R

NEHS0993
March 2008

TOOL
OPERATING
MANUAL
276-7273 Cylinder Sensor Test Box
(In Cylinder Function Test)

SMCS: 1400-081
Important Safety Information The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
Operations that may cause product damage
are identified by “NOTICE” labels on the
product and 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
specifically recommended by Caterpillar is
Think Safety used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
Most accidents that involve product operation, damaged or be made unsafe by the
maintenance, and repair are caused by failure operation, lubrication, maintenance or
to observe basic safety rules or precautions. repair procedures that you choose.
An accident can often be avoided by The information, specifications, and illustrations
recognizing potentially hazardous situations in this publication are on the basis of
before an accident occurs. A person must be information that was available at the time that
alert to potential hazards. This person should the publication was written. The specifications,
also have the necessary training, skills, and torques, pressures, measurements,
tools to perform these functions properly. adjustments, illustrations, and other items can
Improper operation, lubrication, change at any time. These changes can affect
maintenance, or repair of this product can the service that is given to the product. Obtain
be dangerous and could result in injury or the complete and most current information
death. before you start any job.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the WARNING
operation, lubrication, maintenance, and
repair information. When replacement parts are required for this
product, Caterpillar recommends using
Safety precautions and warnings are provided Caterpillar replacement parts or parts with
in this manual and on the product. If these equivalent specifications including, but not
hazard warnings are not heeded, bodily injury limited to, physical dimensions, type,
or death could occur to you or to other strength, and material.
persons.
The hazards are identified by the “Safety Alert Failure to heed this warning can lead to
Symbol” and followed by a “Signal Word” such premature failures, product damage,
as “DANGER”, “WARNING”, or “CAUTION”. personal injury, or death.
The Safety Alert “WARNING” label is shown
below.

WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.

2
Contents Literature Information
Literature Information This manual should be stored with the tool
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 group.
General Information . . . . . . . . . . . . . . . . . . . 3 This manual contains safety information,
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 operation instructions, and maintenance
information.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Section Some photographs or illustrations in this
publication show details that can be different
Safety Icon Nomenclature . . . . . . . . . . . . . . 4
from your service tool. Guards and covers
Personal Protection/Important Information 4 might have been removed for illustrative
Prohibited Action . . . . . . . . . . . . . . . . . . . . 4 purposes.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4 Continuing improvement and advancement of
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . 4 product design might have caused changes to
General Information Section your service tool, which are not included in this
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5 publication.
Additional Contact Information . . . . . . . . . . 6 Whenever a question arises regarding your
References. . . . . . . . . . . . . . . . . . . . . . . . . . 6 service tool or this publication, please consult
Dealer Service Tools (DST) for the latest
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 6 available information.
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 6
Operation Section Safety Section
Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 7 The Safety section lists basic safety
Connect Test Box. . . . . . . . . . . . . . . . . . . . . 7 precautions.
Sensor Test Procedure. . . . . . . . . . . . . . . . . 8 Read and understand the basic precautions
Sensor Voltage Signal . . . . . . . . . . . . . . . . 8 listed in the Safety section before operating or
Sensor Frequency Signal. . . . . . . . . . . . . . 9 performing maintenance and repair on this
Sensor Duty Cycle . . . . . . . . . . . . . . . . . . 10 service tool.
Disconnect Test Box . . . . . . . . . . . . . . . . . 11 General Information Section
Maintenance Section
The General Information section describes
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . 11 tooling functions and features. It provides
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 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 its capabilities.

Maintenance Section
The Maintenance section is a guide to
equipment care.

3
Safety Section Safety Warnings
Safety Icon Nomenclature WARNING
Personal Protection/Important To avoid personal injury or death,
Information carefully read and understand all
instructions before attempting to
Read the manual operate any equipment or tools.
Do not operate or work on a machine unless
you read and understand the instructions
Read applicable manuals
and warnings in this and all other applicable
manuals. Contact Dealer Service Tools for
Eye protection replacement manuals. Proper care is your
responsibility. Always follow all State and
Federal health and safety laws and/or local
Ear protection
regulations.
To prevent possible damage to
Face protection
your hearing, always wear ear
protection when working around
Prohibited Action noise generating tools.
No smoking To avoid eye injury,
always wear protective
Hazard Avoidance glasses or face shield.
Make sure no one can
Fire hazard be injured by flying objects or debris when
using tools or working on a component.
Crushing hazard Clean up all leaked or
spilled fluids immediately.
Oil, fuel, or cleaning fluid
Crushing hazard (hand) leaked or spilled onto any
hot surfaces or electrical components can
Pressurized air cause a fire, resulting in personal injury or
death.
Safety alert symbol Personal injury can result
from slips or falls. DO
NOT leave tools or
Slipping hazard components laying
around the work area and clean up all spilled
Tripping hazard fluids immediately.

4
Safety Warnings (continued) The test box is used with a 146-4080 Digital
Multimeter and can test the sensor signal in
VDC), frequency in Hertz
Direct Current Volts (V
WARNING Hz), and duty cycle in a percentage (%
(H %).
Personal injuries
can occur as a
result of using
pressurized air. RS-232 TRUE RMS MULTIMETER

Maximum air pressure at the nozzle must be HOLD CMP EDIT RANG
HI/LO
E

below 205 kPa (30 psi) for cleaning REC

%
REL
DC/A
C

C/ F
TRIG

purposes. Wear protective clothing, mV

v
Hz

DUTY

protective glasses, and a protective face

10A

TEMP
mA

A OFF

shield when using pressure air. OFF

146-4080

To avoid personal 10A MAX

FUSED 400mA MAX
FUSED
MAX
AC 750V
DC 1000V

MAX
600V
TEMP

injury or death A mA A COM V Hz

REMOVE INPUTS BEFORE SWITCHING RANGES

0993-02
when working
around hydraulic
implement cylinders, carefully read and
understand all instructions before The test box is connected directly to the
attempting to operate any equipment or multimeter. The test box wire harness then
tools. Do not operate or work on a machine plugs into the cylinder position sensor
unless you read and understand the connector. The 1.83 M (6 ft) harness allows
instructions and warnings in this and all the tests to be run from a convenient distance.
other applicable manuals. Test results are shown on the multimeter
display.

NOTE: To measure sensor resistance using

General Information Section the multimeter, the test box must first be
disconnected. For more information on
Introduction measuring sensor resistance, refer to
The 276-7273 Cylinder Sensor Test Box is a REHS2553 Reuse and Salvage Guidelines,
portable, battery-powered tester used to Reuse Guideline for Hydraulic Cylinder
check hydraulic cylinder position sensors. Position Sensors.
Using the test box, cylinder position sensors
can be checked while the cylinder is installed
on a machine.

0993-01

5
Additional Contact Information Nomenclature
For additional product support questions
concerning this tool, contact the Caterpillar 3
Dealer Service Tools Hotline at:
1
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277 4
Fax: 1-309-494-1355
[email protected] 2

References
NEHS0678 146-4080 Digital Multimeter,
Operation Manual 0993-03

NEHS0682 146-4080 Digital Multimeter,

(1) Case With Lexan Cover. (2) Battery Test Button.
Specification, Testing, and
(3) Multimeter Connection Plugs. (4) Wire Harness With
Maintenance Manual
Sensor Connector Plug.
REHS2553 Guideline for Reusable Parts and
Salvage Operation
Specifications
276-7273 Specifications
Item Description
Overall Size 76.2 x 50.8 x 38.1 mm (3 x 2 x 1.5 in)
Material Plastic (Lexan Faceplate)
Cable Length 1.83 M (6 ft)
Harness Connector Three pin (155-2272 Plug Assembly)
Battery 9 Volt (1U-9534)

6
Operation Section 3. Re-install the test box cover and four
screws.
Power Supply
Before using the tool for the first time, install a
1U-9534 9 Volt Battery. NOTICE
1. Use a Phillips screwdriver to remove the To avoid damaging the test box case, do not
four screws. Remove the test box cover. over-tighten the four cover screws.

Connect Test Box

1.. Connect 276-7273 Cylinder Sensor Test
Box to 146-4080 Multimeter by inserting the
two plugs into the VΩHz (++) and COM (--)
ports on the lower right-hand corner of the
multimeter, as shown.

RS
-2
32
TR
UE
RM
HOLD S
MU
LT
IM
ET
REC CMP ER

EDIT
% REL

DC/AC RANG
E
v HI/LO
mV C/ F
TRIG
10
A

mA

A Hz

0993-04 OF
F DU
TY

TE
MP

OF
F
10
A
FU MAX
SE
D

40 14
A
0m
A 6-4
RE
MO
FU MA
SE X A MA 08
VE
D DCC 75X 0
10 0V
IN mA 00
V
PU

2. Install a 1U-9534 9 Volt Battery into the

TS A
BE MA
FO 60 X TE
RE CO 0V MP
SW M
IT
CH
IN
G V

battery holder.
RA H
NG z
ES

NOTE: Match polarity of the battery to the

connector in the battery enclosure, Positive (+)
0993-06
to positive (+) and negative (-) to negative (-).

2.. Select Volts (V

V) on the multimeter.

NOTE: For more information on multimeter

functions, refer to NEHS0678, 146-4080 Digital
Multimeter (Operation Manual) and NEHS0682,
146-4080 Digital Multimeter Specification,
Testing, and Maintenance Manual.

0993-05

7
3.. Check the test box battery voltage by Sensor Test Procedure
pressing and holding the button on the side
of the test box. The multimeter display Sensor Voltage Signal
should read 7 to 10 VDC. Release the
1.. Select Volts (V
V) on the multimeter.
button.

NOTE: For more information on multimeter

functions, refer to NEHS0678, 146-4080 Digital
Multimeter (Operation Manual) and NEHS0682,
146-4080 Digital Multimeter Specification,
MU
LT
IM
ET
ER

E
Testing, and Maintenance Manual.
S G
RM A
N
UE
O
R L
I/ IG
TR HR
32
T

-2 IT
RS D
E
C
P /A
M C
C D F
/
L C
E
R
D
L
O

2.. With the hydraulic cylinder fully retracted,

H
C Hz
E TY
R
% DU
MP
v TE

mV
OF
F
read the signal voltage from the sensor on
10

mA
A

40
80
the multimeter digital display. This value
6-
14
should be from 0.2 VDC to approximately
A
F MP
OF X TE
MA 0VV
75
AC1000
DC X
MA V

4 VDC. Refer to REHS2553 for exact

X
A
MA 60
0 Hz
0m D V ES
40 USE G
F
R AN
AX
A
M M ING
10 SED CO CH

specifications.
FU IT
SW
A ORE
mA B E F
TS
PU
IN
A VE
MO
RE

0993-07

ER

NOTE: If the battery voltage is below 7 VDC, TR

UE
RM
S
MU
LT
IM
ET

R
A
N
L
O
G

I/ IG
E

replace the 1U-9534 Battery in the test box

HR
32
T

-2 IT
RS D
E
C
P /A
M C
C D F
/

before proceeding. For more information on

L C
E
R
D
L
O
H
C Hz
E TY

battery replacement, refer to Power Supply

R
% DU
MP
v TE

F
OF

section in this manual. 10

A
mV

mA 80
40
6-
14
A
F MP
OF X TE
MA 0VV
75
AC1000
DC X
X MA V
A
MA 60
0 Hz
0m D V ES
40 USE

4.. Connect the test box harness.

G
X
F
R AN
MA M ING
A
10 SED CO CH
FU IT
SW
A ORE
mA BEF
TS
PU
IN

a.. Unplug the machine wiring harness

A VE
MO
RE

from the hydraulic cylinder sensor

connector.
0993-08
b.. Insert the hydraulic cylinder sensor
connector into the test box wire
harness plug.
WARNING
To avoid personal
injury or death
when working
around hydraulic
implement cylinders, carefully read and
understand all instructions before
attempting to operate any equipment or
tools. Do not operate or work on a machine
unless you read and understand the
instructions and warnings in this and all
other applicable manuals.

8
3.. Extend and retract the hydraulic cylinder Sensor Frequency Signal
while observing the readings.
1.. Select Hertz (H
Hz) on the multimeter.

NOTE: If necessary, have a second person

operate the cylinder while readings are taken. NOTE: For more information on multimeter
functions, refer to NEHS0678, 146-4080 Digital
Multimeter (Operation Manual) and NEHS0682,
4.. Replace the sensor if any of the following 146-4080 Digital Multimeter Specification,
conditions occur: Testing, and Maintenance Manual.

• With the cylinder fully retracted the

sensor voltage signal goes above 5 VDC 2.. With the hydraulic cylinder fully retracted,
and stays above 5 VDC. read the frequency signal on the multimeter
• The sensor voltage signal reading does digital display.
not increase as the cylinder is extended.
• The sensor voltage signal output is
intermittent.
• The sensor voltage signal is 0 VDC.
ER
ET
IM
LT
MU E
S G
RM A
N
UE
O
R L
I/ IG
TR HR
32
T

R S-2 D
IT
E
C
P /A
M C
C D F
/
L C
E
R
D
L
O
H
C Hz
E TY
R
% DU
MP
v TE

F
OF
mV

A
10

mA 80
40
6-
14
A
F MP
OF X TE
MA 0VV
75
AC1000
DC X
MA V
AX 0 Hz
A
M 60 V ES
0m D
40 USE G
X
F
R AN
MA M ING
A
10 SED C O CH
FU IT
SW
A ORE
mA BEF
TS
PU
IN
A VE
MO
RE

0993-09

3.. The frequency reading should be:

• 100 to 130 Hz for Class Two Sensors
• 400 to 600 Hz for Class Three Sensors
Refer to REHS2553 for exact specifications.

4.. Replace the sensor if the frequency

reading is above or below the correct
values.

9
Sensor Duty Cycle 3.. Extend and retract the hydraulic cylinder
while observing the readings.
1.. Select Duty Cycle on the multimeter.

NOTE: If necessary, have a second person

NOTE: For more information on multimeter operate the hydraulic cylinder while readings
functions, refer to NEHS0678, 146-4080 Digital are taken.
Multimeter (Operation Manual) and NEHS0682,
146-4080 Digital Multimeter Specification,
Testing, and Maintenance Manual. 4.. Replace the sensor if any of the follow
conditions occur:
2.. Duty cycle is the ratio of pulse width to the • The sensor duty cycle is below 1% or
time between pulses displayed as a above 50% with the cylinder fully
percent. The duty cycle reading should be retracted.
between 1% and 50%. • The sensor duty cycle percent value
does not increase as the cylinder is
extended.
Refer to REHS2553 for exact specifications.

ER
ET
IM
LT
MU E
S G
RM A
N
UE
O
R L
I/ IG
TR HR
32
T

R S-2 D
IT
E
C
P /A
M C
C D F
/
L C
E
R
D
L
O
H
C Hz
E TY
R
% DU
MP
v TE

F
OF
mV

A
10

mA 80
40
6-
14
A
F MP
OF X TE
MA 0VV
75
AC1000
DC X
X MA V
A
MA 60
0 Hz
0m D V ES
40 USE G
X
F
R AN
MA M ING
A
10 SED CO CH
FU IT
SW
A ORE
mA B E F
TS
PU
IN
A VE
MO
RE

0993-10

WARNING
To avoid personal
injury or death
when working
around hydraulic
implement cylinders, carefully read and
understand all instructions before
attempting to operate any equipment or
tools. Do not operate or work on a machine
unless you read and understand the
instructions and warnings in this and all
other applicable manuals.

10
Disconnect Test Box Maintenance Section
1.. Disconnect the test box harness.
Cleaning
a.. Unplug the test box harness plug from
the hydraulic cylinder sensor 1.. If necessary, clean the test box with a
connector. clean, dry cloth to remove dust and dirt.

b.. Re-connect the hydraulic cylinder 2.. When replacing the 9 Volt battery, make
sensor connector to the machine sure the test box connector is clean and
harness plug. free of corrosion.

2.. Remove 276-7273 Cylinder Sensor Test Storage

Box from 146-4080 Multimeter by pulling
the test box straight out to disconnect the 1.. Neatly coil the wire harness and plug.
two plugs from the lower right-hand corner 2.. Store the unit in a clean, dry area.
of the multimeter.

NOTICE
If storing the test box for an extended period of
RS
time, remove the battery to avoid possible
battery corrosion and test box damage.
-2
32
TR
UE
RM
HOLD S
MU
LT
IM
ET
REC CMP ER

EDIT
% REL

DC/AC RANG
E
v HI/LO
mV C/ F
TRIG
10
A

mA

A Hz

OF
F DU
TY

TE
MP

OF
F
10
A
FU MAX
SE
D

40 14
A
0m
A 6-4
RE
MO
FU MA
SE X A MA 08
VE
D DCC 75X 0
10 0V
IN mA 00
V
PU
TS A
BE MA
FO 60 X TE
RE CO 0V MP
SW M
IT
CH
IN
G V
RA H
NG z
ES

0993-06a

11
 For information on service tools or shop supplies,
contact Dealer Service Tools on:

Dealer Service Tools

501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
[email protected]

©2008 Caterpillar NEHS0993

12
All Rights Reserved Printed in U.S.A.