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Allows tools to be "updated"' not outdated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them to be "UPDATED" rather than "OUTDATED."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