolt

4

02010-20622

Bolt

4

01010-31020

Bolt

4

Valve

2 1

1 1 1 1

8 2 1 1 1 1

1

9

12 799-201-7171

1 3

2 2 2

2

2

9 3 4 4 4

1

1

1

2

2-2-26

1

1

1

Weights (kg)

Cummins 855 series 799-201-7101

Cummins 743 series 799-201-7201

799-201-7301 155-4

799-201-7401 4D120-11, 130-1

799-201-7601

799-201-7501 4D105-1,2,3

2D94-1

2D92-1

! 2-2

4D92-1, 4D94-1,2

799-201-7701

GROUP 2 ENGINE TOOLS

Tool description

All model

Part No.

Engines

No.

799-201-7801

Ass'y Part No.

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

Remarks

2-2 For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port For sealing the cooling water port To be mounted to No. 7 part To be mounted to No. 7 part To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 and 8 parts To be mounted to Nos. 7 (* marked part No. ), and No. 8 parts

!

! 2-2 1

2

3

4

5 6 7 8

9 10 11 12 13 14 15

790-553-1210 790-553-1310 790-553-1410 790-553-1510 790-553-1610 790-553-1710 790-553-1810 790-553-1220 790-553-1320 790-553-1420 790-553-1520 790-553-1620 790-553-1720 790-553-1820 790-553-1230 790-553-1330 790-553-1430 790-553-1530 790-553-1630 790-553-1730 790-553-1830 790-553-1240 790-553-1340 790-553-1440 790-553-1540 790-553-1640 790-553-1740 790-553-1840 790-553-1250 790-553-1260 799-201-7171 01011-51230 01011-51235 01011-51250 01011-52090 01580-11210 01580-12016 01643-31232 01643-32060 01010-50825 01010-51030 01011-51040 01580-11008 01643-31032 02720-20204

790-553-1301

790-553-1401

790-553-1501

790-553-1601

790-553-1701

790-553-1800

790-553-1900

6D95L

4D105

6D125

140 series

170 series

6D108

6D105

1 1 1 Plate

1 1 1 1

1

1 1 1 Packing

1 1 1 1

1

1 1 1 Plate

1 1 1 1 1

1 1 1 Packing

1 1 1 1

Union Nipple Valve

1 1 1 1 1 1 17 25

1 1 1 18

1 1 1

1 1 1

6

6

1 1 1

1 1 1 1

1 1 1

26 26

Bolt

6 17 25 18

6

5

17 25 18

4

4

26 26 4

Washer 2 Bolt Bolt Nut Washer Plug

26 26 6

Nut

2 2 1 1 1

2

2

1

1

1 1 1

2-2-27

Weights (kg)

790-553-1201

Tool description

4D95L

Part No.

Ass'y Part No.

No.

GROUP 2 ENGINE TOOLS

Engines

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

5.35 7.9 6.6 2.58 3.43 4.6 8.15 0.2 0.3 0.25 0.1 0.13 0.18 0.37 0.38 0.36 0.37 0.27 0.51 0.44 0.35 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.11 0.078 0.08 0.13 0.134 0.15 0.29 0.012 0.05 0.01 0.044 0.01 5 0.03 0.096 0.009 0.007 0.005

Remarks

2-2 For sealing the cooling water port

To be mounted to N0.1 part

For sealing the water outlet

To be mounted to N0.3 part

Same as above To be mounted to N0.1 part To be mounted to N0.1 part

Same as above Same as above To be mounted to N0.3 part To be mounted to N0.1 part Same as above To be mounted to N0.1 part

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

PLATE MOUNTING POSITION

! 2-2

2-2

2-2-28

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

! 2-2

2-2

2-2-29

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-203-9000

GROUP 2 ENGINE TOOLS

MULTI-PURPOSE TACHOMETER

(1) Standard set

! 2-2

2-2

Applicable engine: All models Purpose: This revolution indicator allows many types of revolutions to be measured as described below. For the standard set: 1) For the Komatsu or Cummins engine that has a tachometer drive, correct engine revolutions can be easily measured if the adaptor for the tachometer drive is used. 2) If the reflecting tape is glued to the revolving body and the photoelectric probe used, revolutions can be measured without contact with the revolving body. If the optional clamp set is added: 1) Engine revolutions can be easily measured even for the engine that doesn’t have the tachometer drive. Note 1) Not applicable to the Cummins engine. Note 2) Not applicable to some Komatsu engine. If such is the case, use the tachometer drive and revolution measuring adaptor or use the reflecting tape and photoelectric probe in order to make measurements. Engine models to which no clamp set is applicable: # Ø140 series such as S6D140, SA6D140, and SA12V140. $ Some of S6D95L-1 engines (such as those on PW100-3 and PF3W-1). (Note: Models described in $ have the tachometer drive.) Note 3) When you must measure the revolutions on the Yanmar engine that uses a steel clamp for clamping the injection pipe and when you make measurements by using the clamp set, the clamp on the Yanmar engine needs to be removed.

(2) Clamp set

The part Nos. for the multi-tachometer sets have been modified as described in the table below after above model change. Current Std. set 799-203-8000 Clamp set 799-203-8900 Full set, no Part No.

2-2-30

New Standard set 799-203-8001 (Only the case is changed.) Clamp set 799-203-8901 Full set (standard set plus clamp set) 799-203-9000

For the customer who has the current set: Obtain 799-203-8901, If done so, it can be used together with 799-203-8000. However, the current case is too small, so we recommend you to obtain new case (799-203-8740). If done so, the current set and new clamp set can be contained together in the new case. (Equivalent to 799-203-9000.)

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Component parts: (1) Standard set No.

Part No. 799-203-8001

Tool description

Q't y

Remarks

Multi-purpose tachometer

1

Basic set assembly

1 799-203-8110

! Meter

1

Digital meter with liquid crystal display

2 799-203-8180

! Probe

1

Photoelectric pickup

3 799-203-8200

! Bracket

1

For installation of r.p.m. pickup

4 799-203-8230

!! Nut

1

Metric (M22 × 1.5), marked "M"

5 799-203-8240

!! Nut

1

Imperial (7/8-18 NS), marked "I"

6 799-203-8300

! Stand

1

Magnet stand for securing the probe

7 799-203-8400

! Cable

1

Connects probe to meter (Approx. 5m)

8 799-203-8500

! Reflective tape

1

Set

9

Generally available part

! Dry cell

2

9V (IEC 6F22)

10

Generally available part

! Screwdriver

1

Hexagonal bar, 1.5 mm between opposing faces

11 799-203-8740

! Storage case

1

Padded (Incl. cushion)

12 799-203-8830

! Operation Manual

1

(2) Clamp set No. Part No. 799-203-8901

Tool description

Q'ty

Clamp set

Remarks Clamp set assembly

1 799-203-8920

Sensor

1

Fuel injection pipe-mounted type sensor

2 799-203-8930

Amplifier

1

Amplifier for fuel injection pipe-mounted type sensor

3 799-203-8990

Operation manual

1

Clamp set operation

4

Dry cell

1

9V (lEC 6F22)

Generally available part

Specifications: Standard set Duration of display LCD display Operating modes Measurement range

Clamp set

0.5 to 1.0 seconds Range: 60 19,999 (- - - for off-scale) Battery alarm: Display changes to "B" when battery is low. Illumination: 2 yellow light-emitting diodes (LEDs) connected to MEAS switch MEAS . . . . . measurement HOLD . . . . . . data hold LOCK . . . . . . continuous measurement L-range: 60.0 to 1999.9 rpm L-range: 60.0 to 1999.9 rpm H-range: 60 to 19999 rpm H-range: 60to 6000 rpm

Resolution

L-range: 0.1 rpm, H-range: 1 rpm

Operating temperature

0 to 50°C

5 to 40°C

Datects reflections from Scotch-Lite tape Method of measurement No direct contact Distance from object being measured: 5 to 300 mm (R)

Fuel injection pipe signal sensing, Contact type

Verification of reflection

Tone and display

Power supply

One 9-V dry cell (lEC 6F22)

Continuous operation

LOCK: approx. 7 hours

LOCK: approx. 4 hours

Dimensions

Main unit: 180 × 50 × 30 mm Probe: 15 dia. × 50 mm Probe lead: 5 m (approx.)

Amplifier: 110 × 70 × 35 mm Sensor: 24 dia × 45 mm Sensor cord: 5m (applox)

Weight of unit

Approx. 210 g

Approx. 390 g (Amplifier plus sensor)

2-2-31

2-2

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

How to use: For a more complete description, refer to the Operation Manual accompanying the Multi-Purpose Tachometer. 1. Measuring engine speed 1) Securely attach the provided cord to the connector of the probe and the main unit. 2) Attach the sensor to the engine speed outlet. Note: • Attach the sensor to the servicemeter’s engine speed outlet secure with a ring nut. • Pay special attention to the system of units (mm vs. inches) used at the point of attachment.

3) Apply power and select either the H- or L-range. When the tone sounds and the triangular mark appears on the display, take a reading. 2. Other measurements 1) Apply a piece of Scotch-Lite(R) reflective tape to the object to be measured. Note: • Cut the Scotch-Lite(R) into a strip 10 to 30 mm long, peel off the kraft paper backing, and press onto the object. • Place the tape as close as possible to the circumference of the object. 2) Loosen the knurled screw on the bracket, remove the probe, and clamp the probe to the flexible stand included with the Basic Set. 3) Apply power and select either the H-or L-range. Point the probe at the rotating object and press the MEAS switch so that the red light from the probe strikes the reflective tape. If the positioning is correct, the tone will sound and a triangular mark will appear on the display, indicating that a reading can be taken. The distance between the tape and the probe must be in the range specified in the accompanying drawing. The angle of incidence must be -30° to +30°.

2-2-32

2-2

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Sample Application 1: Measuring the speed of a fan 1) Attach a piece of reflective tape to the outermost part of one of the fan blades. 2) Mount the magnetic base on any convenient surface (for example, hood, side cover, radiator cover, or main frame) and adjust the flexible support so that the light from the probe shines both roughly parallel to the fan's axis of rotation and roughly perpendicular to the fan blade's twist. 3) Further adjust the probe position so that the light shines on the center of the tape. Note: Make sure that the probe does not get in the way of the fan!

Sample Application 2: Other uses For some measurements, it is also possible to hold the probe in your hand or connect it directly to the main unit.

4) This concludes the setting up procedure. Proceed with the normal measuring procedure. Note: If the standard procedure fails to yield a stable reading, try moving the probe further away from the fan or improving the contrast by applying black, non-reflecting paint to the tips of all fan blades before applying the reflective tape.

Note: Electronic flashes, fluorescent lights, and other intermittent light sources can interfere with measurement; never allow them to enter the probe!

2-2-33

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-2500 795-790-2600

GROUP 2 ENGINE TOOLS

TAKEOFF DRIVE

! 2-2

2-2

114

Adapter Seal Seal Adapter Hub Hub W asher Bolt

795-790-2600

6735-21-3410 6732-21-3220 6736-21-7120 6735-21-3450 6735-21-3420 5 6742-01-5498 6 6732-81-5250 7 6735-21-3430

Parts name

102

1 2 3 4

Parts No.

795-790-2500

No.

Ass'y part No. Model

Applicable model and component parts

1 1 1 1 1

1 1 1 1

2 2

1 2 2

2-2-34

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

ADAPTER

795-116-1330 and others

FEELER GAUGE

! 2-2

2-2

Purpose: To be used when measuring the engine rotation (rpm) on PC01.

Tool No. and specifications:

Component parts: No.

Part No.

Tool Yammer Diesel Q't y description number

1 795-126-1110

Gear unit

124250-91400

1

2 795-126-1120

Packing

124250-91412

1

3 01010-50630

Bolt

26117-060322

1

4

Bolt

26117-060162

2

Washer

23414-06000

3

01010-50616

5 01602-20619

Note) When reading the indicator, do carefully because the rpm indicated by the indicator is 1/2 the engine rpm. How to use: 1) Remove the can gear cover from the gear case. 2) Install packing (2) and gear unit (1), then flex cable (6) to gear unit (1). 3) Fit the digital tachometer or Hustler type tachometer to flex cable (6), then measure engine rpm.

No.

Tool No.

Specifications

Weight (kg)

1

795-116-1330

0.35, 0.65 mm

0.1

2

795-125-1210

0.43, 0.8 mm

0.1

3

795-125-1310

0.3, 0.5 mm

0.1

4

795-125-1320

0.4, 0.6 mm

0.1

5

795-125-1330

0.25, 0.45 mm

0.1

6

795-125-1360

0.33, 0.71 mm

0.1

7

795-125-1370

0.35, 0.5 mm

0.1

8

795-125-1380

0.37, 0.90 mm

0.1

9

795-125-1390

0.4, 1.0 mm

0.1

10

795-562-1200

0.41, 0.74 mm

0.1

11

795-562-1300

0.36, 0.69 mm

0.1

Purpose: The feeler gauge is used for adjusting the valve clearance. How to use: Insert the gauging section to adjust the valve clearance.

2-2-35

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-203-7000

GROUP 2 ENGINE TOOLS

FUEL LEAK CHECKER Purpose 1) To find the places where fuel leaks into the engine and to check that the fuel leakage is completely repaired. 2) To measure the nozzle cracking pressure after nozzles are installed to an engine. 3) To check the function of a nozzle assembly when the color of the engine is abnormal or when the engine output is inadequate.

! 2-2

2-2 Specifications 1) Applicable engine: Weight: 15 kg

2) Range of pressure: 3) Fuel to be used: 4) Size of case:

105 and 155 series Cummins 743 series 0 to 40 MPa ASTM D975 No.2 465 × 350 × 170 mm

Component parts No.

Part No.

Tool description

Q't y

Remarks

1

799-203-7100

Checker

1

Main body of fuel leak checker

2

799-203-7200

! Valve unit

1

Valve section above the checker body

3

799-203-7400

Gauge assembly

1

With self-seal coupling, 40 MPa

4

799-203-7410

! Gauge

1

40 MPa

5

799-203-7500

Gauge assembly

1

With self-seal coupling, 2.5 MPa

6

799-203-7510

! Gauge

1

2.5 MPa

7

799-203-7600

Adapter assembly

1

With a complete set of auxiliary parts

8

799-203-7610

! Hose

1

L=2.0 m Hose adapter: 14 × 1.5

9

799-203-7620

! Nipple

1

For 743 series engine, 3/8-24UNF-2A, 14 × 1.5

10

799-203-7630

! Plug

4

For 743 series engine, 7/1 6-24UNS

11

799-203-7640

! Plate

1

For 743 series engine

12

799-203-7650

! Bolt

2

For 743 series engine, 01011-51400

13

799-203-7660

! Nut

2

For 743 series engine, 01580-11411

2-2-36

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

Tool description

GROUP 2 ENGINE TOOLS

No.

Part No.

Q't y

Remarks

14

799-203-7670

! Washer

2

For 743 series engines

15

799-203-7680

! Nipple

2

For Komatsu engines, 14 × 1.5, 14 × 1.5

16

799-203-7690

! Nipple

2

For 6D105 engines, 12 × 1.5, 14 × 1.5

17

799-203-7710

! Plug

3

For Komatsu engines, 14 × 1.5

18

799-203-7720

! Seal washer

5

For Komatsu engines, 07005-01412

19

799-203-7730

! Plug

3

For Komatsu engines, 12 × 1.5

20

799-203-7740

! Seal washer

5

For Komatsu engines, 07005-01212

21

799-203-7750

Tube assembly

1

Straight tube, 14 × 1.5, 14 ×1.5

22

799-203-7760

Tube assembly

1

Straight tube, 12 × 1.5, 14 × 1.5

23

799-203-7770

! Tube assembly

1

Bent tube, 14 × 1.5, 14 × 1.5

24

799-203-7780

! Tube assembly

1

Bent tube, 12 × 1.5, 14 × 1.5

25

799-203-7790

Base

1

Support for checker (wooden)

26

799-203-7800

Case assembly

1

The case is lined with sponge, with belt.

Example of use: Check of a feed pump

Example of use:

2-2-37

Independent check of a nozzle holder

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

790-551-1290

GROUP 2 ENGINE TOOLS

NOZZLE TESTER

! 2-2

2-2

Applicable model: All Komatsu engine models Component parts: No.

Tool No.

Part Name

Q't y

Weight (kg)

1

799-203-7700 Nozzle tester

1

7.3

2

799-203-7750

Tube ass'y

1

0.044

3

799-203-7760

Tube ass'y

1

0.042

4

799-203-7770

Tube ass'y

1

0.080

5

799-203-7780

Tube ass'y

1

0.084

6

799-203-7810

Tube ass'y

1

0.049

7

799-203-7820

Tube ass'y

1

0.087

Purpose: Used when checking the injection pattern and injection pressure on fuel injection nozzle. How to use: Install the tube assembly and nipple to the nozzle tester, screw the fuel injection nozzle in the end, apply fuel oil pressure, and measure the injection pattern and injection pressure. Example of use:

2-2-38

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-790-2220

GROUP 2 ENGINE TOOLS

LEAK TESTER

PLATE

! 2-2

(LEAKAGE TEST)

2-2

Applicable model: 102, 114 engine Purpose: Leak Test Kit Pressure test the element to check for leaks. Component parts: Description

Specifications

Q't y

O-ring

Parker #2-2 17

3

Thumb screw

5/16-18 ×1 1/4 Iong (steel)

4

Nut. Std. hex

5/16-18

8

Washer, plain flat

5/16

4

Plate, Ieakage test See detail

1

Regulator, pressure Watts # R384-02C

1

Gauge, pressure

1

Watts 0-160 P.S.1. 1-5/8 O.D. #4-2MP / #4-2MP (1/8 Male NPT)

Hose (gates) Sheet, instruction

1/4 Duraflex hose 15" Length / EQUIV.

1 1

Example of use:

2-2-39

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

790-828-1000

GROUP 2 ENGINE TOOLS

FUEL METER

Component parts:

! 2-2

2-2

Weight: 7 kg Applicable model: • In-line fuel-injection pump (Bosch type) • Distribution fuel-injection pump (Rotary type) Note) The fuel cannot be measured on the Cummins type. Purpose: Measuring the fuel consumption. 1) Cumulative fuel consumption (Unit: L) Indicates cumulative fuel consumption from the start to the end of measurement. 2) Cumulative fuel consumption rate (Unit: L/H) Indicates cumulative fuel consumption from the start to the end of measurement converted to the rate of consumption per hour. 3) Instantaneous fuel consumption rate (Unit: L/H) Indicates the fuel consumption per second converted to the rate of consumption per hour. (The indicated value changes every second.) 4) Measurement time (Unit: H-M-S) Indicates the duration from the start to the end of measurement in hours-minutes-seconds. " Power source 1) D.C. 12 — 24 volt 2) Built-in chargeable battery (Chargeable from 12 — 24V battery)

No.

Part No.

Part description

790-828-1000 FUEL METER

1

1

790-828-2100 METER

1

2

790-828-2370 STRAP

1

3

790-828-2380 COVER, meter

1

4

790-828-2400 CABLE ASS'Y

2

5

790-828-2500 CABLE ASS'Y

1

6

790-828-2600 CABLE ASS'Y

1

7

790-828-5100 SENSOR ASS'Y

2

8

07271-01430

HOSE

3

9

07206-11014

JOINT, bolt

6

10

07005-01412

GASKET

12

11 790-828-6100 JOINT

Example of use:

2-2-41

Q'ty

-

CLAMP, hose

4

12

07281-00197

13

790-828-5180 CAP

4

14

09014-10200

1

15

790-828-9210 MANUAL (J) (Japanese)

WRENCH

4

1

16

790-828-9250 MANUAL (E) (English)

1

17

790-828-9210 CASE, carrying

1

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

790-829-1030 FUEL MATE (General purpose type fuel meter)

! 2-2

2-2

This FUEL MATE is an electronic fuel consumption q’ty/ratio meter. That is, this computerized handy fuel meter is capable of simply measuring the said fuel consumption q’ty/ratio in large-sized engines for construction machines as well as in small-sized engines for motor-cycles, etc. even during their traveling or running. The fuel consumption q’ty covering the period from the starting to the end of measurement is indicated in the digital form on a liquid crystal display. The momentary fuel consumption ratio varying per second and the mean consumption ratio during the measurement. Thus, the measured data are printed out with the lapse of time covering from the starting to the end of measurement. In addition, after completing the measurement, if the distance covered by a test machine is entered with a “ten-key”, the mean vehicle speed and the distance covered per lit. of the fuel consumed are computed and displayed.

The measured data can be printed out.

2-2-42

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Thus, the FUEL MATE has the following distinctive features. 1. The fuel consumption can be simply measured during the actual operation of a vehicle. 2. The small-sized, lightweight, handy type can be carried and used anywhere. 3. The meter is computerized for high precision measurement and computation. 4. In diesel engines, the q’ty of fuel return in operation is large. Such q’ty of fuel return is subtracted in its computation. 5. Hourly fuel consumption ratio, Km/L or Km/H, is obtained by the computer. 6. Measured values can be printed out. 7. This FUEL MATE is of an interactive type simple in control and provided with a self-diagnostic function. " In an engine abundant in the return fuel, a fuel flow sensor is installed on the return side, too. 8. The power source (6 — 24 V) is available from a cigarette lighter at the operator’s seat. The battery cigarette lighter at the operator’s seat. The battery provided internally can also be used as the power source. Main 0.01 — 9999.99 L 1. Measuring items Fuel consumption q’ty: specifications and measuring Measuring time (When the external power (Main body) range source is used): 99H 59M 59S Fuel consumption ratio (Momentary consumption ratio & mean consumption ratio) When sensor Type A is used: 0.1 — 400.0 L/H When sensor Type B is used: 0.1 — 50.0 L/H Distance covered per lit. of fuel 0.1 — 99.9 Km (computed value): 0.1 — 999.9 Km/H Mean vehicle speed (computed value): Measuring-over alarm function is also provided. 2. Power source Battery built-in, AA, Ni-cd, 4 pcs. When charged fully, serviceable for 10 hrs. External power source on-board battery (DC6 - 24 V), connectable to a cigarette lighter plug, AC adapter as accessory and low-voltage alarming function are also provided. When the external power source is in use, the additional charge of the builtin (internal) battery can be carried out. A flat-faced switch, shift-key type 3. Keyboard When “Distance” button is depressed, “shifted-in” is available, and when “Compute” button is depressed, “shifted-out” is obtained. The “Numeral” key is used to input the distance covered at the time of the “shifted-in”. The “Clear” key is used to correct the numerical input. The “Reset” button is used to prevent the erroneous keyboard operation, if any. When kept depressed for 2 seconds or longer, the meter is actuated. Only while the “Consumption q’ty” button and the “Consumption ratio” button are kept down simultaneously, the momentary fuel consumption ratio is displayed in the real time. 4. Operating temp- 0 to 50°C rature range: 5. Exclusive EPSON C-40 printer: 6. Main body 150 × 115 × 42 mm approx. 520 g dimensions and weight: 2-2-43

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Construction and Component Part No.

! 2-2

2-2

No.

Part No.

Part Name

Q'ty

Remarks

Overall 1

790-829-1030

Fuel mate

1

All component parts listed below are contained in a portable case.

790-829-3100

Meter

1

"Fuel Mate" body ass'y

2

790-828-2370

Strap

1

Hanging strap (made of plain nylon fabric) for FUEL MATE body ass'y.

3

790-828-2380

Cover, meter

1

Cover for FUEL MATE body ass'y (made of soft leather, etc.)

4

790-828-2500

Cable ass'y

1

Power cable ass'y (for connecting the battery terminals)

5

790-828-2600

Cable ass'y

1

Power cable ass'y (for connecting a cigarette lighter on outomobile, etc.)

6

790-828-5100

Sensor ass'y

2

Fuel flow sensor ass'y Type A (Measuring range: 0.1 to 400 L/H)

7

790-828-2400

Cable ass'y

2

Sensor cable ass'y (for connecting FUEL MATE and sensor together)

8

790-829-6100

Printer ass'y

1

EPSON C-40 (MODEL P40BA, CODE A)

9

790-829-6310

Ribbon cassette

1

Spare ribbon cassette EPSON 7Q 1C40

10

790-829-6320

Roll paper

1

11

790-829-6700

Cable ass'y

1

12

07271-01430

Hose

3

Spare roll paper (containing 5 rolls) EPSON 8R1C 40 Power source cable ass'y (for connecting FUEL MATE and the printer together) 2 hoses are used for sensor. One hose is stored in a given position.

13

07206-11014

Joint, bolt

6

4 bolts are used for sensor. 2 bolts are stored in a given position.

14

07005-01412

Gasket

12

8 gaskets are used for sensor. 4 gaskets are stored in a given position.

15

07281-00197

Clamp, hose

2

Stored in a given position. Stored in a given position.

16

790-828-5180

Cap

4

17

790-828-6110

Joint

2

Stored in a given position.

18

790-829-9100

Case, carrying

1

Portable case containing all component parts (with punched sponge)

19

790-829-9250

Manual, operation

1

"FUEL MATE" Operation Manual

20

790-829-9270

Manual, operation

1

Printer Operation Manual.

Sensor ass'y

2

Fuel flow sensor Type B (Measuring range: 0.1-50 L/H)

Option (for separate sale) --

790-828-7100

2-2-44

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

In this FUEL MATE, the following data are computed and displayed, by putting the signals measured with a flow sensor installed on the fuel pipe into an 8-bit computer, then by computing and converting the fuel consumption q’ty per second (cc/sec). # The consumption ratio (momentary L/H) varying momentarily according to the vehicle operating condition. $ The total consumption q’ty (cumulative L) from the starting of measurement up to the present. % The mean hourly consumption ratio from the starting (mean L/H), and & The time which has elapsed from the starting of measurement (H.M.S) If the distance covered by a test vehicle is input with the “ten-key”, the following data will be computed and displayed. ' The distance covered per lit. (Km/L), and ( The mean vehicle speed during the measurement. All these measured data are printed out, excluding the momentary consumption ratio. The measurement starting and stopping pauses can be simply obtained by means of push buttons on the key-board. Thereby, the net actual operating hours and fuel consumption q’ty can be measured.

FUEL MATE Functional Block Diagram

The fuel consumption q’ty and the time can be measured, by classifying them into the fuel consumption per haul cycle for a dump truck or into the fuel consumption per truck loading by a loading machine. Such data classified by the traveling condition as “Uphill road”, “Downhill road”, “Flat road” etc., can be obtained through the keyboard control. If the “Print” button is depressed without depressing the “Stop” button, the following data during the period from the starting of measurement to the starting of printing will be printed out. (1) Fuel consumption q’ty L (2) Measuring time H.M.S (3) Hourly consumption q’ty L/H In this case, the data measured up to that time are cleared up and the measurement is newly started for new data. If the “Print” button is depressed after depressing the “Stop” button, the following data during the period from the starting to the end of measurement are printed out. Then, if started again, the measurement will be restarted continuously from the data obtained just before the restarting. In this case, the input data of the distance covered will be cancelled. (1) Fuel consumption q’ty L (2) Measuring time H.M.S (3) Distance covered (Input data) Km (4) Hourly consumption q’ty L/H (5) Distance covered per lit. Km/L (6) Mean vehicle speed Km/H

2-2-45

2-2

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

(Caution) In some of engines (KOMATSU 125 Series) equipped with Model EP-9 fuel injection pump mfd. by NIPPON DENSO, the fuel consumption measurement may sometimes become difficult due to such a slight reverse flow in the fuel flow as caused by the feed pump structure. When installing flow sensors in a fuel meter, such a preventive measure as described herein should be taken before the measurement of the fuel consumption. The installation procedure of fuel flow sensors is described in detail in the Operation Manual. On machines listed up in Table 1, such a check valve as shown in Fig. 1 may become necessary as a measure against the reverse flow. Therefore, it is advised that necessary parts be prepared, referring to the parts list in Table 2.

1.Machines where the measuring errors with fuel meter are liable to occur due to the reverse fuel flow Table 1 right gives machines requiring a preventive measure of a possible errors in data measured with fuel meter due to the slight fuel reverse flow. On these machines, the fuel consumption should be measured by adding such a check valve as introduced herein to the fuel line. On machines other than those listed in Table 1, too, if the abnormally high fuel consumption data are encountered, the measurements should be made by adding a check valve to them in the same manner.

2-2

Table 1 Examples of machines requiring a check valve for the measurements Machine Engine Machine Engine Model Model Model Model D75S-5 D50A, P-17 D83E-1, -SS D53A, P-17 PC300-3 S6D125-1 D60A, P, S-8 6D1 25-1 PC400-3 D65A, P, S-8 LW250-1 GD600R-3 EM655A-A SA6D125-1 GD605A-3. -5

2-2-46

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

2.Preparation of check valve for measuring the fuel consumption Prepare those parts which are listed in Table 2 and set up as shown in Fig. 1. Table 2 Parts required to prepare a check valve for measuring the fuel consumption Ref.No. in Part Name Part No. Q'ty Fig.1 Check valve DKKC Part No. 131424-1520 ➀ 1 pc. (Overflow valve) ND Part No. 090310-0080 790-829-8130 ➁ Nut 1 pc. * ➂

Gasket

KES Part

07005-01412

4 pcs .

* ➃

Hose

KES Part

07271-01430

1 pc.

Joint bolt KES Part 07206-11014 1 pc. * ➄ ( Note )Parts marked * in the above list are available from the group of accessory parts for a fuel meter.

3. Installation of fuel flow sensors Connect a sensor on the fuel supply side marked S and another sensor on the fuel return side marked R

Marks show the positions where the sensors are installed. If the measurement is difficult due to the fuel reverse flow, and a check valve at a position marked ".

3-1 Installation of sensors in an engine where much fuel return is encountered: (1) Where fuel returns directly to the fuel tank (on WA450, PC400-3, CAT769C, etc.)

2-2-47

2-2

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

(2) Where fuel returns to the feed pump inlet port or to the tube leading to the Inlet port (on HD465-3, etc.)

! 2-2

2-2 (3) Where fuel filter and fuel injection pump are integrated into one unit (on CAT966D, etc.)

3-2 Installation of sensors in an engine where the fuel return is slight; (1) In the normal case (on WA400, PC200-, & PC300-3, etc.)

(2) Where the engine is difficult to start or where the engine power drops:

2-2-48

!

! 2-2

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

4. Hint on the measurement of fuel consumption ratio When measuring the fuel consumption ratio, measure the cumulative fuel consumption ratio during a given period of time, with the indicated momentary fuel consumption q'ty used as a reference data. The reason is such that the indicated momentary fuel consumption q'ty is liable to be unstable, because the velocity of fuel flow varies subtly, even if the engine revolution remains stable. This symptom does not pause a problem of the fuel meter proper and the fuel flow sensor but indicates an ill-effect caused by the structure of a fuel feed pump. Consequently, the stable data can be obtained rather by measuring the cumulative fuel consumption ratio for several minutes.

5. Types of fuel meters Such fuel meters as listed In Table 3 have been introduced up to date. At present, the FUEL MATE (Part No. 790-829-1030) developed on the basis of a simple type fuel meter (Part No. 790-828-1000) is recommended. Hereafter, this general purpose fuel meter. "FUEL MATE" only are manufactured to meet the market trends.

2-2

Table 3 Types of fuel meters Types of fuel meters

Applicable range (Engine Model)

Items to be measured

Output results of measurement

Simple type fuel meter "Fuel meter" Part No. 790-828-1000 1 ) Diesel engines with a line type (Bosch) injection pump 2) Diesel engines with a rotary type injection pump 1 ) Cumulative consumption q'ty Q'ty of fuel consumed during the period from the starting to the stopping of measurement (unit: Iit.) 2) Cumulative fuel consumption q'ty Hourly consumption q'ty converted from the cumulative consumption q'ty (unit: L/H) 3) Momentary fuel consumption q'ty Hourly consumption q'ty converted from the consumption q'ty per second (unit: L/H) 4) Measuring time The period of time elapsed from the starting to the stopping of measurement (unit: H.M.S.) A result of measurement on each item is indicated by a digital display (in its unit).

2-2-49

General purpose type fuel meter "FUEL MATE" Part No. 790-829-1030 In addition to the engines in I ) and 2). 3) Gasoline engines of an electronic fuel injection type 4) Gasoline engines of a carburetor type In addition to the items in 1) thru 4) at the left, 5) Mean machine speed The mean machine speed computed on the basis of the distance traveled during the period from the starting to the stopping of measurement (unit: Km/H) 6) Distance covered-fuel consumption ratio Distance covered per lit. of fuel consumed (unit: Km/L)

A result of measurement on each item is indicated in its unit by a digital display and at the same time, output by a printer.

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-231-1110 and others

GROUP 2 ENGINE TOOLS

R-GAUGE Tool No. Refer to the following list. Select the necessary gauge.

! 2-2

2-2

Purpose: to use for measuring the finished R dimensions at fillets after correcting the crankshaft by means of grinding in the engine crankshaft reconditioning operation. (See Fig. 1.) Tool NO. and applicable engine. Tool No.

Remarks

Applicable engines

795-231-1110

4D92, (S)4D95, (S)6D95

795-231-1120 795-231-1130

4D105, 6D105, (S)6D108, S(A)6D110 (S)6D125

795-231-1140

S4D130

795-231-1150

S(A)6D140

795-231-1160

SA12V140

795-231-1170 795-231-1180

SA12V140 S4D155, S(A)6D155, SA6D170

795-231-1190

SA8V170, SA12V170

795-231-1210

SA16V170

* * * * * for main journal for pin journal * * *

R-gauges marked * are applicable to both main and pin journals.

2-2-50

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

Example of R-Gauges

! 2-2

2-2

How to use a R-gauge Measurement of the radius of the journal fillet of a crankshaft corrected by grinding should be made in the following point with a fillet measuring R gauge and a pencil type flashlight. (1) Set a R-gauge for the max. value to the journal fillet. Then, apply the light from the back of the Rgauge. At this time, clearance profiled like a crescent can be seen with the gauge in contact with the fillet at 2 points or the gauge comes in the full contact with the fillet. In such a case, the radius at the fillet is within the limit of the max. value, which is acceptable, (See Fig. 3.) When the R-gauge (for the max. value) and the fillet are in contact only at one point, the radius of the fillet exceeds the max. value, which is not acceptable. (2) In the same measurement as described above and made by the use of the R-gauge for the min. value: when the R-gauge and the fillet are in contact at one point or in the full contact, the fillet radius is acceptable. (See Fig. 4.) When they are in contact at two points, the fillet radius will be less than the min. value, which is not acceptable.

2-2-51

!

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

799-201-2202

GROUP 2 ENGINE TOOLS

BOOST GAUGE KIT

795-471-1200

GAUGE ASS’Y

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Weight: 0.93 kg Applicable model: All engine Purpose: Used this kit when measuring the air charging pressure to the engines. Component parts : No.

Part No.

Part Name

Q'ty

Remark

1 799-101-5160 Nipple

1 PT 1/8

2

799-401-2610 Hose

1

799-401-2311 Gauge

1

799-401-2291 !Gauge

1

790-261-1130 !Coupling

3

790-261-1140 !Packing

Applicable model: 125E-2, 170E-2, 3 engine 140E-2 Purpose: Used this gauge ass’y when adjusting the fuel injection timing of the engines. Component parts : No.

Part No.

Part Name

Q't y

Weight (kg)

1

791-503-1190

Magnet stand

1

1.4

2

791-503-1060

Dial gauge

1

0.12

3

795-471-1210

Joint

1

0.01

1

4

795-471-1220

Measure point

1

0.002

1

5

795-471-1230

Rod

1

0.185

-760-1500 mmHg

For engines on the WA600-1 and WD600-1, use a dial gauge available on the market (with the gage scale of 0.01 through 20 mm) as the component part item No. 2.

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

795-799-5510

GROUP 2 ENGINE TOOLS

Troubleshooting Unit for HPI Engine, 6D170E-3

From D375A-5, 170-series engine have been modified to -3 conform to Tier 2 engine emission regulation of EPA in USA. In the future, 170 Series engines for models to be introduced to the market will be mounted with -3 one after another. For injectors, fuel pumps, various sensors, controllers, etc. composing the engine fuel ** system (so called HPI), units and parts common to Cummins engines have been used. So, troubleshooting units to be used are partly common to those of Cummins Engine Company. Therefore, we are going to introduce troubleshooting units to be used on 6D170-3 series engines. ** HPI : High pressure injection 1. Newly Set Units No.

Komatsu Part No.

Cummins Part No.

1

795-799-5510

-

Heat gun

To be used for troubleshooting of injector.

2

795-799-5550

3376859

Adapter

To be used for measuring pressure of fuel pump.

3

795-799-5560

-

Oil pressure gauge To be used for measuring pressure at fuel pump inlet.

4

795-799-5520

-

Socket (S)

To be used for troubleshooting of engine speed sensor.

5

795-799-5530

-

Socket (C)

To be used for troubleshooting of water temperature sensor, air intake temperature sensor and exhaust gas temperature sensor.

6

795-799-5540

-

Socket (A)

To be used for troubleshooting of temperature sensor.

7

795-799-5460

3824774

Cable

8

795-799-5470

3824775

Cable

9

795-799-5480

3824776

Cable

Part Name

Application

To be used for troubleshooting of atmospheric pressure sensor, fuel pressure sensor and actuator pressure sensor. To be used for troubleshooting of lubricating oil pressure sensor. To be used for troubleshooting of timing pressure sensor, air intake pressure sensor and pump pressure sensor.

2. Purpose 2-1. Determination of Defective Injector with Heat Gun (Portable infrared thermometer) (Part Number : 795-799-5510) Troubleshooting Method : Wait until the engine to cool down before starting the troubleshooting. Measure temperature of each cylinder on the front surface of the exhaust manifold for 10 minutes right after the engine started. When temperature of a cylinder hardly rises, judge the cylinder to be defective. Covers of the exhaust manifold have been structured so that their surface temperatures can be easily measured.

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Heat gun

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

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2-2 Temperature characteristic when the 2nd cylinder is abnormal

Temperature characteristic when all cylinders are normal

Note : The heat gun has the Part Number set by Komatsu but is not a special one and is generally available in the market. So, if you have any heat gun, you need not purchase a new one. If you purchase it, we recommend Part Number MX2 of Raytek Corp. or equivalent. (For Raytek Corp., contact http://www.raytek.com) 2-2. Diagnosis of Pump Acceptability by Measuring Pump Inlet and Outlet Pressures When the pump inlet pressure is normal (below 27KPa) and the pump outlet pressure at each engine speed is not more than the standard value, the pump is considered to be in the normal state. For the detail, please refer to the Shop Manual. When the inlet pressure is more than the specified value, the fuel filter is supposed to be loaded or the piping is supposed to be clogged or loosened or fuel may be leaking from somewhere. When the outlet pressure is lower, any of the pump body, pressure sensors or the regulator valve is supposed to be defective. 1) Adapter (Part Number : 795-799-5550) The fuel pump is equipped with a quick coupler for measuring pump inlet and outlet pressures. This coupler does not accept our usual couplers in connection, and we have newly set the adapter, which accepts our usual quick couplers and enables to measure pump outlet pressure easily with our usual pressure gauges. Since pump inlet pressure becomes negative, the negative pressure gauge to be introduced in the next paragraph is necessary for measurement. Adapter

Komatsu’s Quick Coupler

Quick coupler for measuring fuel pump inlet pressure

Quick coupler for measuring fuel pump outlet pressure

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

2) Oil Pressure Gauge for Measuring Negative Pressure (Part Number : 785-799-5560) This gauge is used for measuring inlet pressure of the fuel pump. to –0.11MPa.

The measuring range is from 0

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2-3. Diagnosis of Electronic Control System The HPI is equipped with various sensors, and we have set simple sockets and cables to be connected to these sensors for diagnosis. These cables are common to those used by Cummins Corp. 1) Socket This socket is connected to a sensor to check disconnection or short-circuit of the sensor. Part Number How to use Diagnosis Example of Intake Air Temperature Sensor 795-799-5540

795-799-5530 795-799-5520

2) Cable This cable is used in the same way as a T-adapter and for measuring output voltage of a sensor. Also, this cable is used for checking disconnection or short-circuit of a sensor. Part Number 795-799-5460

795-799-5480

How to use Diagnosis Example of Atmospheric Pressure Sensor

795-799-5470

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 2 ENGINE TOOLS

3) T-adapter for DEUTSCH Connector DEUTSCH connectors have been used for connection of engine controller and engine to machine body. The T-adapters for DEUTSCH Connector, which we introduced you in our previous Parts & Service Operation Tips, can be used for connection. Parts & Service Operation Tips No. d 1

799-601-9350 T-adapter (40 poles)

Adapter for controller

SEKN5015

2

799-601-9290 T-adapter (31 poles)

Adapter for body connection connector

SEKN5005

3

799-601-9270 T-adapter (21 poles)

Adapter for body connection connector

SEKN5005

(1) T-adapter for Controller 799-601-9350

Connection to controller of D375A-5

(2) T-adapter for Body Connection Connector 799-601-9270

Body Connection Connector

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799-601-9290

Connection of T-adapter to Body Connection Connector

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