WilTec 51292 User manual

Operation Manual
Compression Tester for Diesel Engines
51292, 51293
Illustration similar, may vary depending on model
Please read and follow the operating instructions and safety information prior to initial operation.
Technical changes reserved!
Illustrations, functional steps and technical data may deviate insignificantly due to continuous further
developments.

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The information contained in this document may alter at any time without prior notice. No part of this
document may be copied or otherwise duplicated without prior written consent. All rights reserved.
WilTec Wildanger Technik GmbH cannot be held liable for any possible mistakes in this operating
manual, nor in the diagrams and illustrations shown.
Although WilTec Wildanger Technik GmbH has made every possible effort to ensure that this operat-
ing manual is complete, accurate and up-to-date, errors cannot be ruled out entirely.
If you have found an error or wish to suggest an improvement, we look forward to hearing from you.
Send us an e-mail to:
[email protected]
or use our contact form:
https://www.wiltec.de/contacts/
The most recent version of this manual in several languages can be found in our online shop:
https://www.wiltec.de/docsearch
Our postal address is:
WilTec Wildanger Technik GmbH
Königsbenden 12
52249 Eschweiler Germany
Do you wish to collect your goods? Our address for collection is:
WilTec Wildanger Technik GmbH
Königsbenden 28
52249 Eschweiler Germany
In order to shorten the waiting time and to allow for an easy on-site processing, we kindly ask you to
contact us briefly beforehand or to place your order via the webshop.
E-mail: [e-mail]
Phone: [phone]
Fax: [phone]
To return your goods for exchange, repair or other purposes, please use the following address. Atten-
tion! To allow for a trouble-free complaint or return, it is important to contact our customer service team
before returning your goods.
Retourenabteilung
WilTec Wildanger Technik GmbH
Königsbenden 28
52249 Eschweiler Germany
E-mail: [email protected]o
Phone: [phone]
Fax: [phone])

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Introduction
Thank you for choosing to purchase this quality product. To minimise the risk of injury, we ask you to
always take some basic safety precautions when using this product. Please read this operating manu-
al carefully and make sure that you understand it.
Keep these operation instructions in a safe place.
General safety instructions
•Keep your working area clean, tidy, and well illuminated. Untidy and badly illuminated
working areas lead to accidents.
•Keep bystanders, children, and visitors away from your working area when you operate
a device or accessory. Distractions may lead to loss of control of the device. Protect other
persons present in your working area, e.g., by installing dividers or protective shields.
•Always stay vigilant and concentrate on what you are doing. Always use devices and ac-
cessories with caution. Do not use devices and accessories if you are tired or under the influ-
ence of alcohol, drugs, or medicine altering the consciousness. A short moment of inattention
may lead to accidents and severe injuries.
•Wear clothing adapted to the work to be performed. Do not wear loose clothing, belts, or
jewellery. Securely tie long hair together. Keep hair, parts of clothing, gloves, etc. away from
moving parts; they might get caught by them, which might lead to accidents.
•Ensure a safe stand hand keep your balance. This will allow a better control of the device in
unforeseen situations.
•When using the device, use a safety equipment, e.g., safety goggles, work gloves, etc.
•Do not use devices by force. Always use the device or tool adapted to the job to be per-
formed. The appropriate device or tool will do a better and safer job if it is used according to
the intended use.
•Store devices, tools, and accessories that are not used out of children’s or other un-
trained persons’ reach. They can be dangerous in untrained persons’ hands.
•Maintain and care for devices and tools with prudence. Do not use any damaged devices
or tools. Mark defective devices and tools until they are repaired to avoid them being used by
others.
•Immediately have damages repaired before using a device or tool. Regularly check de-
vices and tools for loose parts and fastenings, cracks or broken spots, and any other condi-
tions that might impair proper use. Numerous accidents are caused by incorrect maintenance.
•Only use accessories recommended by the manufacturer. Using improper accessories is
dangerous.
•Only a qualified person should repair the device. Repairs performed by unqualified per-
sons might lead to a dangerous situation.
•When maintaining a device, only use identical spare parts. Using unauthorised accesso-
ries or disobeying the instructions might lead to injuries.
Special safety instructions
•Warning!
oNever exceed the maximum pressure of this device (70 bar/1000 psi). Exceeding the
maximum pressure may lead to severe injuries and/or material damages.
oOnly use the compression tester in well-ventilated areas. A running engine generates
harmful exhaust fumes that, being inhaled, may lead to severe respiratory diseases, a
heart attack, or stroke.
oThe warnings, precautionary measures, and instructions of this operation manual cannot
cover all possible conditions and situations. Therefore, always use the device with cau-
tion.
•Read and understand all warnings, precautionary measures, and instructions of the operation
manual of the engine to be tested before using the compression tester.

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•When you heat the engine up before the test, make sure that the gear mechanism is set to
“park”or a neutral gear (with manual mechanism). Also make sure that the handbrake is en-
gaged.
•Keep hands and fingers away from moving parts and heated-up parts of the engine.
Technical specifications
Item number
51292
51293
Accessories
Adapter for injection nozzle thread
M18 × 1.5
M24 × 2.0
M24 × 1.5
M24 × 1.5 / 88 mm
M22 × 1.5 / 73 mm
M24 × 2 / 63 mm
M20 × 1.5 / 75 mm
Adapter for glow plug thread
M10 × 1.0 × 68 mm
M10 × 1.25 × 54 mm
M10 × 1.25 × 68 mm
M12 × 1.25 × 45 mm
M10 × 1.0 / 91 mm
M10 × 1.0 / 119 mm
M10 × 1.0 / 113 mm
M10 × 1.0 / 102 mm
M10 × 1.0 / 83 mm
M10 × 1.0 / 135 mm
M10 × 1.25 / 64 mm
M12 × 1.25 / 47 mm
M22 × 1.5 / 118 mm
Display (bar)
0–70 (1000 psi)
Hose length (㎝)
36
Before using the product
The model TU-15 serves as gauge of the highest pressure generated via the compression stroke in-
side the air cylinder of a diesel engine. It has numerous adapters for different specifications and con-
nections that can measure the different types of diesel engines.
Attention! Disconnect the injection unit from the fuel supply! No fuel must be injected for the
motor could start and cause injuries!
•To perform a typical compression test, the engine is prepared for the test by being started and
heated up to its normal operating temperature. Do not touch any hot parts of this device. Burn-
ing hazard!
•Make sure that the handbrake is firmly engaged and the engine is switched off before begin-
ning work.
•Remove cables from injectors and injection nozzles. To do so, obey the manufacturer’s in-
structions.
Attention! Do not touch the live parts. Danger of electric shock!
•Remove injectors or glow plugs and obey the order of assembly and disassembly.

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№
Name
№
Name
№
Name/description
1
Air outlet knob
3
Adapter connection
1
Pressure gauge
2
Hose
4
Pressure gauge
2
Remove glow plugs
Performing a compression test
Notes!
•Performing a compression test requires two persons, one of them operating the vehicle, the
other operating the compression tester.
•A good cylinder compression of the engine is displayed with a high initial value and a progres-
sive build-up until the final maximum value. A bad cylinder compression of the engine cylinder
is displayed with a low initial value and a slower build-up until the final maximum value. The
compression values for all cylinders of the engine should not vary by more than 10 %.
•Look up the acceptable pressure ranges in your user’s manual or maintenance manual.
1. To perform a typical compression test, the engine is prepared for the test by being started and
heated up to its normal operating temperature. Then switch off the ignition.
Warning! Never let the engine run inside a closed garage or another closed area!
2. If necessary, choose an appropriate adaptor and connect the hose of the pressure gauge to
the thread of the injector or glow plug.
3. Either fix the adaptor connection or hose and the hose connections to the pressure gauge.
4. Start the engine and kick down the accelerator pedal. Floor it until the hand of the pressure
gauge does not increase further on.
5. Observe and note down the maximum value shown on the pressure gauge.
6. As soon the maximum value is reached, do not start the engine any more. Then discharge the
air pressure of the pressure gauge by pressing the air outlet knob.
7. Remove the compression tester from the first cylinder of the engine. Repeat the steps for the
other cylinders of the engine.
Important Note:
Reproduction and any commercial use (of parts) of this operating manual, requires a written permis-
sion of WilTec Wildanger Technik GmbH.