Using the 198-4240 Digital Pressure Indicator Group{0599, 0738, 0788, 1000, 3000, 4000, 5000, 6000} Caterpillar

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Introduction

Important Safety Information

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Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION".

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tool capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Safety Section

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The Power Train Electric Drive System will contain hazardous voltage levels during machine operation and for a short period of time after engine shutdown. Do not remove any covers that will expose energized high voltage electrical components while the engine is operating. Any type of maintenance on the following components can only be performed after the Power Train Electrical System Service Shutdown procedure has been followed: High voltage compartments in the inverter cabinet The rear axle housing that contains the electric drive traction motors The generator The retarding resistor grid, the grid blower motor and the grid system cabling The excitation field regulator The high voltage cables and connection enclosures Failure to follow these instructions could result in personal injury or death.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

General Information Section

Introduction

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198-4240 Digital Pressure Indicator Gp

The 198-4240 Digital Pressure Indicator Gp is a self-contained, microprocessor-based meter that reads and displays vacuum, pressure, differential pressure, and temperature. The indicator uses sensors and cables to allow technicians to take remote measurements from a system being tested.

The 198-4234 Digital Indicator reads pressure in units of pounds per square inch (psi) or Bar. To obtain units in kPa (kilopascal), add two zeros behind the Bar reading. (For example 35 Bar = 3500 kPa)

The indicator has four pressure connectors. The first connector is used for measuring pressure, differential pressure, and vacuum. The remaining three connectors are used for measuring pressure. A Type-K thermocouple temperature probe is also provided to measure temperature.

Note: A 187-3547 Quick Disconnect Coupler As is being used on CAT products for testing pressures over 41386 kPa (6000 psi). The couplings supplied with the pressure pickup sensors will no longer connect to these current style nipples. The 251-9600 Pressure Sensor Gp is designed to fit the High-Pressure Quick Connect Nipple. An optional 6V-8076 Elbow and 3J-1907 O-Ring Seal is available for applications where clearance is a problem.

Components

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198-4240 Digital Pressure Indicator Gp

Specifications

Pressure Pickup Sensors

The 198-4237 Pressure Sensor Gp (0 TO 3,445-KPA (0 TO 500-PSI)) (Blue) is used to measure both vacuum and pressure.

The 198-4238 Pressure Sensor Gp (0 TO 34,450-KPA (0 TO 5,000-PSI)) (Red) is used to measure pressure .

The 198-4239 Pressure Sensor Gp (0 TO 41,369-KPA (0 TO 6,000-PSI)) (Orange) is used to measure pressure.

The 251-9600 Pressure Sensor Gp (0 TO 68,900-KPA (0 TO 10,000-PSI)) (Orange) Pressure Pickup Sensor is used to measure pressure.

Note: The 198-4237, 198-4238, 198-4239, and 251-9600 Pressure Pickup Sensors can only be used with the 198-4234 Digital Pressure Indicator.

Pressure pickup sensors are temperature sensitive. Whenever possible, the pressure pickup sensor should be allowed to warm up to the system temperature. Install the pressure pickup sensor or sensors into the test port or ports of the machine approximately 5 minutes prior to running a test. Zero the sensor or sensors before starting the test.

Operation Section

Functions

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198-4234 Digital Indicator (PRESSURE) (1) Pressure or Vacuum Connector. (2) Pressure Connector. (3) Pressure Connector. (4) Pressure Connector. (5) K-Type Thermocouple Temperature Probe Connector. (6) Min/Max Function Key. (7) Delta Zero Function Key. (8) Sensor Zero Function Key. (9) Sensor Select Function Key. (10) Range Select Switch.

Pressure or Vacuum Connector

The Delta 1 pressure connector (1) can be used for vacuum readings using a blue pressure pickup sensor only. the connector can also be used for pressure readings using the blue, red, or orange pressure pickup sensors.

Differential (Delta) Pressure Connectors

To check differential pressure, use both pressure connectors (1) and (2). Differential pressure can only be measured in pounds per square inch. Range selector switch (10) must also be turned to the Delta 500 psi or the Delta 5000 psi setting. To measure differential

1. Connect extension cables and pressure pickup sensors to the pressure connectors marked Delta 1 (1) and Delta 2 (2) .

2. Select the proper pressure range on range select switch (10) .

3. Zero the sensors as described in the ""Delta Zero Function Key" " section.

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NOTICE
Do not press the delta zero key with pressure on the system.

4. Press DELTA ZERO function key (7) to store the delta zero in memory.

5. Apply pressure to the system.

6. The display will indicate the pressure of Delta 2 in relation to Delta 1.

For example: If Delta 1 is 300 psi and Delta 2 is 250 psi, the display will show -50 psi, indicating that Delta 2 is 50 psi less than Delta 1.

Pressure Connectors

The 198-4234 Digital Indicator can be used to test low and high-pressure systems by connecting pressure pickup sensors into the system being tested. When a pressure pickup sensor is connected to one of the pressure connectors (1), (2), (3), and (4) of the digital pressure indicator, the proper pressure range must also be selected using range select switch (10). Failure to select the proper range for the sensor will result in inaccurate readings.

Pressure pickup sensors are available in blue 0 to 35 Bar (0 to 500 psi), red 0 to 350 Bar (0 to 5,000 psi)' and two orange sensors, 0 to 413 Bar (0 to 6,000 psi) or 0 to 700 Bar (0 to 10,000 psi). These colors correspond to the colors on the pressure indicator (range select switch).

Temperature Connector

1. Plug the 8T-0458 Thermocouple into thermocouple connector (5). Make sure the large blade of the probe fits into the larger connector opening.

2. Select the degrees Celsius or Fahrenheit setting with range select switch (10) .

   Note: The temperature probe must be plugged into the indicator prior to selecting temperature setting. Plugging in the probe allows the microprocessor in the indicator to calibrate the thermocouple prior to the test.

Min/Max Function Key

Minimum and maximum readings are recorded using MIN/MAX key (6). To use this function, continue as follows.

1. Apply pressure to the system.

2. Press MIN/MAX key (6). The MIN/MAX icon will illuminate at the top right of the LCD display, indicating the readings are being recorded.

3. To display minimum readings, press the MIN/MAX key again. The MIN icon will be illuminated and only the minimum readings will be displayed.

4. To display maximum readings, press the MIN/MAX key again. The MAX icon will be illuminated and only maximum readings will be displayed.

5. To scroll between the minimum and maximum readings, continue to press the MIN/MAX key.

6. To exit this function, press and hold the MIN/MAX key for 2 seconds. This turns off the MIN/MAX icon and returns the display to real-time (live) readings.

Delta Zero Function Key

A temporary zero may be set to monitor pressure drops or rises using this function. To monitor a pressure drop or rise, continue as follows.

1. Stabilize the system pressure.

2. Press DELTA ZERO key (7). The LCD will now display "0 PSI".

3. Any decrease in pressure will be displayed as negative pressure, increases will be displayed as positive pressure.

4. Press the DELTA ZERO key again to exit the function.

Sensor Zero Function Key

Note: Pressure pickup sensors are temperature sensitive. Whenever possible, the pressure pickup sensor should be allowed to warm up to the system temperature. Install the pressure pickup sensor(s) into the test port(s) of the machine approximately 5 minutes prior to running a test. Zero the sensor(s) before starting the test.

This function key sets a true zero point prior to testing. Each pressure pickup sensor must be zeroed prior to a test to ensure accuracy. To zero a pressure pickup sensor, continue as follows.

1. Turn range select switch (10) to the appropriate pressure range setting. The "Sensor 1" icon should be illuminated at the top of the LCD display. If another sensor is shown, press SENSOR SELECT key (9) until the "Sensor 1" icon is displayed.

2. Press SENSOR ZERO key (8) to zero sensor 1.

3. If multiple pressure pickup sensors are used, select the next sensor by pressing the sensor select key.

4. When the desired pressure pickup sensor icon is illuminated, press the SENSOR ZERO key to zero the sensor.

5. After all the pressure pickup sensors are zeroed, pressure may be applied to the sensor and the pressure reading will be displayed on the LCD.

Sensor Select Function Key

To select a pressure pickup sensor, continue as follows.

1. Press SENSOR SELECT key (9) and toggle between sensor connectors 1, 2, 3, and 4.

2. When selecting functions, press the related key for one second. This timing feature guards against misreading function changes caused by accidentally pressing a key.

Range Select Switch

The range select switch (10) selects the pressure range and provides a color code for the pressure pickup sensor being used (blue, red, or orange). Readout units on the indicator are in PSI or BAR ( BAR x 100 = kPa). The range select switch is also used to select temperature in degrees C or F.

When changing ranges, turn the range select switch to the OFF position for 2 seconds to clear the memory before selecting the next range.

Always select a higher range pressure pickup sensor than the expected system pressure. If a higher accuracy reading is required, then select a lower range pressure pickup sensor. If the pressure range selected is too low, the indicator will display an over limit (OL) indicator.

The ranges labeled in blue on the digital pressure indicator are low pressure, 0 to 35 Bar, 0 to 100 psi, or 0 to 500 psi, and are used with the blue pressure pickup sensor

The ranges labeled in red on the digital pressure indicator are medium pressure, 0 to 350 Bar, or 0 to 5000 psi, and are used with the red pressure pickup sensor.

The ranges labeled in orange on the digital pressure indicator are high pressure, 0 to 413 Bar, or 0 to 10,000 psi, and are used with the orange pressure pickup sensor.

Operation

The 198-4234 Digital Indicator must be attached to at least one extension cable and pressure pickup sensor or thermocouple temperature probe. Up to four extension cables and pressure pickup sensors may be used at one time.

Temperature Test

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NOTICE
The connector on the thermocouple has a narrow and wide blade. The connector will plug into the indicator in only one direction.

1. Plug the temperature probe into thermocouple connector (5) .

2. Select the Celsius or Fahrenheit setting with range select switch (10) .

3. Install the appropriate temperature probe fitting on the machine test port for available fittings refer to 1 of this manual.

4. The indicator is now ready to take temperature readings from the machine being tested.

Pressure Test

1. Attach a pressure pickup sensor to a 198-4236 Adapter Cable As . Attach the 6V-4144 Quick Connect Coupler to a test fitting installed on the machine.

2. Connect the extension cable to one of the pressure connectors on the pressure indicator

3. Install the appropriate pressure pickup sensor fitting on the machine test port (for available fittings refer to 1 of this manual.

4. The indicator is now ready to take pressure readings from the machine being tested.

Maintenance Section

Maintenance

Keep the indicator, cables, and connections free of oil, dirt, and grime.

To avoid damage to the indicator, keep the indicator away from sources of high temperatures of above 66° C (150. F)or direct sunlight. The life of the temperature probe is also reduced when subjected to temperatures outside the normal operating range of −40° C (−40F) to 1350° C (2500 F).

Service

If the Digital Pressure Indicator does not work correctly, contact Dealer Service Tools for information on how to obtain service.

Dealer Service Tools provides the user of this indicator with a 1 year warranty from the date of purchase. If abuse is determined to be the reason for failure, the warranty will be void. Any out of warranty repairs will be charged to the owner. For any product support questions about your indicator contact your Cat dealer or Dealer Service Tools