guide_2_2e

GROUP 2

ENGINE TOOLS

SECTION 2

MEASURING AND DIAGNOSTIC TOOLS

GROUP 2

ENGINE TOOLS

2-2-1

� 2-2 2-2 �

Purpose :

Intended to measure engine piston compression pressure.

795-502-1205

Weight : 14.5 kg

COMPRESSION GAUGE

Component parts

No. Part No.Tool

description

All

mode

ls3D

68E

-3

3D

72, 7

5, 84

-11D

75-1

, 1

D8

4-1

3D

78

84-2

, 4D

94E

-21A

92-1

94-1

2D

94-2

, 4

D9

4-2

, 4

D95

L4D

95W

, 4D

13

0-1

95-1

102

105

-1, 2,

3

105

-5, 11

0107

E-1

SA

6D

10

8

114

E-2

114

E-3

120

-11, 1

30-1

125

125

E-3

125

E-5

140

-1140

E-3

140

E-5

155

-4

170

-1 (

6D

, 8V

, 12

V )

170

-1 (

16V

)170

E-3

(H

PI)

170

E-5

Cum

min

s 7

43

Cum

min

s 8

55

Cum

min

s K

T1

150

Remarks

1 795-502-1590 Gauge ass'y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1a 795-502-1210 • Gauge • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 0-7 MPa

1b 795-502-1220 • Hose • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Length 390mm

1c 795-502-1230 • Valve • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • With a reset button

2 795-502-1240 Adapter 1 1

3 795-502-1250 Adapter 1 1

4 795-502-1260 Adapter 1 1

5 795-502-1270 Adapter 1 1

6 795-502-1283 Case 1

7 795-502-1291 Adapter 1 1

8 795-502-1310 Adapter 1 1

9 795-502-1320 Adapter 1 1

10 795-502-1330 Adapter 1 1

11 795-502-1340 Adapter 1 1

12 795-502-1350 Adapter 1 1 6D, 8V, 12V

13 795-502-1360 Adapter 1 1

14 795-502-1370 Adapter 1 1 direct injection type

15 795-502-1380 Adapter 1 1 squish chamber type

16 795-502-1500 Adapter ass'y 1 1

16a 795-502-1510 • Adapter • •

16b 795-502-1520 • Plate • •

17 795-502-1530 Adapter ass'y 1 1

17a 795-502-1540 • Adapter • •

17b 795-502-1550 • Plate • •

18 795-101-1580 Adapter ass'y 1 1

18a 795-101-1560 • Adapter • •

18b 795-101-1571 • Joint • • 1

19 795-502-1610 Name plate 1

20 795-502-1560 Packing 1

21 795-502-1570 Packing 1

22 795-502-1580 Packing 1

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-2

� 2-2 2-2 �

How to use:

1) Remove the nozzle holder of the engine cylinder head and attach the adapter (4 — 10) applicable to themachine 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.

Example of use:

Applicable engine:

2D94-2, 4D94-2, 4D95L, 4D95W, 4D130-1Purpose:

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 1 pc.

ADAPTER

Weight: 0.14 kg

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

790-553-1110

(Continued from page 2-2-1 )

No. 23 to No. 45 parts are option

No. Part No.Tool

description

All

mo

de

ls

3D

68

E-3

3D

72

, 7

5,

84

-1

1D

75

-1,

1D

84

-1

3D

78

84

-2,

4D

94

E-2

1A

92

-1

94

-1

2D

94

-2,

4D

94

-2,

4D

95

L4

D9

5W

, 4

D1

30

-1

95

-1

10

2

10

5-1

, 2

, 3

10

5-5

, 1

10

10

7E

-1

SA

6D

10

8

11

4E

-2

11

4E

-3

12

0-1

1,

13

0-1

12

5

12

5E

-3

12

5E

-5

14

0-1

14

0E

-3

14

0E

-5

15

5-4

17

0-1

(6

D,

8V

, 1

2V

)

17

0-1

(1

6V

)

17

0E

-3 (

HP

I)

17

0E

-5

Cu

mm

ins

74

3

Cu

mm

ins

85

5

Cu

mm

ins

KT

11

50

Remarks

23 6217-71-6112 Gasket 1 1 1

24 6261-71-6150 Gasket 1 1 1

25 790-471-1090 Adapter 1 1 see page 2-2-3

26 790-471-1110 Plate 1 1 see page 2-2-3

27 790-472-1370 Adapter 1 1 see page 2-2-3

28 790-553-1110 Adapter 1 1 see page 2-2-2

29 790-553-1120 • Adapter • •

30 790-553-1130 • Adapter • 1 •

31 790-553-1140 • Packing • 1 •

32 795-111-1110 Adapter 1 1

33 795-111-1120 Adapter 1 1 see page 2-2-4

34 795-471-1310 Adapter 1 1

35 795-471-1330 Adapter 1 1

36 795-471-1410 Adapter 1 1

37 795-471-1420 Adapter 1 1

38 795-502-1390 Adapter 1 1 see page 2-2-3

39 795-502-1700 Adapter ass'y 1 1 see page 2-2-4

40 795-611-1210 Adapter 6 6

41 795-611-1220 Adapter 1 1

42 795-790-3610 Gauge 1 1 see page 2-2-4

43 795-790-3710 Tester 1 1 see page 2-2-4

44 795-790-4410 Adapter 1 1

45 795-790-6110 Adapter 1 1

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-3

� 2-2 2-2 �

Tool No. and applicable engine:

No. Tool No. Q'ty Weight (kg) Applicable engine

1 790-472-1370 1 0.2 SA6D108

2 790-471-1090 1 1.2 16V170

790-471-1090 ADAPTER

790-472-1370

Applicable model : 16V170

Purpose :

Used to measure engine compression pressure.

Necessary tool:

Applicable model : 1D75-1, 1D84-1Purpose :

Used when measuring the compression pressure ofengine.

How to use:

To use, see SERVICE TOOL GUIDE 2-2-1 and 2.

Necessary tool:

795-502-1590 Gauge ass'y 1 pc.790-553-1130 Adapter 1 pc.790-553-1140 Packing 1 pc.

Purpose :


Necessary tool :

795-502-1590 Gauge ass'y 1 pc.790-471-1110 Plate (16V170 only) 1 pc.

790-471-1110 PLATE

Weight : 0.7 kg

795-502-1390 ADAPTER

790-471-1090 Adapter 1 pc.795-502-1590 Gauge ass'y 1 pc.

Weight : 0.25 kg

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-4

� 2-2 2-2 �

Applicable model : 3D68E-3 engine

Purpose :

Used to measure Yanmar engine compressionpressure.

Necessary tool:

795-502-1590 Gauge ass'y 1 pc.

795-502-1700 ADAPTER ASS'Y 795-111-1120 ADAPTER

Weight : 0.3 kg Weight : 0.13 kg

Applicable model : 102 engine

Purpose :


Necessary tool :

795-502-1590 Gauge ass'y 1 pc.795-502-1760 Packing

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 TESTER

795-790-3610 GAUGE

Weight: 1.2 kg Weight: 0.8 kg


Purpose :


Necessary tool :

795-790-3610 Gauge 1 pc.


Purpose :

Used to measure 114 engine compression pres-sure.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-5

� 2-2 2-2 �

BLOW-BY CHECKER

Weight: 5 kg

Example of use:

795-790-1900

and others

BLOW-BY TOOL

Purpose:

Used to measure the engine crankcase pressure.

Necessary tool:

795-790-1610 Mano meter

Purpose:

Used to measure engine blow-by pressure.* For details of how to operate, see the Operation

Manual.

Specifications:

1) Applicable engines: Komatsu, Cumminsengines(VTA1710, IH engine: Used option parts)

2) Pressure gauge: Chamber pressure gauge • Measuring range: 0 — 5 kPa (±0.2%) • Min. scale: 0.2 kPa3) Silicon tube: ø 5 × ø 6 × 4,000 mm4) Size: 415 × 300 × 60 mm (Using case)

795-790-1610 Manometer

Specifications:

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

With out mercury.

Tool No. and applicable engines

No. Tool No.Applicable

enginesRemarks

1 795-790-1900102

CUMMINS Part

No.: 3822470

2 795-790-1950 Made in Japan

3 795-790-3300 107, 114

and others

CUMMINS Part

No.: 3822566

4 799-201-1511 Made in Japan

799-201-1504

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-6

� 2-2 2-2 �

Option

799-201-1590

Weight: 0.3 kg

Applicable engines: V type engine

Purpose:

Used when measure V type engine blow-by pres-sure.

Specifications:

Pressure range: 0 - 10 kPaGraduation Min.: 0.2 kPaAccuracy: 1.0 class (JIS)Safety device: With over pressure preventing unit

Necessary tools:

799-201-1504 Blow-by checker 1 pc799-201-1511 Nozzle 2 pcs799-201-1450 Adapter 2 pcs

Component parts:

No. Part No. Tool

description

All

mo

de

l

2D

94

(S

)4,6

D8

5

(m

ark

ed

:{}

no

turb

o)

3D

94

,4D

94

,4D

10

5

(S

)6D

105

,6A

6D

11

0,6

D1

08

102

114

6D

12

5,S

4D

13

0

S(A

)6D

15

5,1

70

Cu

mm

ins N

743

Cu

mm

ins N

855

6D

14

0,

Cu

mm

ins N

TC

743

Cu

mm

ins N

T(A

)855

Cu

mm

ins K

T1

15

0

KT

115

0(5

60

)

VT

(A)1

710

Inte

r D

T2

68

,466

,414

Inte

r D

T8

17

Remarks

799-201-1511 Tool (body) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

795-790-1900 Tool (body) 1 1 Option for 102

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

5 799-201-1521 Adapter 1 1 1

6 799-201-1582 Case 1

7 799-201-1411 Adapter 1 1 1 1 1 1Diams. of joints:

14.5 mm, 16 mm

8 799-201-1460 Plug 3 {3} 3Blind plug for

N743 vent hole

9 799-201-1450 Adapter 1 1 1 1 1 1 1Diams. of joints:

19 mm, 26 mm

10 799-201-1640 Adapter 1 1

11 799-201-1430 Adapter 1 1

12 799-201-1440 Adapter 1 1

13 799-201-1630 Joint 1 1 1 1

14 799-201-1470 Hose 1 1 φ20 xφ26 x 60

15 799-201-1421 Hose 1 1 1 φ16 xφ22 x 60

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 1 2

19 07281-00259 Clamp 1 1 1 1 1 1 1 1

Oil filler mounting

adapter

For I.H engine

only

1

GAUGE

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-7

� 2-2 2-2 �

795-500-1001

795-500-2000

SPECIFIC GRAVITY TESTER

Weight: 0.3 kg

795-500-1000 Old tester can not be measuredantifreeze of a super coolant type (AF-ACL)For the details, refer to the Operation Manual fur-nished with the tester.

Purpose

1) Used to measure the specific gravity of the bat-tery liquid and the charging condition of the bat-tery.

2)Used to measure the freezing temperature whenanti-freeze is use.

Specifications:

How to use

Base line adjustment1) 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 eye-

piece with the tip of the tester directed at light.3) If the boundary line between blue and white devi-

ates from the water line, make them coincide byturning the base line adjusting screw A.

Measurement

1) Put 1 — 2 drops of a solution to be measuredonto the prism face using a sampler and read theposition of the boundary line by looking into theeyepiece.

�

�

795-500-1001 795-500-2000

Gravity of the

battery liquid

Reading

range1.100 ~ 1.300 1.00 ~ 1.30

Measurement

freezing

temperature

Reading

range

-5 ~ -50 °C - 8 ~ -50 °C

AF-PT, AF-ACLNON AMINEType of the anti-freeze

795-500-2010 Cover plate 795-500-2020 Pin

795-790-6800 LEAK TESTER

Applicable engines: 107E-1, 114E-3

Purpose

Used to block a single injector and high pressurefuel connector from the pressurized fuel. This toolhelps identify a failed injector when injector returnflow is excessive.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-8

� 2-2 2-2 �

795-790-5200 ADAPTER KIT 795-790-5300 ADAPTER

CUMMINS Part number: 4918462


Purpose

Used to check fuel pressure/restriction.



Purpose

Used to measure fuel pressure and detect air in thefuel system. Use with tool, part number 3164491(Pressure / Vacuum module).

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-9

� 2-2 2-2 �

795-790-4700 TESRER KIT

795-790-4800 HOSE KIT

795-790-5510 HOSE

795-790-6700 ADAPTER



Purpose

Used to check injector and HPCR pump drain flowIncluded 4918433 and 4918434



Purpose

Used to check fuel return flow flom 12 mm banjofitting connections.



Purpose

Used to check fuel return flow.



Purpose

Used to isolate drain flow flom the fuel drain lineswhere they connect to the fuel drain manifold. Al-lows fuel leakage measurment from the fuel pump,injector, or fuel rail pressure relief valve drain lines.This tool uses a special fitting to connect to the fuelreturn circuits to measure return flow flom the injec-tors and fuel pump (Cummins common rail fuel sys-tem)

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-10

� 2-2 2-2 �

795-790-4520 795-790-6500

795-790-4900

795-790-5110

795-790-4530

LEAK TESTER ADAPTER

ADAPTER KIT

SCREW

FITTING



Purpose

Used to cut injector fuel supply when diagnosing in-jector leakage or malfanction. (Used on fuel rails with18 mm threads).



Purpose

Used to create rated fuel flows through the low-pres-sure fuel system without loading the engine.3045018: 0.043-inch orifice3376859: Compuchek coupling

CUMMINS Part number: 4918324 (795-790-4900) 4918413 (795-790-5110)


Purpose

795-790-4900Used to check fuel pressure/restriction at connec-tions with 12 mm banjo fittings.

795-790-511012 mm banjo screw with 1/8 NPT pipe tap used tocheck fuel pressure/restriction.



Purpose

Used to connect diagnostics machine. With 1/8 NPTconnection.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-11

� 2-2 2-2 �

799-202-9001 RADIATOR CAP TESTER

Purpose:

This tester confirm function of the pressure valveand checks the cooling system for water leakage.

Construction:

The tester is composed of a electric air pump forpressurizing and an adapter.

Component parts:

No. Part No. Tool description* Type of

radiator capRemarks

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



(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 Option

6 799-202-9360 Nipple C CEJN 10 - 220 - 5151 , PT 1/8 Option

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

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-12

� 2-2 2-2 �

Types of radiator caps:

Type AThe cap type in that the radiator cap and water pouring cap are built into a single unit

(for automobile use) (Four sizes by diameters are available, i.e., Ø54, Ø50, Ø41 , and Ø31 )

Type BThe cap type that has a single unit of pressure valve

(Two sizes by the thread pitch of water pouring cap are available)

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

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

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.

Type

Use

Che

ckin

g p

ressure

va

lve

op

era

tio

ns

Che

ckin

g f

or

wa

ter

lea

k

fro

m c

oo

ling

syste

m

Types of combinations:

A type B type C type

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-13

� 2-2 2-2 �

Reference:

List of applicable machine model

Machine modelType of

radiator capMachine 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



D375-2 Serial No. 16001 and up B PC75UU-1 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



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


PC200LC-5 Serial No. 45001 and up A

PC300 Serial No. 20001 and up A


Bulld

ozer

Hydr

aulic

Exc

avat

or

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-14

� 2-2 2-2 �

Machine modelType of

radiator capMachine model

Type of

radiator cap

PW05-1 Serial No. 1001 and up A WA20-1 Serial No. 1001 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




HD200D-3 Serial No. 1001 and up A WA320-1C Serial No. 10001 and up A

HD465-2 Serial No. 4001 and up A WA350-1 Serial No. 10001 and up A

HD785-3 Serial No. 2001and up A WA400-1 Serial No. 10001 and up A


HD200-2 Serial No. 1002and up B WA470-1 Serial No. 20001 and up A

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



HD1600M-1 Serial No. 1007 and up C

Hydr

aulic

Exc

avat

orDu

mp

truck

Whe

el lo

ader

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-15

� 2-2 2-2 �

799-201-1301 PRESSURE GAUGE 799-201-1201 VACUUM GAUGE

Weight: 0.5 kg Weight: 0.6 kg

Applicable engine Cummins engine Applicable engine Cummins engine

Purpose

For measurement of PT pump fuel pressure.Purpose

For measurement of PT pump Vacuum pressure.

Specifications

0 — 2.5 MPaSpecifications

- 101 — 0 kPa {- 762 — 0 mmHg}

How to use How to use

Remove the blind plug of PT pump shut off valveand attach the pressure gauge. Then, measure themax. fuel pressure when the engine is changed overfrom low idle to full throttle.

Attach the vacuum gauge to the PT pump fuel suc-tion side and then measure the vacuum pressure atthe max. engine output or at max. revolutions at non-load.Where vacuum pressures exceed the prescribedone, check to see whether the fuel filter or the fuelpiping is clogged.

Example of use: Example of use:

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-16

� 2-2 2-2 �

795-790-1500 VACUUM GAUGE 795-790-1470 PRESSURE GAUGE

Component parts:

Det Description Req'd

1 Brazed construction 1

2 Hose assembly 1

3 Vacuum gauge 1

Component parts:

Det Description Req'd

1 Pressure gauge 1

2 Pipe coupling 1

3 Hose (#4) 1

4 Male connector 1

5 Male connector 1

Applicable model: 102, 114 engine

Purpose:

Vacuum GaugeCheck the fuel filter restriction during the engine per-formance test. Hose Adapter, Part No. ST-434-2, andvacuum gauge, Part No. ST-434-12, are used to per-form the test.


Purpose:

Pressure Gauge ( 0 — 75 in. Hg.)Used to measure the intake manifold pressure and ex-haust back pressure.

795-790-6400 PRESSURE GAUGE



Purpose

Used to measure gear pump pressure. (low-pressurefuel system)

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-17

� 2-2 2-2 �

795-790-1700 PRESSURE TEST KIT

Component parts:

(3823799)Kit, turbo wastegate air pressure test consists of:

Komatsu tool No. Det. No. ST. No. Description Specifications Q't y

1 Adapter, hose/pipeAeroquip #2000-4-5B (1/4-18 NPT Male ×

1/2-20 THD., #4 Hose)1

2Fitting, socketlesshose

Aeroquip #4753-4-4B (1/4-18 NPT Female× #4 Hose)

1

3Hose, special

Application

Aeroquip #2556, #4, 1/4" I.D. (Textile braid

rubber tube & cover) 18" Long2

4Fitting, socketless

hose

Aeroquip #4738-2-4B (1/8-27 NPT Male ×

#4 Hose)2

5Adapter, pipe

reducing

Aeroquip #2040-2-4S (1/8-27 NPT Male ×

1/4-18 NPT Female)1

795-790-1710 6 ST-990-40 Regulator, pressure Wilkerson, 1/8 NPT Female, #R00-01-000 1

795-790-1720 73823205

*REF.Gauge, pressure

Aspcroft #63-1008-AL-02L-60; Ø2 1/2";

0-60 PSI; 1/4 NPT Lower; 3-2-3% Accuracy1

8 Label, warning See drawing 1


Purpose:

Turbocharger Wastegate Pressure Setting Kit.Used to set wastegate pressure.Gauge 0 — 60 psi.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-18

� 2-2 2-2 �

795-230-4200 ROD FIXTURE

Weight: 12.7 kg

Purpose

Intended to inspect connecting rods for center-to-center distance, deflection and distortion.

How to use

How to mount1) Secure a new connecting rod and cap with a pre-

determined torque.2) Insert the rod mandrel in the piston pin hole and

the clamp pin hole and attach them as shown.3) By moving the dial gauge holder, take the read-

ings on the gauge. Then, put the holder turn in-side out and take the readings on the gauge.

4) Adjust the dial gauge 'zero' point to the averagevalue of deflection.

Measurements of center-to center distance and ofdeflection1) Attach the connecting rod to be inspected.2) Then, the reading on the dial gauge represents

the difference between the center of the new con-necting rod and the center of this connecting rod.

3) The difference between the readings on the leftand right hand represent the deflection.

Inspection for distortion1) Using a thickness gauge, measure the clearance

between the mandrel and the fixture back plate.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-19

� 2-2 2-2 �

799-201-9001 HANDY SMOKE CHECKER

Weight: 3 kgApplicable engine All models

Purpose

Used to measure the concentration of smoke in theengine exhaust gas.

1) Range of measurement:Specifications

2) Size of case:

0 to 70%(Degree of contamina-tion)410 × 300 × 65 mm

How to use

1) Press the pump handle all the way, loosen thescrew on the tip, insert a filter paper into the slit,and tighten the screw.

2) Insert the tip of a sampling tube into the outletpipe of the muffler.

3) From the condition in step 1), slowly pull the pumphandle until it reaches its stroke end. (Time re-quired: 1 to 2 seconds)

4) Loosen the screw, remove the filter paper, andcompare the filter paper with concentrationsamples in the smoke scale to find the scale No.which is most similar to the color of the filter pa-per.

Component parts (each 1 piece)

No. Part No.TooI

descriptionRemarks

1 799-201-9310 Pump With a tube

2 799-201-9320 Nozzle 20SF Coupling

3 799-201-9020 Filter paper Containing 300 sheets

4 799-201-9340 Smoke scale Standard color samples

5 799-201-9330 Nipple 20PM

6 799-201-9350 Case

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-20

� 2-2 2-2 �

795-790-2300 CRACK DETECTOR

795-790-2400 ROD CHECKER

Applicable model: All engine

Purpose:

Used to inspect surface cracks, pores, leaks, seams,etc.Used to clean the threads of the pipe plugs andthreaded bores.(795-790-2310 Cleaner)

Applicable model: 102 engine

Purpose:

When inspecting connecting rods for center-to-center distance, deflection and distortion, this rodmandrel serves as a fixing pin.

Component parts:

Part No. Description Specification Size Q'ty

795-790-2310 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 1

Component parts:

Det. 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


GROUP 2

ENGINE TOOLS

2-2-21

� 2-2 2-2 �

795-790-2800 MANDREL KIT

Applicable model: 114 engine

Purpose:

When inspecting Connecting rod checking fixture,to check length, twist and bore alignment.

Necessary tools:

ST-561 Rod fixture

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-22

� 2-2 2-2 �

799-203-6000 FUEL DRAIN TEST KIT

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 en-gines for defects.

Specifications

1) Application

2) Size of case

743 series engines(with flange type injectors)370 × 200 × 70 mm

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-23

� 2-2 2-2 �

799-201-7101

and others

COOLANT TESTER

Purpose

This tester plate is used for checking if there is anywater leakage from the cylinder head.

How to use

1) Tighten bolt (3) so that centering nut (4) andwasher (5) will be fastened to the cylinder head(to an extent not to leave any clearance betweenthe cylinder head and washer).(Depending on the engine model, the mountingposition of these parts varies; therefore, refer tothe section “Plate mounting position” at a laterpart.).

2) After setting the O-ring to the plate, mount thisplate to the cylinder head.

Tool No. and applicable engines

Tool No. Applicable engines

790-553-1201 4D95L

790-553-1301 6D95L

790-553-1401 4D105-5

790-553-1501 6D125

790-553-1601 140 Series

790-553-1701 170 Series

790-553-1800 6D108

790-553-1900 6D105

795-611-1500 SA(A)6D170E-3

799-201-7101 Cummins 855 Series

799-201-7201 Cummins 743 Series

799-201-7301 155-4

799-201-7401 4D120, 130

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

799-201-7601 4D92, 94

799-201-7701 2D94

799-201-7801 2D92

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-24

� 2-2 2-2 �

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

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) tocheck for water leakage under the application ofa 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 sub-merge the cylinder head in the water to check forair leakage.At this time, the cylinder head must be appliedwith a pneumatic pressure of 0.14 — 0.21 MPa{1.4 — 2.1 kg/cm2} for 30 seconds.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-25

� 2-2 2-2 �

Component parts and applicable engines

Ass'y

Pa

rt N

o.

79

9-2

01

-78

01

79

9-2

01

-77

01

79

9-2

01

-76

01

79

9-2

01

-75

01

79

9-2

01

-74

01

79

9-2

01

-73

01

79

9-2

01

-72

01

79

9-2

01

-71

01

En

gin

es

All

mo

de

l

2D

92

-1

2D

94

-1

4D

92

-1,

4D

94

-1,2

4D

10

5-1

,2,3

4D

12

0-1

1,

13

0-1

15

5-4

Cu

mm

ins 7

43

se

rie

s

Cu

mm

ins 8

55

se

rie

s

799-201-7710 1 1 1 1.0For sealing the water

outlet

799-201-7810 1 1 0.95For sealing the water

outlet


outlet


outlet


outIet


outlet


outlet


outlet


outlet


outlet


outlet


outlet

07000-02016 14 5 4 9 14 8 8To be mounted to No.1

part

07000-02020 24 24 8To be mounted to No.1

part

3 799-201-7120 8 6 6 8 7 8 4 6 4To be mounted to No.1

part

4 799-201-7130 4 4 4 4 4 4 2 2 2To be mounted to No.1

part

5 799-201-7140 16 12 12 16 14 16 8 12 8To be mounted to No 1

part

6 01580-01210 8 6 6 8 7 8 4 6 4To be mounted to No.1

part

*799-201-7630 1 1 1 1For sealing the cooling

water port

*799-201-7530 1 1For sealing the cooling

water port

Flange

Flange

Bolt

Centering nut

Washer

Nut

Plate

Plate

O-ring

O-ring

Plate

PIate

PIate

Plate

Remarks

1

2

7

Plate

Plate

Plate

Plate

PIate

PIate

No. Part No.Tool

description

We

igh

ts (

kg

)

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-26

� 2-2 2-2 �

Ass'y

Pa

rt N

o.

79

9-2

01

-78

01

79

9-2

01

-77

01

79

9-2

01

-76

01

79

9-2

01

-75

01

79

9-2

01

-74

01

79

9-2

01

-73

01

79

9-2

01

-72

01

79

9-2

01

-71

01

En

gin

es

All

mo

de

l

2D

92

-1

2D

94

-1

4D

92

-1, 4

D9

4-1

,2

4D

10

5-1

,2,3

4D

12

0-1

1, 1

30

-1

15

5-4

Cu

mm

ins 7

43

se

rie

s

Cu

mm

ins 8

55

se

rie

s

799-201-7430 1 1For sealing the cooling

water port


water port


water port


water port


water port


water port


water port


water port

799-201-7640 1 1 1 1To be mounted to No. 7

part

799-201-7540 1 1To be mounted to No. 7

part

07000-03038 3 3 2To be mounted to Nos. 7

and 8 parts

07000-03022 2 2To be mounted to Nos. 7

and 8 parts


and 8 parts

01010-30830 9 2 2 2 9To be mounted to Nos. 7

and 8 parts


and 8 parts


and 8 parts


and 8 parts


and 8 parts

12 799-201-7171 2 1 1 1 1 2 1 1 1

To be mounted to Nos. 7

(* marked part No. ), and

No. 8 parts

9

10

11 Bolt

Bolt

Bolt

Gasket

Gasket

O-ring

O-ring

Valve

O-ring

Bolt

Bolt

Remarks

Flange

Flange

Flange

We

igh

ts (

kg

)Flange

No. Part No.Tool

description

Flange

Flange

Flange

Flange

8

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-27

� 2-2 2-2 �

Ass'y

Pa

rt N

o.

79

0-5

53

-12

01

79

0-5

53

-13

01

79

0-5

53

-14

01

79

0-5

53

-15

01

79

0-5

53

-16

01

79

0-5

53

-17

01

79

0-5

53

-18

00

79

0-5

53

-19

00

79

5-6

11

-15

00

En

gin

es

4D

95

L

6D

95

L

4D

10

5

6D

12

5

14

0 s

eri

es

17

0 s

eri

es

6D

10

8

6D

10

5

SA

(A)6

D1

70

E-3

790-553-1210 1 5.35

790-553-1310 1 7.9

790-553-1410 1 6.6

790-553-1510 1 2.58

790-553-1610 1 3.43

790-553-1710 1 4.6

790-553-1810 1 1 8.15

795-611-1510 1 3.2

790-553-1220 1 0.2

790-553-1320 1 0.3

790-553-1420 1 0.25

790-553-1520 1 0.1

790-553-1620 1 0.13

790-553-1720 1 0.18

790-553-1820 1 1 0.37

795-611-1520 1 0.23

790-553-1230 1 0.38

790-553-1330 1 0.36

790-553-1430 1 1 0.37

790-553-1530 1 0.27

790-553-1630 1 0.51

790-553-1730 1 0.44

790-553-1830 1 0.35

790-553-1240 1 0.01

790-553-1340 1 0.01

790-553-1440 1 1 0.01

790-553-1540 1 0.01

790-553-1640 1 0.02

790-553-1740 1 0.02

790-553-1840 1 0.02

5 790-553-1250 1 1 1 1 1 1 1 1 1 0.11

6 790-553-1260 1 1 1 1 1 1 1 1 1 0.078

7 799-201-7171 1 1 1 1 1 1 1 1 1 0.08 To be mounted to N0.1 part

01011-51230 17 25 18 0.13

01011-51235 26 26 0.134

01011-51250 6 6 0.15

01011-61890 7 0.422

01011-52090 6 0.29

01580-11210 17 25 18 6 5 26 26 0.012

01580-01815 7 0.035

01580-12016 6 0.05

01643-31232 17 25 18 4 4 26 26 0.01

01643-31845 7 0.026

01643-32060 4 0.044

01010-50825 2 2 0.01 5

01010-51030 2 2 2 0.03

12 01011-51040 1 1 0.096 To be mounted to N0.1 part

13 01580-11008 1 1 0.009

14 01643-31032 1 1 0.007

15 02720-20204 1 1 0.005 To be mounted to N0.1 part

For sealing the cooling water

port

To be mounted to N0.1 part

RemarksNo. Part No.Tool

description

We

igh

ts (

kg

)

Nipple

Valve

Union

Bolt 8

3 Plate

4 Packing

1

2

Plate

Packing

9

10

Nut

Washer

11 Bolt

For sealing the water outlet


Same as above


Same as above

Same as above

Plug


Same as above

Bolt

Nut

Washer

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-28

� 2-2 2-2 �

PLATE MOUNTING POSITION

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-29

� 2-2 2-2 �

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-30

� 2-2 2-2 �

799-205-1001 TACHOMETER SET

Applicable engine: All models

Purpose:

This revolution indicator allows many types of revo-lutions 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 canbe easily measured if the adaptor for the tachom-eter drive is used.

2) If the reflecting tape is glued to the revolving bodyand the photoelectric probe used, revolutions canbe measured without contact with the revolvingbody.

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-31

� 2-2 2-2 �

Component parts:

No. Part No. Part name Q'ty Remarks

- 799-205-1001 Tachometer set 1

- 799-205-1100 �Tachometer kit 1

1 799-205-1200 ��Tachometer 1 6.0 ~ 99999.9 rpm

2 799-205-1300 ��Bracket 1

3 799-205-1220 ��Probe 1 Photoelectric pickup, Cable length: Approx. 5 m

4 799-203-8300 ��Stand 1

5 799-203-8230 ��Nut 1 Metric (M22 x 1.5), marked"M"

6 799-203-8240 ��Nut 1 Imperial (7/8-18 NS), marked"I"

7 799-205-1400 ��Case 1

- 799-205-1601 �Tachometer kit 1

8 799-205-1701 ��Tachometer 1 400 ~ 10,000 rpm

9 799-205-1800 ��Detector 1 Fuel injection pipe-mounted type sensor

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-32

� 2-2 2-2 �

How to use:

For a more complete description, refer to the Op-eration Manual accompanying the Multi-Purpose Ta-chometer.

1. Measuring engine speed1) Securely attach the provided cord to the connec-

tor of the probe and the main unit.2) Attach the sensor to the engine speed outlet.

Note: • Attach the sensor to the servicemeter’sengine speed outlet secure with a ring nut.

• Pay special attention to the system of units(mm vs. inches) used at the point of at-tachment.

3) Apply power and select either the H- or L-range.When the tone sounds and the triangular markappears on the display, take a reading.

2. Other measurements1) 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 thecircumference of the object.

2) Loosen the knurled screw on the bracket, removethe probe, and clamp the probe to the flexible standincluded with the Basic Set.

3) Apply power and select either the H-or L-range.Point the probe at the rotating object and pressthe MEAS switch so that the red light from theprobe strikes the reflective tape.If the positioning is correct, the tone will soundand a triangular mark will appear on the display,indicating that a reading can be taken.The distance between the tape and the probe mustbe in the range specified in the accompanyingdrawing.The angle of incidence must be -30° to +30°.

50 - 300mm

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-33

� 2-2 2-2 �

Sample Application 1: Measuring the speed of a fan1) Attach a piece of reflective tape to the outermost

part of one of the fan blades.2) Mount the magnetic base on any convenient sur-

face (for example, hood, side cover, radiatorcover, or main frame) and adjust the flexible sup-port so that the light from the probe shines bothroughly parallel to the fan's axis of rotation androughly perpendicular to the fan blade's twist.

3) Further adjust the probe position so that the lightshines on the center of the tape.

Note: Make sure that the probe does not get in theway of the fan!

4) This concludes the setting up procedure. Proceedwith the normal measuring procedure.

Note: If the standard procedure fails to yield astable reading, try moving the probe furtheraway from the fan or improving the contrastby applying black, non-reflecting paint to thetips of all fan blades before applying the re-flective tape.

Note: Electronic flashes, fluorescent lights, andother intermittent light sources can interferewith measurement; never allow them to en-ter the probe!

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-34

� 2-2 2-2 �

795-790-2600 TAKEOFF DRIVE

Applicable model and component parts

Model

102

114

Ass'y

part

No.

-

795-7

90-2

600

1 6735-21-3410 1 1

2 6732-21-3220 1 1

3 6736-21-7120 1 1

4 6735-21-3450 1 1

6735-21-3420 1

6742-01-5498 1

6 6732-81-5250 2 2

7 6735-21-3430 2 2

Washer

Bolt

Adapter

Seal

Seal

Adapter

No. Parts No. Parts name

5Hub

Hub

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-35

� 2-2 2-2 �

ADAPTER 795-116-1330

and others

FEELER GAUGE

Purpose:

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

Note) When reading the indicator, do carefully be-cause the rpm indicated by the indicator is1/2 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 tachom-

eter to flex cable (6), then measure engine rpm.

Tool No. and specifications:

No. Tool No. SpecificationsWeight

(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 valveclearance.

How to use:

Insert the gauging section to adjust the valve clear-ance.

Component parts:

No. Part No.Tool

descriptionYammer Diesel

numberQ't y

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 01010-50616 Bolt 26117-060162 2

5 01602-20619 Washer 23414-06000 3

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-36

� 2-2 2-2 �

799-203-7000 FUEL LEAK CHECKER

Weight: 15 kg

Purpose

1) To find the places where fuel leaks into the en-gine and to check that the fuel leakage is com-pletely repaired.

2) To measure the nozzle cracking pressure afternozzles are installed to an engine.

3) To check the function of a nozzle assembly whenthe color of the engine is abnormal or when theengine output is inadequate.

Specifications

105 and 155 seriesCummins 743 series0 to 40 MPaASTM D975 No.2465 × 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

1) Applicable engine:

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

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-37

� 2-2 2-2 �

No. Part No. Tool description 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: Independent check of anozzle holder

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-38

� 2-2 2-2 �

790-551-1290 NOZZLE TESTER

Applicable model: All Komatsu engine models

Purpose:

Used when checking the injection pattern and in-jection pressure on fuel injection nozzle.

How to use:

Install the tube assembly and nipple to the nozzletester, screw the fuel injection nozzle in the end,apply fuel oil pressure, and measure the injectionpattern and injection pressure.

Example of use:

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

SECTION 2


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2-2-39

� 2-2 2-2 �

795-790-2220 LEAK TESTER PLATE (LEAKAGE TEST)


Purpose:

Leak Test KitPressure test the element to check for leaks.

Example of use:

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 Watts 0-160 P.S.1. 1-5/8 O.D. 1

Hose (gates)

#4-2MP / #4-2MP (1/8 Male NPT)

1/4 Duraflex hose 15" Length /

EQUIV.

1

Sheet, instruction 1

SECTION 2


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2-2-40

� 2-2 2-2 �

795-471-1450 ADAPTER

8 x 1.25 - Rc1/8

Applicable model: SAA6D125E-5

Purpose:

Used to measuring fuel pressure.

Example of use

795T-690-1110 BLOCK

Applicable model: SAA6D170E-5

Purpose:

Used to measuring EGR valve oil pressure.

SECTION 2


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2-2-41

� 2-2 2-2 �

790-828-1000 FUEL METER

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.

No. Part No. Part description Q'ty

- 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 4

12 07281-00197 CLAMP, hose 4

13 790-828-5180 CAP 4

14 09014-10200 WRENCH 1

15 790-828-9210 MANUAL (J) (Japanese) 1

16 790-828-9250 MANUAL (E) (English) 1

17 790-828-9210 CASE, carrying 1

Purpose:

Measuring the fuel consumption.Cumulative fuel consumption (Unit: L)Indicates cumulative fuel consumption from thestart to the end of measurement.Cumulative fuel consumption rate (Unit: L/H)Indicates cumulative fuel consumption from thestart to the end of measurement converted to therate of consumption per hour.Instantaneous fuel consumption rate (Unit: L/H)Indicates the fuel consumption per second con-verted to the rate of consumption per hour. (Theindicated value changes every second.)Measurement time (Unit: H-M-S)Indicates the duration from the start to the end ofmeasurement in hours-minutes-seconds.Power source

1)

2)

3)

4)

�

1) D.C. 12 — 24 volt2) Built-in chargeable battery

(Chargeable from 12 — 24V battery)

Example of use:

Component parts:

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-42

� 2-2 2-2 �

790-829-1030 FUEL MATE

(General purpose type fuel meter)

The measured data can be printed out.

This FUEL MATE is an electronic fuel consumptionq’ty/ratio meter. That is, this computerized handyfuel meter is capable of simply measuring the saidfuel consumption q’ty/ratio in large-sized enginesfor construction machines as well as in small-sizedengines for motor-cycles, etc. even during their trav-eling or running.The fuel consumption q’ty covering the period fromthe starting to the end of measurement is indicatedin the digital form on a liquid crystal display. Themomentary fuel consumption ratio varying per sec-ond and the mean consumption ratio during themeasurement. Thus, the measured data are printedout with the lapse of time covering from the startingto the end of measurement.In addition, after completing the measurement, ifthe distance covered by a test machine is enteredwith a “ten-key”, the mean vehicle speed and thedistance covered per lit. of the fuel consumed arecomputed and displayed.

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� 2-2 2-2 �

Thus, the FUEL MATE has the following distinctivefeatures.

1.

2.

3.

4.

5.

6.7.

8.

The fuel consumption can be simply measuredduring the actual operation of a vehicle.The small-sized, lightweight, handy type can becarried and used anywhere.The meter is computerized for high precisionmeasurement and computation.In diesel engines, the q’ty of fuel return in opera-tion is large. Such q’ty of fuel return is subtractedin its computation.Hourly fuel consumption ratio, Km/L or Km/H, isobtained by the computer.Measured values can be printed out.This FUEL MATE is of an interactive type simplein control and provided with a self-diagnostic func-tion.The power source (6 — 24 V) is available from acigarette lighter at the operator’s seat. The bat-tery cigarette lighter at the operator’s seat. Thebattery provided internally can also be used asthe power source.

In an engine abundant in the return fuel, a fuelflow sensor is installed on the return side, too.

�

Mainspecifications(Main body)

1. Measuring itemsand measuringrange

Fuel consumption q’ty:Measuring time (When the external powersource is used):Fuel consumption ratio (Momentary consump-tion ratio & mean consumption ratio)

2. Power source

When sensor Type A is used:When sensor Type B is used:

Distance covered per lit. of fuel(computed value):Mean vehicle speed (computed value):Measuring-over alarm function is also provided.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 alsoprovided.

When the external power source is in use, the additional charge of the built-in (internal) battery can be carried out.A flat-faced switch, shift-key typeWhen “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 consumptionratio is displayed in the real time.

3. Keyboard

4.

5.

6.

Operating temp-rature range:Exclusiveprinter:Main bodydimensions andweight:

0 to 50°C

EPSON C-40

150 × 115 × 42 mm approx. 520 g

0.01 — 9999.99 L

99H 59M 59S

0.1 — 300.0 L/H0.1 — 40.0 L/H

0.1 — 99.9 Km0.1 — 999.9 Km/H

SECTION 2


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2-2-44

� 2-2 2-2 �

Construction and Component Part No.

No. Part No. Part Name Q'ty Remarks

Over-

all790-829-1030 Fuel mate 1 All component parts listed below are contained in a portable case.

1 790-829-3100 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 300 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 Spare roll paper (containing 5 rolls) EPSON 8R1C 40

11 790-829-6700 Cable ass'y 1Power source cable ass'y (for connecting FUEL MATE and the printer

together)

12 07271-01430 Hose 3 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.

16 790-828-5180 Cap 4 Stored in a given position.

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.

Option (for separate sale)

-- 790-828-7100 Sensor ass'y 2 Fuel flow sensor Type B (Measuring range: 0.1-40 L/H)

SECTION 2


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2-2-45

� 2-2 2-2 �

In this FUEL MATE,the following data are computed and displayed, byputting the signals measured with a flow sensor in-stalled on the fuel pipe into an 8-bit computer, thenby computing and converting the fuel consumptionq’ty per second (cc/sec).

The consumption ratio (momentary L/H) varyingmomentarily according to the vehicle operatingcondition.The total consumption q’ty (cumulative L) fromthe starting of measurement up to the present.The mean hourly consumption ratio from the start-ing (mean L/H), andThe time which has elapsed from the starting ofmeasurement (H.M.S)

�

�

�

�

�

�

If the distance covered by a test vehicle is inputwith the “ten-key”, the following data will be com-puted and displayed.The distance covered per lit. (Km/L), andThe mean vehicle speed during the measure-ment.

All these measured data are printed out, excludingthe momentary consumption ratio.

The measurement starting and stopping pauses canbe simply obtained by means of push buttons on thekey-board. Thereby, the net actual operating hoursand fuel consumption q’ty can be measured.

The fuel consumption q’ty and the time can be mea-sured, by classifying them into the fuel consumptionper haul cycle for a dump truck or into the fuel con-sumption per truck loading by a loading machine.Such data classified by the traveling condition as “Up-hill road”, “Downhill road”, “Flat road” etc., can be ob-tained through the keyboard control.

If the “Print” button is depressed without depressingthe “Stop” button, the following data during the periodfrom the starting of measurement to the starting ofprinting will be printed out.(1) Fuel consumption q’ty(2) Measuring time(3) Hourly consumption q’tyIn this case, the data measured up to that time arecleared up and the measurement is newly started fornew data.

If the “Print” button is depressed after depressing the“Stop” button, the following data during the period fromthe starting to the end of measurement are printedout.Then, if started again, the measurement will be re-started continuously from the data obtained just be-fore the restarting. In this case, the input data of thedistance covered will be cancelled.(1) Fuel consumption q’ty(2) Measuring time(3) Distance covered (Input data)(4) Hourly consumption q’ty(5) Distance covered per lit.(6) Mean vehicle speed

LH.M.SL/H

LH.M.SKmL/HKm/LKm/HFUEL MATE Functional Block Diagram

SECTION 2


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2-2-46

� 2-2 2-2 �

(Caution)

In some of engines (KOMATSU 125 Series) equippedwith Model EP-9 fuel injection pump mfd. by NIPPONDENSO, the fuel consumption measurement maysometimes become difficult due to such a slight re-verse flow in the fuel flow as caused by the feed pumpstructure.When installing flow sensors in a fuel meter, such apreventive measure as described herein should betaken before the measurement of the fuel consump-tion. The installation procedure of fuel flow sensors isdescribed in detail in the Operation Manual. On ma-chines listed up in Table 1, such a check valve asshown in Fig. 1 may become necessary as a mea-sure against the reverse flow. Therefore, it is advisedthat necessary parts be prepared, referring to the partslist 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 preventivemeasure of a possible errors in data measured withfuel meter due to the slight fuel reverse flow.On these machines, the fuel consumption shouldbe measured by adding such a check valve as in-troduced herein to the fuel line. On machines otherthan those listed in Table 1, too, if the abnormallyhigh fuel consumption data are encountered, themeasurements should be made by adding a checkvalve to them in the same manner.

Table 1 Examples of machines requiring a check valve

for the measurements

Machine

Model

Engine

Model

Machine

Model

Engine

Model

D50A, P-17

D53A, P-17

D60A, P, S-8

D65A, P, S-8

GD600R-3

GD605A-3. -5

6D1 25-1

D75S-5

D83E-1, -SS

PC300-3

PC400-3

LW250-1

S6D125-1

EM655A-A SA6D125-1

SECTION 2


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2-2-47

� 2-2 2-2 �

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.

3. Installation of fuel flow sensors

Connect a sensor on the fuel supply side markedand another sensor on the fuel return side 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.)

Marks show the positions where the sensors areinstalled. If the measurement is difficult due to thefuel reverse flow, and a check valve at a positionmarked �.

SR

Table 2 Parts required to prepare a check valve for measuring the fuel consumption

Ref.No. in

Fig.1Part Name Part No. Q'ty

Check valve

(Overflow valve)

DKKC Part No. 131424-1520

ND Part No. 090310-00801 pc.

Nut 790-829-8130 1 pc.

* Gasket KES Part 07005-01412 4 pcs .

* Hose KES Part 07271-01430 1 pc.

* Joint bolt KES Part 07206-11014 1 pc.

( Note )Parts marked * in the above list are available from the group of accessory parts for a

fuel meter.

SECTION 2


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2-2-48

� 2-2 2-2 �

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

(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:

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-49

� 2-2 2-2 �

Table 3 Types of fuel meters

Types of fuel meters

Simple type fuel meter

"Fuel meter"

Part No. 790-828-1000

General purpose type fuel meter

"FUEL MATE"

Part No. 790-829-1030

Applicable range

(Engine Model)

1 ) Diesel engines with a line type (Bosch)

injection pump

2) Diesel engines with a rotary type

injection pump

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

Items to be

measured

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.)

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)

Output results of

measurement

A result of measurement on each item is

indicated by a digital display (in its unit).

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.

5. Types of fuel meters

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

When measuring the fuel consumption ratio, measurethe cumulative fuel consumption ratio during a givenperiod of time, with the indicated momentary fuel con-sumption q'ty used as a reference data. The reasonis such that the indicated momentary fuel consump-tion q'ty is liable to be unstable, because the velocityof fuel flow varies subtly, even if the engine revolutionremains stable.This symptom does not pause a problem of the fuelmeter proper and the fuel flow sensor but indicatesan ill-effect caused by the structure of a fuel feedpump.Consequently, the stable data can be obtained ratherby measuring the cumulative fuel consumption ratiofor several minutes.

4. Hint on the measurement of fuel consumption

ratio

SECTION 2


GROUP 2

ENGINE TOOLS

2-2-50

� 2-2 2-2 �

795-231-1110

and others

R-GAUGE

Purpose:

to use for measuring the finished R dimensions atfillets after correcting the crankshaft by means ofgrinding in the engine crankshaft reconditioningoperation. (See Fig. 1.)

Tool No.Refer to the following list.Select the necessary gauge.

Tool NO. and applicable engine.

Tool No. Applicable engines Remarks

795-231-1110 4D92, (S)4D95, (S)6D95 *

795-231-1120 4D105, 6D105, (S)6D108, S(A)6D110 *

795-231-1130 (S)6D125 *

795-231-1140 S4D130 *

795-231-1150 S(A)6D140 *

795-231-1160 SA12V140 for main journal

795-231-1170 SA12V140 for pin journal

795-231-1180 S4D155, S(A)6D155, SA6D170 *

795-231-1190 SA8V170, SA12V170 *

795-231-1210 SA16V170 *

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

SECTION 2


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2-2-51

� 2-2 2-2 �

Example of R-Gauges

In the same measurement as described aboveand made by the use of the R-gauge for the min.value: when the R-gauge and the fillet are in con-tact at one point or in the full contact, the filletradius is acceptable. (See Fig. 4.)When they are in contact at two points, the filletradius will be less than the min. value, which isnot acceptable.

How to use a R-gauge

Measurement of the radius of the journal fillet of acrankshaft corrected by grinding should be made inthe following point with a fillet measuring R gauge anda pencil type flashlight.

Set a R-gauge for the max. value to the journalfillet. Then, apply the light from the back of the R-gauge. At this time, clearance profiled like a cres-cent can be seen with the gauge in contact withthe fillet at 2 points or the gauge comes in the fullcontact with the fillet. In such a case, the radiusat 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 thefillet are in contact only at one point, the radius ofthe fillet exceeds the max. value, which is notacceptable.

(1)

(2)

SECTION 2


GROUP 2

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2-2-52

� 2-2 2-2 �

799-201-2202 BOOST GAUGE KIT 795-471-1200 GAUGE ASS’Y

Weight: 0.93 kg

Applicable model: All engine

Purpose:

Used this kit when measuring the air charging pres-sure 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

3

799-401-2311 Gauge 1

799-401-2291 �Gauge 1 -760-1500 mmHg

790-261-1130 �Coupling 1

790-261-1140 �Packing 1

Applicable model: 125E-2, 170E-2, 3 engine140E-2

Purpose:

Used this gauge ass’y when adjusting the fuel in-jection timing of the engines.

For engines on the WA600-1 and WD600-1, use adial gauge available on the market (with the gage scaleof 0.01 through 20 mm) as the component part itemNo. 2.

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

4 795-471-1220 Measure point 1 0.002

5 795-471-1230 Rod 1 0.185

SECTION 2


GROUP 2

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2-2-53

� 2-2 2-2 �

From D375A-5, 170-series engine have been modified to -3 conform to Tier 2 engine emission regulationof EPA in USA.In the future, 170 Series engines for models to be introduced to the market will be mounted with -3 oneafter another. For injectors, fuel pumps, various sensors, controllers, etc. composing the engine fuelsystem (so called HPI), units and parts common to Cummins engines have been used. So, troubleshootingunits 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

2. Purpose

2-1. Determination of Defective Injector with HeatGun (Portable infrared thermometer)(Part Number : 795-799-5510)Troubleshooting Method : Wait until the en-gine to cool down before starting the trouble-shooting. Measure temperature of each cyl-inder on the front surface of the exhaustmanifold for 10 minutes right after the en-gine started. When temperature of a cylinderhardly rises, judge the cylinder to be defec-tive. Covers of the exhaust manifold havebeen structured so that their surface tem-peratures can be easily measured.

795-799-5510 Troubleshooting Unit for HPI Engine, 6D170E-3

Heat gun

**

No.Komatsu Part

No.Cummins Part

No.Part Name Application

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, airintake temperature sensor and exhaust gas temperaturesensor.

6 795-799-5540 - Socket (A) To be used for troubleshooting of temperature sensor.

7 795-799-5460 3824774 CableTo be used for troubleshooting of atmospheric pressuresensor, fuel pressure sensor and actuator pressure sensor.

8 795-799-5470 3824775 CableTo be used for troubleshooting of lubricating oil pressuresensor.

9 795-799-5480 3824776 CableTo be used for troubleshooting of timing pressure sensor, airintake pressure sensor and pump pressure sensor.

SECTION 2


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2-2-54

� 2-2 2-2 �

Temperature characteristic when the 2nd cylinderis abnormal

Temperature characteristic when all cylinders arenormal

Note : The heat gun has the Part Number set by Komatsu but is not a special one and is generally availablein the market. So, if you have any heat gun, you need not purchase a new one. If you purchase it, werecommend 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 PressuresWhen the pump inlet pressure is normal (below 27KPa) and the pump outlet pressure at each enginespeed is not more than the standard value, the pump is considered to be in the normal state. Forthe 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 orthe piping is supposed to be clogged or loosened or fuel may be leaking from somewhere. Whenthe outlet pressure is lower, any of the pump body, pressure sensors or the regulator valve issupposed 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. Thiscoupler does not accept our usual couplers in connection, and we have newly set the adapter, whichaccepts our usual quick couplers and enables to measure pump outlet pressure easily with our usualpressure gauges. Since pump inlet pressure becomes negative, the negative pressure gauge to beintroduced in the next paragraph is necessary for measurement.

Quick coupler for measuring fuel pump inletpressure

Komatsu’s Quick Coupler

Quick coupler for measuring fuel pump outletpressure

Adapter

SECTION 2


GROUP 2

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2-2-55

� 2-2 2-2 �

2) Oil Pressure Gauge for Measuring Negative Pressure (Part Number : 795-799-5560)This gauge is used for measuring inlet pressure of the fuel pump. The measuring range is from 0to –0.1MPa.

2-3. Diagnosis of Electronic Control SystemThe HPI is equipped with various sensors, and we have set simple sockets and cables to be con-nected to these sensors for diagnosis. These cables are common to those used by Cummins Corp.

1) SocketThis socket is connected to a sensor to check disconnection or short-circuit of the sensor.

Part Number How to useDiagnosis Example of Intake Air Temperature Sensor

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 How to use

Diagnosis Example of Atmospheric Pressure Sensor

795-799-5540

795-799-5520

795-799-5530

795-799-5460 795-799-5480

795-799-5470

SECTION 2


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2-2-56

� 2-2 2-2 �

3) T-adapter for DEUTSCH ConnectorDEUTSCH connectors have been used for connection of engine controller and engine to machinebody. 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

Connection of T-adapter to BodyConnection Connector

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

Connection to controller of D375A-5(1) T-adapter for Controller 799-601-9350

799-601-9290

guide_2_2e

Documents

adapter assy

engine compression pressure

engine tools2

applicable engine

gauge assy

engine toolssection

engine cylinder head

cummins kt1150remarks23