SERVICE TOOL GUIDE

TABLE OF CONTENTS

SECTION 2
MEASURING & DIAGNOSTIC TOOLS
This section introduces the application and method of use of trouble shooting equipment and measuring tools to be used for trouble shooting of machines or components and for judgement of accuracy or service limit of them.

Group 1: General purpose tools Group 2: Engine tools Group 3: Power train and hydraulic system tools Group 4: Undercarriage tools Group 5: Electric and electronic system tools Group 6: Others

GROUP 1 GENERAL PURPOSE TOOLS

SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 1 GENERAL PURPOSE TOOLS

799-101-1502

DIGITAL THERMOMETER

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Specifications (1) Display temperature range: (2) Accuracy: (3) Temperature range for use: (4) Temperature sensor: (5) Display: (6) Power: (7) Length of use: (8) Dimensions: (9) Weight:

Component parts:

-99.9 1299C
No. Part No. Part Name Dry cell Q'ty 1 2 1 2 2 1 1 1 1 Extension cable Exhaust temperatures measurement use Up to 199: SUM3 Remarks

0.2% (measured value) 0 40C (20 80% RH) K (chromel-alumel) thermocouple LCD (Liquid crystal) 3V (SUM3 x 2) Approx. 80 hours 352(W) x 146(D) x 90(H)mm 1.06 kg

1 79A-262-1910 Meter 1A 790-261-1180 2 79A-262-1920 Sensor 3 79A-262-1930 Sensor 4 79A-262-1940 Adapter 5 790-262-1980 Adapter 6 799-101-1510 Case assembly 7 799-201-1110 Cable

Features (1) Compared to conventional thermistor temperature gauges, it can measure minus temperatures down to 99.9C below zero. (2) It has four channels, so up to four places can be measured by operating the selector knob (selector switch). (3) The display unit is compact and light, so measurement can be carried out when holding it in one hand.

8 6215-11-8180 Sensor

Optional part: 79A-262-1971 Sensor (for surface temperatures) Note: 799-101-1501 is changed to 799-101-1502 in order to add Cable No. 7 and No. 8.

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GROUP 1 GENERAL PURPOSE TOOLS

Digital thermo meter (complete set):

2. Bar sensor

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Part No. : 79A-262-1930 Measurment range: -50C to +350C Purpose: Suitable for measuring temperatures of pressurized fluids PT1/8 (water temperature, oil temperature). There are the following two types of mounting adapter: 79A-262-1940 (for normal temperatures) 790-262-1980 (for setting of above mentioned adapter)

1 .Flexible sensor

3. Surface temperature sensor (option)

Part No.:79A-262-1920 Measurment range: -50C to +280C Purpose: Inserted through the oil filler port to measure the oil temperature.

Part No.: 79A-262-1971 Measurment range: to +300C Purpose: Used for measuring the surface temperatures of brake discs, wet-type track bushings, etc.

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GROUP 1 GENERAL PURPOSE TOOLS

799-101-6700

THERMO LABEL

2-1 How to use: (1) Remove all oil, water, dirt, dust, and rust from the surface, and make sure that the surface is smooth and dry before sticking on the label. (2) Peel off the backing, stick the label on, then press it lightly with a cloth or your finger to make sure that it is stuck firmly in position. Note: (1) If you press the label hard when sticking it in position, the temperature display portion on the inside may be damaged, and it will not display the temperature properly. (2) If you cut the area around the temperature display, the label will lose its resistance to water and heat.

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Purpose: This is stuck to the place where the temperature is to be measured. It displays the temperature of the surface of the place where it is stuck. (1) When it reaches the display temperature, it changes color. Once it has changed color, it does not return to its original color. (2) The element displaying the temperature is a heatresistant film, and it is completely sealed, so it is not affected by water, chemicals, or oil. Example

Component parts:
Part No. 799-101-6710 799-101-6720 799-101-6730 799-101-6740 799-101-6750 Temperature range 50C - 55C - 60C - 65C - 70C (122F) - (131F) - (140F) - (149F) - (158F) 75C - 80C 85C 90C 95C (167F) - (176F) - (185F) - (194F) - (203F) 100C - 105C - 110C - 115C - 120C (212F) - (221F) - (230F) - (239F) - (248F) 125C - 130C - 140C - 150C - 160C (257F) - (266F) - (284F) - (302F) - (320F) 170C - 180C - 190C - 200C - 210C (338F) - (356F) - (374F) - (392F) - (410F) Color change precision 2C 2C 2C 2C 2C Q't y 1 1 1 1 1 White Black Original Color after color change

* Each part number consists of a set of 20 thermo labels.

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GROUP 1 GENERAL PURPOSE TOOLS

799-101-6500

THERMO CRAYON

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Purpose: Used to check the temperature of areas subject to heat. (1) Draw a line on the place where the temperature is be measured, and check if the crayon melts or not. This will show if the place is above or below the specified temperature. (2) The crayon consists of a compound with specific melting properties, and it is in the form of a pencil to allow it to be carried easily.
Component parts: Part No. 799-101-6510 799-101-6520 799-101-6530 799-101-6540 799-101-6550 799-101-6560 799-101-6570 799-101-6580 799-101-6590 799-101-6610 799-101-6620 799-101-6630 799-101-6640 799-101-6650 Green Pale red Pale red Green Purple Yellowish orange Green White Light brown Bluish purple Reddish purple Orange Green Gray Color of crayon Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1

How to use: (1) Remove the thermo crayon from its plastic bag, insert it in the holder, and secure it with the clip. (2) The thermo crayon is used to measure the temperature of heated objects. Simply draw a mark on the place to be measured. If the mark does not melt, the temperature at that place is lower than the specified transmission of the thermo crayon. (3) The thermo crayon is adversely affected by humidity. When not using it, keep it in its plastic bag.

Specified temperature C(F) 100 (212) 150 (302) 200 (392) 255 (491) 300 (572) 365 (689) 430 (806) 490 (914) 545 (1013) 590 (1094) 645 (1193) 700 (1292) 855 (1571) 1,010 (1850)

Precision 2C

1.0%

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GROUP 1 GENERAL PURPOSE TOOLS

799-301-1500

OIL LEAK TESTER KIT

Purpose (1) Used to check the operating condition of the clutch piston of the Torqflow transmission. (2) Used to check oil leaks of the final drive case. (3) Used to check the condition of the floating seal of the track rollers and idlers.

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799-301-1600

OIL LEAK TESTER KIT (A)

799-301-1800

OIL LEAK TESTER KIT (B)

Purpose For checking the operation of the clutch piston of the Torqflow transmission.

Purpose For checking the final drive case for oil leaks (for field use).

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Component parts: No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

GROUP 1 GENERAL PURPOSE TOOLS

Part No.
799-301-2200 799-301-1310 799-301-1550 799-301-1320 799-301-1330 799-301-1340 799-301-2300 799-301-1350 799-301-1360 799-301-1540 799-301-1410 799-301-1700 799-301-1420 799-301-1510 799-301-1390 799-301-1410 799-301-1900 799-301-1530 799-301-1520 799-302-1110 799-301-1380 799-302-1141 799-302-1161 799-302-1181 799-302-1211 799-302-1221 799-302-1230 799-302-1240 799-302-1290 799-301-1590

Tool description
Adapter assembly Rubber tube Rubber tube Plug Nipple Bushing Check valve assembly Tee Check valve Coupler Nipple Valve assembly Coupler Valve Regulator valve Nipple Adapter assembly Adapter Coupler Gauge Gauge Tube Adapter Adapter Adapter Adapter Adapter Adapter Plug Tool box

Q't y
1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 KIT (A)

Remarks

KIT (A), KIT (B)

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KIT (A)

KIT (B)

KIT (B) 0 - 0.2 MPa KIT (A) 0 - 1 MPa KIT (B) M30, P=1.5 M36, P=1.5 M24, P=1.5 M42, P=1.5 M12, P=1.5 M16, P=1.5 PT1/4 Width length height 350mm290mm85mm

Reference pressure
Section to be measured Final drive Parts such as roller (carrier and track rollers, and idler) Reference pressure Checking for oil leakage

0.026MPa Keep the ref. pressure as is for 10 seconds {0.25 kg/cm2} to see that no gauge pointer lowers.

0.1MPa Same as above {1 kg/cm2 }

For transmissions, see applicable Shop Manuals.

How to use 1. Check the operation of the clutch piston of the Torqflow transmission. 1) Assemble the parts as illustrated. Gauge (16) is for 1 MPa. Seal the taper thread with a seal tape. 2) Connect the compressor hose and adjust the pressure. Block the tip of the rubber tube (1) with a finger and control regulator valve (11) to attain the standard pressure. Keep valve (10) open when adjusting and close it after adjustment. 3) Press the tip of rubber tube (1) to the oil inlet of the Torqflow transmission and check how the piston works by opening and closing valve (10).

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS 2.Checking the final drive case for oil leaks (in the field). 1) Assemble the parts as illustrated. Gauge (15) is for 0.2 MPa. Seal the taper thread with a seal tape. 2) Remove the plugs of the oil supply port and the oil level check port of the final drive case; attach an applicable adapter and connect it to tube (17). With models mounted with a breather for the final drive case, dismount the breather and block the opening with a plug (24). 3) Increase the final drive case pressure up to the standard pressure by using a manual pump (bicycle pump for instance) available on the market and check for oil leaks.

GROUP 1 GENERAL PURPOSE TOOLS

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3. Checking the final drive case for oil leaks (using a compressor). 1) Assemble the parts as illustrated. (assemble tube (17) after pressure adjustment). Gauge (15) is for 0.2 MPa. Seal the taper threaded part with a seal tape. 2) Adjust the pressure by connecting a compressor hose. Block the discharge port with a finger and adjust the pressure so as to get the standard value by manipulating the regulator valve (11). Keep valve (10) open when adjusting the pressure and close it after adjustment is made. 3) Dismount the plug at the oil level check port or the oil supply port of the final drive case, and instead attach the applicable and adapter and connect it to the tube end. Dismount the models which have a breather and fit a plug (24). 4) Gradually open valve (10), increase the final drive case pressure up to the standard pressure and check for oil leaks. * If the final drive case pressure exceeds the standard pressure, the floating seal and the oil seal will get damaged. So before connecting the tube, be sure to adjust the air pressure.

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS 4. Checking the condition of the floating seal of the lower track roller and idler (in the field). 1) Assemble the parts as illustrated. Gauge (16) is for 1 MPa. Seal the taper threaded part with a seal type. 2) Dismount the oil supply port plug of the lower track roller and idler, attach an applicable adapter instead and connect it to tube (17). 2-1 3) Increase the pressure up to the standard pressure by using a manual pump (bicycle pump, for instance) on the market and check for oil leaks.

GROUP 1 GENERAL PURPOSE TOOLS

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5. Checking the condition of the floating seal of the track roller and idler (when a compressor is used). 1) Assemble the parts as illustrated. Gauge (16) is for 1 MPa. Seal the taper threaded part with a seal tape. 2) Connect the compressor hose and adjust the pressure. See the Section on the Torqflow transmission. * If oil becomes insufficient after checking for oil leaks, be sure to replenish it. * For the standard pressure and checking methods, see the shop manual of the machine.

* Models and applicable adapters table (final drive)

Adapter part No. 799-302-1211 799-302-1161 799-302-1181 799-302-1221 Applicable model D10-1 D20,21-3,5 D30,31-15,16 All the other models D355-1,3 Serial No.1117 and up Remarks M24,P=1.5 M30,P=1.5 M36,P=1.5 M42,P=1.5

* Models and applicable adapters table (rollers and idlers)

Adapter part No. 799-302-1230 799-302-1240 Applicable model D20,21-3 D31-16 All the other models Remarks M12,P=1.5 M16,P=1.5

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 1 GENERAL PURPOSE TOOLS

799-101-1403

THICKNESS METER

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This SERVICE TOOL GUIDE introduces a highperformance small-size ultrasonic thickness meter that is capable of measuring the thickness of a steel plate in the portion where it is impossible to make measurement with a Vernier caliper and that can be used as a replacement of the current thickness meter (Part No. 799-101-1402). Specifications 1) Display method : 2) Min. unit : 3) Accuracy : 4) Measurement range : 5) Sonic speed measurement range : 6) Power source : 7) External dimensions : 8) Weight : 9) Temperature when using : 10) Metals for measurement :

Liquid crystal digital 0.1 mm 0.1 mm 1.5 250 mm (steel) 1000 12,000 m/s SUM3 alkali dry cell battery 1 (1.5V) (Life : Min. 90 hours continuous) 69(W) 144(D) 29.5(H) mm 1.76 N {180 g} 5 50C Steel, aluminium, copper, brass, etc.

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 1 GENERAL PURPOSE TOOLS

79A-264-0021 (0 to 294 N {0 to 30 kg}) 79A-264-0091 (0 to 490 N {0 to 50 kg}) PUSH-PULL SCALE

Accessories

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Purpose Used to measure the manual operating effort of the steering lever, or the weight required for the brake pedal, or the rotation of the bevel gears. This push scale can measured pushing and pulling force only with it.
Specifications
Parts No. Item 1. Measurement range 2. Minimum scale 3. Stroke 4. Dimensions (with case) 5. Weight (with case) 79A-264-0021 0.25N {0.25 kg} 10 mm 224 x 64 17.65N {1.8 kg} 79A-264-0091 5N {0.5 kg} 10 mm 224 x 64 17.65N {1.8 kg} 0-300N {0 to 30 kg} 0-500N {0 to 50 kg}

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 1 GENERAL PURPOSE TOOLS

799-101-8210 and others

ROUGHNESS GAUGE
Purpose These roughness gauges allow the roughness (rms: root-mean-square) of machined surfaces to be easily measured in either the tactical (perceived by the sense of touch) or visual way. These gauges can be applied when checking the surface roughness of a troubled precision part after disassembling or when checking the surface roughness of a part after reworking.

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To o l N o . a n d ap p lic ab le pro c es s
Pa rt No . 799-101-8210 799-101-8220 799-101-8250 P art name S tanda rd spe cimen of surface roug hne ss (rms) S tanda rd spe cimen of cylind rical o utside surface roughness (rms) Note ) Rms: root-mean-sq uare A pplicab le machining pro cess Smooting a nd polishing with sa ndpa per; surfa ce grind ing ; sha ping Fa ce milling ; milling Grinding; turning Rema rks 2-pc. set

How to use Use the standard specimens of roughness when (1) disassembling a part and checking the surface roughness of the part, especially a troubled part, or (2) checking the surface roughness of a part after reworking or re-machining the part. Note: The two most commonly used methods of measuring the surface roughness are (1) visual and (2) tactical (or perceived by the sense of touch). Compared to the former, the latter or tactical method allows you to make more precise roughness measurements because the latter requires you to directly touch and sense both the actual part whose surface roughness needs to be measured and the standard roughness specimen in order to compare the roughnesses of the actual part and standard specimen. Example of use The stand roughness specimens can be conveniently used in order to measure and determine the surface roughnesses of following engine parts when reworking or repairing them: 1) The surface of the main journal, that of the pin journal, and that of the seal, on crankshaft 2) The surface of the crankshaft journal to which a metal is installed 3) Finished surface in counterbored area 4) The surface in the hole for valve insert 5) The cylinder head mounting surface, etc.

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SECTION 2 MEASURING AND DIAGNOSTIC TOOLS

GROUP 1 GENERAL PURPOSE TOOLS

799-101-7002

SOUND LEVEL METER

Example of use

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FEATURES This is a hand-held integrating sound level meter it is ideally suited for measuring factory and community noises especially for noise with large level fluctuation. Specifications 1) Performance standards : 2) Microphone : 3) Measurement ranges : 4) Frequency range : 5) Weightings : 6) Dynamic characteristics : 7) Measurement modes (display) : IEC Pub. 60804: 2000 Type 2, JIS C 1502-1990 1/2-inch prepolarized condenser type UC52 28 to 130 dB (A), 33 to 130 dB (C), Six ranges: 10 dB step 20 8000 Hz A and C, Flat Fast and Slow LP (Instantaneous /Maximum level), Leg/LE (Manual/Preset measurement time: 10 s, 1 , 5 , 10 , 15 , 30 min, 1, 8, 24 h) L max,L min

8) Sensitivity adjustment (calibration) : Electrical calibration by internal 1000 Hz sinusoidal wave signal 9) Maximum level hold : Provided 10) Display : 11) Outputs : 12) Ambient conditions : 13) Power : 14) Dimensions : 15) Weight : 16) Standard accessories : 128 62 dot AC & DC Temperature: 10 to +50C, Humidity: Approx. 10 to 90% RH IEC R6 or ANSI AA battery 4, LR-6: 34 hour, R6P: 14 hour 260 (H) 76 (W) 33 (D) mm Approx. 400 g (including batteries) Windscreen 1, Battery R6P 4, Jack cover 1, Carrying case 1, Hand strap 1

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