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 sys-
tem tools
Group 4: Undercarriage tools
Group 5: Electric and electronic system
tools
Group 6: Others
 GROUP 1

GENERAL PURPOSE TOOLS

 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

799-101-1502 DIGITAL THERMOMETER

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Specifications Component parts:

(1) Display temperature -99.9 1299C
range: No. Part No. Part Name Q'ty Remarks
(2) Accuracy: 0.2% (measured value) 1 79A-262-1910 Meter 1
(3) Temperature range 0 40C 1A 790-261-1180
Dry cell 2 SUM3
for use: (20 80% RH)
(4) Temperature sensor: 2 79A-262-1920 Sensor 1
K (chromel-alumel)
thermocouple 3 79A-262-1930 Sensor 2
(5) Display: LCD (Liquid crystal) 4 79A-262-1940 Adapter 2 Up to 199:
(6) Power: 3V (SUM3 x 2)
(7) Length of use: Approx. 80 hours 5 790-262-1980 Adapter 1
(8) Dimensions: 352(W) x 146(D) x 90(H)mm 6 799-101-1510 Case assembly 1
(9) Weight: 1.06 kg
Extension
7 799-201-1110 Cable 1
Features cable
(1) Compared to conventional thermistor tempera- Exhaust
temperatures
ture gauges, it can measure minus temperatures 8 6215-11-8180 Sensor 1
measurement
down to 99.9C below zero. use
(2) It has four channels, so up to four places can be
measured by operating the selector knob (selec-
tor switch).
(3) The display unit is compact and light, so mea- Optional part:
surement can be carried out when holding it in 79A-262-1971 Sensor (for surface temperatures)
one hand.
Note:
799-101-1501 is changed to 799-101-1502 in order
to add Cable No. 7 and No. 8.

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MEASURING AND DIAGNOSTIC TOOLS 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 Part No.: 79A-262-1971

Measurment range: -50C to +280C Measurment range: to +300C

Purpose: Purpose:
Inserted through the oil filler port to measure the oil Used for measuring the surface temperatures of brake
temperature. discs, wet-type track bushings, etc.

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 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

799-101-6700 THERMO LABEL

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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.
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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 dis-
play, the label will lose its resistance to water
and heat.

Example

Component parts:

Original Color after

Part No. Temperature range Color change precision Q't y
color change
50C - 55C - 60C - 65C - 70C
799-101-6710 2C 1
(122F) - (131F) - (140F) - (149F) - (158F)
75C - 80C - 85C - 90C - 95C
799-101-6720 2C 1
(167F) - (176F) - (185F) - (194F) - (203F)
100C - 105C - 110C - 115C - 120C
799-101-6730 2C 1 White Black
(212F) - (221F) - (230F) - (239F) - (248F)
125C - 130C - 140C - 150C - 160C
799-101-6740 2C 1
(257F) - (266F) - (284F) - (302F) - (320F)
170C - 180C - 190C - 200C - 210C
799-101-6750 2C 1
(338F) - (356F) - (374F) - (392F) - (410F)
* Each part number consists of a set of 20 thermo labels.

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MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

799-101-6500 THERMO CRAYON

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How to use:
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.
(1) Remove the thermo crayon from its plastic bag, in-
sert it in the holder, and secure it with the clip.
(2) The thermo crayon is used to measure the tempera-
ture 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 speci-
fied transmission of the thermo crayon.
(3) The thermo crayon is adversely affected by humid-
ity. When not using it, keep it in its plastic bag.

Component parts:

Part No. Color of crayon Q'ty Specified temperature C(F) Precision

799-101-6510 Green 1 100 (212)
799-101-6520 Pale red 1 150 (302) 2C
799-101-6530 Pale red 1 200 (392)
799-101-6540 Green 1 255 (491)
799-101-6550 Purple 1 300 (572)
799-101-6560 Yellowish orange 1 365 (689)
799-101-6570 Green 1 430 (806)
799-101-6580 White 1 490 (914)
799-101-6590 Light brown 1 545 (1013) 1.0%
799-101-6610 Bluish purple 1 590 (1094)
799-101-6620 Reddish purple 1 645 (1193)
799-101-6630 Orange 1 700 (1292)
799-101-6640 Green 1 855 (1571)
799-101-6650 Gray 1 1,010 (1850)

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 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS 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 Purpose
For checking the operation of the clutch piston of For checking the final drive case for oil leaks (for
the Torqflow transmission. field use).

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MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

Component parts:

No. Part No. Tool description Q't y Remarks

799-301-2200 Adapter assembly 1 KIT (A)
1 799-301-1310
Rubber tube 1
799-301-1550
Rubber tube 1
2 799-301-1320
Plug 1
3 799-301-1330
Nipple 1
4 799-301-1340
Bushing 1
799-301-2300 Check valve assembly 1 KIT (A), KIT (B)
5 799-301-1350
Tee 1

2-1 6 799-301-1360
Check valve 1 2-1

7 799-301-1540
Coupler 1
8 799-301-1410
Nipple 1
799-301-1700 Valve assembly 1 KIT (A)
9 799-301-1420
Coupler 2
10 799-301-1510
Valve 1
11 799-301-1390
Regulator valve 1
12 799-301-1410
Nipple 1
799-301-1900 Adapter assembly 1 KIT (B)
13 799-301-1530
Adapter 1
14 799-301-1520
Coupler 1
15 799-302-1110 Gauge 1 KIT (B) 0 - 0.2 MPa
16 799-301-1380 Gauge 1 KIT (A) 0 - 1 MPa
17 799-302-1141 Tube 1 KIT (B)
18 799-302-1161 Adapter 1 M30, P=1.5
19 799-302-1181 Adapter 1 M36, P=1.5
20 799-302-1211 Adapter 1 M24, P=1.5
21 799-302-1221 Adapter 1 M42, P=1.5
22 799-302-1230 Adapter 1 M12, P=1.5
23 799-302-1240 Adapter 1 M16, P=1.5
24 799-302-1290 Plug 1 PT1/4
Width length height
25 799-301-1590 Tool box 1
350mm290mm85mm

Reference pressure
Reference
Section to be measured Checking for oil leakage
pressure
0.026MPa Keep the ref. pressure as is for 10 seconds
Final drive
{0.25 kg/cm2} to see that no gauge pointer lowers.

Parts such as roller (carrier 0.1MPa

Same as above
and track rollers, and idler) {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 pres-
sure.
Block the tip of the rubber tube (1) with a finger
and control regulator valve (11) to attain the stan-
dard 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 pis-
ton works by opening and closing valve (10).

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 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE 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

2-1 final drive case, dismount the breather and block
the opening with a plug (24).
2-1

3) Increase the final drive case pressure up to the
standard pressure by using a manual pump (bi-
cycle pump for instance) available on the mar-
ket and check for oil leaks.

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 compres-

sor 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 pres-
sure 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 stan-

dard 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 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE 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 pres-
2-1

sure by using a manual pump (bicycle pump, for
instance) on the market and check for oil leaks.

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

* Models and applicable adapters table (rollers and idlers)

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

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 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

799-101-1403 THICKNESS METER

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This SERVICE TOOL GUIDE introduces a high-

performance 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 : Liquid crystal digital
2) Min. unit : 0.1 mm
3) Accuracy : 0.1 mm
4) Measurement range : 1.5 250 mm (steel)
5) Sonic speed measurement range : 1000 12,000 m/s
6) Power source : SUM3 alkali dry cell battery 1 (1.5V)
(Life : Min. 90 hours continuous)
7) External dimensions : 69(W) 144(D) 29.5(H) mm
8) Weight : 1.76 N {180 g}
9) Temperature when using : 5 50C
10) Metals for measurement : Steel, aluminium, copper, brass, etc.

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MEASURING AND DIAGNOSTIC TOOLS 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 79A-264-0021 79A-264-0091
1. Measurement range 0-300N {0 to 30 kg} 0-500N {0 to 50 kg}
2. Minimum scale 0.25N {0.25 kg} 5N {0.5 kg}
3. Stroke 10 mm 10 mm
4. Dimensions (with case) 224 x 64 224 x 64
5. Weight (with case) 17.65N {1.8 kg} 17.65N {1.8 kg}

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 SECTION 2 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS GENERAL PURPOSE TOOLS

799-101-8210 ROUGHNESS
and others GAUGE
Purpose
These roughness gauges allow the roughness (rms:
root-mean-square) of machined surfaces to be eas-
ily 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 re-

2-1 working. 2-1

To o l N o . a n d ap p lic ab le pro c es s

Pa rt No . P art name A pplicab le machining pro cess Rema rks

Smooting a nd polishing with sa nd-
799-101-8210
S tanda rd spe cimen of surface pa per; surfa ce grind ing ; sha ping 2-pc. set
roug hne ss (rms)
799-101-8220 Fa ce milling ; milling
S tanda rd spe cimen of cylind rical
799-101-8250 Grinding; turning
o utside surface roughness (rms)
Note ) Rms: root-mean-sq uare

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 GROUP 1
MEASURING AND DIAGNOSTIC TOOLS 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 : IEC Pub. 60804: 2000 Type 2, JIS C 1502-1990
2) Microphone : 1/2-inch prepolarized condenser type UC52
3) Measurement ranges : 28 to 130 dB (A), 33 to 130 dB (C), Six ranges: 10 dB step
4) Frequency range : 20 8000 Hz
5) Weightings : A and C, Flat
6) Dynamic characteristics : Fast and Slow
7) Measurement modes (display) : LP (Instantaneous /Maximum level), Leg/LE (Manual/Preset mea-
surement 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 : 128 62 dot
11) Outputs : AC & DC
12) Ambient conditions : Temperature: 10 to +50C, Humidity: Approx. 10 to 90% RH
13) Power : IEC R6 or ANSI AA battery 4, LR-6: 34 hour, R6P: 14 hour
14) Dimensions : 260 (H) 76 (W) 33 (D) mm
15) Weight : Approx. 400 g (including batteries)
16) Standard accessories : Windscreen 1, Battery R6P 4, Jack cover 1, Carrying case 1,
Hand strap 1

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