Usage:
The pickup group can be easily installed on any fuel injection line. The only preparation necessary is the removal of a small amount of paint from the injection line where the pickup group is to be clamped. The injection line speed pickup group can be used either for temporary testing or for permanent installation.
NOTE: Modifications must be made to some earlier 6V2100 Multitachs before the speed measurement can be taken accurately. See page 2 for this procedure to determine if modifications must be made to your multitach.
Components Of The 6V4950 Injection Line Speed Pickup Group
1. 6V6114 Pickup 2. 6V6113 Amplifier
Modification Of 6V2100 Multitach
(1) Check your 6V2100 Multitach; if there is an "A" at the location shown, no modifications are needed to the multitach. If there is no "A", modifications must be made to the multitach. See Special Instruction Form SEHS8224 "TROUBLESHOOTING AND REPAIR OF THE 6V2100 MULTITACH", page 23, for the update modifications needed on the multitach. These modifications, if needed, must be made to the multitach to get the correct accuracy of the speed readings.
Optional Items For Use With The 6V4950 Injection Line Speed Pickup Group
1. 6V2100 Multitach A programmable digital tachometer used as the speed readout for the injection line speed pickup group.
2. 6V4190 Autoprogrammer An accessory for the 6V2100 Multitach which provides automatic programming whenever the multitach is powered and when switching between PH (photo) and MAG (magnetic) inputs.
3. 5P7366 Power Cable Used for connecting 11 - 40 VDC power to the multitach.
4. 6V2198 Extension Cable Photo input extension cable used for connecting 6V4950 Pickup Group to the 6V2100 Multitach.
Specifications
Operation Instructions
IMPORTANT: To avoid personal injury and possible damage to the equipment, always observe the following warnings and cautions when using the injection line speed pickup group.
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All bare metal locations on the fuel injection lines must be repainted after removal of the pickup group and before the engine is put back into service. If this is not done, the bare metal fuel injection lines can corrode. This could result in a fire if fuel is sprayed on hot engine parts. |
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Always install the speed pickup group in a location as far from hot engine parts (such as the exhaust manifold, turbocharger, etc.) as possible. |
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Keep the cables and amplifier away from hot engine parts. |
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Do not over-tighten the thumbscrew on the pickup; tighten by hand only. Do not use any tools to tighten the thumbscrew or damage to the pickup may result. |
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Do not use abrasive materials to clean the inner bore of the pickup contact or damage to the pickup may result. |
(A) Installation Of The Pickup
1. Select a location for mounting the pickup on one of the engine's fuel injection lines. Although the pickup will work on any straight section of fuel injection line, the location selected should have sufficient clearance to permit installation of the pickup without touching other parts of the engine. This location on the injection line must have a minimum of 15 mm (.6") of clearance with adjacent injection lines and a minimum of 25 mm (1.0") clearance under the line as shown above. Do not attempt to install the pickup on a curved section of the injection line.
2. Use a knife or emery paper to remove paint from the injection line at the pickup mounting location. Remove the paint completely from around the line in a band approximately 10 mm (.38") wide as shown above. Be careful not to nick or otherwise damage the injection line.
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Repaint the fuel injection line after the pickup has been removed and the engine has cooled. Do not leave the bare metal of the injection line exposed. See the warning on page 3. |
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3. Loosen thumbscrew (1) on the pickup by turning it c counterclockwise. Open pickup (2) and place it over the fuel injection line at the location where the paint has been removed. Close the pickup over the line and tighten the thumbscrew finger-tight. Do not use any tools to tighten the thumbscrew or damage to the pickup may result.
4. After the pickup has been installed as shown above, check to be sure it is not touching any part of the engine except the injection line on which it is installed. Connect ground clip (3) on the pickup to bare metal on the engine.
5. Connect pickup signal cable (4) to amplifier (5). Make sure signal cable (4) does not contact any hot parts of the engine; if necessary fasten the cable temporarily in place. Make sure amplifier (5) does not contact the engine.
6. Connect output connector (6) of the amplifier to the PH (Photo) input connector on the 6V2100 Multitach. If a longer cable is necessary, use the 6V2198 Photo Pickup Extension Cable.
(B) Using The Injection Line Speed Pickup Group
1. Refer to Special Instruction Form SEHS7807, "USING THE 6V2100 MULTITACH AND 6V3121 MULTITACH GROUP" to become familiar with the operation of the multitach. Connect the 5P7366 Power Cable to the multitach and to the power source as shown in the Special Instruction. Start the engine. Program the multitach for 0.5 P/REV, and to read R/MIN on the PH (Photo) input.
2. Read engine speed on the digital display of the multitach. If engine speed is steady, the multitach reading should be stable. If the reading on the multitach is not stable, check the NO INPUT SIGNAL light. When the engine speed is steady, there should either be a steady dim light or the light should be flashing off and on at a constant rate. This rate will vary with engine speed. The rate will be easier to observe at lower engine speeds when it will be slower. If the NO INPUT SIGNAL light is on constant bright or is flashing erratically, the pickup is either faulty or incorrectly installed. See the following section for troubleshooting information.
3. If the engine speed readings have been successfully completed, remove the multitach, amplifier and the pickup from the engine. After the engine has cooled, repaint the fuel injection line at all locations where the paint has been removed.
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All bare metal locations on the fuel injection lines must be repainted after removal of the pickup group and before the engine is put back into service. If this is not done, the bare metal fuel injection lines can corrode. This could result in a fire if fuel is sprayed on hot engine parts. |
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(C) Troubleshooting Operational Problems
If the NO INPUT SIGNAL light is on constant bright or is flashing erratically when the engine is running at a steady speed, the following steps should be taken to solve the problem.
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Do not rotate the pickup around the injection line if the thumbscrew is tight or damage to the pickup and/or line may result. |
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Do not use emery paper or any other abrasive to clean any part of the pickup or damage to the pickup may result. |
1. Remove the pickup from the injection line. Check to be sure the pickup and injection line are clean and dry. The inner bore of the pickup that contacts the injection line must be clean and dry. If necessary, clean the inner bore with a soft dry cloth. If the pickup is damp, dry it in an oven at approximately 50°C (122°F) before reinstalling on the fuel injection line.
2. Check the fuel injection line on which the pickup was installed. Make sure all paint has been removed from around the line and that clean bare metal is exposed. Use fine emery paper to clean the line if necessary.
3. Reinstall the pickup on the fuel injection line. Make sure the thumbscrew is tight and the pickup is not touching anything except the line. Observe the NO INPUT SIGNAL light and the digital readout on the multitach. If the light stays on bright all the time and the digital display reads 0 when the engine is running, the pickup is not operating. Remove the pickup and amplifier, and test the pickup and amplifier as shown on pages 6 and 7, or use a different pickup and amplifier.
4. If the pickup is operating but the NO INPUT SIGNAL light and digital readout are erratic, the pickup output signal is either too low or it is noisy. Run the engine at low and high speeds. If the output signal is too low, the pickup will operate better at high engine speeds. If the signal is noisy, the pickup will usually perform better at low engine speeds. To correct either of these problems, loosen the thumbscrew and rotate the pickup to a new position on the line. Tighten the thumbscrew. Check to see if this solves the problem. To correct noisy operation, it may also be necessary to remove the pickup and reverse it 180° so the signal line points in the opposite direction.
5. If pickup operation is still erratic after performing the previous steps, move the pickup to a new location on the same line or to a different line. Make sure each new location is properly prepared before installing pickup. To correct noisy operation (erratic signal and high speed readings), try a pickup location as close as possible to a point where the injection line is fastened to the engine.
(D) Use Of The Pickup During Wet Conditions
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal. If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly. If it is not possible to keep the pickup dry, use the following procedure.
If the pickup must be used during wet conditions, it may be possible to protect it from moisture by using a water displacing spray such as WD-40 (a trademark of the WD-40 Company). Remove the pickup from the engine. Thoroughly spray the pickup from all directions. Make sure the pickup is completely covered with the spray. Reinstall the pickup on the engine and check its operation. When water first contacts the pickup, the unit may stop working temporarily, but will start working again after the water has been displaced by the solution. If necessary, spray the solution on the pickup after installation on the injection line.
(E) Permanent Installation On The Engine
If the pickup is to be permanently installed on the engine, install the pickup on the fuel injection line in the usual manner. Make sure the thumbscrew is hand tightened securely but not overtightened. Run the engine and check operation of the pickup. Make sure pickup and line are clean and dry. If the pickup is working correctly, use a can of spray paint to thoroughly paint the pickup from all directions. Several coats should be applied. Let the paint dry before operating the engine.
Checking The Operation Of The Amplifier And Pickup
Use the following procedure to ensure correct operation of the amplifier and pickup. The following equipment is necessary to check the amplifier and pickup.
- 1. 6V2100 Multitach
- 2. 5P9698 Calibrator
- 3. 5P7366 Power Cable
- 4. 6V3030 Digital Multimeter
- 5. Screwdriver [blade approximately 150 mm (6") long with 6mm (.25") diameter shaft of round bare metal (not anodized or insulated)]
- 6. 6V6152 Adapter [phono plug to BNC connector]
- 2. 5P9698 Calibrator
*Modifications must be made to the calibrator; see Special Instruction Form SMHS7504-01 "MAINTENANCE AND TROUBLESHOOTING OF 5P9698 CALIBRATOR" for the procedure to make the modifications.
(A) Checking The 6V6113 Amplifier
1. Install 6V6152 Adapter Plug (1) on the end of the output cable on 5P9698 Calibrator (2). Plug the adapter into 6V6113 Amplifier (3).
2. Check the operation of the multitach being used by performing the CHECKING PHOTO OPERATION test procedure shown on page 12 of Special Instruction Form SEHS7807, "USING THE 6V2100 MULTITACH AND 6V3121 MULTITACH GROUP", to be sure it is operating properly on PHOTO operation.
3. Plug connector (4), on the end of the amplifier output cable, into the PH (photo) connector on the multitach. Attach 5P7366 Power Cable (5) to the multitach and to a suitable power source. Refer to multitach Special Instruction for correct connection of power.
4. Program the multitach for 0.5 P/REV and to read R/MIN on the PH (photo) input. Turn knob (6) on the calibrator to the 25 Output Hz position. Make sure BATTERY indicator needle (7) is in the white part of the scale. NO INPUT SIGNAL light (8) on the multitach should go off or go dim, and the number 3000 (plus or minus 1) should appear on the digital readout. If this number is correct, the amplifier is working properly.
NOTE: The 25 Output Hz position is the only calibrator position that can be used for this test.
5. Leave the test equipment connected to the amplifier, and check the pickup as shown in the following procedure.
(B) Checking The 6V6114 Pickup
1. Make sure the pickup is clean and dry. Perform the preceding test procedure "CHECKING THE 6V6113 AMPLIFIER".
2. Remove 5P9698 Calibrator (1) and 6V6152 Adapter Plug (2) from amplifier (3). Connect cable (4) of the pickup to amplifier (3). Leave the multitach programmed to read R/MIN as described in the amplifier test procedure.
3. Install the pickup on the shaft of the 150 mm (6") screwdriver as shown. Do not use a screwdriver with anodized or insulated shaft. The pickup should be positioned approximately 13 mm (.5") from the handle. Connect the ground clip to the screwdriver shaft next to (but not touching) the pickup.
4. Hold the screwdriver with the pickup by the handle (be careful not to touch the shaft). Hold another screwdriver by the shaft in the other hand. Rapidly strike the shaft of screwdriver with the pickup with the handle of the other screwdriver as shown. Be careful not to hit the pickup or clamp.
5. Observe the NO INPUT SIGNAL light on the multitach. The light should go out whenever the shaft is struck with screwdriver handle. After the shaft has been struck steadily for a minimum of 5 seconds, a number in the range of 200 to 800 should appear on the digital readout of the multitach. The number will vary with the rate the screwdriver is struck. If this number appears, the pickup is operating correctly. However, the pickup should also be checked on an engine to verify proper operation.
6. If the pickup does not operate, an additional test can be performed using a 6V3030 Digital Multimeter to check for a short circuit. Remove the pickup connector from the amplifier. Use the multimeter on the 20 M Ohms (20 Meg ohms) scale to measure the resistance between the outer shell and the center conductor of the connector as shown. The multimeter should read OL (infinite ohms) on the readout. If the readout indicates a smaller (finite) resistance, the pickup is faulty or contaminated, or there is a short in the signal cable.
Repair Of The 6V4950 Pickup Group
If the 6V4950 Injection Line Speed Pickup Group fails to operate correctly, check the performance of the amplifier and pickup as shown on pages 6 and 7. If either unit is found faulty, it can be returned to the manufacturer for repair. A letter should accompany the returned unit stating the problem and date of purchase from Caterpillar. Units 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. Send the unit for repair to the following address.
Design Technology Inc.758 Burr Oak
Westmont, Illinois 60559
U.S.A.
Telephone No. (312) 920-1300