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Caterpillar Engine Tools Cat Overhaul 3512 Page 262

Operation and Maintenance Manual
2596044
2596071
2596089
3-262
Engine Tools
Fuel System Repair and Adjust
9U-7227 Injector Height Setting Gauge
187-0482 Spacer Sleeve
Model: 3406E Engines
Warranty: Six Months
9U-7227 Injector Height Setting Gauge
• Used to adjust injector Prestroke
• Leavesbothhandsfreetomakeadjustments
187-0482 Spacer Sleeve
• Usedtohelppreventimproperinjectorheightsettings
• Used with 9U-7227 Injector Height Gauge with a straight indicator pin (spacer
sleevecanbeorderedseparately)
• Sleeverestsagainstinjectorspringtokeepgaugesquareonspringretainer
• Earliergaugeswithasupportaremachinedontotheindicatorpindonotneed
this spacer
• Allnewgaugesincludeaspacersleeve
References
SENR5580,ServiceManual
SENR6421,ServiceManualModule,DisassemblyandAssembly3406EEngines
Item Part Number Description
1 9U-7227 Injector Height Gauge Assembly
2 187-0482 SpacerSleeve
3 4L-5966 Setscrew
4 1U-9084 Flag
1U-8780 Nozzle Puller Group
Model: 3200, 3300
Warranty: Six Months
• Workstopullall7000SeriesFuelNozzleson3200and3300SeriesEngines;short
enough to use on rear cylinders on 3208 Engines in highway trucks
• Strong enough to pull stuck nozzles on 3300 Series Engines
• Replaces two nozzle pullers: 6V-6980 Nozzle Puller Group for 3300 Series En-
gines and 6V-6976 Nozzle Puller Group for 3204 Engines
• Has two adapters, one with full clamp for 3300 Series Engines and one with half
clamp for 3200 Series Engines
Part Number Description
1U-8780 Nozzle Puller Group
6V-7025 Guide
Model: 3406
Warranty: Six Months
• Replaces discontinued 5P-4755
Guide
• Used to properly install 5P-2060 Seal
onto 4N-3761 Direct Injection Cap-
suleValveAdapteron3406Engines
Part Number Description
6V-7025 Guide
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Contents Summary of Caterpillar Engine Tools Cat Overhaul 3512

  • Page 1Search Table of Contents Engine Tools Air Induction.................................................................................................................................................................... 3-3 Cooling System..................................................................
  • Page 2Table of Contents Search Engine Tools 3-2 Home
  • Page 3Search Air Induction Air Induction 2586326 FT1984 Pressurizing Group Model: 3176, 3208, 3304B, 3306B, 3406B Warranty: None • Used to test air-to-air aftercoolers on 3306B and 3406B Truck Engines • Aids in detecting defects in air-to-air aftercoolers • Includes complete parts description and parts so
  • Page 4Air Induction Search 2586364 152-2067 Differential Pressure Gauge Model: Multiple Engine Models Warranty: Six Months • Used to monitor aftercooler pressure drop in applications with crankcase fumes recirculation • Minimize risk of engine reliability problems • Helps eliminate premature plugging of a
  • Page 5Search Air Induction 2641610 Turbocharging Reconditioning Tools (Continued) Model: Multiple Engine Models Warranty: Six Months 1 9S-6343 replaced FT0622 2 9S-6363 replaced FT0621 2641571 Manufacturer: AiResearch Part No. Descrip- T6 T12 T114 T18 T24 T3019 T04 TV81 TW81 tion Engine Tools FT0165¹ Fixt
  • Page 6Air Induction Search 2696371 370-4653 C7.1 Turbocharger Alignment Tool Model Usage: Perkins C7.1 Engines Warranty: 6 Months • Used to counterbalance the turbocharger for easier installation and alignment • Used in assembly and removal of Turbocharger • Material: Steel Part Number Description Size We
  • Page 7Search Air Induction 2641740 FT0165 Modified Fixture • Existing FT0165 Fixture can be modified according to boxed dimensions so that only one adapter is needed for disassembly and assembly of all turbochargers • Material: SAE 1020 steel 2642172 Engine Tools FT0168 Fixture Adapter • Used to service t
  • Page 8Air Induction Search 2641956 FT1354 Turbocharger Fixture Adapter • Used with FT0165 Fixture for disassembly of AiResearch TV81 and TW81 Turbo- chargers • Material: SAE 1020 steel Engine Tools 2641884 FT0626 Spacer Block • Used to service turbocharger (see chart) • Material: SAE 1020 steel 2641812 FT
  • Page 9Search Air Induction 2586472 304-9575 Bellows Tool Assembly Essential Tool C175-16 Generator Set Engine Warranty: Six Months • Used to remove and install turbocharger exhaust bellows • Fits over bellows to maintain proper shape and help prevent deforming of inlet and outlet • Covers and protects bel
  • Page 10Air Induction Search 2887713 361-5661 Exhaust Bellows Remove and Install Tool Model Usage: C9.3, C13, C15, C18, C27, and C32 Tier4 interim and Tier4 final machines Warranty: Six Months • Used to safely compress exhaust bellows for removal and installation • Facilitates removal of bellows without rem
  • Page 11Search Air Induction 2586550 Fabricated Tools for Installing Turbine Shaft Seal Rings in Turbochargers Model: Multiple Engine Models Warranty: None • Special tools designed to assist serviceman when installing shaft seal rings in turbochargers • Eliminate possibility of ring damage resulting from ov
  • Page 12Air Induction Search 2887583 375-2606 Twin Turbocharger Alignment Tool Model Usage: C4.4 Warranty: Six Months • Used to correctly align turbochargers for the bellows assembly Part Number Description Dimensions Weight 375-2606 Twin Turbocharger 275 x 158 x 80 mm 2.75 kg (6.1 lb) Alignment Tool (10.8
  • Page 13Search Air Induction 2586600 FT2229 Puller Plate Model: 3406B Warranty: None • Required to remove impeller from water pump shaft on 3406B Engines (8S-2264 Puller Group, used to pull water pump impellers on 3406 Engines, cannot be used for this task on 3406B) • Designed to fit narrower bolt hole spac
  • Page 14Air Induction Search 2586646 319-2189 Diesel Particulate Filter Ash Cleaning Tool Model: Cat® Engines Warranty: Six Months • Cleaning process (patent pending) that utilizes pulsed air • Fully automated computer-controlled process • Pre-clean DPF check to verify that DPF can be cleaned • Cleans all C
  • Page 15Search Air Induction 2586683 Differential Pressure Regulator Testing and Reconditioning Apparatus Model: Multiple Engine Models Warranty: Six Months • Required to test and calibrate differential pressure regulators • Basic test apparatus required for fuel operated pressure ratio controls and exhaust
  • Page 16Air Induction Search 2586705 6V-7060 Gauge Group (Continued) Model: Multiple Engine Models Warranty: Six Months Part Number Description Size 6V-7021 Gauge 1.689 mm (0.0665 in) 6V-7022 Gauge 1.676 mm (0.0600 in) 6V-7023 Gauge 1.659 mm (0.0653 in) 6V-7060 Gauge Group -- Engine Tools 6V-6045 Case - Pla
  • Page 17Search Air Induction 2586751 2P-2333 High Temperature Sealer Warranty: Six Months Model: Multiple Engine Models • Used on all exhaust manifold joints, either flat or cylindrical • Retains sealing characteristics at temperatures up to 980° C (2000° F) Part Number Description 2P-2333 High Temperature
  • Page 18Air Induction Search 2586816 349-3548 Slotted Socket Essential Tool Model: All Tier 4 Engines Warranty: Six Months • Used to remove and install flame Part Number Description detect sensor on Cat® Tier 4 Engines 349-3548 Slotted Socket with Caterpillar® Regeneration System (CRS) heads Engine Tools •
  • Page 19Search Cooling System Cooling System 2586859 FT2554 Holding Fixture Model: 793C Trucks Warranty: None • Used to provide safe method for holding radiator and cowling group during removal and installation of modular front end • Prevents bottom of radiator tank from being crushed • Allows use of fork l
  • Page 20Cooling System Search 2586895 315-0009 Tool Group (Continued) Essential Tool Model: 793D and 793F MD Off-Highway Truck Warranty: Six Months Item Part Number Description Quantity 3 8T-0666 Bolt, M24 x 76.2 mm (3.0 in) long -- 4 6V-8237 Hard Washer -- 2586922 Engine Tools 178-3704 Lift Bracket Assembl
  • Page 21Search Cooling System 2586957 307-6728 Air Wand (Continued) 240-9588 Twist-lock Coupler Model: D8T and D9T Track Type Tractors Warranty: Manufacturer’s • Lightweight design for easy use • Compliant with OSHA standards • Rebuild kits are available (see charts) Part Number Description Engine Tools 307
  • Page 22Cooling System Search 2643151 317-6938 Valve Rebuild Kit Item Description Part Number Description 1 O-ring 317-6938 Valve Rebuild Kit 2 Top Packing 3 Spring 4 Packing Nut 5 Valve Stem 6 Poppet Skirt Engine Tools 7 Poppet Seal 8 Spring 9 O-ring 10 Valve Cap 2586983 FT2978 Nozzle Model: Most Models Wa
  • Page 23Search Cooling System 2587009 2S-9528 Blade Reversing Tool Model: Multiple Engine Models Warranty: Six Months Part Number Description • Used to change fan blade pitch on 2S-9528 Blade Reversing Tool machines equipped with reversible fan blades Engine Tools 2587024 Tooling for Variable Speed Fan Clut
  • Page 24Cooling System Search 2587042 Disassembly and Assembly Tooling for 200 Rockford Fan Clutch (Continued) Model: Multiple Engine Models Warranty: None Item Part Number Description Material 1 FT2814 Bearing Remover SAE 4140 steel 2 FT2815 Bearing Installer SAE 4140 steel 3 FT2816 Bearing Installer SAE 4
  • Page 25Search Cooling System 2587075 FT0203 Spring Compressor Model: Multiple Engine Models Warranty: None • Water temperature regulators can be disassembled by fabricating a short length of pipe as illustrated Engine Tools 2587087 FT0161 Thermometer Adapter Model: D8H Engine Warranty: None • Used to mount
  • Page 26Cooling System Search 2587117 9S-8140 Pressurizing Pump Model: Multiple Engine Models Warranty: Six Months • Used to pressurize cooling systems to detect leaks • Can also test dash gauges, relief valves, and pressure caps • All items in figure are included Reference SMHS8303, Special Instruction Eng
  • Page 27Search Cooling System 2587166 FT0200 Seal Case Removal Tool Model: Multiple Engine Models Warranty: None • Used to remove brass case on any water pump equipped with carbon thrust washer and bellows-type seal on D9H, 776, 777, 777B • Material: SAE 1020 steel Engine Tools 2587179 5P-9722 Seal Driver M
  • Page 28Cooling System Search 2587229 FT1783 Fixture Model: Multiple Engine Models Warranty: None • Facilitates drilling of vent holes in water pump impellers • Consists of locating plate and threaded T-bar (can be fabricated according to FT1783 drawings) Engine Tools 2587242 Impeller Installers Model: 3204
  • Page 29Search Cooling System 2587273 Fabricated Tools for Reconditioning and Testing 3208 Engine Water Pumps Group 1 Model: 3208 Warranty: None Group 1 Item Part Number Description Use 1 FT1700 Fixture Used to hold water pump shaft during Engine Tools pump assembly 2 FT1706 Installer Used with arbor press
  • Page 30Cooling System Search 2643220 FT1733 Fixture Item Part Number Description Use 11 FT1733 Fixture Used with Zero au- tomated glass bead machine to clean pump housings, pul- leys and impellers Engine Tools 2643228 FT1732 Salvage Fixture Item Part Number Description Use 12 FT1732 Salvage Fixture Used wi
  • Page 31Search Cooling System 2587318 248-3310 Spanner Wrench 248-3311 Holding Fixture Model: G3520B and G3520C Engines in Large Mining Trucks Warranty: Six Months Part Number Description • Used to disassemble and assemble 248-3310 Spanner Wrench jacket water (JW) pumps and separate circuit aftercooler (SCA
  • Page 32Cooling System Search 2587377 135-7629 Water Pump Seal Installer Model: 3406 Engines Warranty: Six Months • Used to correctly and quickly install Part No. Description the 118-9163 Seal Group in water 135-7629 Water Pump Seal Installer pumps • Replaces discontinued 2W-9102 Installation Tool (Water Pu
  • Page 33Search Cooling System 2587438 183-4028 Seal Installer Essential Tool Model: 3176, C-10, C-12, and 3196 Engines Warranty: Six Months Part No. Description • Used to install 147-5088 Pump Seal 183-4028 Seal Installer into 153-8053 Pump • Provides quick, easy installation Engine Tools 3038372 417-6000 S
  • Page 34Cooling System Search 2969376 FT3202 Seal Installer Model Usage: C15, C18, 3400 Engines Warranty: None • Used to install 349-2654 Pump Seal • Correctly installs seal without damage • Provides quick, easy installation • Make from Mild steel FT3202 Seal Installer Engine Tools 2587458 FT3171 Seal Insta
  • Page 35Search Cooling System 2587492 9U-5103 Slotted Socket Model: 3406E, C-15, and C-16 Engines Warranty: Six Months Part Number Description • Used to remove and install coolant 9U-5103 Slotted Socket temperature sensor • Deep well design easily reaches sensor • Slotted side for sensor wire clear- ance En
  • Page 36Cooling System Search 2587553 9U-6956 Water Pump Seal Installer Model: 3408 and 3412 Marine Engines Warranty: Six Months • Used to remove and install ceramic seals on most pumps that use a 5N-6055 Seal Group • Used with 1U-8306 Socket-Spanner for rebuilding 6I-1898 and 4C-3613 Water Pumps • One-piec
  • Page 37Search Cooling System 2587595 Temporary Strainers Model: 3400, 3500, 3600 Family Engines Warranty: Six Months • Convenient to install in coolant lines on 3600, 3500 and some 3400 Family En- gines • Filter particles larger than 1.58 mm (1/16 in) diameter • Used during initial startups and after overh
  • Page 38Cooling System Search 2587645 334-0114 Mounting Bar Essential Tool Model: C27, C30, C32, and 3412E Marine Engines Warranty: Six Months • Used to align and preload aftercooler plates during assembly • Bars align aftercooler plates and threaded adjuster compresses plates to proper preload • Makes repa
  • Page 39Search Cooling System 2587701 359-4915 Fan Drive Installer, 359-4916 Fan Drive Installer Essential Tool Model: D6R, D6T Track-Type Tractors, 937D Track-Type Loader Warranty: Six Months Item Part Number Description • Used to install wear sleeves on 336- 1 359-4915 Fan Drive 7696 and 350-5637 Fan Driv
  • Page 40Cooling System Search 2979422 373-4792 Turbo Alignment Bracket Model Usage: CT660 Truck Warranty: Manufacturer’s • Required to properly install and align the turbo assembly Specifications Dimensions 355.6 x 279.4 x 304.8 mm (14.0 x 11.0 x 12.0 in) Weight 2.3 kg (5.0 lb) Engine Tools Part Number Desc
  • Page 41Search Cooling System 2979659 373-4794 Thermostat Housing Extension Tube Seal Installer Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to properly install the extension tube seal into the thermostat housing Specifications Dimensions 137.2 x 177.8 x 134.6 mm (5.4 x 7.0 x 5.3 in) Weight 0.29
  • Page 42Cooling System Search 2980735 379-9007 Fan Clutch Wrench Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to easily remove fan hub nut on CT660 engines • Force can be applied using air hammer or by hand using included attachment and standard hammer or mallet • Fan clutch wrench can be used w
  • Page 43Search Cooling System 2901307 385-1861 Coolant Line Plug Model Usage: All C7 thru C18, Industrial and Captive Engines Warranty: Manufacturer’s • Used to plug the coolant line to the DEF injector during DPF removal • Two coolant line plugs are required per engine for this procedure • Effects all Tier
  • Page 44Crankshaft, Main Bearings and Flywheel Search Crankshaft, Main Bearings and Flywheel 2587749 Crankshaft Gear Installation Tools Model: Cat® Engines Warranty: Six Months • Used to install crankshaft gears on most engines with tool setup illustrated Item Part Number Description 6 FT1410 Sleeve Engine
  • Page 45Search Crankshaft, Main Bearings and Flywheel 2587811 FT1410 Sleeve Model: Cat® Engines Warranty: None • Replacement for 5H-1273 Sleeve • Material: SAE 1020 steel Engine Tools 2587824 FT1033 Puller Adapter Model: D8K Warranty: None • Used to facilitate removal of crankshaft pulley and damper on late
  • Page 46Crankshaft, Main Bearings and Flywheel Search 2587851 5P-3546 Puller Plate Model: D10, D11N, 245B, 992C Warranty: Six Months • Used to remove 9S-3013 Crankshaft Part Number Description Gear on D343 and 1693 Engines 5P-3546 Puller Plate • Used with 6V-3160 Hydraulic Puller, 9M-6592 Guide, three 6F-49
  • Page 47Search Crankshaft, Main Bearings and Flywheel 2587905 FT1576 Puller Plate Model: D10 Warranty: None • Used with 9M-6592 Guide and three 1K-9418 Bolts to remove crankshaft gear on D346, D348 and D349 Engines • Can be fabricated from dimensions given in Detail “A”, or by modifying 5P-3546 Puller Plate
  • Page 48Crankshaft, Main Bearings and Flywheel Search 2587955 5P-8718 BrakeSaver Rotor Support Model: 3406, 3406B, 3408, 3408B Warranty: Six Months • Used to prevent damage to seals Part Number Description during BrakeSaver removal and 5P-8718 BrakeSaver Rotor installation on 3400 Series Engines Support • A
  • Page 49Search Crankshaft, Main Bearings and Flywheel 2980876 393-2572 Flywheel Stopper Plate Model Usage: C3.8 Warranty: Manufacturer’s • Used to loosen and tighten the flywheel screw Specifications Dimensions 140 x 78.7 mm (5.51 x 3.10 in) Weight .662 kg (1.45 lb) Engine Tools Part Number Description 393-
  • Page 50Crankshaft, Main Bearings and Flywheel Search 2887656 364-7210 Timing Case Cover Alignment Tool Model Usage: C7.1, C6.6 Warranty: Six Months • Used to correctly align pressed timing case cover Specifications Dimensions Outer Diameter: 79.35 mm (3.12 in) Depth: 44.45 mm (1.75 in) Weight 1.12 kg (2.49
  • Page 51Search Crankshaft, Main Bearings and Flywheel 2588060 FT2711 Special Bolt FT2712 Guide Stud Model: 3196 Rear Power Take-Off Engines and 365B Hydraulic Excavator Warranty: None • Used to align and support rear crankshaft gear while oil seal is being installed • Eliminates oil seal damage during insta
  • Page 52Crankshaft, Main Bearings and Flywheel Search 2588079 Crankshaft Seal and Wear Sleeve Installation Tools (Silicone and Hydrodynamic) (Continued) Model: 1100, 3100, 3200, 3300, 3400 Warranty: Six Months CURRENT ENGINES CURRENT ENGINES Item Location Part Number Description Qty. Item Location Part Numb
  • Page 53Search Crankshaft, Main Bearings and Flywheel 2588079 Crankshaft Seal and Wear Sleeve Installation Tools (Silicone and Hydrodynamic) (Continued) Model: 1100, 3100, 3200, 3300, 3400 Warranty: Six Months CURRENT ENGINES CURRENT ENGINES Item Location Part Number Description Qty. Item Location Part Numb
  • Page 54Crankshaft, Main Bearings and Flywheel Search 2588079 Crankshaft Seal and Wear Sleeve Installation Tools (Silicone and Hydrodynamic) (Continued) Model: 1100, 3100, 3200, 3300, 3400 Warranty: Six Months CURRENT ENGINES CURRENT ENGINES Item Location Part Number Description Qty. Item Location Part Numb
  • Page 55Search Crankshaft, Main Bearings and Flywheel 2588079 Crankshaft Seal and Wear Sleeve Installation Tools (Silicone and Hydrodynamic) (Continued) Model: 1100, 3100, 3200, 3300, 3400 Warranty: Six Months CURRENT ENGINES Item Location Part Number Description Qty. D379, D398, D399, G379, G398 and G399 E
  • Page 56Crankshaft, Main Bearings and Flywheel Search 3044611 422-7508 PTO Seal Installer Tool Assembly Model Usage: 3500 Machine Engines Warranty: Six Months • Used to quickly and easily install rear PTO oil seal • Necessary to correctly install seal without damage • Decreases installation time • Made from
  • Page 57Search Crankshaft, Main Bearings and Flywheel 2588150 9U-6170 Installer Group Model: 3064 and 3066 Engines Warranty: Six Months • Used to install rear seal and wear sleeve onto crankshaft (assures seal lip will bear uniformly around the crankshaft) • Prevents seal damage during installation — longer
  • Page 58Crankshaft, Main Bearings and Flywheel Search 2588225 155-8795 Crankshaft Distortion Gauge Model: All Engines, 3500 and Up Warranty: Six Months • Used to check crankshaft bearing alignment or shaft deflection without engine disassembly • Also used as a strain gauge on frame of running engine • Will
  • Page 59Search Crankshaft, Main Bearings and Flywheel 2588278 1U-7325 Distorter Adapter Model: 3508, 3512, 3516, 789, 793, 994 Warranty: Six Months • Used with 5P-7409 Distorter to remove front and rear crankshaft wear sleeves from 3500 Series Engines with 1W-6974 Seal Group and 1W-6977 Seal Group • Positio
  • Page 60Crankshaft, Main Bearings and Flywheel Search 2588329 FT2794 Crankshaft Seal Installer Model: 3508 Engines in D10R Track-Type Tractors Warranty: None • Used to install front crankshaft seal • Used with two 3E-3883 Eyebolts • Allows in-chassis installation • Greatly reduces labor time Reference Servi
  • Page 61Search Crankshaft, Main Bearings and Flywheel 2588379 9U-6200 Alignment Group Model: 3056 Engines Warranty: Six Months Part Number Description • Used to install front cover (correctly 9U-6201 Alignment Group aligns it for easier installation) • Designed to fit around crankshaft and into seal recess
  • Page 62Crankshaft, Main Bearings and Flywheel Search 2588430 Crankshaft Oil Seal Installers Essential Tool Model: 3034 Engines Warranty: Six Months • Used to install front and rear crank- Part Number Description shaft oil seals 159-9074 Front Seal Installer • 159-9074 for front and 159-9071 for 159-9071 Re
  • Page 63Search Crankshaft, Main Bearings and Flywheel 2588472 9U-6180 Front Seal Installer Group Model: 3064 and 3066 Engines Warranty: Six Months Item Part No. Description • Used to install crankshaft front seal -- 9U-6180 Front Seal without removing front cover Installer • Makes installation easier and pr
  • Page 64Crankshaft, Main Bearings and Flywheel Search 2588539 Cat® C6.6 Engine / Perkins Vista D Engine Tools Essential Tool Model: C6.6 Engines Warranty: None Part Number Description Use 276-1207 Front Crankshaft Locator Install front shaft seal in engine 276-1209 Installer Install front shaft seal in engi
  • Page 65Search Crankshaft, Main Bearings and Flywheel 2588568 4C-6375 Locator 127-1591 Rear Oil Seal Installer Model: 3046 Diesel Engine Warranty: Six Months 4C-6375 • Used to install crankshaft rear seal (assures seal lip will bear uniformly around crankshaft) • Prevents seal damage during installation Eng
  • Page 66Crankshaft, Main Bearings and Flywheel Search 2897071 367-3534 Seal Installer Model Usage: C7.1, C6.6, C4.4 Warranty: Six Months • Used to correctly remove and assemble front crankshaft oil seal Part Number Description 367-3534 Seal Installer Engine Tools 2696411 363-3031 Seal Installer Assembly Mod
  • Page 67Search Crankshaft, Main Bearings and Flywheel 2588618 Thread Repair Kits (Continued) Essential Tool Model: 3406, G3406, 3408, G3408, 3508, G3508, 3512, G3512, 3516, and G3516 Engines Warranty: Six Months Engine Insert Item Part Number Description Model 1st Ream 2nd Ream 3rd Ream 1st Tap 2nd Tap Slee
  • Page 68Crankshaft, Main Bearings and Flywheel Search 2588668 Bearing Cap Tools (Continued) Model: 1100, 3100, 3208, D342, D379, D398, D399, 3512, D397, G397, D375, G375, D364, 3500 Warranty: Six Months • 9U-5023 Main Bearing Wrench used to remove and install crankshaft main bear- ings on 3500 Family Engine
  • Page 69Search Crankshaft, Main Bearings and Flywheel 2588714 3500 Engine Main Bearing Cap Removal/Installation Tool (Continued) Model: All 3500 Engines Warranty: Six Months Part Number Use 230-5843 Early 3500 Engines with 3/4 in thd. bearing caps 236-6688 Later 3500 Engines with 7/8 in thd. bearing caps 25
  • Page 70Crankshaft, Main Bearings and Flywheel Search 2588763 Bearing Removal and Installation Tools (Continued) Model: Cat® Engines Warranty: Six Months Bearing Thickness Part Number Models: D353, D379, D398, D399 / Bore Size: 159 mm (6.25 in) 4.55 - 14.76 mm (0.179 - 0.581 in) 2P-5517 Models: D339, D342,
  • Page 71Search Crankshaft, Main Bearings and Flywheel 2588819 FT1206 Pusher Plate Model: 16G Motor Graders and 623B Elevating Scrapers Warranty: None • Used for engine in-chassis seal and wear sleeve installation Engine Tools 2588833 FT0884 Dimensions to Modify 1P-2321 Puller Assembly Model: Cat® Engines Wa
  • Page 72Crankshaft, Main Bearings and Flywheel Search 2588867 FT0101 Driver Body Model: D8K, D9H, D353 Warranty: None • Used to install rear oil thrower on crankshaft of D353 Engine • Used with FT0108 Driver Handle • Material: SAE 4140 steel Engine Tools 2588884 FT0102 Driver Body Model: D353 Warranty: None
  • Page 73Search Crankshaft, Main Bearings and Flywheel 2588919 FT0807 Driver Body Model: D9H Warranty: None • Used to install front oil thrower on crankshaft of D353 Engine • Used with FT0108 Driver Handle • Material: SAE 1020 steel Engine Tools 2588934 FT0107 Driver Body Model: 641, 650, 651, 657, 660, and
  • Page 74Crankshaft, Main Bearings and Flywheel Search 2588969 FT0105 Push Plate Model: D379B, D398B, D399 Warranty: None • Used to install oil thrower on crankshaft of D397, D375 and G375 Engines Engine Tools 2588986 171-7212 Repair Sleeve Model: 3114, 3116, 3126, 3126B Engines Warranty: Six Months • Used t
  • Page 75Search Crankshaft, Main Bearings and Flywheel 2589024 FT0143 Driver Model: D375 and D397 Engines Warranty: None • Used to install crankshaft plugs • Used with FT0144 Handle • Material: SAE 4140 steel Engine Tools 2589038 FT0144 Handle Model: D7G Engine Warranty: None • Used with FT0128, FT0130, FT01
  • Page 76Crankshaft, Main Bearings and Flywheel Search 2589067 332-9511 Bearing Puller Assembly Essential Tool Model: 793F Off-Highway Truck Warranty: Six Months • Used to remove 146-7411 Bearing Part Number Description Sleeve from 146-7404 Cage Assem- 332-9511 Bearing Puller Assembly bly in flywheel housing
  • Page 77Search Cylinder Block and Liners Cylinder Block and Liners 2589091 FT1855 Block Pressure Test Group Model: 1100, 3100, 3208 Warranty: None • Used to check porosity of cylinder block in rebuilt engines (Engine blocks often become pitted on outer wall of cylinder due to improper cooling system main- t
  • Page 78Cylinder Block and Liners Search 2589110 9U-6274 Compression Test Kit (Continued) Model: 3046, 3054, 3056, 3064, and 3066 Engines Warranty: Six Months Item Part No. Description Not Shown -- 9U-6385 Foam Block 1 Part of Cylinder Pressure Group (Gas Engines) 2589150 Engine Tools 193-5859 Cylinder Pres
  • Page 79Search Cylinder Block and Liners 2589181 1P-3565 Chamfering Group Model: 1100, 3100 Warranty: Six Months Part Number Description • Used to break sharp corner at bot- 1P-3565 Chamfering Group tom of cylinder bore after honing cylinder bores on 1100 and 3100 1P-3564 Abrasive Cone (6) Series Engines En
  • Page 80Cylinder Block and Liners Search 2589213 Plate Pullers Model: 3126 Engines Warranty: Six Months • Used to install 107-7604 Cylinder Part Number Description Sleeve in cylinder blocks with dam- 129-9196 Puller Plate (lower) aged cylinder walls 129-9197 Puller Plate (upper) • Used with 1P-0820 Hydrauli
  • Page 81Search Cylinder Block and Liners 2589268 4C-4377 Stress Plate Group 142-2285 Cylinder Head Stress Plate Model: See below Warranty: Six Months Part Number Description Model • Used to hone cylinder bores (neces- 4C-4377 Stress Plate 3114, 3116 sary tool to properly recondition Group cylinder bores) •
  • Page 82Cylinder Block and Liners Search 2589312 Tools for Reconditioning Cylinder Block Counterbores Model: Multiple Engine Models Warranty: Six Months Engine blocks which develop cracks in the cylinder liner coun- terbore area can be repaired. The repair consists of machining a new counterbore and install
  • Page 83Search Cylinder Block and Liners 2644434 Application Chart for Counterboring Tools (18) (11) (12) (13) (14) (15) (17) Engine Liner Seat Master Depth Cutter As- Cutter Setting Holder Mounting Water Special Model Insert Installer Gauge sembly Gauge Group Bolts Ferrule Instructions 5.4 / 90 V-8 5P-0937
  • Page 84Cylinder Block and Liners Search 2589345 9U-7988 Riser Plate Group Model: 3300 Engines with Spacer Plate Warranty: Six Months • Used during salvage operation of Part Number Description liner seats which are cracked or 9U-7988 Riser Plate Group damaged • Used with 9U-7990 Counterbore Tool Group, 9U-7
  • Page 85Search Cylinder Block and Liners 2644131 Counterbore Tool Group (Continued) Model: 3176, 3300 (with spacer plate), and 3406 (with spacer plate) Engines Warranty: Six Months Not Shown Item Description Metal Case Basic Counterbore Tool Group Case Base and Micrometer Group Engine Tools Item 1 Part Numb
  • Page 86Cylinder Block and Liners Search 2644037 Machining Dimensions for Cylinder Block Liner Seats (Continued) Liner Inserts Bore Diameter Depth of Cut Liner Inserts Bore Diameter Depth of Cut 3406 Engine (Continued) 3406 Engine (Continued) 6I-4365 166.05 mm (6.537 in) 2.660 mm (0.1047 in) 101-0523 166.05
  • Page 87Search Cylinder Block and Liners 2589442 9U-7993 Depth Gauge Assembly Model: 3300, 3400, and 3176 Engines Warranty: Six Months • Used to measure actual depth of liner seat counterbore — used during rework procedure of 3176, 3300, and 3400 Engine cylinder blocks • Used with 9U-7990 Counterbore Tool G
  • Page 88Cylinder Block and Liners Search 2589460 1P-4000 Line Boring Tool Group (Continued) Model: Multiple Engine Models Warranty: Six Months Item Part Number Description Qty. Item Part Number Description Qty. -- 1P-4000 Line Boring Tool Group -- Item 16, Micrometer Bracket Assembly includes: 4 Item 1, Upr
  • Page 89Search Cylinder Block and Liners 2589542 6V-7840 Deck Checking Tool Assembly Model: 518 Warranty: Six Months • Provides very accurate measurements, which are compared to block specifica- tions, to determine how much of top surface of cylinder block has been ma- chined (when an engine is reconditione
  • Page 90Cylinder Block and Liners Search 2589590 362-4250 Tool Kit (Deck Height Measuring Tool) (Continued) Essential Tool Model: C15, C-15, C16, C-16, C18, C-18, 3400, C27 and C32 Warranty: Six Months Part Number Description 362-4250 Tool Kit (Deck Height Measuring Tool) Service/Repair Parts 362-4251 Thru-
  • Page 91Search Cylinder Block and Liners 2589641 5P-8665 Cylinder Liner Puller (Continued) Model: Multiple Engine Models Warranty: Six Months Item Part Number Description Qty. Item Part Number Description Qty. 7 5P-8671 Foot 2 10 8T-5103 Arm Assembly 2 8 6V-4133 Wedge Bracket (see infor- -- 11 131-6118 Lift
  • Page 92Cylinder Block and Liners Search 2589697 7F-1857 Liner Puller Discontinued — Service Parts Available • Discontinued and replaced by 5P-8665 Cylinder Puller liner Service / Repair Parts Item Description 3 Handle 11 Swivel Engine Tools Item Part Number Description Quantity Service/Repair Parts 1 1B-43
  • Page 93Search Cylinder Block and Liners 2589731 8T-0455 Liner Projection Tool Group Model: Multiple Engine Models Warranty: Six Months • Provides easy, accurate way to determine cylinder liner projection and counter- bore depth Reference SMHS7727, Special Instruction Item Part Number Description Engine Too
  • Page 94Cylinder Block and Liners Search 2589788 Cylinder Pack Pullers Model: See Chart Warranty: Six Months • Used to pull liner, piston and connecting rod, as an assembly, from engines • Very useful when used for in-frame overhauls because it eliminates need for ridge reaming and dirt generated by reaming
  • Page 95Search Cylinder Block and Liners 2589802 322-3564 Puller Group Essential Tool Model: C175 Engines Warranty: Six Months European Union compliant, CE marked • Used to remove and install cylinder liner, piston, and connecting rod as an as- sembly • Very useful when used for in-frame overhauls because r
  • Page 96Cylinder Block and Liners Search 2589865 Cylinder Liner Puller Plates and Leg Model: 3054 and 3056 Engines Warranty: Six Months • Used to remove and install cylinder liners • 9U-6234 Puller Plate used to remove liners, 9U-6235 to install liners • Legs used between puller plates and additional toolin
  • Page 97Search Cylinder Block and Liners 2589901 5P-8709 Piston Cooling Jet Alignment Tool Group (Continued) Model: Older Cat® Engines including D353, D377, D398, D899, G379, and G399 only Warranty: Six Months Item Part Number Description Quantity Where Used 1 5P-8596 Screen 1 with all benches (FITB, FIETS,
  • Page 98Cylinder Block and Liners Search 319-6486 Alignment Tool Essential Tool Model: C4.4 and C6.6 Industrial Engine Warranty: Six Months • Used to align front housing on Part Number Description engine block 319-6486 Alignment Tool • Used with three 8T-4185 Bolts (M10 x 50 mm long, dealer supplied) to Eng
  • Page 99Search Cylinder Block and Liners 2590023 Drivers Model: 3200 Warranty: Six Months • Used for installing piston cooling orifices and plugs Engine Tools Item Part Number Description Model Use 2 6D-3039 Pin -- -- 3 6V-7771 Driver 3208 Install piston cooling jet plugs 1 6V-7772 Driver 3204 and 3208 Spri
  • Page 100Cylinder Block and Liners Search 2590058 5P-8595 Honing Tool Group (Continued) Model: 6.25 inch Bore, 6-Cylinder Diesel Engines Warranty: Six Months Engine Tools Part Number Description 5P-8595 Honing Tool Group Service/Repair Parts 5P-8592 Stone, 114.03 - 182.88 mm (4.5 - 7.2 in) Diameter (70 Grit)
  • Page 101Search Cylinder Block and Liners 2590093 FT1711 Light Table Model: Multiple Engine Models Warranty: None • Used for inspecting all Cat® cylinder liners • Fluorescent light source mounted under plexiglass plate • As many as 6 liners can be placed on fixture at same time • Adjustable to allow differen
  • Page 102Cylinder Block and Liners Search 2590135 356-9752 Protective Plug Model: 3500 Engines Warranty: Six Months • Used to cover open cylinder bores Part Number Description during service 356-9752 Protective Plug • Easily and quickly installed and removed • Covers can be used on 3500 cylinder liners or ba
  • Page 103Search Cylinder Head, Valves and Cam Followers Cylinder Head, Valves and Cam Followers 2590157 Thread Insert Installation Tools Model: All Engines Models Warranty: Six Months • Installation of thread inserts provides relatively easy, inexpensive method of reconditioning cylinder heads in which pre-
  • Page 104Cylinder Head, Valves and Cam Followers Search 2644492 Thread Insert Installation Tools (Continued) (1) (2) (3) (4) (5) (6) (7) (8) Engine Drill Size Thread Tap Pilot Tap Guide Drill Pre - As- Sleeve Nib Bore Size Size Winder sembly Insert 137.31 mm 29/32 in 7/8 in - 12 9M-6595 9M-6591 9M-6592 9M-65
  • Page 105Search Cylinder Head, Valves and Cam Followers 2590169 Valve Guide Drivers and Bushings (Continued) Model: All Cat® Diesel Engines, except 1100, 3100, 3208 Warranty: Six Months Valve Guide Drivers and Bushings Bore Size Engine and Engine Driver Part No. Bushing Part No. Application 130 mm (5.125 in)
  • Page 106Cylinder Head, Valves and Cam Followers Search 2590220 124-9057 Guide Collar (Swirl) Model: 3406C Engines with Swirl Inlet Valve Seats/Inserts Warranty: Six Months • Used to quickly and accurately install discontinued 121-4317 Valve Guide to proper installation height • Used with 9U-6895 Valve Guide
  • Page 107Search Cylinder Head, Valves and Cam Followers 2590265 9U-6954 Guide Collar Model: 3300 Engines Warranty: Six Months Part Number Description • Used to install stepped valve guides 9U-6954 Guide Collar to correct height • Prevents damage to valve guide during installation • Saves time by automaticall
  • Page 108Cylinder Head, Valves and Cam Followers Search 2590324 342-6109 Stop Collar Model: C9 Engines Warranty: Six Months • Used to install 259-5829 Valve Guide Part Number Description to proper height 342-6109 Stop Collar • Used with 4C-6366 Guide Driver • Prevents damage to valve guide during installatio
  • Page 109Search Cylinder Head, Valves and Cam Followers 2590362 275-2423 Valve Guide Installer Model: G3408 and G3412 Engines Warranty: Six Months Part Number Description • Used to install both intake and ex- 275-2423 Valve Guide Installer haust valve guides to two different heights (depends on which end of
  • Page 110Cylinder Head, Valves and Cam Followers Search 2590398 6V-7770 Valve Guide Tool Kit (Continued) 6V-7755 Spring Seat Guide Model: 1100, 3100, 3200 Warranty: Six Months Item Part Number Description Size 1 6V-7770 Valve Guide Kit -- 2 6V-7755 Spring Seat Guide -- Service/Repair Parts for 6V-7770 Kit, I
  • Page 111Search Cylinder Head, Valves and Cam Followers 2590454 149-6115 Valve Seat Installer (Continued) Model: 3126B Engines Warranty: Six Months Part Number Description Length of tubing 103 mm (4.0 in) 149-6115 Valve Seat Installer minimum Small end of driver intake seats Larger end of exhaust seats drive
  • Page 112Cylinder Head, Valves and Cam Followers Search 2590511 9U-6460 Guide Collar Model: 3176 Engines Warranty: Six Months • Used to install stepped valve guide Part Number Description without damage to guide 9U-6460 Guide Collar • Used with 1U-9169 Driver for valve guide removal with discontinued 1U-9654
  • Page 113Search Cylinder Head, Valves and Cam Followers 2901152 C9.3 Valve Guide and Valve Seat Installer Tools Model Usage: C9.3 Warranty: Six Months • Used to install valve guides and seats for C9.3 engines • Long pilot, valve seat installer, serves as a guide during installation • Assures seats and guides
  • Page 114Cylinder Head, Valves and Cam Followers Search 2590606 1P-7451 Valve Guide Honing Group (Continued) Model: Multiple Engine Models Warranty: Six Months Item Part Number Description 1 1P-7455 Mandrel 2 1P-7454 Stone (7) 3 1P-7457 Truing Sleeve 4 1P-7458 Driver Engine Tools 5 1P-7459 Reamer, 9.42 mm (0
  • Page 115Search Cylinder Head, Valves and Cam Followers 2590662 5P-3536 Valve Guide Gauge Group Model: Multiple Engine Models Warranty: Six Months Part Number Description • Provides method for quickly and 5P-3536 Valve Guide Gauge accurately measuring all current Group valve guides for size, taper, and out-
  • Page 116Cylinder Head, Valves and Cam Followers Search 2590704 5S-1330 Pneumatic Valve Spring Compressor Model: All Engines except 3600 Warranty: Six Months • Timesaver when removing and installing valve keepers • Discontinued 5S-1326 Special Adapter used in place of regular jaws for servic- ing D343 and 16
  • Page 117Search Cylinder Head, Valves and Cam Followers 2590759 7F-4292 Valve Spring Compressor Group Model: 1100, 3100, 3208 Warranty: Six Months • Used to remove and install valve springs manually • Engines with recessed valve spring chambers require 7M-3976 Adapter; 1100 and 3100 Series and 3208 Engines r
  • Page 118Cylinder Head, Valves and Cam Followers Search 2590796 9U-6145 Air Connector (Continued) Model: 3064 and 3066 Engines Warranty: Six Months Overall length 153 mm (6.0 in) Part Number Description Small end diameter 7.15 mm (0.281 in) 9U-6145 Air Connector Body diameter 16.75 mm (0.659 in) Air connecti
  • Page 119Search Cylinder Head, Valves and Cam Followers 2675913 Later Style Nozzle Adapters Item Description 1 Plate Assembly 2 Adapter Assembly 3 Adapter Assembly Engine Tools Home 3-119
  • Page 120Cylinder Head, Valves and Cam Followers Search 2590852 Service Tools for Jacobs Vehicle Systems (Jake Brake®) Essential Tool Model: C-10, C-12, 3176/B, 3306B/C, 3406B/C/E Truck Engines Warranty: Six Months • Used to quickly and accurately install or service Jake Brake Units on Cat® On-Highway Truck
  • Page 121Search Cylinder Head, Valves and Cam Followers 2590852 Service Tools for Jacobs Vehicle Systems (Jake Brake®) (Continued) Essential Tool Model: C-10, C-12, 3176/B, 3306B/C, 3406B/C/E Truck Engines Warranty: Six Months Item Part Number Description Item Part Number Description 12 150-3618 Pressure Tes
  • Page 122Cylinder Head, Valves and Cam Followers Search 2590940 228-3610 Feeler Gauge (C15) 235-0032 Lash Gauge (C13) Model: C13 and C15 Engines Warranty: Six Months • Used to set variable valve actuators Part Number Description 228-3610 Feeler Gauge Engine Tools 235-0032 Lash Gauge 2590957 241-0124 Spring C
  • Page 123Search Cylinder Head, Valves and Cam Followers 2591008 Valve Spring Compressor Group for 3176 Engine Model: 3176 Engine Warranty: Six Months Item Part Number Description • Used to remove and install valve springs of 3176 Engine 4C-6726 Valve Spring Compressor Group • Compresses all valve springs on
  • Page 124Cylinder Head, Valves and Cam Followers Search 2591080 276-1221 Valve Spring Assembly Essential Tool Model: C6.6 Engines Warranty: Six Months • Used to remove valve spring without Part No. Description removing cylinder head 276-1221 Valve Spring Assembly • Used with 9U-6195 Valve Spring Compressor G
  • Page 125Search Cylinder Head, Valves and Cam Followers 2591121 8S-2263 Valve Spring Tester Model: All Engines Warranty: Six Months Part Number Description • Provides fast, accurate testing for 8S-2263 Valve Spring Tester old valve springs which should be tested before installing in recondi- tioned head • Sc
  • Page 126Cylinder Head, Valves and Cam Followers Search 2591173 166-7441 Valve Seat Extractor Tool Group Model: All Cat® Engines except 3600 Warranty: Six Months • Replaces discontinued 6V-4805 Valve Seat Extractor Tool Group and discontinued 9S-3080 Valve Seat Insert Puller Group • Used to remove valve seat
  • Page 127Search Cylinder Head, Valves and Cam Followers 2591203 Valve Seat Extractors Model: 3054 and 3056 Engines Warranty: Six Months • Used with 9S-3095 Handle Assembly to remove valve seat insert Dimension Extractor Item Part No. Description (A, B) Length Use 1 9U-6396 Extractor 49.5 mm (1.95 102 mm (4 i
  • Page 128Cylinder Head, Valves and Cam Followers Search 2696440 366-5728 G3500 Engine Valve Guide Installer Model Usage: G3500 Engines with water cooled inserts Warranty: Six Months • Used to install intake and exhaust valve guides on G3500 engines with water cooled inserts, used during rework process • This
  • Page 129Search Cylinder Head, Valves and Cam Followers 2591281 130-1449 Valve Seat Puller Group Model: All 3600 and G3600 Engines Warranty: Six Months • Replaces discontinued 9U-5099 Valve Seat Puller Group (9U-5099 includes 9U- 5096 Bridge Assembly) • Used to remove intake and exhaust valve seat inserts •
  • Page 130Cylinder Head, Valves and Cam Followers Search 2921934 C4.2 and C6.4 Valve Guide Install and Removal Tools Model Usage: C4.2, C6.4 Warranty: Six Months • Used to install remove and install valve guides during rework process • Made of hardened steel and black oxide coated for durability and corrosion
  • Page 131Search Cylinder Head, Valves and Cam Followers 2591351 9U-6176 Valve Seat Driver 9U-6177 Exhaust Driver Plate Model: 3064 and 3066 Engines Warranty: Six Months • Used to install both intake and exhaust valve seats • Correctly aligns insert during installation • Knurled handle for better handling Ref
  • Page 132Cylinder Head, Valves and Cam Followers Search 2591418 Valve Seat Drivers Model: 3406E Engines Warranty: Six Months • Used to install valve seat inserts • Serves as guide for proper alignment of insert during installation • Knurled handle for better grip (zinc coated for corrosion resistance) Refere
  • Page 133Search Cylinder Head, Valves and Cam Followers 2591454 FT1767 Valve Seat Insert Shrinker Model: Most Cat® Engines Warranty: None • Used with carbon dioxide (CO2) to decrease (shrink) outside diameter of valve seat inserts for easy installation • Takes about 10 seconds to shrink an insert • Can also
  • Page 134Cylinder Head, Valves and Cam Followers Search 2591490 155-1536 Valve Recession Tool Kit Model: 3500 and G3500 Engines Warranty: Six Months • Used to determine actual valve and Item Part No. Description valve seat wear 1 258-6575 Dial Indicator • Digital Indicator displays inches and 2 5P-4814 Colle
  • Page 135Search Cylinder Head, Valves and Cam Followers 2591515 213-9285 Valve Recession Tool Kit (Continued) Model: G3400 Engine Warranty: Six Months Item Part Number Description -- 213-9285 Valve Recession Tool Kit Included with 213-9285 -- 4C-3975 Case -- 213-9386 Foam Block Engine Tools -- 213-9198 Valve
  • Page 136Cylinder Head, Valves and Cam Followers Search 2591570 FT1741 Vacuum Tester Model: 3612, 3616 Warranty: None • Used to check for leaks between valve face and seat on cylinder heads after valves and seats have been ground and valve springs assembled • Consists of vacuum pump with connecting parts and
  • Page 137Search Cylinder Head, Valves and Cam Followers 2591611 Valve Recession Tooling (Continued) Essential Tool Model: C175 Engines Warranty: Six Months • 326-7698 Base Assembly (5) features 2 set screw locations -Lower set screw is used with 3600 and G3600 Engines -Upper set screw is used with C175 Engin
  • Page 138Cylinder Head, Valves and Cam Followers Search 2591657 5P-7333 Bridge Dowel Repair Tool Group (Continued) Model: 3400 Warranty: Six Months Item Part Number Description Item Part Number Description 1 5P-7330 Screw 5 5P-7326 Drill Bushing 2 5P-7325 Driver 6 5P-7328 Drill Bushing 3 5P-7331 Reamer 7 5P-
  • Page 139Search Cylinder Head, Valves and Cam Followers 2591734 Valve Lash Setting Tools Essential Tool Model: 3500A and 3500B Diesel, 3500 Magneto and EIS Gas Engines Warranty: Six Months • Used to accurately set engine valve lash with factory setting methods • Installation of tools is quick and easy with a
  • Page 140Cylinder Head, Valves and Cam Followers Search 2591774 146-2597 Push Rod Holder Model: 3114, 3116, and 3126 Engines with MUI Fuel Systems Warranty: Six Months • Used to hold all three push rods in Part Number Description place while rocker arm assembly is 146-2597 Push Rod Holder installed to cylind
  • Page 141Search Cylinder Head, Valves and Cam Followers 2591823 Valve Lash Setting Tool Model: 3500 Engines Warranty: Six Months • Replaces discontinued 4C-8241 Valve Lash Setting Gauge • Used to provide valve lash settings on 3500 A Series diesel engines • Dial indicator eliminates guesswork by measuring ex
  • Page 142Cylinder Head, Valves and Cam Followers Search 2591849 Lifting Bracket Assemblies (Continued) Model: 3406E Engines and C11/13 Engines Warranty: Six Months Part Number Description Model 124-2946 Lifting Bracket Assembly 3406E Rocker Arm 293-2989 Lifting Bracket Assembly C11/13 Rocker Arm 2591869 8S-6
  • Page 143Search Cylinder Head, Valves and Cam Followers 2591928 199-1418 Hook Assembly Model: 3406E, C-15, and C-16 Engines Warranty: Six Months • Used to quickly and easily lift cylinder head cores (camshaft must be removed prior to using tool) • Used with an overhead lifting device • Attaches easily withou
  • Page 144Cylinder Head, Valves and Cam Followers Search 2591984 165-4638 Guide Manifold Model: 3400 Engines Warranty: Six Months • Used to install exhaust manifolds Part Number Description • Threads onto manifold stud for posi- 165-4638 Guide Manifold tive retention Engine Tools 2592000 1U-8264 Head Lifting
  • Page 145Search Cylinder Head, Valves and Cam Followers 2828271 367-3535 Timing Case Cover Alignment Tool Model Usage: C7.1 Warranty: Six Months • Used to correctly align pressed steel timing case cover to the timing case Specifications Dimensions 5.8 x 3.75 x 3.75 in (147 x 95.25 x 95.25 mm) Material Steel
  • Page 146Cylinder Head, Valves and Cam Followers Search 2848692 370-8083 Cylinder Head Lifting Bracket Model: 3406E, 3456, C-15, C-16 Engines Warranty: Six Months European Union compliant, CE marked • Used to quickly and easily lift cylinder heads with exhaust manifold and turbo charger attached. • Includes
  • Page 147Search Cylinder Head, Valves and Cam Followers 2592062 Sleeve Replacement Tools (Continued) Model: 3114, 3116 and 3126 Engines Warranty: Six Months Item Description 18 Bolt Included (Not shown) NEEG2748 Decal Engine Tools NEHS0675 Tool Operating Manual, “Using the143-2099 Sleeve Re- placement Tool G
  • Page 148Cylinder Head, Valves and Cam Followers Search 2644751 143-2098 Sleeve Removal Tool Group Warranty: Six Months Included (Not shown) Item Description NEEG2748 Decal NEHS0675 Tool Operating Manual, “Using the 143- 2099 Sleeve Replacement Tool Group on 3114, 3116 and 3126 Engines” Engine Tools 143-2098
  • Page 149Search Cylinder Head, Valves and Cam Followers 2592157 131-8362 Reamer Head Essential Tool Model: 3114, 3116, and 3126 Engines Warranty: Six Months Part Number Description • For reaming tapered injector seat in 131-8362 Reamer Head copper alloy injector sleeves • Used with 143-2099 Sleeve Replace- m
  • Page 150Cylinder Head, Valves and Cam Followers Search 2592200 151-4832 Sleeve Remover Assembly Model: 3126B HEUI Engines Warranty: Six Months • Used to easily remove injector sleeves • Designed for non-grooved injector sleeves • Includes 177-7804 Segment Collet Application Procedure 1. Insert tool fully in
  • Page 151Search Cylinder Head, Valves and Cam Followers 2592221 173-1530 Injector Seating Tool Group (Continued) Essential Tool Model: 3114, 3116, 3126 MUI and 3116, 3126 2-Valve HEUI Engines Warranty: Six Months Included (Not shown) Item Description NEEG2838 Decal, Case Engine Tools Item Part Number Descrip
  • Page 152Cylinder Head, Valves and Cam Followers Search 2592287 131-3921 Puller Group (HEUI) Model: 3408 and 3412 HEUI Engines Warranty: Six Months • Used to easily remove carbon-fouled injectors from cylinder head • Puller has large, balled end, handle for easier removal • Puller bridge assembly sits on cyl
  • Page 153Search Cylinder Head, Valves and Cam Followers 2592329 4C-8714 Guide Bushing (Large), 4C-8715 Guide Bushing (Small) 9U-5671 Reaction Sleeve Model: 3114 and 3116 Engines Warranty: Six Months Part Number Description • Used to replace and ream injector 4C-8714 Guide Bushing sleeves without removing val
  • Page 154Cylinder Head, Valves and Cam Followers Search 2592391 312-3204 Injector Brush Essential Tool Model: C175 Engine Warranty: Six Months • Used to clean injector bores before Part Number Description inserting injectors 312-3204 Injector Brush • Tapered design for easy insertion and efficient cleaning a
  • Page 155Search Cylinder Head, Valves and Cam Followers 2592455 169-3374 Injector Sleeves Tool Group Model: 3176 and 3176B Engines Warranty: Six Months • Used to quickly and easily remove brass injector sleeves • Eliminates sleeve tapping (threading) operation — no brass chips to fall into engine • Similar t
  • Page 156Cylinder Head, Valves and Cam Followers Search 2848709 372-7975 C7 Injector Sleeve Removal/Installation Tool Model: C7 Engines Warranty: Six Months • Used to remove and install the injector sleeve on C7 Engines • Uses a 1/4” - 28 x 6” long tap, purchased separately (example McMaster - Carr 2589A26)
  • Page 157Search Cylinder Head, Valves and Cam Followers 2592522 Drive-In Precombustion Chamber Tools Model: Most Cat® Engines Warranty: Six Months Part Number Description • Hydraulic puller combined with 6V-3160 Cylinder Group tools shown provides simple and ef- ficient method of removing drive-in type preco
  • Page 158Cylinder Head, Valves and Cam Followers Search 2592578 5P-0125 Precombustion Chamber Wrench Model: 3204, D3, 910, 931 Warranty: Six Months Model: 3204, D3, 910, 931 • Used to remove and install precombustion chambers on 3204 Engine in D3 Trac- tors, 910 Wheel Loaders, and 931 Track Loaders Part Numb
  • Page 159Search Cylinder Head, Valves and Cam Followers 2980794 390-1134 Plug Adapter Model Usage: C3.3B engines Warranty: Manufacturer’s • Used to check engine compression from a glow plug port • Used to verify that compression is at correct level Specifications Dimensions 193.6 x 19.1 mm (7.6 x .75 in) Eng
  • Page 160Cylinder Head, Valves and Cam Followers Search 2592677 FT0869 Cylinder Head (or Hydraulic Cylinder) Storage Rack Model: All Cat® Engines Warranty: None • Provides excellent facility for storing cylinder heads • With modifications, can also be used for hydraulic cylinder storage Engine Tools 2592690
  • Page 161Search Cylinder Head, Valves and Cam Followers 2592728 FT0868 Cylinder Head Component Parts Rack Model: All Cat® Engines Warranty: None • Provides storage for fourteen 305 x 610 mm (12 x 24 in) wire baskets • During cylinder head rebuild, storage space is required for small items like valves, spring
  • Page 162Cylinder Head, Valves and Cam Followers Search 2592770 FT0806 Cylinder Head Repair Bench Model: All Cat® Engines Warranty: None • Provides cradle which will mount all Cat® cylinder heads • Cradle is well balanced and supported by ball bearings • Foot-operated release mechanism enables serviceman to
  • Page 163Search Cylinder Head, Valves and Cam Followers 2592806 6V-9050 Stud Removal Tool Group (Continued) Model: 3200, 3300, 3400, C9, C15, C-16, C18, C27, C32 Warranty: Six Months Item Part Number Description Item Part Number Description 5 164-3756 Alignment Bushing, 9.53 7 164-3758 Drill Bushing, 3.18 mm
  • Page 164Cylinder Head, Valves and Cam Followers Search 2592875 357-4646 Drilling Plate \ Model: 3054 Engines Warranty: Six Months • Used to remove broken exhaust manifold studs and bolts from engine • Used with 188-3922 Exhaust Stud and Bolt Removal Group • Used in place of 188-3914 Drilling Plate • Designe
  • Page 165Search Cylinder Head, Valves and Cam Followers 2592918 FT1766 Pilot Adapters \ Model: All Cat® Engines Warranty: None • Can be installed in cylinder head and used as guide when surface is ground • Can be made in 3 different sizes which will fit all Cat® cylinder heads equipped with precombustion cha
  • Page 166Cylinder Head, Valves and Cam Followers Search 2828228 375-2773 Installation Tool Model Usage: C13 & C15 Engines Warranty: Six Months • Used to install valve seal using hand pressure • Prevents damage to valve seal during installation Specifications Dimensions 150 x 26.8 mm (5.90 x 1.05 in) Weight .
  • Page 167Search Cylinder Head, Valves and Cam Followers 2592984 Cylinder Condition Analysis Tools (Continued) Model: All Models Warranty: Six Months Item Part Number Description Item Part Number Description 1 6K-5875 Hose Assembly 8 9S-7341 Fitting [6.35 mm ( 1/4 in) 2 1P-5564 Adapter (D.I. Engines) tube, 3.
  • Page 168Cylinder Head, Valves and Cam Followers Search 2887758 359-4208 G3500 Valve Seat Removal Tool Model Usage: G3500 Warranty: Six Months • Safely removes valve seats from Gas 3500 engines • Eliminates insert breakage • Reduces repair time • Reduces rework due to broken inserts Specifications Engine Too
  • Page 169Search Electrical and Ignition Tools Electrical and Ignition Tools 2593054 FT1031 Bearing Driver Model: Prestolite Starters Warranty: None • Used to properly install Oilite bearings in Prestolite starting motors • Act as insertion and sizing tool during installation of bearings • Driver does not des
  • Page 170Electrical and Ignition Tools Search 2645025 1P-2977 Alternator Pulley Tool Group Model: Delco-Remy Alternators Warranty: Six Months • Used to remove pulley retaining nut Part on shaft of Delco-Remy 20-SI and Item Number Description 25-SI Series Alternators -- 1P-2977 Alternator Pulley Tool Group 1
  • Page 171Search Electrical and Ignition Tools 3038281 398-6915 Mounting Ring Socket Wrench Model Usage: Various Warranty: Manufacturer’s • Used to tighten retaining nut on Emergency Stop Push Button assembly 109- 6507 with 124-3176 Guard • Double ended wrench can be used for 18 mm (.71 in) and 30 mm (1.2 in)
  • Page 172Electrical and Ignition Tools Search 2593180 132-8263 Terminal Spanner Wrench Model: All G3500 and G3600 EIS Engines Warranty: Six Months • Used to install and remove 127-8893 Part Number Description Terminal Assembly 132-8263 Terminal Spanner • Required to allow proper torquing of Wrench terminal a
  • Page 173Search Electrical and Ignition Tools 2593228 9U-7516 Spark Plug Gauge Model: 3300, 3400, 3500, and 3600 Spark Ignited Engines Warranty: Six Months • Used to check spark plug gap on spark ignited engines • Compact size — easy to carry from job to job • Gap wires are retractable — prevents damage when
  • Page 174Electrical and Ignition Tools Search 2593284 225-8266 Clamp On Ammeter Model: All Warranty: Manufacturer’s One Year European Union compliant, CE marked • Used to measure AC or DC current • Compact size and low cost make this unit indispensible • Clamp-on probe replaces standard test leads (allows cu
  • Page 175Search Lube System Lube System 2593324 175-7546 Oil Filter Cutter Group Model: All Models Warranty: Six Months • Used to cut open spin-on filters to inspect filter media for contaminants, a common practice when diagnosing potential machine problems and internal contaminants. • Aluminum frame constru
  • Page 176Lube System Search 2901172 371-4330 Oil Filter Drainer Group Model Usage: Any Engine Application Warranty: Six Months • Used to cleanly drain an oil filter before removal from engine • Designed to puncture a hole in side of the inverted oil filters to allow easy oil drainage • Do not remove oil filt
  • Page 177Search Lube System 2593365 4C-6780 Bushing Removal Tool Group Model: 3208 Engines Warranty: Six Months • Removes oil pump bushing fast without damaging timing gear cover • Works on both naturally aspirated and turbo-charged engines • Marked for each engine for easy use Item Part Number Description -
  • Page 178Lube System Search 2593401 9S-9273 Coupler (Continued) 9S-9274 Plug Model: D8H, 583H, D9G, DD9G, 594 Warranty: Six Months • Has 41.3 mm (1.62 in) hex for installing 3/4 inch-14 NPTF threaded end into ser- vice hose fitting Length 70.6 mm (2.78 in) Diameter 50.8 mm (2.00 in) Engine Tools Item Part Nu
  • Page 179Search Lube System 2828441 301-0285 Alignment Tool Model Usage: C1.5 and C2.2 Engine Warranty: Six Months • Properly orients the oil pump to the engine block • Provide protection of the oil pump during the installation process Reference: KENR9149, KENR6948, KENR6229 Part Number Description Engine To
  • Page 180Engine Test Tools Search Engine Test Tools 2593495 FT0949 Dynamometer Adapter Storage Rack FT0940 Water Line Adapter, FT0941 Hose Hanger Model: All Vehicle Engine Models Warranty: None • 2 sets of FT0940 Adapters needed to adapt standard size quick disconnect couplings into water lines between cooli
  • Page 181Search Engine Test Tools 2593511 FT0790 Cooling Tower Group Model: All Vehicle Engine Models Warranty: None • Efficient, economical means for engine cooling for dyna- mometer installations • Many parts available from Parts Department; some must be purchased locally; Bill of Material which includes s
  • Page 182Engine Test Tools Search 2645062 Tractors Model Serial number Adapter D3 6N, 79U, 83U FT0730-4 D4 6U, 7U FT0720-01 D4C 39A, 40A, 54A, 55A FT0719-2 D4D 67A, 78A, 88A, 91A, 22C, 97F, 44H, 18J,20J, 49J, 58J, 59J, 60J, 61J, 65J, 66J, 82J, 83J, 84J, 69K, 7R Engine Tools D4E 27X, 28X, 29X, 70X, 71X FT0719
  • Page 183Search Engine Test Tools 2645097 Pipelayers Model Serial Number Adapter 561B 62A FT0719-2 561C 85H, 92J FT0719-2 561D 54X FT0719-2 571A 64A FT0725 571F 95N FT0719-2 571G 16W FT0719-2 Engine Tools 572E 21A, 65A FT0725 572F 96N FT0719-2 572G 40U FT0719-2 583C-E 16A FT0724-2 583H 38A, 61A FT0724-2 583K
  • Page 184Engine Test Tools Search 2645123 Motor Graders Model Serial Number Adapter 12 80C, 70D, 71D FT0720-01 12E 99E, 12F, 21F, 29H, 17K FT0719-2 12F 73G, 59H, 89H, 13K, 33K FT0719-2 12G 61M FT0719-2 14B 64C, 78E FT0720-01 14C 35F FT0719-2 Engine Tools 14D 96F FT0719-2 14E 72G, 99G, 12K FT0719-2 14G 96U FT
  • Page 185Search Engine Test Tools 2645131 Tractor-Scrapers Model Serial Number Adapter DW15 45C, 59C, 70C, 75D, 76D FT0725 DW20 21C, 57C, 67C, 87E, 88E FT0725 DW21 58C, 69C, 85E, 86E FT0725 613 71M FT0730-4 613B 38W FT0730-4 619B 89E, 90E FT0725 Engine Tools 619C 61F¹, 62F FT0718-1 621 23H FT0723-1 621B 45P,
  • Page 186Engine Test Tools Search 2645139 Tractor-Scrapers (Continued) Model Serial Number Adapter 633C 66M FT1177-3 633D 25W FT1177-3 637 64M, 91N, 92N FT0719-2 637 65M FT0775-2 637D 26W, 27W FT1177-3 641 64F1-317 FT0729-1 Engine Tools 641 64F318, 41M FT0727-1 641B 65K FT0776-1 650 63F FT0729-1 650 63F, 77F
  • Page 187Search Engine Test Tools 2645154 Skidders Model Serial Number Adapter 518 50S, 55U, 94U, 95U FT0719-2 528 51S, 78W FT0719-2 814 90P, 14R FT0719-2 815 91P, 15R FT0719-2 816 57U FT0719-2 824 29C¹ FT0718-1 Engine Tools 824B 36H1-313¹ FT0718-1 824B 36H314 FT0775-2 826B 58U FT0775-2 834 43E1-313¹ FT0718-
  • Page 188Engine Test Tools Search 2645170 Engines Model Serial Number Adpater D311H 51B FT0717-1 311 7S, 9S, 4V FT0728-1 D312 1N FT0720-01 D315 9S, 4V, 5V FT0720-01 D315G 48B, 52B FT0720-01 D318 3V, 5V, 6V FT0720-01 Engine Tools D318G 45B, 53B FT0720-01 D320A 63B FT0717-1 D326 25B, 26B, 27B FT0725 D326F 39B,
  • Page 189Search Engine Test Tools 2645172 Engines (Continued) Model Serial Number Adapter D343 62B1-5738¹ FT0718-1 D343A 33B1-2489¹ FT0718-1 D343 62B-5739, 97N FT0775-2 D343A 33B-2490, 63M FT0775-2 D346 39J, 40J, 98N FT0776-1 D348 36J, 38J, 57K, 92R FT0776-1 Engine Tools D349 61P, 62P, 32R, 93R FT0776-1 D353
  • Page 190Engine Test Tools Search 2645180 Engines (Continued) Model Serial Number Adapter 1145 97B FT0730-4 1150 96B FT0730-4 1160 95B FT0730-4 3145 96M, 65P FT0730-4 3150 97M, 66P FT0730-4 3160 98M, 67P, 68P FT0730-4 Engine Tools 3204 45V FT0730-4 3208 90N, 40S, 75V, 79V FT0730-4 1670 61B FT0719-2 1673 74B
  • Page 191Search Engine Test Tools 2593579 FT1438 Dynamometer Testing Aftercooler Model: 3176, 3208, 3304B, 3306B, 3406B Warranty: None • Air-to-water aftercooler used for dyno testing air-to-air aftercooled engines in 621, 623, 627, 631, 637, 641, 650, 651, 657, 660 and 666 Tractor-Scrapers; 772 and 773 Truc
  • Page 192Engine Test Tools Search 2593598 4C-3502 Engine Repair Indicator Kit (Continued) Model: All Earthmoving Machines Warranty: Six Months Part Number Description Part Number Description 4C-4732 Filter Minder and Filter Service Indicator 1S-0178 Fitting 4C-4733 Crankcase Pressure Gauge 5H-8936 Adapter 4C
  • Page 193Search Engine Test Tools 2593650 196-3165 Tool Kit, C-9 Engine (Continued) Model: C-9 Engine Warranty: Six Months 1 Includes 176-5484 Plate Assembly, 176-5486 Plug Assembly, and 187-1852 Holding Clamp 2645210 173-5533 Repair Stand Bracket Warranty: Six Months Part Number Description Engine Repair St
  • Page 194Engine Test Tools Search 2593689 9U-7530 Tool Kit, 3406E Engine (Continued) Model: 3406E, C-15, C-16 Warranty: Six Months Part Number Description Part Number Description Service/Repair Parts (Continued) Service/Repair Parts (Continued) 9U-7244 End Brush 7X-1403 Adapter Cable Assembly 9U-7237 Drill E
  • Page 195Search Engine Test Tools 2828303 356-8752 G3600 Operator Tool Group (Continued) Model Usage: G3606 (3XF), G3608 (4WF), G3612 (1YG), G3616 (4CG) Warranty: Six Months • Aids in gathering oil samples Media Number Description NEHS0680 Data Sheet Pad Part Number Description 356-8752 Operator Tool Group E
  • Page 196Engine Test Tools Search 3038295 399-7930 Crack Detection Group Cap Model Usage: C7, C9 Warranty: Six Months • Used with 360-9664 Crack Detection Group to measure leakage of soot through DPF Systems • Provides proper fitting flanges to restrict exhaust flow during crack detection test • Fits 4 inch
  • Page 197Search Engine Test Tools 2593773 195-0875 Marine Tool Kit (Not Serviced) (Continued) Model: 3116, 3126, 3126B, 3176, 3196 Marine Engines with Metric Fasteners Warranty: Six Months Part Number Description Part Number Description 195-0875 Marine Tool Kit (Not Serviced) Recommended Tool List (Continued
  • Page 198Engine Test Tools Search 2979922 373-4726 Seal Installer Model Usage: CT660 Truck, CT11, CT13 Warranty: Manufacturer’s • Used to install the crankshaft rear oil seal on the 11L and 13L engines Specifications Dimensions 182.9 x 177.8 mm (7.2 x 7.0 in) Weight 4.5 kg (9.9 lb) Engine Tools Part Number D
  • Page 199Search Engine Test Tools 2979682 373-4796 High Pressure Pump Drive Holding Plate Model Usage: CT660 Truck, CT11, CT13 Warranty: Manufacturer’s • Holding fixture used for high pressure pump • Mounts in a vise for installation of pump drive gear Specifications Dimensions 261.6 x 170.2 x 175.3 mm (10.3
  • Page 200Engine Test Tools Search 2980316 373-4799 EGR Coolant Housing Upper Elbow Extension Tube Seal Installer (small) Model Usage: CT660 Truck, CT11, CT13 Warranty: Manufacturer’s • Used to install the small extension tube seal into the upper EGR coolant housing Specifications Dimensions 25.4 x 25.4 x 25.
  • Page 201Search Engine Test Tools 2980625 376-7698 Crankcase Pressure Test Adapter Model Usage: CT660 Truck, CT11, CT13 Warranty: Manufacturer’s • Used to measure combustion gas flow out of the engine breather • Can be used with the digital manometer from the 368-8645 Blow-by Group or the 8T-0452 Water Manom
  • Page 202Fuel System Test Tools Search Fuel System Test Tools 2593816 FT2642 Nozzle Block to Filter Block Tubing FT2643 Filter Block to Metering Unit Tubing Model: AVM 12C Fuel Injection Test Bench Warranty: None • Provides more durable outer tubing wrap for early test benches • Used with discontinued 132-97
  • Page 203Search Fuel System Test Tools 2593852 158-2262 AVM 2-PC Fuel Injection Equipment Test Stand Model: Cat® Engines Warranty: Manufacturer’s One Year European Union compliant, CE marked Test benches are capable of operating in the 380-480 Volt range but actual voltage will be checked and or changed duri
  • Page 204Fuel System Test Tools Search 2593852 158-2262 AVM 2-PC Fuel Injection Equipment Test Stand (Continued) Model: Cat® Engines Warranty: Manufacturer’s One Year • High-speed, 12-cylinder advanced metering system reduces test time Operation • Control console pivots to permit operation from either side o
  • Page 205Search Fuel System Test Tools 2648027 Worldwide Compatibility (Continued) Part Number Description 158-2262 AVM 2-PC Fuel Injection Equipment Test Stand, 380 to 480 volt, 50/60 Hz, 3-phase 2645288 Installation Requirements These items are necessary for installation and must be or- dered separately. •
  • Page 206Fuel System Test Tools Search 2645412 Computer Drive System Computer: PC Routeco Processor Pentium P633 Hard disk drive 10 GB RAM 64 MB Operating system NT Workstation Engine Tools Floppy disk drive 3.5 in 1.44 MB CD-ROM drive Mouse (PS/2 connection) Serial ports 2 Parallel port 1 Expansion Standard
  • Page 207Search Fuel System Test Tools 2645428 Instrumentation Instrumentation On-screen Resolution Stability Range Display Units display Tachometer Numerical 1 RPM ±1 RPM Fuel Supply 1 - 4 bars On-screen as bar, Mpa, psi, numerical value mmHg, mbar, and analogue hPa, kPa Engine Tools representation Auxiliar
  • Page 208Fuel System Test Tools Search 2645301 Hydraulic System Test Oil Supply and Controls Electric motor Direct pump drive Pressure rating 550 L/hr and 0 - 4 bar (0 - 60 psi) Pressure phase supply 0 - 80 bar Tank 45 L (10 gal) capacity Temperature Control Temperature controlling ±2° C Engine Tools Lube Oi
  • Page 209Search Fuel System Test Tools 2593938 FIETS Nozzle Block and Lines Model: Fuel Injection Equipment Test Stand Warranty: Six Months Nozzle block and replacement lines are applicable to all Fuel Injection Equipment Test Stands (discontinued 6V-7900, discontinued 6V-7901, discontinued 6V-7902, disconti
  • Page 210Fuel System Test Tools Search 2645491 9U-7697 Discharge Conduit Group Warranty: Six Months Item Part Number Description -- 9U-7697 Discharge Conduit Group Discharge Conduit Group Consists of: 1 9U-7457 Conduit Bracket 2 9U-7458 Conduit Fitting 3 9U-7459 Flexible Conduit Engine Tools 4 9U-7701 Arm Li
  • Page 211Search Fuel System Test Tools 2594009 Fuel Injection Tube Assemblies (Continued) Model: Cat® Fuel Injection Test Bench (FITB) and Fuel Injection Equipment Test Stand (FIETS) Warranty: Six Months Part Number Overall Length Use 9U-5298 76 cm (30 in) Used for testing all in-line pumps and 3208 9U-5299
  • Page 212Fuel System Test Tools Search 2594071 NEHS0594 Using TMI for Finding Injection Pump Off Engine Test Specifications Model: Fuel Injection Equipment Test Stand Warranty: None • Contains complete instructions to obtain test specifications through TMI on Caterpillar® Network • New data format gives larg
  • Page 213Search Fuel System Test Tools 2594125 9U-7840 Calibration Fluid and Diesel Fuel Test Kit Model: FIETS, FITB, AVM, All Cat® Engines Warranty: Six Months • Used to measure viscosity and specific gravity of SAE J967D (ISO4113) calibration fluid • Used with fuel injection equipment test stand (FIETS) an
  • Page 214Fuel System Test Tools Search 2594154 136-8330 Basic Mounting/Setup Group (Not Serviced) Model: All Fuel Injection Equipment Test Stands (FITB, FIETS, and AVM) Warranty: Six Months • Replaces discontinued 1U-7426 Pump Adapter Group • Used to adapt injection pump mounting and drive groups to test sta
  • Page 215Search Fuel System Test Tools 2645746 Additional Service/Repair Parts Warranty: Six Months Service/Repair Parts (without Part Numbers) for discontinued 1P-3520 Control Group Item Description Qty. 3 Lug 1 9 Pin 1 13 Stud 1 Engine Tools Additional Service Part Hose Assembly #6 (37 degree) [9/16 - 18 t
  • Page 216Fuel System Test Tools Search 2645746 Additional Service/Repair Parts (Continued) Warranty: Six Months Item Part No. Description Qty. Where Used Item Part No. Description Qty. Where Used Additional Parts (Continued) Additional Parts (Continued) 10 6V-6103 Screw As- -- fixture assembly -- 9U-5298 Tub
  • Page 217Search Fuel System Test Tools 2594225 135-2916 Mounting Drive Group (Not Serviced) Model: 3406B, 3406C, and 3406 PEEC Engines Warranty: Six Months • Replaces discontinued 6V-4990 Adapter Group • Used to mount and test fuel injection pumps • Used with fuel injection equipment test stands (FITB, FIETS
  • Page 218Fuel System Test Tools Search 2645855 Additional Required Hardware for 135-2916 Mounting Drive Group Warranty: Six Months The following list of hardware is required, but not included as part of the 135-2916 Mounting Drive Group (not serviced). This tooling can be purchased as needed. Drive Adapters
  • Page 219Search Fuel System Test Tools 2646060 Test Hardware (PEEC and Non-PEEC Engines) Item Part Number Description Quantity 1 8T-1002 Position Probe (X4) 1 2 5P-4160 Point - Indicator Contact, 19.05 1 mm (0.75 in) long 3 5P-4814 Collet As - Clamp 1 4 7B-2742 Bolt 1 5 8T-9198 Rack Indicator Bracket Assem-
  • Page 220Fuel System Test Tools Search 2646079 Fixture Group / Mounting Plate Item Part Number Description Use 1 4C-5602 Fixture Group 1 hold pump in any position for ease of repair (can greatly increase mechan- ic’s efficiency during overhaul) 2 4C-5603 Mounting Plate bolts to fuel injection pump and attach
  • Page 221Search Fuel System Test Tools 2646133 Disassemble Tools for Zexel and Nippondenso Fuel Pump (Continued) Item Part Number Description Use 7 4C-4956 Nut Socket removes and installs flyweight retaining nut (specially de- signed) 2646144 195-0768 Thread Adapter This adapter is used to adapt the 4C-5601
  • Page 222Fuel System Test Tools Search 2594346 Zexel and Nippondenso Fuel Pump and Governor Test and Adjust Tools (Continued) Model: 3046, 3064 and 3066 Engines Warranty: Six Months Item Part Number Description Use Item Part Number Description Use Mounting Tools (Continued) Mounting Tools (Continued) 10 6V-9
  • Page 223Search Fuel System Test Tools 2646117 Adjustment Tools (Continued) Item Part Number Description Use Adjustment Tools (Continued) 7 4C-5085 Wrench (3064 and adjusts the setting of torque 3066 only) idling screw 8 4C-5567 Torque Adjusting adjusts the setting of torque Socket idling screw 9 4C-6509 Plu
  • Page 224Fuel System Test Tools Search 2646246 Indicator Tools (Continued) Item 1 Part Number Description Use Indicator Tools 2 8T-1002 Position Probe (X4) obtain rack measurement speci- fications 3 5P-4160 Point - Indicator obtain rack measurement speci- Contact, 19.05 mm fications (0.75 in) long Engine Too
  • Page 225Search Fuel System Test Tools 2646436 4C-8145 Throttle Control Indicator Group Sets rack and throttle control angle Item Includes 1 Base Assembly and Upper Plate 2 Indicator Assembly and Ad- justing Block 3 Column Assembly and Upright Engine Tools Bar 4 Throttle Control Linkage, Sleeve and Pin 5 Adj
  • Page 226Fuel System Test Tools Search 2594459 Injection Pump Off-Engine Disassembly, Assembly, and Bench Test Model: Early 3054 and 3056 Pre-Emission Engines Warranty: Six Months • Used to disassemble and assemble Stanadyne DB2 and DB4 fuel injection pump and governor used on pre-emission 3054 and 3056 engi
  • Page 227Search Fuel System Test Tools 2646522 Bench Mounting Tools and Testing Tools Item Description Use 2 Pump Mounting Plate mount pump on 6V-9132 Base Plate Rail Adapter Item Part Number Description Use Quantity Bench Mounting Tools and Testing Tools 1 8S-2264 Puller Group remove 9U-7493 Drive -- Engine
  • Page 228Fuel System Test Tools Search 2646470 FT2559 Plate Part Number Description FT2559 Plate Engine Tools 2646617 Calibration Fluid and Lube Line Tooling Item Part Number Description Y 1 127-4365 Fuel Injector Test connect injection pump to Tube Assembly master nozzle 2 4C-6827 Screwdriver -- 3 4C-8126 I
  • Page 229Search Fuel System Test Tools 2594513 4C-6907 Governor Drive Group (Continued) 4C-8740 Air Supply and Test Group Model: 3500 and 3600 Family Engines with Woodward 3161 Governors Warranty: Six Months Item Part Number Description Quantity -- 4C-6907 Governor Drive Group -- 4C-6907 Governor Drive Group
  • Page 230Fuel System Test Tools Search 2646655 Section B-B Item Part Number Description Qty. 15 9S-4182 Plug 2 16 6V-5048 Seal 2 17 and 18 9F-2247 Pipe Plug 2 Engine Tools 2646661 4C-8740 Air Supply and Test Group Item Description 6 9.53 mm (3/8 in) Tubing, 0.46 m (1.5 ft) 7 Air Bulb (W.A. Baum Co. Inc. Cata
  • Page 231Search Fuel System Test Tools 2594567 4C-6100 Tool Group, 3161 Governor Torque Control Model: Multiple Engine Models Warranty: Six Months • Used to perform variety of in-vehicle engine governor and fuel system settings for D11 Track-Type Tractor and the 777, 785 and 789 Off-Highway Trucks • Easily i
  • Page 232Fuel System Test Tools Search 2594614 1U-6661 Tester Discontinued — Service/Repair Parts Available References SEHS8867, Using the 1U-6661 Pop Tester SEHS8858, Using the 6V-4022 Injector Tester to Test 1.1 L Fuel Injectors SEHS8922, Installation of 1U-6667 Conversion Group SEHS8884, Unit Injector Tes
  • Page 233Search Fuel System Test Tools 2594713 5P-4150 Nozzle Tester Group Model: 1100, 3100, 3208, 3400 Warranty: Six Months • Used to test all fuel nozzles, including pencil-type nozzles on 1100 and 3100 Se- ries and 3208 Engines, direct injection capsule-type fuel nozzles on 3400 Series Engines, and capsu
  • Page 234Fuel System Test Tools Search 2594748 1U-9578 Repair Kit Model: Cat® Engines Warranty: Six Months • Used to disassemble and assemble 5P-4150 Nozzle Tester Group Part Number Description • Contains gaskets, seals, O-rings, steel balls and filter, along with printed parts 1U-9578 Repair Kit breakdown i
  • Page 235Search Fuel System Test Tools 2594797 Tube Assemblies Model: D6D, 528, 3300, 3046, 3054, 3056, 3064, 3066 Warranty: Six Months • Used with 5P-4150 Nozzle Tester and 5P-7448 Adapter to test fuel nozzles in 3300 Series DI Engines • 6V-2170 and 5P-7448 are used on 3054, 3056, 3064 and 3066 Engines (14
  • Page 236Fuel System Test Tools Search 2594842 1U-7326 Governor Calibration Bench (Continued) Model: 3114, 3116, and 3126 MUI Engines Warranty: Six Months Part Number Description 1U-7326 Governor Calibration Bench Service/Repair Parts 4C-4167 Motor Pump Unit, 230 VAC 4C-4168 Motor Pump Unit, 115 VAC 1 Engine
  • Page 237Search Fuel System Test Tools 2646783 1U-9088 Governor Disassembly and Assembly Tool Group (Continued) Discontinued Service/Repair Parts Item Part Number Description Not shown 1 1 6V-7145 Case -- 1U-7307 Governor Repair Fixture -- 1U-7637 Foam Insert Set Engine Tools -- 6V-6106 Dial Indicator -- 8S-
  • Page 238Fuel System Test Tools Search 2646737 1U-9087 Governor Adjust Tool Group (Not Serviced) (Continued) Item Part Number Description Item Part Number Description 6 1U-7299 Adjustment (FRC) Wrench 9U-6880 Throttle Lever Tool Group Serviced (Continued) (“Type V” 1994 and later 15 9U-6883 Pusher Block Asse
  • Page 239Search Fuel System Test Tools 2594964 148-3605 Wrench Model: 3116 Engines Warranty: One Year Part Number Description Model: 3116 Engines • Replaces discontinued 131-5009 148-3605 Wrench Wrench • Used to remove and install tamper resistant plugs on 3116 governors installed after 01/01/96 Engine Tools
  • Page 240Fuel System Test Tools Search 2595005 Fuel System Tools (Continued) Essential Tool Model: C4.4 and C6.6 Engines Warranty: Six Months except 298-5564 which is Manufacturer’s Lifetime References SEBD9416, Service Manual (298-5564) TIBU4874, Bulletin (300-4988) Part Number Description Engine Tools 300-
  • Page 241Search Fuel System Test Tools 2595063 FT1979 Forcing Screw Assembly Model: 3204 Engine Warranty: None • Used to remove fuel injection pump housing and governor from 3204 Engine in D3C, D4C, IT12, 931C, 935C • Mounts in timing gear cover in place of cover plug and forces fuel injection pump camshaft
  • Page 242Fuel System Test Tools Search 2887548 370-4657 Rocker Arm Assembly Aid Model Usage: C7.1, C6.6, C4.4 Warranty: Six Months • Used to hold rocker arms in place for assembly and disassembly • One required for each cylinder Specifications Dimensions 59 x 52 x 37 mm (2.3 x 2.0 x 1.5 in) Weight 0.08 kg (0
  • Page 243Search Fuel System Repair and Adjust Fuel System Repair and Adjust 2595104 Connector Assemblies Essential Tool Model: C175-16 Engine - S/N WYB1-UP Warranty: Six Months • Used to back flush common rail fuel system on C175 Engines • Used with 295-5490 Filter Cart, 170-8500 Particle Analyzer, and vario
  • Page 244Fuel System Repair and Adjust Search 2595141 8T-5246 Engine Timing Indicator Group Model: Multiple Engine Models Warranty: Six Months • Used to determine piston true top dead center (TDC) and fuel injection pump timing of most Cat® engines • Replaces discontinued 3S-2954 Indicator Group • Components
  • Page 245Search Fuel System Repair and Adjust 2595141 8T-5246 Engine Timing Indicator Group (Continued) Model: Multiple Engine Models Warranty: Six Months Item 1 Part Number Description Size 4 6V-6105 Block -- 5 6V-3072 Case - Plastic, NEEG2574 Group De- -- cal on lid (9U-7402 Group) 6 8T-5247 Block (not ser
  • Page 246Fuel System Repair and Adjust Search 2595207 2P-8256 Timing Decal Model: 1100, 3100 Warranty: Six Months • Attach to crankshaft pulley or Part Number Description damper pulley on 1100 and 3100 2P-8256 Timing Decal Series Engines as alternate method for flow checking static timing with- out removing
  • Page 247Search Fuel System Repair and Adjust 2595256 127-1069 Timing Pin Model: 3054 and 3056 Engines Warranty: Six Months • Used to set engine piston at 100° before top dead center (BTDC) when timing Lucas fuel pump (at this location, the piston can be more accurately set to a specific position) • Whistle
  • Page 248Fuel System Repair and Adjust Search 2595318 136-4632 Timing Pin 220-2793 Timing Pin Model: 1.1L, 1.2L, 3300, 3176 and 3400 Engines Warranty: Six Months • Used to determine when crankshaft is positioned at top dead center • Spring loaded pin presses against flywheel; as engine is rotated pin will dr
  • Page 249Search Fuel System Repair and Adjust 2595369 268-1966 Timing Adapter Pin Essential Tool Model: C6.6 Engines Warranty: None Part Number Description • Allows use of a timing pin 268-1966 Timing Adapter Pin Engine Tools 2969086 364-9107 Fuel Pump Locking Pin Model Usage: C7.1, C6.6, C4.4 Warranty: Six
  • Page 250Fuel System Repair and Adjust Search 2595404 338-1054 Pump Timing Tool Group Essential Tool Model: C6.6 Engines Warranty: Six Months • Used to set timing of common rail Part Number Description fuel pump 338-1054 Pump Timing Tool • Required for installation to ensure Group proper operation of fuel pu
  • Page 251Search Fuel System Repair and Adjust 2595457 299-9126 Crankshaft Turning Group Essential Tool Model: C4.2, C6.4, 3054, and 3096 Engines Warranty: Six Months Part Number Description • Used to rotate engine crankshaft 299-9126 Crankshaft Turning • Used with 1/2 inch drive Group • Designed with interna
  • Page 252Fuel System Repair and Adjust Search 2595495 329-3831 Barring Group (Continued) Model: 3500, 3600, and C175 Engines Warranty: Six Months Part Number Description 329-3831 Barring Group Service/Repair Parts 328-2307 Muffler 334-3258 Service Kit Engine Tools 2595527 279-3473 Barring Device Model: C175
  • Page 253Search Fuel System Repair and Adjust 2595565 Tools for Rotating Crankshaft (Continued) Model: 3114, 3116 and 3126 Engines Warranty: Six Months Engine Tools Part Number Description Size Measure dimension X on starter housing to determine which part to use 9U-6943 Shaft Housing Assembly 146 mm (5.75 i
  • Page 254Fuel System Repair and Adjust Search 2595630 178-8615 Socket Model: 3114, 3116, 3126 MUI, HEUI, and 3126B Engines Warranty: Six Months • Used to turn engine crankshaft by Part Number Description hand 178-8615 Socket • Socket crossbars engage all four bolt heads in front pulley hub • Prevents over-ti
  • Page 255Search Fuel System Repair and Adjust 2595671 5F-2807 Cap 2F-2990 Plug Model: D5B, D6D, D9N, IT28, 943, 953, 963, 973 Warranty: Six Months Part Number Description • Used to protect fuel pumps (cap) 2F-2990 Plug and lines (plug) when removing them from engine 5F-2807 Cap Engine Tools 2595694 6V-4089 R
  • Page 256Fuel System Repair and Adjust Search 2595730 8S-2245 Cleaning Tool Group Model: 1100, 3100, 3208 Warranty: Six Months • Used to properly service pencil-type injection nozzles used in 1100 and 3100 Series and 3208 Engines Reference SEHS7292 Item Description Engine Tools 4 Pad Item Part Number Descrip
  • Page 257Search Fuel System Repair and Adjust 2595774 Fuel Injection Valve Nut Removal Tools Model: Cat® Engines Warranty: Six Months • Used for fuel injection valve nut removal on early engines Item Description Size 2 Wrench 17/8 in hex Item Part Number Description Size Engine Tools 3 4B-9918 Handle -- 1 9B
  • Page 258Fuel System Repair and Adjust Search 2647255 6V-4054 Nozzle Puller Group Model: D5B, D6D, 225B, 225B-3208, 3208, 518 Warranty: Six Months • 6V-4054 Puller Group used with Item Part Number Description 6V-4061 Group to remove 7N-0449 1 0S-1618 Bolt Nozzles in 3300 Series DI Engines -- 6V-4054 Nozzle P
  • Page 259Search Fuel System Repair and Adjust 2595865 6V-6976 Puller Group Model: 3204 Warranty: Six Months Item Part Number Description • Used to remove discontinued 1W- 1 1B-4206 Nut 3996 Direct Injection Fuel Nozzles on 3204 Engines; nozzles tend to 2 1 2S-5657 Washer stick in their bores due to carbon 3
  • Page 260Fuel System Repair and Adjust Search 2595921 6V-6981 Nozzle Puller Group Model: 3406 Warranty: Six Months • Used for removal of 8N-7006 Direct Item Part Number Description Injection Fuel Nozzles from 3406 1 1B-4206 Nut Engines 2 2S-5658 Washer • Uses several parts from earlier 6V- 4061 Nozzle Puller
  • Page 261Search Fuel System Repair and Adjust 2595984 4C-8175 Nozzle Puller Assembly Model: 3306 Engine Warranty: Six Months Part Number Description • Used to remove 104-9450 Direct 4C-8175 Nozzle Puller Assembly Injection Fuel Nozzle Assembly • Required for nozzle removal (carbon build-up around nozzle stem
  • Page 262Fuel System Repair and Adjust Search 2596044 9U-7227 Injector Height Setting Gauge 187-0482 Spacer Sleeve Model: 3406E Engines Warranty: Six Months 9U-7227 Injector Height Setting Gauge • Used to adjust injector Prestroke • Leaves both hands free to make adjustments 187-0482 Spacer Sleeve Engine Too
  • Page 263Search Fuel System Repair and Adjust 2596106 9U-5127 Tool Group, 3408 PEEC, and 3412 PEEC Model: 3408 and 3412 PEEC Engine Warranty: Six Months • Replaces discontinued 4C-9579 Tool Group • Used to test and adjust fuel pump timing on 3408 and 3412 PEEC Engines • Increased accuracy • On-engine field a
  • Page 264Fuel System Repair and Adjust Search 2596143 9U-5219 Tool Group 3406 PEEC Engines (Continued) Model: 3406B PEEC Engine Warranty: Six Months Item Part Number Description Size Item Part Number Description Size 1 8T-9198 Rack Indicator -- 7 5P-0326 Crowfoot Wrench 19.05 mm ( 3/4 in) Bracket Assem- 8 1U
  • Page 265Search Fuel System Repair and Adjust 2596211 8T-5160 Gas Regulator Setting Tool Group Model: All gas engines with Fisher Gas Regulators (Use FT2613 for gas engines with the discontinued 7E-3407 Sprague Gas Regulator) Warranty: Six Months • Used to adjust gas line pressure regulator on entire current
  • Page 266Fuel System Repair and Adjust Search 2647515 Assembled Setting Tool (Continued) Model: All gas engines with Fisher Gas Regulators (Use FT2613 for gas engines with the discontinued 7E-3407 Sprague Gas Regulator) Warranty: Six Months 3304, 3306 Positive Pres- 1 each Adapter sure Regulator Tool 8T-5149
  • Page 267Search Fuel System Repair and Adjust 2596235 FT2613 Gas Regulator Cap Assembly (Continued) Model: All Models with discontinued 7E-3407 Gas Regulators Warranty: None Item Part Number Description Gas Regulator Adjusting Tool 1 155-3062 Regulator Adjusting Tool 2 8T-5149 Fitting 3 123-5974 O-ring Engin
  • Page 268Fuel System Repair and Adjust Search 2596285 6V-7050 Compressor Group (Continued) Model: 3406 Warranty: Six Months Item Part Number Description 4 4B-1228 Screw 5 4B-2046 Nut -- 6V-7050 Compressor Group Not shown 1 Engine Tools -- 148-5677 Block -- 148-5675 Case 1 Also not shown: Block 2596310 6V-418
  • Page 269Search Fuel System Repair and Adjust 2925031 Additional Tools Needed But Not Included in 6V-4180 Group Engine Tools Additional Tools Needed But Not Included in 6V-4180 Group Item Part Number Description 32 5P-6570 Shaft 33 8S-2272 Shaft Assembly 34 1B-3680 Bolt 35 3F-1417 Washer 36 6V-2012 Gauge Gro
  • Page 270Fuel System Repair and Adjust Search 2647708 Application Charts for 6V-4180 Tool Group (Continued) Components of 6V-4180 Tool Group (Fig. 1) D311, D312, D315, D318, D339, D342, D364, D375, D386, D397, D468, D3400, D4400, D4600, D6100, D6600, Engine Tools D7700, D8800, D326, D337, D11000, D13000, D34
  • Page 271Search Fuel System Repair and Adjust 2647741 Compact Fuel System (Continued) Components of 6V-4180 Tool Group (Fig.1) D311H, D320, 1140, 1145, D330D, D333, 1670, 1150, 1160, 1673, D8, 583, 3204, D334, D343, 3145, 3150, Item Part Number Description 3304, 3306 1674, 6193 D336, 1676 3160 3406, 3408, 34
  • Page 272Fuel System Repair and Adjust Search 2596361 Tools for Accessory Drive Gear Model: 3204 Vehicular Engines Warranty: None • 4 fabricated tools needed to loosen accessory drive gear from shaft without removing radiator on 3204 Vehicular Engines • FT1537 Socket and FT1539 Puller used on 45V Vehicular E
  • Page 273Search Fuel System Repair and Adjust 2596407 Sockets for Special Applications Model: 3208, 1100, D379, D398, D399 Warranty: Six Months Engine Tools Item Part Number Description Size Use 1 9S-5031 1 Deep Well Socket 5/8 in, 3/8 in drive Required for tachometer drive adapter shaft removal on 1100 and
  • Page 274Fuel System Repair and Adjust Search 2596471 Decal for 1P-7410 Degree Wheel Model: 3406B Warranty: Six Months • Used to time 3406 Direct Injection Part Number Description Truck Engines (1978 Truck Model 1P-7410 Degree Wheel Year) with static fuel injection timing • Decal, SEHS7306, must be applied t
  • Page 275Search Fuel System Repair and Adjust 2596528 5P-6217 Fixture 5P-6218 Bearing Driver Model: 3408, 3412 Warranty: Six Months Part Number Description • Used to install tanged fuel rack 5P-6217 Fixture bearings on 3408 and 3412 Engines 5P-6218 Bearing Driver Engine Tools 2596545 FT1251 Pump Housing Stan
  • Page 276Fuel System Repair and Adjust Search 2596571 6V-4824 Driver 6V-4825 Plate Model: 3406B Warranty: Six Months • Used to install D-shaped rack bear- Part Number Description ing in fuel injection pump housing 6V-4824 Driver on 3406B Engines 6V-4825 Plate • 6V-4825 Plate, bolted to pump hous- Engine Tool
  • Page 277Search Fuel System Repair and Adjust 2596622 6V-7942 Hook Model: Cat® Engines Warranty: Six Months Part Number Description • Used to pull rack against rack cen- 6V-7942 Hook tering pin on engines with negative rack settings • Necessary because on some of these engines, overfueling spring may not mov
  • Page 278Fuel System Repair and Adjust Search 2596672 6V-9128 Rack Position Tool Group Model: Cat® Engines Warranty: Six Months • Provides convenient and accurate way to set or check rack position on Cat® Engines • Used to measure fuel rack position during normal operation of engine, or mea- sure fuel rack p
  • Page 279Search Fuel System Repair and Adjust 2596672 6V-9128 Rack Position Tool Group (Continued) Model: Cat® Engines Warranty: Six Months Item Part Number Description Size -- 6V-9128 Rack Position Tool Group -- Not Shown -- 4C-3474 Cap -- 1 Also Item 13 Engine Tools 2 Also Item 10 and 19 2647849 9S-0227 Br
  • Page 280Fuel System Repair and Adjust Search 2596743 6V-6070 Tool Group Model: Cat® Engines Warranty: Six Months • Used to check and adjust rack and fuel ratio control link- age on all engines with New Scroll Fuel Systems (NSFS) — new procedure now used to check and adjust rack on these engines • Replaces d
  • Page 281Search Fuel System Repair and Adjust 2596783 FT2532 Oil Shield Model: 3304 and 3306 Engines equipped with New Scroll Fuel Systems Warranty: None • Used to create a shield to prevent oil leaking from indicator bracket when checking fuel-to-air ratio with engine running • Used with 6V-2014 Bracket Ass
  • Page 282Fuel System Repair and Adjust Search 2596823 5P-4203 Sleeve Metering Field Service Tool Group (Continued) Model: Cat® Engines Warranty: Six Months Part Part Item Number Description Size Qty. Item Number Description Size Qty. 1 3P-1549 Block -- -- 21 3P-1544 Pin -- -- 1 2P-8306 Box Assembly -- -- 22
  • Page 283Search Fuel System Repair and Adjust 2596880 FT1632 Bolt Model: D5B, D6D, D7G, 225B, 225B-3208, 3208, 518, 613C Warranty: None • Fabricated by modifying 2H-3740 Bolt in 5P-4203 Field Service Tool Group • Used to remove 4N-2954 Sleeve modification prevents damage to threads Engine Tools 2596900 3P-22
  • Page 284Fuel System Repair and Adjust Search 2648050 Additional Calibration Tools Engine Tools Item Part Number Description Additional Tools from 5P-4203 Tool Group Required for Pump Calibration 1 8S-2243 Wrench 2 5P-6602 Adapter 3 5P-4205 Wrench 1 4 5P-4206 Wrench 5 1D-4533 Bolt 6 1D-4538 Bolt 7 5P-4209 Ga
  • Page 285Search Fuel System Repair and Adjust 2596974 5P-6577 Fuel Setting Tool Group Model: Cat® Engines Warranty: Six Months • Contains only those tools needed for checking and adjusting fuel setting on engines with Sleeve Metering Fuel Systems • All tools in this group also contained in 5P-4203 Field Serv
  • Page 286Fuel System Repair and Adjust Search 2597003 Calibration Tools (Continued) Model: 3208 Engines with Heavy Sleeve Metering Fuel System Warranty: Six Months Engine Tools Item Part Number Description Used with Used to 1 141-6727 Calibration Pump As- 3P-2200 Calibration Tool Group Set sleeve lever posit
  • Page 287Search Fuel System Repair and Adjust 2597047 FT1525 Alignment Pin, FT1526 Fixture FT1698 Driver Model: 3208 Warranty: None • Used to salvage governor housings on 3208 Engines with Sleeve Metering Fuel Systems • Provide accurate method for maintaining proper location when reworking throttle shaft bus
  • Page 288Fuel System Repair and Adjust Search 2597083 Fabricated Tools for Reconditioning 3208 Engine Fuel Systems Model: 3208 Warranty: None • Used to recondition 3208 Engine fuel systems Item Part Number Description 1 FT1693 Holding Fixture 2 FT1690 Holding Fixture 3 FT1691 Parts Basket Engine Tools 4 FT16
  • Page 289Search Fuel System Repair and Adjust 2597134 6V-4822 Tip Driver Model: Cat® Engines Warranty: Six Months Part Number Description • Used to separate tip assembly from 6V-4822 Tip Driver nut during disassembly of injector • Can be used as alignment tool dur- ing assembly Engine Tools 2597150 149-2955
  • Page 290Fuel System Repair and Adjust Search 2597186 180-0186 Removal Tool Model: 3126B HEUI Engine Warranty: Six Months • Used to quickly and easily separate Part Number Description 175-3236 High-Pressure Hose from 180-0186 Removal Tool fitting • Insert beveled edge between fitting collar and hose collar;
  • Page 291Search Fuel System Repair and Adjust 2597224 Injector Installation and Removal Tooling (Continued) Essential Tool Model: 3126B, C7, C9 Engines Warranty: Six Months Item Part Number Description Used with Used To Used On Injector Installation and Removal Tooling 1 152-1057 Injector Installation Tool -
  • Page 292Fuel System Repair and Adjust Search 2597267 9U-5132 Timing Tool Group Model: 3500 EUI and MUI Engines Warranty: Six Months • Replaces discontinued 6V-7880 Tool Group (to upgrade 6V-7880 to 9U-5132, order 6V-3072 Plastic Case, 9U-5138 Set Gauge, 9U-5233 Timing Fixture, 9U-5136 Foam Insert, 129-8602
  • Page 293Search Fuel System Repair and Adjust 2597267 9U-5132 Timing Tool Group (Continued) Model: 3500 EUI and MUI Engines Warranty: Six Months Item Part Number Description Size Optional Tooling 12 369-2607 Digital Indicator -- 15 5P-4814 Collet As - Clamp -- 16 136-4588 Collet Extension -- Engine Tools 18
  • Page 294Fuel System Repair and Adjust Search 2597335 6V-6999 Lapping Plates (Continued) Model: Cat® Engines Warranty: Six Months Item Part Number Description 1 6V-7011 Lapping Plate Case 2 6V-6999 Lapping Plate 3 6V-7151 Lapping Compound 2597355 Engine Tools 6V-7151 Lapping Compound Model: Cat® Engines Warr
  • Page 295Search Fuel System Repair and Adjust 2597391 223-2454 Fuel System and Governor Tool Group, 3114-3116 (Continued) Model: 3114, 3116, and 3126 Engines Warranty: One Year 123-4940 Magnetic Base Indicator Group • Attaches directly to tappet on top of each unit injector • Saves time — moves from cylinder
  • Page 296Fuel System Repair and Adjust Search 2597391 223-2454 Fuel System and Governor Tool Group, 3114-3116 (Continued) Model: 3114, 3116, and 3126 Engines Warranty: One Year Engine Tools Item Part Number Description Size 1 1 128-9640 Injector Synchronization Fixture Group -- -- 223-2454 Fuel System and Go
  • Page 297Search Fuel System Repair and Adjust 2597391 223-2454 Fuel System and Governor Tool Group, 3114-3116 (Continued) Model: 3114, 3116, and 3126 Engines Warranty: One Year Item Part Number Description Size Miscellaneous Engine Tools 16 4 5P-0302 Bar (Injector Removal) -- 17 1 4 123-4941 Valve Setting Ga
  • Page 298Fuel System Repair and Adjust Search 2648673 136-4149 Governor Connection Pliers The 136-4149 Governor Connection Pliers can be used for inspection procedures as outlined in Special Instruction REHS0601, if modified. Remove 10 mm (0.4 in) of rubberized coating from tips of pliers to expose metal tee
  • Page 299Search Fuel System Repair and Adjust 2597517 1U-9563 Offset Wrench (Continued) Model: 3114, 3116 Warranty: Six Months Part Number Description • Has all metric socket sizes required to adjust valve lash on any 1.1 liter engine; 1U-9563 Offset Wrench discontinued 1U-8771 Offset Wrench had 2 sizes, 17
  • Page 300Fuel System Repair and Adjust Search 2597575 195-0761 Pressure/Vacuum Pump Group Model: 3000 Series Engines With Stanadyne Fuel Injection Pumps Warranty: Manufacturer’s 5 year (see details) • Used to check and adjust aneroid capsule • Includes other accessories for general diagnostic, testing, and a
  • Page 301Search Fuel System Repair and Adjust 2597594 FT1906 Air Test Kit Model: 16G Warranty: None • Used to check leakdown rate of fuel-air ratio controller with engine at low idle • Used to read dynamic fuel-air ratio control setting • Used to adjust fuel-air ratio control setting Reference SENR5594, 3306
  • Page 302Fuel System Repair and Adjust Search 2597641 FT1820 Assembly Fixture Model: Cat® Engines Warranty: None FT1820 (Change No. 1) • Redesigned (simplified) combination of former FT1820 (Change No. 0) and FT1821 Fixtures • Inexpensive device used to hold fuel ratio controls; fuel ratio controls are awk-
  • Page 303Search Fuel System Repair and Adjust 2597687 8T-3226 Ring Expander Model: 3300, 3406 Warranty: Six Months • Used for ring expanding and seal protection on all 3300 New Scroll Fuel Systems and on all 3406 New Scroll Fuel Systems • Primary function: expander tool used with 6V-2163 Spring Compressor to
  • Page 304Fuel System Repair and Adjust Search 2597740 4C-4354 Applicator Model: 3114, 3116 Warranty: Six Months • Required to install Waldes Truarc Part Number Description ring (9X-2315 Retaining Ring, Series 4C-4354 Applicator 5139-18) on servo on the 3114 and 3116 Governor • Truarc ring requires a special
  • Page 305Search Fuel System Repair and Adjust 2597786 6V-6169 Check Valve Installer Model: 3204, 3304B, 3306B, 3406B Series Engines with New Scroll Fuel Systems (NSFS) Warranty: Six Months Part Number Description • Used to install check valves in fuel 6V-6169 Check Valve transfer pumps Installer Engine Tools
  • Page 306Fuel System Repair and Adjust Search 2828211 377-5782 High Pressure In-Line Flow Sight Model Usage: C13, C15, 3204, 3300, 3406B, 3406C Warranty: Six Months • Used to view fuel passing through fuel line during priming on engines • Also used to inspect fluid clarity for other applications • Used in ap
  • Page 307Search Fuel System Repair and Adjust 2597864 185-3630 Filter Strap Wrench (Continued) Model: Cat® Engines Warranty: Six Months 1 Warranty: Six Months 2597883 Special Sockets for Fast Fill Fuel System Adapters Model: Cat® Engines Warranty: Six Months Item Part Number Description Fast-fill fuel system
  • Page 308Fuel System Repair and Adjust Search 2696571 369-2607 Digital Dial Indicator (Continued) Model Usage: 3116, 994 Warranty: Six Months Engine Tools Part Number Description 369-2607 Digital Indicator 2597930 FT2650 Vacuum Fuel Cap Model: 525, 527, and 545 Skidders Warranty: None • Used to minimize fuel
  • Page 309Search Fuel System Repair and Adjust 2597949 171-1085 Bolt Remover Kit, 171-1088 Torque Screw Locknut Wrench, 171-1089 Idle Adjustment Locknut Wrench (Continued) Essential Tool Model: 3054 and 3056 Engines with Stanadyne Pumps Warranty: Six Months NOTE: Use of these tamper resistant fastener tools i
  • Page 310Fuel System Repair and Adjust Search 2598013 342-9517 Pry Bar Essential Tool Model: C9 Engines Warranty: Six Months • Used to aid in removal of fuel injectors • Provides leverage to remove injectors without damage • Indexable tip allows adjustment to best fit each injector • Tip can be locked at 17
  • Page 311Search Fuel System Repair and Adjust 2979162 372-5215 High Pressure Rail Block off Plugs Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to test high pressure fuel system for leaks • 6 pieces per set Specifications Weight 0.14 lb per piece (0.90 lb complete set) Size 1.15 x .875 in per piec
  • Page 312Fuel System Repair and Adjust Search 2979513 372-5258 Fuel Filter Wrench Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to loosen the top collar on Fuel Pro 382 models when replacing fuel filter, cap seal and vent cap seal. • Tool should not be used to tighten the collar after replacement
  • Page 313Search Fuel System Repair and Adjust 2979818 373-4723 Injector Installer Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to manually install injector into cylinder head Specifications Dimensions 50.8 x 25.4 mm (2.0 x 1.0 in) Weight 0.01 kg (0.4 oz) Engine Tools Part Number Description 373-4
  • Page 314Fuel System Repair and Adjust Search 2980034 373-4730 Air & Fuel System Caps (Continued) Model Usage: CT660 Truck Warranty: Manufacturer’s Part Number Description 373-4730 Air & Fuel System Caps 2991103 Fuel System Caps TYPE Dim A Dim B Dim C Dim D Dim E Dim F CHART Engine Tools Tapered 4.990 5.200
  • Page 315Search Fuel System Repair and Adjust 2990877 Air System Caps Chart B 2980067 Engine Tools 373-4731 Fuel Injector Cups Model Usage: CT660 Truck Warranty: Manufacturer’s • Used to protect and prevent dirt and debris from damaging injectors while out of engine Specifications Dimensions 304.8 x 203.2 x
  • Page 316Fuel System Repair and Adjust Search 2887504 380-8305 Timing Case Cover Alignment Tool Model Usage: C4.4 Warranty: Six Months • Used to correctly align pressed steel timing case cover to the timing case Specifications Dimensions 150 x 95 x 95 mm (5.9 x 3.7 x 3.7 in) Material Steel Weight 0.77 kg (1.
  • Page 317Search Pistons, Rings and Connecting Rods Pistons, Rings and Connecting Rods 2598037 5P-3519 Piston Ring Groove Gauge Model: Cat® Engines Warranty: Six Months • Used to check top and intermediate ring grooves (rectangular) to determine piston reusability • Includes 5 plug-type gauges that cover all
  • Page 318Pistons, Rings and Connecting Rods Search 2598078 1U-6431 Gauge Group Model: 3406B Warranty: Six Months • Used for checking ring groove wear on 7C-0473, 7C-3496 and 7W-3668 Pistons found in some 3406B Truck Engines beginning with 1985 production • Replaces discontinued 8T-3150 Gauge Group; consists
  • Page 319Search Pistons, Rings and Connecting Rods 2598104 9U-5931 Piston Ring Groove Gauge Model: 3114 and 3116 Engines Warranty: Six Months Part Number Description • Used to measure piston ring groove 9U-5931 Piston Ring Groove • Checks top and intermediate ring Gauge grooves to determine piston reus- abil
  • Page 320Pistons, Rings and Connecting Rods Search 2670191 Piston Ring Groove Gauges Model: 3500B Engines: Serial Numbers 7TR, 2GR, and 7RN Warranty: Six Months • Used to quickly and accurately Part No. Description Used On check 278-0247 Monotherm Piston 329-2630 Ring Groove top piston ring Ring Grooves for
  • Page 321Search Pistons, Rings and Connecting Rods 2598207 FT1022 Gauge Model: 1100, 3100 Warranty: None • Used to determine if correct pistons and crankshaft have been installed in 1100 and 3100 Series Engines • Material: SAE 1020 steel Engine Tools 2598220 1U-7616 Compressor Group Model: 3500 Warranty: Six
  • Page 322Pistons, Rings and Connecting Rods Search 2598240 329-8877 Piston Ring Compressor Tool Group Model: 3600 Engines Warranty: Six Months • Used to compress piston rings for piston installation on 3600 Engines (fits into top of cylinder liner and guide piston into cylinder) • Used with overhead lifting
  • Page 323Search Pistons, Rings and Connecting Rods 2598288 Piston Ring Expanders Model: Cat® Engines Warranty: Six Months • Used to easily and safely remove and install piston rings • When removing or installing piston rings without suitable tool, rings apt to be broken or overstressed so they no longer fit
  • Page 324Pistons, Rings and Connecting Rods Search 2670216 Scissors Type Ring Compressor (Continued) Engine Bore Compressor Scissors Type Ring Compressor (Continued) 146.10 mm (5.75 in) 5P-3527 158.80 mm (6.25 in) 5P-3528 Scissors Type Ring Compressor (3126 and 3126B Engines) 110 mm (4.33 in) 173-5529 Scisso
  • Page 325Search Pistons, Rings and Connecting Rods 2598388 FT2984 Piston Pin Installer FT2985 Piston Pin Installer Model: 3500A and B; 3500B HD Engines Warranty: None • Used to properly align piston crown, piston skirt, and connecting rod bores prior to installing the piston pin • Eliminates damage to piston
  • Page 326Pistons, Rings and Connecting Rods Search 2598429 9U-5917 Pin Mandrel, Bushing Out 9U-5918 Pin Mandrel, Bushing In Model: 3114 and 3116 Engines Warranty: Six Months • Used to check connecting rods • Provides accurate method for measuring bore misalignment and rod distortion • Rod can be checked befo
  • Page 327Search Pistons, Rings and Connecting Rods 2670308 Service Parts for 5P-8655 Connecting Rod Tool Group (Standard) Item Part Number Description 1 5P-8663 Adapter 2 5P-8661 Spacer 2 5P-8662 Spacer 2 1 5P-8654 Spacer 2 2 5P-8647 Spacer 3 5P-8656 Adapter, D320 or 3204, 3208, D330 and 3300 Engine Tools 3
  • Page 328Pistons, Rings and Connecting Rods Search 2598480 Tools for Removing and Installing Tapered Connecting Rod Bearings (Continued) Model: Cat® Engines Warranty: Six Months Engine Tools Item Part Number Description 1 5P-8653 Adapter 2 6V-2049 Adapter 3 6V-4819 Spacer 4 5P-8650 Adapter 5 5P-8645 Adapter
  • Page 329Search Pistons, Rings and Connecting Rods 2670421 Base Plate Engine Tools 2598527 1U-9032 Pin Bushing Adapter 1U-9033 Spacer, 1U-9034 Push Adapter Model: 3406E Engine Warranty: Six Months • Used to remove and install connecting rod pin bearing (9Y-6054 Connecting Rod Assembly) • Used with 5P-8639 Pr
  • Page 330Pistons, Rings and Connecting Rods Search 2598559 Reconditioning Connecting Rod Tools Model: Cat® Engines Warranty: Six Months • Used to produce smoother surface finish (10 MU or less required) in piston pin bearing when new piston pin bearing is installed in connecting rod and 4W-7402 Piston is use
  • Page 331Search Pistons, Rings and Connecting Rods 2598611 4C-9749 Push Adapter 4C-9750 Bushing Adapter, 4C-9751 Spacer Model: All 1.1 Liter Engines Warranty: Six Months • Used to remove and install connecting rod bearings • Provides economical means to rebuild connecting rods Part Number Description 4C-9749
  • Page 332Pistons, Rings and Connecting Rods Search 2598664 Fabricated Tools for Use in Reconditioning Piston and Connecting Rod Assemblies Model: Cat® Engines Warranty: None • Used when reconditioning large numbers (batch processing) of pistons and/or connecting rod assemblies • Make it possible to work on s
  • Page 333Search Pistons, Rings and Connecting Rods 2598691 360-3040 and 364-1170 Induction Heaters Essential Tool Model: All models Warranty: Manufacturer’s European Union compliant, CE marked • Replaces canceled 6V-6996 and 6V-7118 Bearing Heaters • Used to heat metal bearings, gears, rings, and bushings wh
  • Page 334Pistons, Rings and Connecting Rods Search 2670383 360-3040 and 364-1170 Induction Heaters (Continued) Voltage 360-3040 110 V 364-1170 220V Frequency 50 or 60 Hz Power 3.6 kVA Residual magnetism less than 2 A/cm Temperature mode maximum 240° C (464° F) Engine Tools Temperature control ±2° C (3.6° F)
  • Page 335Search Pistons, Rings and Connecting Rods 2598720 274-5875 Connecting Rod Guide Assembly Essential Tool Model: C175 Engine Warranty: Six Months • Used in pairs to position C175 Engine connecting rods during removal and instal- lation • Covers connecting rod end to prevent crankshaft and bearing jour
  • Page 336Pistons, Rings and Connecting Rods Search 2696828 364-2837 Installer Assembly (Ring Compressor) Essential Tool Model Usage: G3512E and G3520E Engines Warranty: Six Months • Used to install piston and connecting rod assembly into engines with 350-0074 Cuffed Liners • Fits inside of liner allowing rin
  • Page 337Search Camshaft and Timing Gear Tools Camshaft and Timing Gear Tools 2598762 FT0751 Camshaft Alignment Sleeve Models: D379, G379, D398, G398, D399, G399 Warranty: None • Used when installing camshaft • Fits over tapered end of camshaft and guides it into position, minimizing pos- sibility of bearing
  • Page 338Camshaft and Timing Gear Tools Search 2598801 Camshaft Installation Tools (Continued) Model: 3500 Warranty: Six Months Item Part No. Description Size Qty. Item Part No. Description Size Qty. 1 8T-3167 Guide As- -- 1 4 8S-3887 Bolt 1/2 in - 13 x 11 4 sembly inL 2 8T-3168 Pilot Assembly -- 2 5 4J-7945
  • Page 339Search Camshaft and Timing Gear Tools 2598834 Camshaft Removal and Installation Tools Model: C175 Engine Warranty: Six Months Part Number Description • Used to remove and install camshaft 255-2820 Camshaft Pilot As- from front or rear of engine sembly • Pilot assembly used with 8T-3169 Turning Handl
  • Page 340Camshaft and Timing Gear Tools Search 2598880 125-0201 Camshaft Guide Assembly Model: 3500B Engines Warranty: Six Months • Used to install camshaft from either Part Number Description end of engine 125-0201 Camshaft Guide • Reduces installation time and helps Assembly prevent camshaft bearing damage
  • Page 341Search Camshaft and Timing Gear Tools 2598899 Camshaft Removal and Installation Tools (Continued) Model: 3406E Engines Warranty: Six Months Engine Tools Item Part Number Description 1 9U-7256 Guide Assembly 1 274-7932 Guide Assembly - Front 1 274-7933 Guide Assembly - Rear 2 9U-7243 Alignment Sleeve
  • Page 342Camshaft and Timing Gear Tools Search 2598914 177-8003 Cam Tool Group (Continued) Model: 3406E, 3456, C-15, C-16, C27/C32 Warranty: Six Months Item Part Number Description Item Part Number Description 1 177-8001 Pilot Sleeve 3 1F-7958 Full Nut (1/2 - 13) (fork 2 249-2936 Adapter (C27/C32 front mount
  • Page 343Search Camshaft and Timing Gear Tools 2598995 1P-5545 Adapter Group Model: 1100, 3100, 3208 Warranty: Six Months Part Number Description • Used with 8S-2241 Tool Group to 1P-5545 Adapter Group install camshaft bearings on 1100 and 3100 Series and 3208 Engines 0S-0509 Bolt (3/8 - 16) 2599012 Engine T
  • Page 344Camshaft and Timing Gear Tools Search 2667261 Installation of Camshaft Bearing Larger diameter of pilot 97.9 mm (3.85 in) Small diameter of pilot 85.9 mm (3.38 in) Outside diameter of sleeve 92.1 mm (3.63 in) Engine Tools 2599050 6V-4077 Camshaft Bearing Tool Group Model: D11N, 3512, 3516, 777B, 785
  • Page 345Search Camshaft and Timing Gear Tools 2599084 Camshaft Bearing Remove/Install Tools (Continued) Model: C-10 and C-12 Engines Warranty: Six Months 129-6673 Bearing Pilot Overall outside diameter 80.92 mm (3.186 in) Outside diameter of bearing pilot 74.850 mm (2.9469 in) Item Description Engine Tools
  • Page 346Camshaft and Timing Gear Tools Search 2599140 Camshaft Bearing Removal and Installation Tools (Continued) Model: 3406E Engines Warranty: Six Months Overall Dimensions (Diameter x Item Part Number Description Thickness) 1 9U-7210 Puller Plate 95.0 x 19.0 mm (3.75 x 0.75 in) 2 9U-7223 Alignment Bushin
  • Page 347Search Camshaft and Timing Gear Tools 2599204 Gear Installation Tools Model: 933, 951, 955, 977 Warranty: Six Months Item Part Number Description • Necessary only when installing 2 4M-3251 Adapter accessory drive shaft with engine installed in 933 Traxcavators and 1 1B-4210 Nut in 951, 955, and 977
  • Page 348Camshaft and Timing Gear Tools Search 2599244 8F-3672 Gear Removal Plate Model: Cat® Engines Warranty: Six Months • Removal of camshaft or accessory Item Part Number Description drive gear with hydraulic puller (2) is 1 8F-3672 Plate simple operation combining use of 2 6V-3160 Cylinder plate (1) and
  • Page 349Search Camshaft and Timing Gear Tools 2599296 9U-6896 Guide Bolt Model: 3406E Engines Warranty: Six Months Part Number Description • Used to easily align camshaft gear 9U-6896 Guide Bolt during installation by supporting weight of camshaft gear • Used with 1P-7405 Eyebolt • Length: 127 mm (5.0 in) •
  • Page 350Camshaft and Timing Gear Tools Search 2599344 4C-5613 Puller Group (Continued) Model: 3406 Warranty: Six Months • Has wide puller jaws that distribute Item Part Number Description load across more surface area on -- 4C-5613 Puller Group gear and prevent damage to splined 1 4C-5628 Crossarm teeth; co
  • Page 351Search Camshaft and Timing Gear Tools 2599389 4C-9991 Idler Shaft Retrofit Tool Group (Continued) Model: 3500 Warranty: Six Months Item Part Number Description Size 4 9X-8883 Bolt 5/8 in to 11 x 2 3/4 in 5 6V-4857 Lockscrew (2) -- 6 4C-9993 Guide Plate -- 7 4C-9994 Drill Bushing 12.7 mm (0.50 in) En
  • Page 352Camshaft and Timing Gear Tools Search 2599438 9U-6148 Idler Shaft Removal Group (Continued) Model: 3064 and 3066 Engines Warranty: Six Months Item Part Number Description Not Shown -- 6V-8231 Nut (M10 x 1.25) 2599458 Engine Tools FT2781 Alignment Tool Model: G3600 Engines Warranty: None • Used to ac
  • Page 353Search Camshaft and Timing Gear Tools 3026211 398-9615 Air Gap Measuring Gauge Model Usage: C3.8 Warranty: Manufacturer’s European Union Compliant, CE marked • Used to measure the crankshaft position sensor • Provides a quick and efficient method for checking crankshaft position sensor • Use with 9S
  • Page 354Starting Systems Search Starting Systems 2599492 FT0201 Clutch Adjustment Tool Model: Cat® Engines Warranty: None • Used to adjust clutch on 53.98 mm (2 1/8 in) bore, 53.98 mm (2 1/8 in) stroke start- ing engines Engine Tools 2599504 277-7088 Spanner Wrench Essential Tool Model: G3516B and G3520B En
  • Page 355Search Starting Systems 2599534 FT3089 Offset Socket Essential Tool Model: 3500 Engines Warranty: None • Used to remove top bolt of starting motor on 3500 Engines (5/8 inch socket with offset provides access) • Used with 1/2 inch square drive wrench • Made from 8S-1595 Bolt Socket Engine Tools • Not
  • Page 356Engine Lifting and Positioning Search Engine Lifting and Positioning 2599552 6V-0097 Engine Rebuild Stand Model: All engine models from 3204 through D348 and 3412 Warranty: Six Months • Designed to provide most efficient means for engine reconditioning • Design permits dynamometer testing of engine
  • Page 357Search Engine Lifting and Positioning 2599584 4C-9832 Large Engine Roll-Over Stand Model: 3508, 3512 and 3516 Engines Warranty: Six Months • Used for disassembly and assembly of 3508, 3512 and 3516 Engines • Self-contained hydraulic system • Air-driven hydraulic pump and hoses included • Protective
  • Page 358Engine Lifting and Positioning Search 2599584 4C-9832 Large Engine Roll-Over Stand (Continued) Model: 3508, 3512 and 3516 Engines Warranty: Six Months Item Part Number Description Item Part Number Description Additional Service/Repair Parts (Not Shown, Sold Sepa- Additional Service/Repair Parts (Not
  • Page 359Search Engine Lifting and Positioning 2599680 C175 Engine Rollover Plates Essential Tool Model: C175 Engine Warranty: Six Months • Used with 4C-9832 Engine Rollover Stand to rotate engine for maintenance work • Front and rear plates are marked and cannot be inter- changed Engine Tools • Center hole
  • Page 360Engine Lifting and Positioning Search 2599725 FT1858 Engine Stand Adapter Model: 3204 Warranty: None • Used with 1U-7502 Engine Stand for rebuilding 3204 Engines • Holds engine at convenient working height during disas- sembly or assembly Engine Tools 2599739 1U-9352 Engine Stand, 1000 lb Model: Eng
  • Page 361Search Engine Lifting and Positioning 2599759 1U-5750 Diesel Engine Repair Stand, 2722 kg (6000 lb) Model: Engines within 6000 lb Warranty: Six Months • 1U-5750 includes universal engine adapter assembly which permits use of engine mounting adapters • Integral, 10.89 MT (12 ton) jack raises work to
  • Page 362Engine Lifting and Positioning Search 2647364 Adapter Plates Sold Separately Engine Tools Sold Separately Item Part Number Description Model Use 1 1 1U-7517 Adapter Plate For International Harvester engines: DT-466 in-line 6-cylinder; DV-550, MV-404, MV-446, V304, V345, V392, 4-152, 4-196, 4-194, 9.
  • Page 363Search Engine Lifting and Positioning 2599792 FT2942 Transmission Support Assembly Model: 924G and 928G Medium Wheel Loader Warranty: None • Used to mount transmission to an engine repair stand • Used with 1U-5750 Engine Repair Stand Reference Service Manual, 924G and 928G Power Train Disassembly an
  • Page 364Engine Lifting and Positioning Search 2599823 206-0030 Foot Plate (Continued) Model: 1U-5750 Rollover Stand Warranty: Six Months Part Number Description 206-0030 Plate 2599846 173-5533 Repair Bracket Assembly Essential Tool Engine Tools Model: C-9 Engine Warranty: Six Months • Used to mount C-9 Engi
  • Page 365Search Engine Lifting and Positioning 2599864 180-2877 Adapter Group (Continued) Model: MY2000 C-15 and C-16 Engines and 3406E Engines Warranty: Six Months Item Part Number Description Item Part Number Description 1 180-2876 Plate (Not serviced) 4 180-2875 Spacer Assembly (Not 2 2J-3506 Nut serviced
  • Page 366Engine Lifting and Positioning Search 2599948 FT0864 Jib Crane Model: 773 Warranty: None • Mounted underneath canopy of 773 Truck to lift tie-arch or engine components and deposit them on service truck • Used with 9S-8535 Trolley and 8S-9906 Ratchet • Can be used in other applications where a crane
  • Page 367Search Engine Lifting and Positioning 2599997 8F-2550 Engine Tilting Group Model: D364, D375, D379, G379, D386, D397, D398, G398, D399, G399 Warranty: Six Months • Used to remove and install crankshafts; refer to charts (many parts are part of 8F-2250 Engine Tilting Group) Item Description Qty. 6 Sp
  • Page 368Engine Lifting and Positioning Search 2647408 8F-2550 Engine Tilting Group Parts Part Number No. Req’d D399, No. Req’d D398, No. Req’d D379, Description Length mm (in) Thread Ends G399 G398 G379 FT0733-2 3 2 2 Stud 203,2 (8.00) RH FT0111 3 2 2 Stud 254,0 (10.00) RH FT0111-A 3 2 2 Stud 520,7 (20.5) R
  • Page 369Search Engine Lifting and Positioning 2678791 8F-2550 Engine Tilting Group Parts (Continued) (Continued) No. Reqd: D399, No. Reqd: D398, No. Reqd: D379, Part Number G399 G398 G379 Description Size 1D-4717 12 8 8 Nut 9.53 mm (3/8 in) 6V-6546 6 4 4 Bolt, 1/2-13 x 356 mm (14 12.7 - 342.9 mm (1/2 - in)
  • Page 370Engine Lifting and Positioning Search 2647498 Studs Part Number Description FT0111 Stud FT0111A Stud FT0733 Stud Engine Tools 2647507 Support Bracket Part Number Description FT0736 Support Bracket 2647535 Lifting Channel Part Number Description FT0732 Lifting Channel 3-370 Home
  • Page 371Search Engine Lifting and Positioning 2600045 FT2972 Engine Adapter Model: 303C CR Mini Excavator Warranty: None • Used to remove and install engine • Used with 6V-2082 Hook Group • Adapter prevents front and rear engine lifting chains from slipping while lifting with an overhead lifting device Refe
  • Page 372Engine Lifting and Positioning Search 2600073 FT2792 Engine Lift Bracket Model: 3512 Engine Warranty: None • Used to lift the engine out of the D10R track-type tractor using 2 normal lift points at front of engine and this bolt-on bracket at rear of engine • Bracket mounts to top, rear side of engin
  • Page 373Search Engine Lifting and Positioning 2600086 Motor Grader Rear Engine Support Groups (Continued) Model: All G-Series Motor Grader Engines Warranty: Six Months Part Number Description Qty. Part Number Description Qty. Engine Support Group A 1 Engine Support Group D (Use 3 washers between support as-
  • Page 374Engine Lifting and Positioning Search 2696852 368-0005 Lifting Bracket Essential Tool Model Usage: Skid Steer Loaders Warranty: Six Months European Union compliant, CE marked • Used to remove and install 3034, 3024C, and 3044C Engines • Used with an overhead lifting device • Top rail of bracket has
  • Page 375Search Engine Lifting and Positioning 3038211 394-0867 793F AC Engine R&I Rail Tool Group Model Usage: 793F AC Warranty: Six Months • Used to support the C175 engine during removal and installation • Allows removal and installation of engine without removing electrical cabinet off the machine • Used
  • Page 3763600 Engine Tools Search 3600 Engine Tools 2600159 8T-9209 Turbocharger Blocking Tool Model: 3600 Engines Warranty: Six Months • Prevents rotation of turbocharger impeller (allows emer- gency engine operation at reduced power) • When rotation of turbocharger is prevented, air flow through turbo is m
  • Page 377Search 3600 Engine Tools 2600202 4C-8769 Valve Seat Driver Model: 3600 Engines Warranty: Six Months • Used to install water-cooled valve seat inserts • Serves as guide and driver, helping to prevent insert damage during installation and ensuring insert is uniformly installed in cylinder head • Overa
  • Page 3783600 Engine Tools Search 2600258 4C-6593 Valve Lash Tool Model: 3600 Engines Warranty: Six Months • Used to easily check and adjust valve lash clearance of intake and exhaust valve • Part of 4C-6594 Timing and Fuel Setting Tool Group • Used with 6V-3075 Dial Indicator and 8S-3675 Contact Point (part
  • Page 379Search 3600 Engine Tools 2600297 4C-6987 Socket Model: All 3600 Engines except 3618 Warranty: Six Months Part Number Description • Used for removal and installation of 4C-6987 Socket cylinder head nuts • Saves time by installing nuts prior to use of tensioners and removing nuts after releasing torqu
  • Page 3803600 Engine Tools Search 2600353 130-6993 Injector Seat Cleaning Brush Model: 3600 Engines Warranty: Six Months • Used to clean injector bore seats (also part of 9U-5106 Diesel Tool Group) • Used with 1/4 inch drive drill • Made of stainless steel — provides best cleaning results without causing dam
  • Page 381Search 3600 Engine Tools 2600409 1U-9570 Dowel Puller Group Model: 3600 Engines Warranty: Six Months • Used for pulling 15.875 mm ( 5/8 in) and 19.05 mm ( 3/4 in) dowels • Makes the job quick and easy Stand height 88.9 mm (3.5 in) Shaft length 452.6 mm (17.81 in) Engine Tools Slide hammer weight 2.7
  • Page 3823600 Engine Tools Search 2600461 128-5113 Thread Repair Insert Model: 3600 Engines Warranty: Six Months • Replaces discontinued 4C-6409 Thread Repair Insert • Used to repair stud holes with damaged threads (only one of four holes per head can be repaired using this insert) • Install by drilling dama
  • Page 383Search 3600 Engine Tools 2600504 133-1531 Threaded Insert Model: 3600 Engines with Turbochargers Warranty: Six Months • Used to repair stripped or damaged threads in turbocharger housings • Used with 4C-9730 Tap and 8T-2793 Installation Tool • Will withstand 540° C (1000° F) temperatures • Thread sp
  • Page 3843600 Engine Tools Search 2667400 4C-8568 Liner Puller Group (part of 9U-5107 Group) (Continued) Model: 3600 Spark Ignited Engines Warranty: Six Months Item Part Number Description Qty. Item Part Number Description Qty. 7 316-1493 Hydraulic Puller Group 2 13 4H-6996 Spring Pin 8 8 6V-7079 Bridge -- -
  • Page 385Search 3600 Engine Tools 2667598 9U-5156 Cleaning Tool Group (part of 9U-5107 Group) (Continued) Model: 3600 Spark Ignited Engines Warranty: Six Months Item Part Number Description 1 150-5431 Pad Cut Down Disc 1 2 150-5483 EXL Unitized Roloc Disc 3 1U-9023 Pilot Assembly -- 9U-5156 Cleaning Tool Gro
  • Page 3863600 Engine Tools Search 2668359 9U-5105 Basic Tool Group for Miscellaneous Tools 8T-3034 Water Pump Seal Driver (Part of 9U-5105 Group) Model: 3600 Engines Warranty: Six Months • Used to seat ceramic ring and rubber seat into water pump housing (knurled handle for better grip) • Also installs carbo
  • Page 387Search 3600 Engine Tools 2667902 4C-6173 Fuel Drain Tray Assembly (Part of 9U-5105 Group) Model: 3600 Engines Warranty: Six Months • Used to drain fuel from filter housing (keeps engine clean, captures all fuel, reduces cleanup costs) • 7V-0198 Hose and 4C-6173 Tray catches fuel; 5N-5566 Hose routes
  • Page 3883600 Engine Tools Search 2668652 8T-0890 Puller Group (Part of 9U-5105 Group) Model: 3600 Engines • Used to remove rotor cover from centrifugal oil filter (allows replacement of 7C-8390 Rotor Liner) References SENR3594, Service Manual Module of SENR3590 Service Manual SENR3600, Service Manual Module
  • Page 389Search 3600 Engine Tools 2668672 References (Continued) SENR3594, Service Manual Module of SENR3590 Service Manual SENR3600, Service Manual Module of SENR3595 Service Manual SENR4259, Service Manual Module of SENR4255 Service Manual Item Part Number Description Item Part Number Description 1 8T-0916
  • Page 3903600 Engine Tools Search 2668701 Crankshaft and Camshaft (Continued) 8T-3029 Camshaft Segment Support Group (Part of 9U-5105 Group) Model: 3600 Engines Item Description 3 3/8 in - 16 Bolt (not part of 8T-3029) Item Part Number Description 1 8T-3049 Swivel Assembly Engine Tools 2 8T-3050 Bracket 4 1U
  • Page 391Search 3600 Engine Tools 2668807 References SENR3594, Service Manual Module of SENR3590 Service Manual SENR3600, Service Manual Module of SENR3595 Service Manual SENR4259, Service Manual Module of SENR4255 Service Manual Cylinder Capacity 180 kN (20 ton) Stroke 76 mm (3.0 in) Maximum operating press
  • Page 3923600 Engine Tools Search 2668861 134-0932 Main Bearing Driver (Part of 9U-5105 Group) Model: 3600 Engines • Used to remove and install crankshaft main bearings (older 6I-4528 Main Bear- ing and new 111-3378 Main Bearing) without removing crankshaft • Bearings are easily removed by inserting tool int
  • Page 393Search 3600 Engine Tools 2668913 8T-3022 Rod Guide Group (Part of 9U-5105 Group) (Continued) Model: 3606 and 3608 Engines Item Description 1 Guide (not serviced separately) Item Part Number Description -- 8T-3022 Rod Guide Group Rod Guide Group Consists of: Engine Tools 2 8T-2859 Nut 2668930 4C-6357
  • Page 3943600 Engine Tools Search 2669002 136-1452 Internal Pliers Assembly (Part of 9U-5105 Group) Model: 3600 Engines • Used to remove and install piston pin retainer or snap ring (pliers have locking handles for easier installation) • Use with 9U-5981 Snap Ring Retainer to provide added protection if snap
  • Page 395Search 3600 Engine Tools 2669047 235-0632 Cylinder Installation Tool Group (Part of 9U-5105 Group) (Continued) Model: 3600 Engines Item Part Number Description Quantity Cylinder Installation Tool Group Consists of: (Continued) 5 0V-0375 Bolt 2 6 4C-9040 Bracket 2 7 235-0612 Bracket Assembly 1 266909
  • Page 3963600 Engine Tools Search 2669127 Vibration Damper and Flywheel 4C-9426 Damper Guide Pin (Part of 9U-5105 Group) Model: 3600 Engines • Used to align and support vibration damper during assembly and disassembly of 3606, 3608, and 3612 Engines (2 required) • 1/2 inch square drive socket for easy instal
  • Page 397Search 3600 Engine Tools 2600812 9U-5106 Diesel Tool Group Model: 3600 Diesel Engines Warranty: Six Months Part Number Description Part Number Description 9U-5106 Diesel Tool Group 9U-5106 Consists of: (Continued) 9U-5106 Consists of: 5P-0328 Crowfoot Wrench, 7/8 in (Fuel Line) 130-6993 Injector Bor
  • Page 3983600 Engine Tools Search 2669394 8T-3268 Bolt (Part of 9U-5106 Group) Model: 3600 Engines • Used to remove unit injector by evenly tightening two bolts at the same time References SENR3594, Service Manual Module of SENR3590 Service Manual SENR3600, Service Manual Module of SENR3595 Service Manual Pi
  • Page 399Search 3600 Engine Tools 2669451 1U-8795 Governor Torque Arm (Part of 9U-5106 Group) Model: 3600 Engines • Holds governor or actuator terminal shaft to fuel “ON” position while injectors are being adjusted • When torque arm is installed with weight in horizontal position, 18.6 N·m (13.65 ft-lb) is a
  • Page 4003600 Engine Tools Search 2600902 146-2726 Maintenance Tool Group (Continued) Model: G3600 Engines Warranty: Six Months Engine Tools Item Part Number Description Use 1 6V-9124 Screwdriver Used for terminal strips 2 146-2739 Cylinder Pressure Connects outside air pressure source to cylinders on Adapte
  • Page 401Search 3600 Engine Tools 2600902 146-2726 Maintenance Tool Group (Continued) Model: G3600 Engines Warranty: Six Months Item Part Number Description Use 16 6L-5897 Bolt, 7/8 in long Waste gate tool 17 143-8997 Dummy Check Valve Checks leak down fixture (143-8995) before testing check valves 18 4C-460
  • Page 4023600 Engine Tools Search 2600970 4C-6583 Governor Calibration Tool Model: 3600 Locomotive Engine with PGEV Governor Warranty: Six Months • Holds the governor shaft to the fuel on position when synchronizing injectors • Makes it easier to rotate governor terminal shaft and easier to hold it in positi
  • Page 403Search 3600 Engine Tools 2601006 147-2285 Diesel Valve Seat Group (Continued) Model: 3600 Diesel Engines Warranty: Six Months Overall Item Part No. Description Seat Angle Length Pilot Diameter Not Shown — 6V-3072 Case - Plastic, -- -- -- NEEG2574 Group Engine Tools Decal on lid (9U- 7402 Group) 2601
  • Page 4043600 Engine Tools Search 2601031 207-5034 Stud Tensioner Tool Group (Continued) Model: 3600 Engines Warranty: Six Months Item Part Number Description -- 207-5034 Stud Tensioner Tool Group 1 207-4607 Threaded Collar (bearing stud) 2 8T-0889 Threaded Collar (head stud) 3 8T-0898 Cylinder Head Pedestal
  • Page 405Search 3600 Engine Tools 2601077 8T-0820 Pressure Gauge (Continued) Model: 3600 Engines Part Number Description 8T-0820 Standard Pressure Gauge 2601092 8T-3035 Lines Group Model: 3600 Engines Engine Tools • Used to connect hydraulically operated tool to hydraulic pump — 3S-6224 Hydraulic Pump (115V)
  • Page 4063600 Engine Tools Search 2601092 8T-3035 Lines Group (Continued) Model: 3600 Engines Item Part Number Description -- 8T-3035 Lines Group 1 6D-7726 Hydraulic Hose (2) 2 3J-5390 Plug - NPTF (Ext Hex) 3/8 in-18 NPTF external to 1/8 in-27 NPTF internal 3 8T-5206 Manifold Engine Tools 4 1P-2375 Coupler A
  • Page 407Search 3600 Engine Tools 2601149 178-5063 Rod Cap Guide (3618) Model: 3618 Engines (2MW1-Up) Warranty: Six Months Part Number Description • Used to easily remove and install 178-5063 Rod Cap Guide connecting rod cap • Guides (2) thread into lower portion of connecting rod • Helps prevent damage to c
  • Page 4083600 Engine Tools Search 2601203 151-8689 Template Seal Model: 3600 and G3600 Engines Warranty: Six Months • Just outline ID and OD of template Part Number Description to reveal sealing surface 151-8689 Template Seal • Used to easily and quickly identify area of cylinder head that needs a smooth sea
  • Page 409Search 3600 Engine Tools 2669532 9U-7522 Head Repair Tool Group (Continued) Model: All 3600 and G3600 Engines Warranty: Six Months Item Part Number Description -- 9U-7522 Head Repair Tool Group 1 Includes discontinued 8T-2677 Driver and discontinued 8T-2678 Sleeve 2601239 Compressor Group (Item 12)
  • Page 4103600 Engine Tools Search 2601289 9U-6249 Cylinder Tool Group 9U-6250 Pump Tool Group Model: 3600 Engines Warranty: Six Months • Both tool groups used together to disassemble and as- semble 3600 Engine turbochargers • Used with 6V-7030 Micrometer Depth Gauge Group (met- ric) or 6V-2012 Micrometer Dep
  • Page 411Search 3600 Engine Tools 2601342 195-8104 ABB Turbocharger Tool Kit (TPL61) Model: 3612 Marine Engines Warranty: Six Months • Used to disassemble and assemble ABB TPL61 turbo- chargers Reference REHS0811, Special Instruction, Disassembly and Assembly of TPL61 Turbocharger Engine Tools Item Descripti
  • Page 4123600 Engine Tools Search 2601358 187-3703 Tool Group (NA297) (Continued) Essential Tool Model: 3600 Engines Warranty: Six Months Item Part Number Description Item Part Number Description -- 187-3703 Tool Group (NA297) 3 177-9856 Turbo Impeller Removal 1 177-9811 Turbo Thrust Collar Tool Tool Group G
  • Page 413Search 3600 Engine Tools 2601381 179-1904 Stud Tensioner Tool Group (Continued) Essential Tool Model: 3618 Engines Warranty: Six Months Tensioning Force at Part Number Description Max. Pressure Maximum Stroke Overall Dimensions Weight 153-8487 Stud Tensioner 1100 kN at 150 mPa 8 mm (0.31 in) 161.5 m
  • Page 4143600 Engine Tools Search 2669647 Main Bearing Cap Handling Group Item Part Number Description 156-7168 Main Bearing Cap Handling Group (part of 179-1904 Stud Tensioner Tool Group) 1 160-0476 Bearing Cap Lift Base 2 160-0464 Air Cylinder 3 160-0473 Lift Assembly 4 178-9141 Bearing Cap Lift Bracket En
  • Page 415Search 3600 Engine Tools 2669708 Basic Tooling Required for 301-5215 Stud Tensioner Tool Group Item Description Qty. 6 Spanner Wrench 2 7 Swivel Head 2 Ratchet (1/2 in square drive) Engine Tools Item Part Number Description Qty. Item Part Number Description Qty. 301-5215 Stud Tensioner Tool Group (r
  • Page 4163600 Engine Tools Search 2669802 Basic Tooling Required Engine Tools Item Part Number Description Qty. Item Part Number Description Qty. -- 253-3274 Pump Accessory -- Pumps, Hose, and Coupler (requires one 229-9453 Group and Group (Not shown) one pump option) (Continued) Pumps, Hose, and Coupler (re
  • Page 417Search 3600 Engine Tools 2669950 Service/Repair Parts Engine Tools Item Part Number Description Qty. Item Part Number Description Qty. Service/Repair Parts Service/Repair Parts (Continued) 8 178-9312 Hose Assembly 1 17 175-0191 Seal Kit (for 191-5323 Main 1 9 178-9313 Distribution Coupler 1 Bearing
  • Page 4183600 Engine Tools Search 2670033 Optional Tooling 191-5322 Cylinder (Cylinder Head Studs) Maximum tensioning force 1100 kN (247,289 lb) Maximum operating pressure 150 mPa (21,755 psi) Effective piston surface 73.2 cm² (11.35 in 2) Stroke 10.0 mm (0.39 in) Weight 9.5 kg (21 lb) 191-5323 Cylinder (Mai
  • Page 419Search 3600 Engine Tools 2670110 160-4901 Support Tray Rail Model: 3618 Engines Warranty: Six Months • Used to support 153-8488 Tensioning Cylinder being manually placed onto 156- 7168 Bearing Cap Handling Group • Tray support rail easily fits onto engine oil pan baffles Reference RENR1333, Service
  • Page 420Search Engine Tools 3-420 Home