Using The Inspection Borescopes 1U5268 and 8T9290 Borescopes Caterpillar

Using 1U5268 and 8T9290 Inspection Borescopes

All Caterpillar Machines

Reference: Guideline for Reusable Parts:

The large inspection borescope with light source can be used to make a visual inspection of internal surfaces of many Caterpillar products. This inspection can be done, in most cases, without disassembly of the product. The large borescope is 6.5 mm dia. (.256"dia.) and 580 mm (23.0") long. Large borescope has a 0 degree direction of view and the 1U5269 Mirror Tube adapter with a 7.24 mm diameter (.285"dia.) provides a 90 degree direction of view. These two components give the flexibility necessary to inspect most internal areas. One of three light sources is used to provide illumination for the borescope in areas where there is insufficient light for normal viewing and inspection; 1U5266-110 VAC Light Source, 1U5267-220 VAC Light Source or 1U5265 portable Light Source (with 110 VAC battery charger).

NOTE: Before a component is inspected, the borescope operator should get the "GUIDELINE FOR REUSEABLE PARTS" for the component that he is inspecting. An index of the "GUIDELINES FOR REUSEABLE PARTS" is given in Form SEBF8029-09.

1U5268 Borescope With:

- 1U5269 Mirror Tube Adapter- 6V9459 Fiber Optic Light Cable- 6V9461 Right Angle Viewing Adapter- 1U5265 Battery Light Source- 1U6345 Instrument Case

8T9290 Borescope

The smaller 8T9290 Borescope is 7.9 mm dia. (.312"dia.) and a length of 240 mm (9.5") and a view angle of 90 degrees from the borescope axis. This light source is nonrechargeable battery powered.

Description And Parts of 1U5268 Borescope

1. 1U5268 Direct View Borescope

2. 1U5269 Mirror Tube - 90 degree direction of view

3. 6V9459 1830mm (72") Fiber Optic Light Cable

4. 6V9461 Right Angle (90 degree) Viewing Adapter

5. 1U6345 Instrument Case

6. 1U5265 Battery Light Source

--- Not Shown ---

7. 1U6346 Foam Packing (Inside Case)

8. 1U5266 Light Source - 110 Volt

9. 1U5267 Light Source - 220 Volt

10. 1U5792 Lamp, 21 Volt (1U5266 & 1U5267 Replacement)

11. 6V9465 Eye Piece

12. 6V9468 Camera Adapter (Olympus OM1 & OM2)

1. 1U5268 Borescope (Forward Oblique) has a 0 degree forward direction of view and a 60 degree field of view as shown.

2. 1U5269 Tube Mirror Provides An Inverted Image 90 degree direction of view as shown when used with 1U5268 Borescope.

Cleaning Mirror Surface:

3. 6V9459 Fiber Optic Cable (3) is used to transmit light from the borescope light source to the borescope.

4. 6V9461 Right Angle Viewing Adapter (4) gives the operator a 90° direction of view. This adapter, when installed on borescope (1), can be used in areas with limited access to the regular eyepiece on the borescope.

NOTE: If 6V9461 Right Angle Viewing Adapter or 1U5269 Mirror Tube are used, the imaged will be reversed.

Description And Parts Of 1U5266 & 1U5267 Light Source

1U5266 Or 1U5267 Light Source

The light source is a compact, lightweight unit which provides illumination, supplied by a 150 watt lamp, to the input end of the light cable, has a variable intensity over a wide range. The intensity is controlled by varying the voltage output of a solid state dimmer located on the left side of the front panel. The light cable plugs into a 1/4" receptacle in the center of the front panel and is retained by an internal snap ring located in the bushing. Cooling is supplied by a fan which is turned on-off through the switch function of the solid state dimmer.

The lamp circuit is protected with a 2 amp fuse or circuit breaker which is replaceable/resetable from the front panel.

Lamp Replacement

The lamp replacement is easily made by removing the back panel with a screwdriver blade or a thin coin engaging the 1/4 turn (CCW to open) fasteners on each side. 1U5792 Light Bulb is available for replacement purposes for either 1U5266 or 1U5267.

Show/hide table

Never touch a hot lamp with bare hands.

The lamp can easily be removed by pulling the lever on the right side of the ceramic receptacle rearward to push the lamp "up" towards the top of the light source. The lamp can then be removed by lifting upwards out of the slots which engage the pins. After lamp has been removed, be certain to push the lever forward toward the front of the box before attempting to insert a new lamp.

To insert a new lamp, align the pins to the slots, parallel to the bottom and push lamp downwards, making certain the reflector engages the springs in the front of the lamp receptacle.

Replace rear door before inserting input plug into the power source.

Description And Parts Of 1U5265 Light Source (Rechargeable From 110 VAC)

1. 1U5265 Battery Light Source 2. Light/Power Cord 3. Battery Charger

Always keep the light source in a warm dry place when it is not in use.

Allow 16-20 hours to recharge 1U5265 Battery Light Source to full charge, item (1).

Always recharge the battery as soon as possible after use. However, do not leave the battery on charge continuously when not in use.

Recharge access uses the same phono. plug jack connection at the battery that the light uses.

Using The 1U5268 Borescope Assembly

NOTE: Never leave a borescope in a component access hole when it is not being used. The borescope can easily get bent or damaged. Be sure the borescope and accessories are in the locations in the instrument case before the lid is closed. Damage could result if the cover is closed on a borescope or an accessory.

The features of the borescope are; light output lens, objective lens (1), fiber optic cable connection (2), focusing adjustment (3), eyepiece with removeable 6V9465 Rubber Eyepiece (4), 1U5268 borescope (5), inspection 90 degrees from borescope axis with 1U5269 Mirror Tube (6).

To use the borescope, connect fiber optic cable (8) to fiber optic cable connection (2) and to light output connection (9) on borescope light source (10). Turn on light source using light intensity control (11).

Insert the borescope into the component being inspected. Look into the borescope and turn focusing adjustment (3) until the object comes into clear focus. Adjust light intensity control (11) until the desired light intensity is reached (110 & 220 VAC operation only).

To inspect a cylinder and valves in a diesel engine, remove the fuel injection line and the fuel injector or fuel injection nozzle from the engine. To inspect a cylinder and valves on a natural gas engine, disconnect the spark plug and remove the spark plug from engine.

Slowly lower the borescope into the cylinder until it touches the piston. Lift the borescope off the piston approximately 6.0 mm (.25"). Be careful not to bend the borescope probe.

Look into the eyepiece and turn the focus adjustment until the cylinder and valves come into clear focus. Adjust the light intensity control (110 & 220 VAC powered only) on the borescope until the desired intensity is reached.

Rotate the borescope and light cable 360 degrees and visually inspect all components; piston, cylinder walls, valves, cylinder head and gaskets (precombustion chamber and glow plug on some diesel engines). Make a comparison between what is seen and the correct Reuseability Guideline for the component being inspected.

Using the 8T9290 Borescope

This borescope group is designed to see into inaccessible areas as combustion chambers. It will fit into a bore as small as 8mm (.32") and reach 240mm (9.5") into the cavity. It is equipped with a battery operated lamp. The battery handle can be attached directly to the scope, or it can be remotely coupled to the scope by using the extension cable supplied (This is helpful in most close quarter situations).

The borescope couples directly to the battery handle by pushing the three-grooved fitting on the scope into the top of the handle. It will lock automatically. To remove, rotate the knurled collar (1) counterclockwise and pull the scope off.

To focus on an image, rotate the knurled sleeve (located just forward of the eyeguard) clockwise for distant objects, and counterclockwise for close objects. This borescope will focus from infinity to within 3.2mm (.125") of the tube surface. To operate the lamp, push the white button (2) in and rotate the black chamfered ring (3) clockwise to brighten the lamp. It is best to use the minimum lamp intensity required to do the job to obtain maximum battery life. Always turn the light off while the scope is not in use. Remove batteries when not in use for prolonged periods to avoid damage from battery leakage.

NOTE: This borescope is not intended for photographic use.

Lamp replacement - 1U6862 Lamp Assembly (6). Turn the tip (6) counterclockwise to remove the lamp assembly. Replace after wiping the polished surfaces clean (Use cotton swab and 1/2 solution of alcohol).

Battery replacement - use 3 "C" cells (1.5V). Remove bottom cap. Place batteries with positive (+) poles towards the electrical connection. Replace cap.

Objective window (4) wipe with a clean dry cloth, if grease and dirt persist, use a clean dry cloth or cotton swab, moistened lightly (do not saturate) with alcohol to remove dirt, then dry with a clean dry cloth.

Final Drive Gear And Differnetial Inspection

NOTE: Only a few final drive gear teeth can be seen at one time, so in order to inspect a machine quickly, it is recommended that both the left and right final drives be inspected at one time. After all the visible gear teeth on each final drive gear are inspected, the machine can be moved slightly to bring another section of the gear into view.

Remove the oil fill plug from the final drive housings. Assemble the borescope, light cable and light source as shown earlier in this instruction.

Put the borescope into the oil fill opening; adjust the light intensity on the light source (if applicable) as needed. Inspect the gears for broken or cracked gear teeth and the wear pattern. Inspect the other final drive gears the same way. Remove the borescope from the final drive. Move the machine slightly so the next section of the gear teeth can be inspected. Do not move the machine with the borescope in the final drive housing. Inspect both final drives at the same time.

Internal components of differentials can be inspected without draining the fluid and removing covers if the oil fill plug will give access to the inside of the compartment. Put the borescope through the oil fill plug opening to check for cracks or broken teeth on the gears. The wear pattern on the gear teeth can also be checked for misalignment or signs of other types of deterioration.

Additional Accessories For The 1U5268 Borescope

1. 6V9467 MAGNIFIER (2X)

When magnification is needed, 6V9467 Magnifier (1) can be used. With the 6V9467 Magnifier the view is magnified two times on this borescope (2) but the field of view is reduced to 1/2 the previous field of view.

NOTE: The magnifier shows a reversed image from the previous image seen through the borescope.

To install magnifier (1) on borescope (2). Remove rubber eyepiece (3) from borescope (2). Install magnifier (1), then install rubber eyepiece (3) on magnifier (1).

Photography

Photographs can be taken through the larger 1U5268 borescope. Photos of components can be taken and compared to the Reuseability Guide or to another component. This will help determine if the part should be replaced. Photos of damaged components can be kept in the machine history folder for reference at a later date. This will help determine if the part has deteriorated and should be replaced or repaired.

Olympus OM-1 and OM-2 cameras are recommended for borescope photography. These automatic cameras average the available light evenly over the entire film plane, and not just on one spot in the film. A 6V9468 Adapter is used to connect the borescope to the body.

Any major brand 35 mm SLR (single lens reflex) camera can be used to take borescope photos. Adapters for different brand cameras are available from Lenox Instruments Inc. The chart that follows has the Lenox Instrument part number for adapters for different cameras. For best results use a camera with a clear viewing screen.

Black and White film is recommended over color film with "hand processing" for best possible quality of image representation.

40960 & 41489

Pentax K, Astra 35, Catalina Reflex, Columbia Console, Edixa Reflex, Grand-reflex, Hexacon, Mamiya Reflex CP, Mamiya TL, Pentacon, Praktica, Pracktiflex Ritacon, Rival, Yashica Penta J3, J4, J5, Zeiss

40950 & 41491

Topcon, Exa, Exacta all SLR models, Mamiya NP, Mamiya Prismat, Mamiya Sekor Series SLR

40958 & 41492

Automex III, Automex Sensorex Miranda

40957 & 41493

Minolta

WD-12MP

Mamiya Prismatic Series

WD-10PB

Petriflex - all SLR models, Petriflex 7 (bayonet), Petri

WD-T90F

Olympus, OM-1 and Om-2

40956 & 41490

Nikon, Rikon Singlex

41819

Canon

WD-T7KF

Konica Flex F

WD-T8YR

Yashica Pentamatic Series

WD-11PS

Petri Penta B, Petri Penta V2 Mamiya Reflex CP

WD-13KA

Konica, Auto Reflex

PT #880011-1

Corbina, Praktina FX

Available from Lenox Instrument Company Inc., 265 Andrews Road, Scottsville Industrial Park, Trevose, Pa., 19047.

NOTE: The individual components of the 1U5268 borescope are intended as replacement / service parts for the previous 6V7000 group that is no longer available under the 6V7000 part number.

Following are some hints for borescope photography:

A) Photography through a borescope requires additional considerations based on the film speed (ASA), the viewing distance, and amount of reflected light into the borescope.

B) A typical light source exposure with 400 ASA film would be 1 sec. exposure at a viewing distance of 1 1/2-2" in a medium reflectance location (inside an engine cylinder) with full intensity on the lamp control.

C) The best way to establish the correct exposure is to use a Polaroid back on the 35mm camera and take several test photos. This adapter is available as an optional accessory from Lenox Instrument Company. When using an Olympus OM-2 "automatic" exposure camera, the only requirements are to set the proper film speed and have the image in sharp focus. The correct exposure will occur when the camera is tripped, the "auto" exposure system will compute the amount of available light striking the film during exposure and stop the exposure up to a 2 minute setting. This is adequate for most borescope applications.

D) To aid the operator in viewing the image through the camera viewer, a special bright screen (unfrosted) is available from Lenox Instrument Co. If the viewing distance is longer than 1 1/2"-2" a rule of thumb is to double the exposure time for each 1" increase in the viewing distance. If for some reason the light intensity is poor then double the exposure time. (This will be the case when using DC voltage power for the light source.)

E) To reduce image motion during long exposures (over 1/30 sec.) use a cable release to avoid touching the camera, and a tripod or some fixed installation to support the additional camera weight on the borescope.

F) To insure optimum photographic quality, we recommend three exposures for each subject. Use one full stop under-exposure (1/2 × Exp. Time) when in a dark, poorly illuminated area. This will show details often missed when visually inspecting through the borescope.

G) When further assistance is required or special camera accommodations are needed, contact Lenox Instrument Co.

NOTE: During borescope photography, if long exposure times are experienced, try adding more light in the area of the borescope tip if possible. If this is not possible with the equipment shown in this instruction, a special high intensity light source is available from Lenox Instrument Company (order part number F11000/150 Light Source).

Remove the camera lens and install adapter (1) (see the chart for the adapter part number) on the camera where the lens was removed. Remove the rubber eyepiece from borescope (2). Install the borescope on adapter (1). The borescope focus control now becomes the camera focus.

To enlarge the image on the film plane, 2X Telextender (3) can be used between adapter (1) and the camera. Telextender (3) will enlarge the image two times the original size. This will give a larger, more detailed photograph.

Polaroid Back For 35 MM Cameras

If you want instant photo results, a Polaroid film back can be attached to most major brand 35 mm cameras. With this system the guess work is taken out of borescope photography. The list that follows gives the cameras that Lenox Instrument Company has Polaroid film backs for:

Canon A-SeriesOlympus OM 1 & 2Nikon FM-FENikon F, F2, F3Cannon F1 (old and new style)Cantax 137, 139 & RTSMinolta X700Leica R-3, R-4Pentax ME-MFPentax MX

To use the Polaroid back on a 35 mm camera, remove the original back from the camera. Install Polaroid Film back (1) on the camera in place of the former back. Do not put 35 mm film in the camera at location (A). Install film in back (1) as shown in the manufacturers operating instructions.

Videotape Camera Borescope Adapters

Videotape camera borescope adapters are available for videotape filming of an inspection. These adapters work just like the camera adapters shown earlier in this instruction. Contact Lenox Instrument Company, Inc. and specify the type of videotape camera that you have and the size of the vidion. They can supply the type of videotape camera adapter that you need.

NOTE: Taking a video picture through a borescope is very difficult because of the low light levels.

Warranty / Repair

Both the 1U5268 and 8T9290 Borescope systems are warranted to be free from defects in material and workmanship for a period of 12 months from the original purchase date from Caterpillar Inc.

If repair is necessary, contact Lenox Instrument Company Inc., for information on obtaining required service.

For Further Application Information, CALL:

OUTSIDE ILLINOIS 1-800-542-TOOL

INSIDE ILLINOIS 1-800-541-TOOL

CANADA 1-800-523-TOOL

Or WRITE:

Borescopes less than one year old will be repaired under warranty (EXCEPT FOR ABUSE). Cost of out-of warranty repairs will be charged to the owner.