GROUP 2

ENGINE TOOLS
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-502-1205 COMPRESSION GAUGE

Purpose :
Intended to measure engine piston compression
pressure.

2-2 2-2

Weight : 14.5 kg

Component parts
2D94-2, 4D94-2, 4D95L

170-1 (6D, 8V, 12V )

Cummins KT1150
84-2, 4D94E-21A

4D95W, 4D130-1
1D75-1, 1D84-1

Tool
3D72, 75, 84-1

120-11, 130-1

Cummins 743
Cummins 855
No. Part No. Remarks

170E-3 (HPI)
description

170-1 (16V)
105-1, 2, 3
105-5, 110
All models

SA6D108
3D68E-3

107E-1

114E-2
114E-3

125E-3
125E-5

140E-3
140E-5

170E-5
140-1

155-4
3D78

92-1
94-1

95-1
102

125

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

2-2-1
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

(Continued from page 2-2-1 )

No. 23 to No. 45 parts are option

2D94-2, 4D94-2, 4D95L

170-1 (6D, 8V, 12V )

Cummins KT1150
84-2, 4D94E-21A

4D95W, 4D130-1
1D75-1, 1D84-1
Tool

3D72, 75, 84-1

120-11, 130-1

Cummins 743
Cummins 855
No. Part No. Remarks

170E-3 (HPI)
description

170-1 (16V)
105-1, 2, 3
105-5, 110
All models

SA6D108
3D68E-3

107E-1

114E-2
114E-3

125E-3
125E-5

140E-3
140E-5

170E-5
140-1

155-4
3D78

92-1
94-1

95-1
102

125
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

2-2 28
29
790-553-1110
790-553-1120
Adapter
Adapter
1

1

see page 2-2-2
2-2

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

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

790-553-1110 ADAPTER
Applicable engine:
2D94-2, 4D94-2, 4D95L, 4D95W, 4D130-1
Purpose:
Used to measure engine compression pressure.
How to use:
Remove the glow plug of engine.
Screw the adapter and set a gauge.
Then, measure the compression pressure.
Necessary tool:
795-502-1590 Gauge ass'y 1 pc.

Example of use:

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

2-2-2
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

790-471-1090 ADAPTER 790-471-1110 PLATE

790-472-1370

2-2 2-2

Weight : 0.7 kg

Tool No. and applicable engine:

Applicable model : 16V170
No. Tool No. Q'ty Weight (kg) Applicable engine
1 790-472-1370 1 0.2 SA6D108 Purpose :
2 790-471-1090 1 1.2 16V170 Used to measure engine compression pressure.

Necessary tool:
Purpose :
790-471-1090 Adapter 1 pc.
Used to measure engine compression pressure.
795-502-1590 Gauge ass'y 1 pc.
Necessary tool :
795-502-1590 Gauge ass'y 1 pc. 795-502-1390 ADAPTER
790-471-1110 Plate (16V170 only) 1 pc.

Weight : 0.25 kg

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

Purpose :
Used when measuring the compression pressure of
engine.

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

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

2-2-3
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

Weight : 0.3 kg Weight : 0.13 kg

Applicable model : 102 engine Applicable model : 3D68E-3 engine

Purpose : Purpose :
Used to measure engine compression pressure. Used to measure Yanmar engine compression
pressure.
Necessary tool :
795-502-1590 Gauge ass'y 1 pc. Necessary tool:
795-502-1760 Packing 795-502-1590 Gauge ass'y 1 pc.

Component parts:
No. Tool No. Part name Q'ty Weight (kg)
1 795-502-1710 Adapter 1 0.05
2 795-502-1720 Sleeve 1 0.05 795-790-3610 GAUGE
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

Weight: 1.2 kg Weight: 0.8 kg

Applicable model : 114 engine Applicable model : 114 engine

Purpose : Purpose :
Used to measure engine compression pressure. Used to measure 114 engine compression pres-
sure.
Necessary tool :
795-790-3610 Gauge 1 pc.

2-2-4
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-201-1504 BLOW-BY CHECKER 795-790-1900 BLOW-BY TOOL

and others

2-2 2-2

Weight: 5 kg
Tool No. and applicable engines
Purpose: Applicable
No. Tool No. Remarks
Used to measure engine blow-by pressure. engines
* For details of how to operate, see the Operation CUMMINS Part
1 795-790-1900
Manual. 102 No.: 3822470
2 795-790-1950 Made in Japan
Specifications: CUMMINS Part
1) Applicable engines: Komatsu, Cummins 3 795-790-3300 107, 114
No.: 3822566
engines(VTA1710, IH engine: Used option parts) and others
2) Pressure gauge: Chamber pressure gauge 4 799-201-1511 Made in Japan
Measuring range: 0 5 kPa (0.2%) Purpose:
Min. scale: 0.2 kPa Used to measure the engine crankcase pressure.
3) Silicon tube: 5 6 4,000 mm
4) Size: 415 300 60 mm (Using case) Necessary tool:
795-790-1610 Mano meter

795-790-1610 Manometer

Example of use:

With out mercury.

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

2-2-5
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Component parts:

(S)6D105,6A6D110,6D108

6D140, Cummins NTC743

Inter DT268,466,414
(marked:{} no turbo)

Cummins NT(A)855
3D94,4D94,4D105

Cummins KT1150
Tool

S(A)6D155,170
Cummins N743
Cummins N855
6D125,S4D130
No. Part No. Remarks

KT1150(560)
description

Inter DT817
VT(A)1710
(S)4,6D85
All model
2D94

102
114
799-201-1511 Tool (body) 1 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

2-2 2 799-201-1541 Gauge 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 kPa 2-2

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 Oil filler mounting
5 799-201-1521 Adapter 1 1 1 adapter
6 799-201-1582 Case 1
Diams. of joints:
7 799-201-1411 Adapter 1 1 1 1 1 1
14.5 mm, 16 mm
Blind plug for
8 799-201-1460 Plug 3 {3} 3
N743 vent hole
Diams. of joints:
9 799-201-1450 Adapter 1 1 1 1 1 1 1
19 mm, 26 mm
10 799-201-1640 Adapter 1 1
11 799-201-1430 Adapter 1 1 For I.H engine
12 799-201-1440 Adapter 1 1 only
13 799-201-1630 Joint 1 1 1 1
14 799-201-1470 Hose 1 1 20 x26 x 60
15 799-201-1421 Hose 1 1 1 16 x22 x 60
16 799-201-1480 Hose 1 1 1 1 14 x20 x 60
17 799-201-1490 Hose 2 2 2 2 14 x20 x 1000
18 07281-00289 Clamp 2 1 2
19 07281-00259 Clamp 1 1 1 1 1 1 1 1

Option

799-201-1590 GAUGE Applicable engines: V type engine

Purpose:
Used when measure V type engine blow-by pres-
sure.
Specifications:
Pressure range: 0 - 10 kPa
Graduation Min.: 0.2 kPa
Accuracy: 1.0 class (JIS)
Safety device: With over pressure preventing unit

Necessary tools:
799-201-1504 Blow-by checker 1 pc
799-201-1511 Nozzle 2 pcs
Weight: 0.3 kg 799-201-1450 Adapter 2 pcs

2-2-6
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-6800 LEAK TESTER 795-500-1001 SPECIFIC GRAVITY TESTER

795-500-2000

2-2 2-2

Weight: 0.3 kg
Purpose
Applicable engines: 107E-1, 114E-3 1) Used to measure the specific gravity of the bat-
tery liquid and the charging condition of the bat-
Purpose tery.
Used to block a single injector and high pressure 2)Used to measure the freezing temperature when
fuel connector from the pressurized fuel. This tool anti-freeze is use.
helps identify a failed injector when injector return Specifications: 795-500-1001 795-500-2000
flow is excessive. Gravity of the Reading
1.100 ~ 1.300 1.00 ~ 1.30
battery liquid range
Measurement
freezing Reading -5 ~ -50 C - 8 ~ -50 C
temperature range
Type of the anti-freeze AF-PT, AF-ACLNON AMINE

How to use
Base line adjustment
1) Put 1 2 drops of clean water (service water)
onto the prism face of the tester.
2) Close the light intake plate and look into the 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 by
turning the base line adjusting screw A.
Measurement
1) Put 1 2 drops of a solution to be measured
onto the prism face using a sampler and read the
position of the boundary line by looking into the
eyepiece.
795-500-2010 Cover plate
795-500-2020 Pin

795-500-1000 Old tester can not be measured

antifreeze of a super coolant type (AF-ACL)

For the details, refer to the Operation Manual fur-
nished with the tester.
2-2-7
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

CUMMINS Part number: 4918462 CUMMINS Part number: 3164044

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

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

2-2-8
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-4700 TESRER KIT 795-790-5510 HOSE

2-2 2-2

CUMMINS Part number: 4918354 CUMMINS Part number: 4918434

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

Purpose Purpose
Used to check injector and HPCR pump drain flow Used to check fuel return flow.
Included 4918433 and 4918434

795-790-4800 HOSE KIT 795-790-6700 ADAPTER

CUMMINS Part number: 4918295 CUMMINS Part number: 3164618

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

Purpose Purpose
Used to check fuel return flow flom 12 mm banjo Used to isolate drain flow flom the fuel drain lines
fitting connections. where 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 fuel
return circuits to measure return flow flom the injec-
tors and fuel pump (Cummins common rail fuel sys-
tem)

2-2-9
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-4520 LEAK TESTER 795-790-6500 ADAPTER

2-2 2-2

CUMMINS Part number: 4918298 CUMMINS Part number: 3164621

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

Purpose Purpose
Used to cut injector fuel supply when diagnosing in- Used to create rated fuel flows through the low-pres-
jector leakage or malfanction. (Used on fuel rails with sure fuel system without loading the engine.
18 mm threads). 3045018: 0.043-inch orifice
3376859: Compuchek coupling

795-790-4900 ADAPTER KIT 795-790-4530 FITTING

795-790-5110 SCREW

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

CUMMINS Part number: 3377244
4918413 (795-790-5110)
Applicable engines: 107E-1, 114E-3
Applicable engines: 107E-1, 114E-3

Purpose
Purpose
Used to connect diagnostics machine. With 1/8 NPT
795-790-4900
connection.
Used to check fuel pressure/restriction at connec-
tions with 12 mm banjo fittings.

795-790-5110
12 mm banjo screw with 1/8 NPT pipe tap used to
check fuel pressure/restriction.

2-2-10
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-202-9001 RADIATOR CAP TESTER

2-2 2-2

Purpose:
This tester confirm function of the pressure valve
and checks the cooling system for water leakage.

Construction:
The tester is composed of a electric air pump for
pressurizing and an adapter.

Component parts:
* Type of
No. Part No. Tool description Remarks
radiator cap
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. 38
(5) 799-202-9240
Joint A 41 41 H =73
(6) 799-202-9250
Joint A 50 41 H=62
(7) 799-202-9260
Joint A 54 41 H=54
(8) 799-202-9271
Adapter A Rubber outer dia. 48
(9) 799-202-9281
Adapter A Rubber outer dia. 50
(10) 799-202-9311
Hose - L=1m
(11) 799-202-9320
Cable - Power cable
2 799-202-9330 Joint A 31 41 H =78 Option
3 799-202-9340 Adapter A Rubber outer dia. 27.5 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".

2-2-11
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Specifications of basic unit of pump:

Power source, battery: 12 VDC
Pressure, delivery: 0.6MPa {6kg/cm2}, max.
Pressure gauge: 0 0.2MPa {02kg/cm2}, containing glycerine
Valve: with regulator valve

Types of radiator caps:

The cap type in that the radiator cap and water pouring cap are built into a single unit
Type A
(for automobile use) (Four sizes by diameters are available, i.e., 54, 50, 41 , and 31 )
The cap type that has a single unit of pressure valve
Type B
(Two sizes by the thread pitch of water pouring cap are available)

2-2 Type C The cap type made by WISCO and that has a plug hole in the upper tank 2-2

Types of combinations:
Type
Use
A type B type C type
Checking pressure
valve operations
Checking for water leak
from cooling system

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

2-2-12
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Reference:
List of applicable machine model
Type of Type of
Machine model Machine model
radiator cap 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

2-2 D50,53-18 Serial No. 83001 and up B PC25 Serial No. 1001 and up A
2-2

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
Hydraulic Excavator

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
Bulldozer

D275-1 Serial No. 10002 and up B PC60L Serial No. 8001 and up A
D355-3 Serial No. 11728 and up B PC60 Serial No. 28001 and up A
D355-5 Serial No. 12622 and up B PC70 Serial No. 34101 and up A
D375-2 Serial No. 16001 and up B PC75UU-1 Serial No. 1001 and up A
D475-1 Serial No. 10001 and up B PC90 Serial No. 1001 and up A
D475-2 Serial No. 10201 and up B PC100L-5C Serial No. 14001 and up A
D575-2 Serial No. 10001 and up B PC100-5C Serial No. 28001 and up A
DR450-1 Serial No. 10001 and up B PC100-5 Serial No. 30083 and up A
PC120-5 Serial No. 30001 and up A
PC150-5 Serial No. 6001 and up A
PC200,220-5C Serial No. 35001 and up A
PC200-5 Serial No. 45001 and up A
PC200LC-5 Serial No. 45001 and up A
PC300 Serial No. 20001 and up A
PC400-5 Serial No. 20001 and up A

2-2-13
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Type of Type of
Machine model Machine model
radiator cap radiator cap
PW05-1 Serial No. 1001 and up A WA20-1 Serial No. 1001 and up A
PW20-1 Serial No. 1001 and up A WA20-2 Serial No. 10001 and up A
PW30-1 Serial No. 1001 and up A WA30-3 Serial No. 9001 and up A
PW100-3 Serial No. 1862 and up A WA30-5 Serial No. 15001 and up A
Hydraulic Excavator

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

2-2 WA50-1 Serial No. 10001 and up A 2-2

PC650-3 Serial No. 10501and up B WA70 Serial No. 10001 and up A
PC1000-1 Serial No. 10001 and up B WA100 Serial No. 20001 and up A
WA150-1 Serial No. 20001 and up A
WA200-1 Serial No. 20001 and up A
WA300-1 Serial No. 30001 and up A
HD200D-3 Serial No. 1001 and up A WA320-1C Serial No. 10001 and up A
Wheel loader

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
WA450-1 Serial No. 20001 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
Dump truck

HD200-2 Serial No. 1215 and up C WA600-1 Serial No. 10001 and up B
HD320-2 Serial No. 2001 and up C WA800-1 Serial No. 10001 and up B
HD320-3 Serial No. 2501 and up C
HD325-2 Serial No. 1002and up C
HD325-3 Serial No. 1501 and up C
HD325-5 Serial No. 2001 and up C
HD1600M-1 Serial No. 1007 and up C

2-2-14
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

Weight: 0.5 kg Weight: 0.6 kg

Applicable engine Cummins engine Applicable engine Cummins engine

Purpose Purpose
For measurement of PT pump fuel pressure. For measurement of PT pump Vacuum pressure.

Specifications Specifications
0 2.5 MPa - 101 0 kPa {- 762 0 mmHg}

How to use How to use

Remove the blind plug of PT pump shut off valve Attach the vacuum gauge to the PT pump fuel suc-
and attach the pressure gauge. Then, measure the tion side and then measure the vacuum pressure at
max. fuel pressure when the engine is changed over the max. engine output or at max. revolutions at non-
from low idle to full throttle. load.
Where vacuum pressures exceed the prescribed
one, check to see whether the fuel filter or the fuel
piping is clogged.

Example of use: Example of use:

2-2-15
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

Applicable model: 102, 114 engine Applicable model: 102, 114 engine

Purpose: Purpose:
Vacuum Gauge Pressure Gauge ( 0 75 in. Hg.)
Check the fuel filter restriction during the engine per- Used to measure the intake manifold pressure and ex-
formance test. Hose Adapter, Part No. ST-434-2, and haust back pressure.
vacuum gauge, Part No. ST-434-12, are used to per-
form the test.

Component parts: Component parts:

Det Description Req'd Det Description Req'd
1 Brazed construction 1 1 Pressure gauge 1
2 Hose assembly 1 2 Pipe coupling 1
3 Vacuum gauge 1 3 Hose (#4) 1
4 Male connector 1
5 Male connector 1

795-790-6400 PRESSURE GAUGE

CUMMINS Part number: 3375932

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

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

2-2-16
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-1700 PRESSURE TEST KIT

2-2 2-2

Applicable model: 102, 114 engine

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

Component parts:
(3823799)Kit, turbo wastegate air pressure test consists of:
Komatsu tool No. Det. No. ST. No. Description Specifications Q't y
Aeroquip #2000-4-5B (1/4-18 NPT Male
1 Adapter, hose/pipe 1
1/2-20 THD., #4 Hose)
Fitting, socketless Aeroquip #4753-4-4B (1/4-18 NPT Female
2 1
hose #4 Hose)
Hose, special Aeroquip #2556, #4, 1/4" I.D. (Textile braid
3 2
Application rubber tube & cover) 18" Long
Fitting, socketless Aeroquip #4738-2-4B (1/8-27 NPT Male
4 2
hose #4 Hose)
Adapter, pipe Aeroquip #2040-2-4S (1/8-27 NPT Male
5 1
reducing 1/4-18 NPT Female)
795-790-1710 6 ST-990-40 Regulator, pressure Wilkerson, 1/8 NPT Female, #R00-01-000 1
3823205 Aspcroft #63-1008-AL-02L-60; 2 1/2";
795-790-1720 7 Gauge, pressure 1
*REF. 0-60 PSI; 1/4 NPT Lower; 3-2-3% Accuracy
8 Label, warning See drawing 1

2-2-17
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-230-4200 ROD FIXTURE

2-2 2-2

Weight: 12.7 kg

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

How to use
How to mount
1) 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 average
value of deflection.
Measurements of center-to center distance and of
deflection
1) 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 left
and right hand represent the deflection.
Inspection for distortion
1) Using a thickness gauge, measure the clearance
between the mandrel and the fixture back plate.

2-2-18
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-201-9001 HANDY SMOKE CHECKER

2-2 2-2

Weight: 3 kg
Applicable engine All models

Component parts (each 1 piece)

TooI
No. Part No. Remarks
description
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

Purpose
Used to measure the concentration of smoke in the
engine exhaust gas.

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

2-2-19
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-2300 CRACK DETECTOR

Applicable model: All engine

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

2-2 2-2

Component parts:
Part No. 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

795-790-2400 ROD CHECKER

Applicable model: 102 engine

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

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

2-2-20
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-2800 MANDREL KIT

2-2 2-2

Applicable model: 114 engine

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

Necessary tools:
ST-561 Rod fixture

2-2-21
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-203-6000 FUEL DRAIN TEST KIT

2-2 2-2

Weight: 2.5 kg

Applicable engine Cummins 743 series engines

(with flange type injectors)

Component parts:
No. Part No. Tool description Q't y
1 799-203-6100 Adapter assembly 1
2 799-203-6200 Tube assembly 6
3 799-203-6270 Cylinder 1
4 799-203-6290 Case 1

Size of case 370 200 70 mm

Necessary tools
1) Multi-tachometer (799-203-8000)
2) Stopwatch (Commercially available)

Purpose
Used to check the fuel injectors on 743 series en-
gines for defects.

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

2-2-22
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-201-7101 COOLANT TESTER

and others

2-2 2-2

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

Purpose
This tester plate is used for checking if there is any
water leakage from the cylinder head.

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

2-2-23
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

3) Lock plate (1) to the cylinder head, using bolt (3),

washer (5), and nut (6).

2-2 2-2

4) Mount valve (12) to flange (7) or (8).

5) Fit O-ring (10) (or gasket (9) with Komatsu 2D92
and over) to flange (7) and (8).
6) Mount flanges (7) and (8) to the cooling water
ports of the cylinder head, using bolt (11).

Valve (12) is used for purging air from inside the
cylinder head at the time of the hydraulic test.

7) Connect the hydrostatic tester to flange (7) to

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

2-2-24
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Component parts and applicable engines

Ass'y Part No.

799-201-7801
799-201-7701
799-201-7601
799-201-7501
799-201-7401
799-201-7301
Cummins 743 series 799-201-7201
Cummins 855 series 799-201-7101

Weights (kg)
Tool
No. Part No. Remarks
description

4D92-1, 4D94-1,2

4D120-11, 130-1
4D105-1,2,3

2-2 All model

Engines

2D92-1
2D94-1
2-2

155-4
For sealing the water
799-201-7710 Plate 1 1 1 1.0
outlet
For sealing the water
799-201-7810 Plate 1 1 0.95
outlet
For sealing the water
799-201-7720 Plate 1 1 0.75
outlet
For sealing the water
799-201-7610 Plate 1 1 2.2
outlet
For sealing the water
799-201-7620 PIate 1 1 1.9
outIet
For sealing the water
799-201-7510 PIate 1 1 2.7
outlet
1
For sealing the water
799-201-7520 Plate 1 1 2.0
outlet
For sealing the water
799-201-7410 PIate 1 1 3.7
outlet
For sealing the water
799-201-7420 PIate 1 1 3.7
outlet
For sealing the water
799-201-7210 Plate 1 1 3.2
outlet
For sealing the water
799-201-7110 Plate 1 1 3.5
outlet
For sealing the water
799-201-7310 Plate 1 1 5.1
outlet
To be mounted to No.1
07000-02016 O-ring 14 5 4 9 14 8 8
part
2
To be mounted to No.1
07000-02020 O-ring 24 24 8
part
To be mounted to No.1
3 799-201-7120 Bolt 8 6 6 8 7 8 4 6 4
part
To be mounted to No.1
4 799-201-7130 Centering nut 4 4 4 4 4 4 2 2 2
part
To be mounted to No 1
5 799-201-7140 Washer 16 12 12 16 14 16 8 12 8
part
To be mounted to No.1
6 01580-01210 Nut 8 6 6 8 7 8 4 6 4
part
For sealing the cooling
*799-201-7630 Flange 1 1 1 1
water port
7
For sealing the cooling
*799-201-7530 Flange 1 1
water port

2-2-25
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Ass'y Part No.

799-201-7801
799-201-7701
799-201-7601
799-201-7501
799-201-7401
799-201-7301
Cummins 743 series 799-201-7201
Cummins 855 series 799-201-7101

Weights (kg)
Tool
No. Part No. Remarks
description

4D92-1, 4D94-1,2

4D120-11, 130-1
4D105-1,2,3

2-2 All model

Engines

2D92-1
2D94-1
2-2

155-4
For sealing the cooling
799-201-7430 Flange 1 1
water port
For sealing the cooling
799-201-7220 Flange 1 1
water port
For sealing the cooling
799-201-7150 Flange 1 1
water port
For sealing the cooling
799-201-7320 Flange 1 1
water port
8
For sealing the cooling
799-201-7440 Flange 2 2
water port
For sealing the cooling
799-201-7230 Flange 1 1
water port
For sealing the cooling
799-201-7160 Flange 1 1
water port
For sealing the cooling
799-201-7330 Flange 1 1
water port
To be mounted to No. 7
799-201-7640 Gasket 1 1 1 1
part
9
To be mounted to No. 7
799-201-7540 Gasket 1 1
part
To be mounted to Nos. 7
07000-03038 O-ring 3 3 2
and 8 parts
To be mounted to Nos. 7
10 07000-03022 O-ring 2 2
and 8 parts
To be mounted to Nos. 7
07002-12434 O-ring 2 2
and 8 parts
To be mounted to Nos. 7
01010-30830 Bolt 9 2 2 2 9
and 8 parts
To be mounted to Nos. 7
01010-30845 Bolt 3 3
and 8 parts
To be mounted to Nos. 7
11 02010-00519 Bolt 4 4
and 8 parts
To be mounted to Nos. 7
02010-20622 Bolt 4 4
and 8 parts
To be mounted to Nos. 7
01010-31020 Bolt 4 4
and 8 parts
To be mounted to Nos. 7
12 799-201-7171 Valve 2 1 1 1 1 2 1 1 1 (* marked part No. ), and
No. 8 parts

2-2-26
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Ass'y Part No.

790-553-1201
790-553-1301
790-553-1401
790-553-1501
790-553-1601
790-553-1701
790-553-1800
790-553-1900
SA(A)6D170E-3 795-611-1500

Weights (kg)
Tool
No. Part No. Remarks
description

140 series
170 series
Engines
4D95L
6D95L
4D105
6D125

6D108
6D105

2-2 2-2

790-553-1210 1 5.35
790-553-1310 1 7.9
790-553-1410 1 6.6
790-553-1510 1 2.58 For sealing the cooling water
1 Plate
790-553-1610 1 3.43 port
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
2 Packing To be mounted to N0.1 part
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
3 790-553-1530 Plate 1 0.27 For sealing the water outlet
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
4 790-553-1540 Packing 1 0.01 To be mounted to N0.3 part
790-553-1640 1 0.02
790-553-1740 1 0.02
790-553-1840 1 0.02
5 790-553-1250 Union 1 1 1 1 1 1 1 1 1 0.11
Same as above
6 790-553-1260 Nipple 1 1 1 1 1 1 1 1 1 0.078
7 799-201-7171 Valve 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
8 01011-51250 Bolt 6 6 0.15 To be mounted to N0.1 part
01011-61890 7 0.422
01011-52090 6 0.29
01580-11210 17 25 18 6 5 26 26 0.012
9 01580-01815 Nut 7 0.035 Same as above
01580-12016 6 0.05
01643-31232 17 25 18 4 4 26 26 0.01
10 01643-31845 Washer 7 0.026 Same as above
01643-32060 4 0.044
01010-50825 2 2 0.01 5
11 Bolt To be mounted to N0.3 part
01010-51030 2 2 2 0.03
12 01011-51040 Bolt 1 1 0.096 To be mounted to N0.1 part
13 01580-11008 Nut 1 1 0.009
Same as above
14 01643-31032 Washer 1 1 0.007
15 02720-20204 Plug 1 1 0.005 To be mounted to N0.1 part

2-2-27
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

PLATE MOUNTING POSITION

2-2 2-2

2-2-28
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

2-2 2-2

2-2-29
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-205-1001 TACHOMETER SET

2-2 2-2

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 can
be easily measured if the adaptor for the tachom-
eter drive is used.
2) If the reflecting tape is glued to the revolving body
and the photoelectric probe used, revolutions can
be measured without contact with the revolving
body.

2-2-30
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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


Nut

2-2 5 799-203-8230 1 Metric (M22 x 1.5), marked"M"
2-2

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

2-2-31
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

How to use:
For a more complete description, refer to the Op-
eration Manual accompanying the Multi-Purpose Ta-
chometer.
1. Measuring engine speed
1) 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 servicemeters
engine speed outlet secure with a ring nut.
Pay special attention to the system of units

2-2 (mm vs. inches) used at the point of at-
tachment.
2-2

50 - 300mm

3) Apply power and select either the H- or L-range.

When the tone sounds and the triangular mark
appears on the display, take a reading.

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

2-2-32
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Sample Application 1: Measuring the speed of a fan

1) Attach a piece of reflective tape to the outermost
part of one of the fan blades.
2) Mount the magnetic base on any convenient sur-
face (for example, hood, side cover, radiator
cover, or main frame) and adjust the flexible sup-
port so that the light from the probe shines both
roughly parallel to the fan's axis of rotation and
roughly perpendicular to the fan blade's twist.
3) Further adjust the probe position so that the light

2-2 shines on the center of the tape. 2-2

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

4) This concludes the setting up procedure. Proceed

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

Note: Electronic flashes, fluorescent lights, and

other intermittent light sources can interfere
with measurement; never allow them to en-
ter the probe!

2-2-33
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-790-2600 TAKEOFF DRIVE

2-2 2-2

Applicable model and component parts

Ass'y part No. Model
102
114
795-790-2600

No. Parts No. Parts name

-

1 6735-21-3410 Adapter 1 1
2 6732-21-3220 Seal 1 1
3 6736-21-7120 Seal 1 1
4 6735-21-3450 Adapter 1 1
6735-21-3420 Hub 1
5
6742-01-5498 Hub 1
6 6732-81-5250 Washer 2 2
7 6735-21-3430 Bolt 2 2

2-2-34
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

ADAPTER 795-116-1330 FEELER GAUGE

and others

2-2 2-2

Purpose: Tool No. and specifications:

To be used when measuring the engine rotation Weight
No. Tool No. Specifications
(rpm) on PC01. (kg)
1 795-116-1330 0.35, 0.65 mm 0.1
Component parts: 2 795-125-1210 0.43, 0.8 mm 0.1
Tool Yammer Diesel 3 795-125-1310 0.3, 0.5 mm 0.1
No. Part No. Q't y
description number
4 795-125-1320 0.4, 0.6 mm 0.1
1 795-126-1110 Gear unit 124250-91400 1
5 795-125-1330 0.25, 0.45 mm 0.1
2 795-126-1120 Packing 124250-91412 1
6 795-125-1360 0.33, 0.71 mm 0.1
3 01010-50630 Bolt 26117-060322 1
7 795-125-1370 0.35, 0.5 mm 0.1
4 01010-50616 Bolt 26117-060162 2
8 795-125-1380 0.37, 0.90 mm 0.1
5 01602-20619 Washer 23414-06000 3
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
Note) When reading the indicator, do carefully be-
cause the rpm indicated by the indicator is
1/2 the engine rpm.
Purpose:
How to use: The feeler gauge is used for adjusting the valve
1) Remove the can gear cover from the gear case. clearance.
2) Install packing (2) and gear unit (1), then flex cable
(6) to gear unit (1). How to use:
3) Fit the digital tachometer or Hustler type tachom- Insert the gauging section to adjust the valve clear-
eter to flex cable (6), then measure engine rpm. ance.

2-2-35
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-203-7000 FUEL LEAK CHECKER

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 after
nozzles are installed to an engine.
3) To check the function of a nozzle assembly when
the color of the engine is abnormal or when the
engine output is inadequate.

2-2 2-2

Specifications
1) Applicable engine: 105 and 155 series
Cummins 743 series
Weight: 15 kg 2) Range of pressure: 0 to 40 MPa
3) Fuel to be used: ASTM D975 No.2
4) Size of case: 465 350 170 mm

Component parts
No. Part No. Tool description Q't y Remarks
1 799-203-7100 Checker 1 Main body of fuel leak checker
2 799-203-7200
Valve unit 1 Valve section above the checker body
3 799-203-7400 Gauge assembly 1 With self-seal coupling, 40 MPa
4 799-203-7410
Gauge 1 40 MPa
5 799-203-7500 Gauge assembly 1 With self-seal coupling, 2.5 MPa
6 799-203-7510
Gauge 1 2.5 MPa
7 799-203-7600 Adapter assembly 1 With a complete set of auxiliary parts
8 799-203-7610
Hose 1 L=2.0 m Hose adapter: 14 1.5
9 799-203-7620
Nipple 1 For 743 series engine, 3/8-24UNF-2A, 14 1.5
10 799-203-7630
Plug 4 For 743 series engine, 7/1 6-24UNS
11 799-203-7640
Plate 1 For 743 series engine
12 799-203-7650
Bolt 2 For 743 series engine, 01011-51400
13 799-203-7660
Nut 2 For 743 series engine, 01580-11411

2-2-36
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 21 799-203-7750 Tube assembly 1 Straight tube, 14 1.5, 14 1.5 2-2

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 a

nozzle holder

2-2-37
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

790-551-1290 NOZZLE TESTER

2-2 2-2

Applicable model: All Komatsu engine models

Component parts:
No. Tool No. Part Name Q't y Weight (kg)
1 799-203-7700 Nozzle tester 1 7.3
2 799-203-7750 Tube ass'y 1 0.044
3 799-203-7760 Tube ass'y 1 0.042
4 799-203-7770 Tube ass'y 1 0.080
5 799-203-7780 Tube ass'y 1 0.084
6 799-203-7810 Tube ass'y 1 0.049
7 799-203-7820 Tube ass'y 1 0.087

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

How to use:
Install the tube assembly and nipple to the nozzle
tester, screw the fuel injection nozzle in the end,
apply fuel oil pressure, and measure the injection
pattern and injection pressure.

Example of use:

2-2-38
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

Applicable model: 102, 114 engine

Purpose:
Leak Test Kit
Pressure test the element to check for leaks.

Component parts:
Description Specifications Q't y
O-ring Parker #2-2 17 3
Thumb screw 5/16-18 1 1/4 Iong (steel) 4
Nut. Std. hex 5/16-18 8
Washer, plain flat 5/16 4
Plate, Ieakage test See detail 1
Regulator, pressure Watts # R384-02C 1
Gauge, pressure Watts 0-160 P.S.1. 1-5/8 O.D. 1
#4-2MP / #4-2MP (1/8 Male NPT)
Hose (gates) 1/4 Duraflex hose 15" Length / 1
EQUIV.
Sheet, instruction 1

Example of use:

2-2-39
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-471-1450 ADAPTER

Example of use

2-2 8 x 1.25 - Rc1/8 2-2

Applicable model: SAA6D125E-5

Purpose:
Used to measuring fuel pressure.

795T-690-1110 BLOCK

Applicable model: SAA6D170E-5

Purpose:
Used to measuring EGR valve oil pressure.

2-2-40
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

790-828-1000 FUEL METER Component parts:

2-2 2-2

Weight: 7 kg

Applicable model:
In-line fuel-injection pump (Bosch type)
Distribution fuel-injection pump (Rotary type)
Note) The fuel cannot be measured on the
Cummins type.
Purpose:
Measuring the fuel consumption.
1) Cumulative fuel consumption (Unit: L)
Indicates cumulative fuel consumption from the
start to the end of measurement.
2) Cumulative fuel consumption rate (Unit: L/H) No. Part No. Part description Q'ty
Indicates cumulative fuel consumption from the - 790-828-1000 FUEL METER 1
start to the end of measurement converted to the
1 790-828-2100 METER 1
rate of consumption per hour.
3) Instantaneous fuel consumption rate (Unit: L/H) 2 790-828-2370 STRAP 1
Indicates the fuel consumption per second con- 3 790-828-2380 COVER, meter 1
verted to the rate of consumption per hour. (The 4 790-828-2400 CABLE ASS'Y 2
indicated value changes every second.)
5 790-828-2500 CABLE ASS'Y 1
4) Measurement time (Unit: H-M-S)
Indicates the duration from the start to the end of 6 790-828-2600 CABLE ASS'Y 1
measurement in hours-minutes-seconds. 7 790-828-5100 SENSOR ASS'Y 2

Power source 8 07271-01430 HOSE 3
1) D.C. 12 24 volt
9 07206-11014 JOINT, bolt 6
2) Built-in chargeable battery
(Chargeable from 12 24V battery) 10 07005-01412 GASKET 12
11 790-828-6100 JOINT 4
Example of use:
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

2-2-41
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

790-829-1030 FUEL MATE

(General purpose type fuel meter)

2-2 2-2

This FUEL MATE is an electronic fuel consumption

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

2-2-42
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Thus, the FUEL MATE has the following distinctive

features.
1. The fuel consumption can be simply measured
during the actual operation of a vehicle.
2. The small-sized, lightweight, handy type can be
carried and used anywhere.
3. The meter is computerized for high precision
measurement and computation.
4. In diesel engines, the qty of fuel return in opera-
tion is large. Such qty of fuel return is subtracted
in its computation.
5. Hourly fuel consumption ratio, Km/L or Km/H, is

2-2 obtained by the computer. 2-2

6. Measured values can be printed out.
7. This FUEL MATE is of an interactive type simple
in control and provided with a self-diagnostic func-
tion.
In an engine abundant in the return fuel, a fuel
8. The power source (6 24 V) is available from a flow sensor is installed on the return side, too.
cigarette lighter at the operators seat. The bat-
tery cigarette lighter at the operators seat. The
battery provided internally can also be used as
the power source.
Main 1. Measuring items Fuel consumption qty: 0.01 9999.99 L
specifications and measuring Measuring time (When the external power
(Main body) range source is used): 99H 59M 59S
Fuel consumption ratio (Momentary consump-
tion ratio & mean consumption ratio)
When sensor Type A is used: 0.1 300.0 L/H
When sensor Type B is used: 0.1 40.0 L/H
Distance covered per lit. of fuel
(computed value): 0.1 99.9 Km
Mean vehicle speed (computed value): 0.1 999.9 Km/H
Measuring-over alarm function is also provided.
2. Power source Battery built-in, AA, Ni-cd, 4 pcs. When charged fully, serviceable for 10 hrs.
External power source
on-board battery (DC6 - 24 V), connectable to a cigarette lighter plug,
AC adapter as accessory and low-voltage alarming function are also
provided.
When the external power source is in use, the additional charge of the built-
in (internal) battery can be carried out.
3. Keyboard A flat-faced switch, shift-key type
When Distance button is depressed, shifted-in is available, and when
Compute button is depressed, shifted-out is obtained.
The Numeral key is used to input the distance covered at the time of the
shifted-in.
The Clear key is used to correct the numerical input.
The Reset button is used to prevent the erroneous keyboard operation,
if any. When kept depressed for 2 seconds or longer, the meter is actuated.
Only while the Consumption qty button and the Consumption ratio
button are kept down simultaneously, the momentary fuel consumption
ratio is displayed in the real time.
4. Operating temp- 0 to 50C
rature range:
5. Exclusive EPSON C-40
printer:
6. Main body 150 115 42 mm approx. 520 g
dimensions and
weight:

2-2-43
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Construction and Component Part No.

2-2 2-2

No. Part No. Part Name Q'ty Remarks

Over-
790-829-1030 Fuel mate 1 All component parts listed below are contained in a portable case.
all
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
Power source cable ass'y (for connecting FUEL MATE and the printer
11 790-829-6700 Cable ass'y 1
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)

2-2-44
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

In this FUEL MATE, The fuel consumption qty and the time can be mea-
the following data are computed and displayed, by sured, by classifying them into the fuel consumption
putting the signals measured with a flow sensor in- per haul cycle for a dump truck or into the fuel con-
stalled on the fuel pipe into an 8-bit computer, then sumption per truck loading by a loading machine.
by computing and converting the fuel consumption Such data classified by the traveling condition as Up-
qty per second (cc/sec). hill road, Downhill road, Flat road etc., can be ob-
 The consumption ratio (momentary L/H) varying tained through the keyboard control.
momentarily according to the vehicle operating
condition. If the Print button is depressed without depressing
 The total consumption qty (cumulative L) from the Stop button, the following data during the period
the starting of measurement up to the present. from the starting of measurement to the starting of
 The mean hourly consumption ratio from the start- printing will be printed out.

2-2 ing (mean L/H), and (1) Fuel consumption qty L 2-2

 The time which has elapsed from the starting of (2) Measuring time H.M.S
measurement (H.M.S) (3) Hourly consumption qty L/H
If the distance covered by a test vehicle is input In this case, the data measured up to that time are
with the ten-key, the following data will be com- cleared up and the measurement is newly started for
puted and displayed. new data.
 The distance covered per lit. (Km/L), and
 The mean vehicle speed during the measure- If the Print button is depressed after depressing the
ment. Stop button, the following data during the period from
the starting to the end of measurement are printed
All these measured data are printed out, excluding out.
the momentary consumption ratio. Then, if started again, the measurement will be re-
started continuously from the data obtained just be-
The measurement starting and stopping pauses can fore the restarting. In this case, the input data of the
be simply obtained by means of push buttons on the distance covered will be cancelled.
key-board. Thereby, the net actual operating hours (1) Fuel consumption qty L
and fuel consumption qty can be measured. (2) Measuring time H.M.S
(3) Distance covered (Input data) Km
(4) Hourly consumption qty L/H
(5) Distance covered per lit. Km/L
FUEL MATE Functional Block Diagram (6) Mean vehicle speed Km/H

2-2-45
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

(Caution)
In some of engines (KOMATSU 125 Series) equipped
with Model EP-9 fuel injection pump mfd. by NIPPON
DENSO, the fuel consumption measurement may
sometimes become difficult due to such a slight re-
verse flow in the fuel flow as caused by the feed pump
structure.
When installing flow sensors in a fuel meter, such a
preventive measure as described herein should be
taken before the measurement of the fuel consump-
tion. The installation procedure of fuel flow sensors is
described in detail in the Operation Manual. On ma-

2-2 chines listed up in Table 1, such a check valve as 2-2

shown in Fig. 1 may become necessary as a mea-
sure against the reverse flow. Therefore, it is advised
that necessary parts be prepared, referring to the parts
list in Table 2.

1.Machines where the measuring errors with fuel Table 1 Examples of machines requiring a check valve
meter are liable to occur due to the reverse fuel for the measurements
flow Machine Engine Machine Engine
Table 1 right gives machines requiring a preventive Model Model Model Model
measure of a possible errors in data measured with D50A, P-17 D75S-5
fuel meter due to the slight fuel reverse flow. D53A, P-17 D83E-1, -SS
On these machines, the fuel consumption should PC300-3 S6D125-1
D60A, P, S-8
be measured by adding such a check valve as in- 6D1 25-1
D65A, P, S-8 PC400-3
troduced herein to the fuel line. On machines other
GD600R-3 LW250-1
than those listed in Table 1, too, if the abnormally
high fuel consumption data are encountered, the GD605A-3. -5 EM655A-A SA6D125-1
measurements should be made by adding a check
valve to them in the same manner.

2-2-46
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

2.Preparation of check valve for measuring the fuel consumption

Prepare those parts which are listed in Table 2 and set up as shown in Fig. 1.

Table 2 Parts required to prepare a check valve for measuring the fuel consumption
Ref.No. in
Part Name Part No. Q'ty
Fig.1
Check valve DKKC Part No. 131424-1520
1 pc.
(Overflow valve) ND Part No. 090310-0080
Nut 790-829-8130 1 pc.
* Gasket KES Part 07005-01412 4 pcs .
Hose KES Part 07271-01430 1 pc.

2-2 *
* Joint bolt KES Part 07206-11014 1 pc.
2-2

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

3. Installation of fuel flow sensors Marks show the positions where the sensors are
Connect a sensor on the fuel supply side marked S installed. If the measurement is difficult due to the
and another sensor on the fuel return side marked R fuel reverse flow, and a check valve at a position
marked
.

3-1 Installation of sensors in an engine where much fuel return is encountered:

(1) Where fuel returns directly to the fuel tank (on WA450, PC400-3, CAT769C, etc.)

2-2-47
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

2-2 2-2

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

3-2 Installation of sensors in an engine where the fuel return is slight;

(1) In the normal case (on WA400, PC200-, & PC300-3, etc.)

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

2-2-48
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

4. Hint on the measurement of fuel consumption 5. Types of fuel meters

ratio Such fuel meters as listed In Table 3 have been intro-
When measuring the fuel consumption ratio, measure duced up to date. At present, the FUEL MATE (Part
the cumulative fuel consumption ratio during a given No. 790-829-1030) developed on the basis of a simple
period of time, with the indicated momentary fuel con- type fuel meter (Part No. 790-828-1000) is recom-
sumption q'ty used as a reference data. The reason mended. Hereafter, this general purpose fuel meter.
is such that the indicated momentary fuel consump- "FUEL MATE"
tion q'ty is liable to be unstable, because the velocity only are manufactured to meet the market trends.
of fuel flow varies subtly, even if the engine revolution
remains stable.
This symptom does not pause a problem of the fuel
meter proper and the fuel flow sensor but indicates

2-2 an ill-effect caused by the structure of a fuel feed 2-2

pump.
Consequently, the stable data can be obtained rather
by measuring the cumulative fuel consumption ratio
for several minutes.

Table 3 Types of fuel meters

Simple type fuel meter General purpose type fuel meter
Types of fuel meters "Fuel meter" "FUEL MATE"
Part No. 790-828-1000 Part No. 790-829-1030
In addition to the engines in I ) and 2).
1 ) Diesel engines with a line type (Bosch)
3) Gasoline engines of an electronic fuel
Applicable range injection pump
injection type
(Engine Model) 2) Diesel engines with a rotary type
4) Gasoline engines of a carburetor type
injection pump
1 ) Cumulative consumption q'ty In addition to the items in 1) thru 4) at the left,
Q'ty of fuel consumed during the period 5) Mean machine speed
from the starting to the stopping of The mean machine speed computed on the
measurement (unit: Iit.) basis of the distance traveled during the
2) Cumulative fuel consumption q'ty period from the starting to the stopping of
Hourly consumption q'ty converted from measurement
the cumulative consumption q'ty (unit: Km/H)
Items to be (unit: L/H) 6) Distance covered-fuel consumption ratio
measured 3) Momentary fuel consumption q'ty Distance covered per lit. of fuel consumed
Hourly consumption q'ty converted from (unit: Km/L)
the consumption q'ty per second
(unit: L/H)
4) Measuring time
The period of time elapsed from the
starting to the stopping of measurement
(unit: H.M.S.)
A result of measurement on each item is A result of measurement on each item is
Output results of
indicated by a digital display (in its unit). indicated in its unit by a digital display and at
measurement
the same time, output by a printer.

2-2-49
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

795-231-1110 R-GAUGE
and others Tool No.
Refer to the following list.
Select the necessary gauge.

2-2 2-2

Purpose:
to use for measuring the finished R dimensions at
fillets after correcting the crankshaft by means of
grinding in the engine crankshaft reconditioning
operation. (See Fig. 1.)

Tool NO. and applicable engine.

Tool No. 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.

2-2-50
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

Example of R-Gauges

2-2 2-2

How to use a R-gauge

Measurement of the radius of the journal fillet of a
crankshaft corrected by grinding should be made in
the following point with a fillet measuring R gauge and
a pencil type flashlight.

(1) Set a R-gauge for the max. value to the journal

fillet. Then, apply the light from the back of the R-
gauge. At this time, clearance profiled like a cres-
cent can be seen with the gauge in contact with
the fillet at 2 points or the gauge comes in the full
contact with the fillet. In such a case, the radius
at the fillet is within the limit of the max. value,
which is acceptable, (See Fig. 3.)
When the R-gauge (for the max. value) and the
fillet are in contact only at one point, the radius of
the fillet exceeds the max. value, which is not
acceptable.
(2) In the same measurement as described above
and made by the use of the R-gauge for the min.
value: when the R-gauge and the fillet are in con-
tact at one point or in the full contact, the fillet
radius is acceptable. (See Fig. 4.)
When they are in contact at two points, the fillet
radius will be less than the min. value, which is
not acceptable.

2-2-51
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

799-201-2202 BOOST GAUGE KIT 795-471-1200 GAUGE ASSY

2-2 2-2

Weight: 0.93 kg

Applicable model: All engine

Applicable model: 125E-2, 170E-2, 3 engine
Purpose: 140E-2
Used this kit when measuring the air charging pres-
Purpose:
sure to the engines.
Used this gauge assy when adjusting the fuel in-
jection timing of the engines.
Component parts :
No. Part No. Part Name Q'ty Remark Component parts :
1 799-101-5160 Nipple 1 PT 1/8 No. Part No. Part Name Q't y Weight (kg)
2 799-401-2610 Hose 1 1 791-503-1190 Magnet stand 1 1.4
799-401-2311 Gauge 1 2 791-503-1060 Dial gauge 1 0.12
799-401-2291
Gauge 1 -760-1500 mmHg 3 795-471-1210 Joint 1 0.01
3
790-261-1130
Coupling 1 4 795-471-1220 Measure point 1 0.002
790-261-1140
Packing 1 5 795-471-1230 Rod 1 0.185

For engines on the WA600-1 and WD600-1, use a

dial gauge available on the market (with the gage scale
of 0.01 through 20 mm) as the component part item
No. 2.

2-2-52
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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

From D375A-5, 170-series engine have been modified to -3 conform to Tier 2 engine emission regulation
of EPA in USA.
In the future, 170 Series engines for models to be introduced to the market will be mounted with -3 one
after another. For injectors, fuel pumps, various sensors, controllers, etc. composing the engine fuel
**
system (so called HPI), units and parts common to Cummins engines have been used. So, troubleshooting
units to be used are partly common to those of Cummins Engine Company.
Therefore, we are going to introduce troubleshooting units to be used on 6D170-3 series engines.

2-2 ** HPI : High pressure injection 2-2

1. Newly Set Units
Komatsu Part Cummins Part
No. Part Name Application
No. No.
1 795-799-5510 - Heat gun To be used for troubleshooting of injector.
2 795-799-5550 3376859 Adapter To be used for measuring pressure of fuel pump.
3 795-799-5560 - Oil pressure gauge To be used for measuring pressure at fuel pump inlet.
4 795-799-5520 - Socket (S) To be used for troubleshooting of engine speed sensor.
To be used for troubleshooting of water temperature sensor, air
5 795-799-5530 - Socket (C) intake temperature sensor and exhaust gas temperature
sensor.
6 795-799-5540 - Socket (A) To be used for troubleshooting of temperature sensor.
To be used for troubleshooting of atmospheric pressure
7 795-799-5460 3824774 Cable
sensor, fuel pressure sensor and actuator pressure sensor.
To be used for troubleshooting of lubricating oil pressure
8 795-799-5470 3824775 Cable
sensor.
To be used for troubleshooting of timing pressure sensor, air
9 795-799-5480 3824776 Cable
intake pressure sensor and pump pressure sensor.

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

2-2-53
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

2-2 2-2

Temperature characteristic when the 2nd cylinder Temperature characteristic when all cylinders are
is abnormal normal

Note : The heat gun has the Part Number set by Komatsu but is not a special one and is generally available
in the market. So, if you have any heat gun, you need not purchase a new one. If you purchase it, we
recommend Part Number MX2 of Raytek Corp. or equivalent.
(For Raytek Corp., contact http://www.raytek.com)

2-2. Diagnosis of Pump Acceptability by Measuring Pump Inlet and Outlet Pressures
When the pump inlet pressure is normal (below 27KPa) and the pump outlet pressure at each engine
speed is not more than the standard value, the pump is considered to be in the normal state. For
the detail, please refer to the Shop Manual.
When the inlet pressure is more than the specified value, the fuel filter is supposed to be loaded or
the piping is supposed to be clogged or loosened or fuel may be leaking from somewhere. When
the outlet pressure is lower, any of the pump body, pressure sensors or the regulator valve is
supposed to be defective.

1) Adapter (Part Number : 795-799-5550)

The fuel pump is equipped with a quick coupler for measuring pump inlet and outlet pressures. This
coupler does not accept our usual couplers in connection, and we have newly set the adapter, which
accepts our usual quick couplers and enables to measure pump outlet pressure easily with our usual
pressure gauges. Since pump inlet pressure becomes negative, the negative pressure gauge to be
introduced in the next paragraph is necessary for measurement.
Adapter Komatsus Quick Coupler

Quick coupler for measuring fuel pump inlet Quick coupler for measuring fuel pump outlet
pressure pressure

2-2-54
 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

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 0
to 0.1MPa.

2-2 2-2

2-3. Diagnosis of Electronic Control System

The 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) Socket
This socket is connected to a sensor to check disconnection or short-circuit of the sensor.
Part Number How to use
Diagnosis Example of Intake Air Temperature Sensor

795-799-5540 795-799-5530
795-799-5520

2) Cable
This cable is used in the same way as a T-adapter and for measuring output voltage of a sensor. Also,
this cable is used for checking disconnection or short-circuit of a sensor.
Part Number How to use
795-799-5460 795-799-5480 Diagnosis Example of Atmospheric Pressure Sensor

795-799-5470

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 SECTION 2 GROUP 2
MEASURING AND DIAGNOSTIC TOOLS ENGINE TOOLS

3) T-adapter for DEUTSCH Connector

DEUTSCH connectors have been used for connection of engine controller and engine to machine
body. The T-adapters for DEUTSCH Connector, which we introduced you in our previous Parts &
Service Operation Tips, can be used for connection.
Parts & Service Operation Tips No. d
1 799-601-9350 T-adapter (40 poles) Adapter for controller SEKN5015
2 799-601-9290 T-adapter (31 poles) Adapter for body connection connector SEKN5005
3 799-601-9270 T-adapter (21 poles) Adapter for body connection connector SEKN5005

2-2 (1) T-adapter for Controller 2-2

799-601-9350 Connection to controller of D375A-5

(2) T-adapter for Body Connection Connector

799-601-9270 Body Connection Connector

799-601-9290

Connection of T-adapter to Body

Connection Connector

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