Using the Inspection Head (ISH) Ultrasonic Reader for G3600, 3600, and C280 Connecting Rod Bolts{0769, 1218} Caterpillar

Engine: All 3600 All C280 All G3600

Introduction

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

This Special Instruction explains the operation of the Intellifast Ultrasonic IHS Reader. The Intelifast IHS Ultrasonic Reader is used to measure the load on the 369-7181 Bolt As connecting rod bolt.

Illustration 1	g02488678
"LoadProbe 3000B Intellifast Reader"

The memory stick, that can be found in one of the pouches of the carrying case lid, contains the complete users manual. The users manual documents the operation of the device in more detail. The users manual also explains the process of saving the files to text and then saving the files to a memory stick. The files can then be downloaded to an Excel spreadsheet for review and storage.

Quick Start Procedure For Using the Ultrasonic Reader

The "LoadProbe 3000B Intellifast Reader" uses a Windows XP-based program. A Microsoft compatible mouse can be plugged into one of the USB ports. Using the mouse makes navigation through the program quicker and easier.

Note: Always use the same sequence for recording the engine bolt loads. Using the same sequence will simplify finding a particular bolt for inspection at a later date. A typical sequence would be to start with cylinder (1) and proceed to the last cylinder.

1. Charge the batteries in the battery charger before continuing with this procedure.

2. Plug the charged batteries into the left side of the reader.

   Note: The batteries can be changed while using the reader. The reader will operate on a single battery.

   Note: The reader can also be powered using the AC power supply. The power supply operates on 120 VAC at 60 Hz or 240 VAC at 50 Hz.

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Illustration 2	g02745059
(1) Ultrasonic sensor connector (2) Temperature sensor connector (3) Communication cable connector (4) Bar code reader connector

3. Plug the four cables into the right side of the reader.

   1. The ultrasonic sensor signal cable (1) plugs into the front receptacle that is labeled "Probe". Ensure that the red dot on the connector is on top and aligns with the dot on the reader.

   2. The temperature sensor (2) plugs into the next receptacle that is labeled "PT100".

   3. The communication cable (3) plugs into the 9-pin serial connection.

   4. The bar code reader (5) plugs into one of the USB ports on the right side of the reader.
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   Illustration 3	g02745060
   (5) Ultrasonic sensor

   5. Uncoil the cables and be sure that ultrasonic sensor (5) is exposed to free air and not in contact with any metal.

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NOTICE
Do not unplug any of the cables while the unit is powered up. The ultrasonic sensor could be damaged. Turn the unit OFF before unplugging any cables.

4. Turn on the reader by pressing the "Power" button. Wait for Win XP to load and then start the software.

   The "Store STOF" box should be highlighted. If the box is not highlighted, use the arrow or the tab keys to toggle to the "Store STOF" box. The box will then be highlighted.

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Illustration 4	g02502217
Information box

5. Press the "Enter" button. The "Enter" button is the lower button on the right side of the main control panel, which is marked with an arrow.

   An information box will pop up telling you to remove the contact pin from the PMTS sensor for calibration of sensor cable (0). Refer to Illustration 4. Do not remove the pin from the sensor. Verify that the sensor magnetic face is not in contact with anything.

6. Press the "Enter" button. The probe will automatically calibrate.

7. The small print at the bottom of the screen will display the joint label "Caterpillar_Conrods_10988." This is where you enter the engine serial number or the project name.

   1. Use the arrow keys or the mouse to select the "Set Project" button. Press the "Enter" key or the left mouse button.

   2. Select the "Create" project button. Press the "Enter" key or use the left mouse button.

   3. Use the alphanumeric keys to enter the serial number. Use the left arrow key to move to the extreme left of the file name box. Erase the (*) but keep the (.lp3) file extension. Enter the serial number with the .lp3 file extension.

   4. To enter numbers, type the number. To enter letters, click the "1..A" key. The key will light up. To use capital letters, click the "1..A" key and the "a..A" key. Both of the keys will be lite up and the letters will be capitalized.

      Note: To erase an entry, use the back arrow key. Always leave the .lp3 file extension.

   5. After entering the serial number, press the "Enter" key or select "Save" and use the left mouse button.

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Illustration 5	g02745199
"Periphery" drop-down menu

8. Use the "Tab" key or the mouse to select the drop-down "Perighery" menu. Verify that both the "PT100 Thermometer" and the "Inspection Head with Barcode Reader" are checked. If not, select the items.

9. You will be taken back to the "Measure" screen and the "Start Measurement" box will be highlighted. If the "Start Measurement" box is not highlighted, use the "Tab" key (– – >) to highlight the "Start Measurement" box.

10. Press the "Enter" key and the "Start Measurement" box will appear. Select the "Manual" box. If the "Manual" box is not highlighted, use the "Tab" key to select the "Manual" box and press the "Enter" key.

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Illustration 6	g02502257
Set bolt box

11. Press the "Enter" button and the "Set Bolt" box will appear. Verify that the serial number or project name is listed at the bottom of the screen. Also, verify that the "Bolt" number box is highlighted and the "Joint ID" box is not highlighted. Refer to Illustration 6.

    None of the three check boxes that are below should be checked. If one of the boxes is checked, tab to the checked box and click "Enter" to erase the check. Tab back to the "Bolt" number box. The bolt ID number must be highlighted.

12. In order for the bar code to be read properly, the end of the bolt must be clean. Clean the bolt with solvent and wipe until dry. Verify that there is no lubricant in the pocket under the lip of the bolt that could interfere with the bar code reader.

13. Place the temperature sensor on the balance pad of the number 1 cylinder connecting rod.

14. Place the IHS reader over the nut for bolt number 1. Orient the body of the reader toward the balance pad on the connecting rod. Press the center button on the reader one time.

    After 2 seconds, the "IDENT" indicator will be green. If the indicator is red, the bar code did not register. Clean the bolt or reposition the reader slightly and try again.

    When the bar code is registered, the bolt ID number changes to the current bolt and the "IDENT" indicator is green.

15. Continue to hold the OHS reader firmly in position for 5 seconds.

    When the reading of the bolt load is complete, the "LOAD" indicator turns green. Proceed to the next bolt.

    If the "LOAD" indicator is blue, the bold load was not completed or the reading is out of range. Clean the bolt or reposition the reader slightly and try again.

16. After all of the bolts have been successfully read, move the temperature sensor to the balance pad on the connecting rod for the next cylinder. Repeat the procedure.

17. After all of the bolts have been successfully read, use the "Measure" label on the upper task bar. Select "Measure" and select "Off Line".

    You can use the data window to scroll through the recorded bolt loads in order to verify that the bolts are within the acceptable range.

18. Move the cursor to the "Profile" label in the upper task bar. Select "Save As Text".

    The data is saved in a text document located in the following directory:

    C:\Program Files\Intellifast\PFWT\Data Protocol
    

    The file can be transferred to a memory stick. The file can be imported into an Excel spreadsheet for retention.

Contact Information for "Intellifast LoadProbe 3000B" Sales and Service: