- Engine: All 3600 Engines All C280 Engines
Introduction
Do not perform any of the following procedure until you have read and understand all of the information. The following procedure explains the operation of the Intellifast® Ultrasonic IHS Reader. The Intellifast Ultrasonic IHS Reader is used to measure the load on the 369-7181 Bolt As , connecting rod bolt.
Parts Needed
Table 1 contains the part numbers needed for these instructions.
Note: A computer is also needed for this torque tool group to operate.
| Qty | Part Number | Part Description |
|---|---|---|
| 1 | 438-3338 | Torque Tool Gp |
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| Illustration 1 | g03681996 |
(1) Data Acquisition Unit (DAU) (2) Software Compact Disc (3) Battery charger (4) Ethernet cable (5) Measurement head (6) Temperature probe | |
Installation
- Push and hold the "POWER" button (2) on the DAU (3). Watch for the WLAN green indicator light (1) to flash.
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| Illustration 2 | g03677434 |
(1) WLAN green indicator light (2) Power button (3) DAU | |
- Push the reader button (4) and watch for the three red indicator lights (5) to turn on.
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| Illustration 3 | g03686036 |
- Connect to the DAU wireless network.
- Power on the computer.
- Click on the wireless network utility.
- Click on "MyWLAN" to connect.
- If unable to connect to "MyWLAN", use an ethernet cable for connection between DAU and the computer.
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| Illustration 4 | g03684932 |
- Click on the "Intellifast" icon on the desktop.
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| Illustration 5 | g03677483 |
- Enter your name into the "Username" field and click "OK".
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| Illustration 6 | g03677522 |
- Click on the "Cable Calibration" tab.
- To configure the cable, click the "Configuration" tab. Illustration 8 will appear, prompting removal of the contact pin from the sensor for calibration of the measurement cable. Click the "OK" tab.
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Illustration 8 g03686083
- The "Cable Calibration" tab will change from red to green once calibrated.
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| Illustration 7 | g03677535 |
- If the inspection head is configured properly, there will be a green check mark in the box. If there is a red "X" in the box, click the red "X" to change to a green check mark. If the inspection head will not properly configure, start over at Step 1.
- Verify that the "COM-Port" field valve is "6".
- Verify that the "Pt 100" field is a red "X". This field is for manual temperature inputs.
Note: A red "X" indicates that the inspection head is using the provided temperature probe. If the temperature probe is damaged or not being used, the red "X" should be clicked to display a green check mark. The temperature of the connecting rod should be obtained with an infrared temperature gun. The value is then put into the "Pt 100" field for the most accurate results. The "Pt 100" should contain a number and never be left blank.
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| Illustration 9 | g03677832 |
- Click on the "Create Project" tab.
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| Illustration 10 | g03686509 |
- Complete the following fields of the screen shown in Illustration 11.
- Enter the serial number of the engine in the "Projectname" field.
- Enter the number of cylinders in the "Number of Cylinders" field.
- Click the "Create project" tab.
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| Illustration 11 | g03677897 |
- Use solvent to clean the bar code on each rod bolt. Wipe the rod bolt dry after cleaning.
- Click on the "Measurement" tab.
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| Illustration 12 | g03678005 |
- Position the crankshaft for a vee configuration engine on cylinder 1 Bottom Dead Center (BDC). All cylinder rod bolts can be read in this position.
Note: Always start with cylinder 1 connecting rod and work in sequence until reaching the last cylinder.
- Place temperature probe (7) on the side of the connecting rod cap that is being measured as shown in Illustration 14.
Note: On vee configuration engines, the odd cylinders will have the number 1 bolt on the upper left-hand side of the cap. Even cylinders will have the number 1 bolt on the lower right-hand side of the cap. Number 1 bolt is always located on the tab and serial number side of the connecting rod cap.
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| Illustration 13 | g03678016 |
Vee configuration sequence for measuring bolts | |
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| Illustration 14 | g03713489 |
In-line configuration sequence for measuring bolts (6) Measurement head (7) Temperature probe | |
- To measure the bolts on a connecting rod, place the temperature probe (7) on the side of the rod cap and the measurement head (6) on bolt (1). Align the cables over the center of the connecting rod cap. Press the reader button and wait for the LED to light up green. Repeat for bolts (2), (3), and (4).
Note: If the reader head needs cleaned use contact cleaner or isopropyl alcohol and a cotton swab. Other solvents can damage the plastic. To capture the information and therefore turn on the green LED indicator lights, several attempts may be needed for the measurements.
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| Illustration 15 | g03686112 |
Note: Use Illustration 15 for the measurement head LED references.
- Record the measurements and verify that the readings are between 215 kN (48334 lb) and 275 kN (61823 lb).
- Click on the "Project" tab.
- Select the appropriate serial number and click on "Print".
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| Illustration 16 | g03678064 |
- Verify that the readings are within tolerance and place the printout with the appropriate documentation. Table 2 contains the tolerances for the bolts.
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Table 2 Expected Load Ranges (Nominal Load Is
245 kN (55078 lb)Bolt Type Minimum Maximum Do Not Use New Bolt Unloaded
−5 kN (−1124 lb)
5 kN (1124 lb)New Bolt Loaded
215 kN (48334 lb)
275 kN (61822 lb)New Bolt Loaded After 1000+ Hours
195 kN (43837.95000 lb)
255 kN (57327lb)Used Bolt Unloaded (1)
1 kN (224 lb)
20 kN (4496 lb)
20+ kN (4496+ lb)Used Bolt Retorque (1)
235 kN (52830 lb)
295 kN (66319lb)Show/hide table( 1 ) Used bolt is defined as a bolt having 1,000 or more service hours.