Adaptadores Elec

Diagnostic and Repair Tools Diagnostic Tools
Power Train Tools
Power Train Tools
9U-7500 Transmission Analyzer II Group

Various Cables and Adapters
SMCS Code: 3000, 3150, 3418, and 4800-038
Model: Machines with Electrical Transmission Controls
Warranty: One Year
• Replaces discontinued 1U-7446 Transmission Shift Analyzer Group • Analyzer can determine if shift lever is functioning correctly on transmissions not
• Used to test and adjust proportional valves which control transmission (connects controlled by autoshift electronic control feature
directly to solenoids of transmission) • Software updated annually to accommodate New Product Introduction Software
• Analyzer works on Powershift planetary, Powershift countershaft, Individual Subscription NETG5021.
Clutch Modulation (ICM), Challenger transmissions, H-Series Motor Grader
transmissions, and Electronic Clutch Pressure Control (ECPC) transmissions H-Series Motor Graders
• Designed and built with an Intel microprocessor with flash memory (provides • Analyzer can turn on solenoids in a timeline sequence
dealers with capability of updating analyzer for new types of transmissions, • Modulates current to one or all of initialized solenoids at any point in time
without purchasing a new analyzer)
• Easy to read menus provide step-by-step sequence for analyzer operation Challenger and ECPC Transmissions
• Lighted LCD makes it easy to see readings on display screen • Analyzer outputs pulse width modulated (PWM) current (required for this type
• Performs three basic functions: checks solenoid condition, shifts transmission, of transmission)
and checks shift lever operation
• Analyzer performs automatic or manual testing for shorted or open solenoid coils Reference
on one or all solenoids (can also alert mechanic to intermittent problems with NEHS0644 Tool Operating Manual
solenoid coils)
Size 393 x 311 x 171 mm (15.5 x 12.3 x 6.7 in)

Weight
Group 6.2 kg (13.8 lbs)
Tester 4.04 kg (8.9 lbs)
Operating voltage (DC power) 11 to 40 VDC
Minimum current requirements
(DC power) (Challenger 35, 45, and 55) 20 amps
Minimum current requirements (all other units) 10 amps
AC power 110 or 240 VAC
Memory one megabyte CMOS flash memory
Microprocessor Intel 80C51FA
LCD display size 43 x 124 mm (1.7 x 4.88 in); four line x 20 characters
Operating temperature range -18 to 60°C (0 to 140°F)
Storage temperature range -40 to 60°C (-40 to 140°F)
Overcurrent protection protected with a current limiting electronic circuit and against
a short circuit fault by a 40 amp quick-trip circuit breaker
Part No. Description

9U-7499 Transmission Analyzer II
Not shown
1U-9485 AC Power Cable
1U-9486 DC Power Cable
9U-7497 Test Cable
9U-7496 Test Cable
Optional Tools
1U-9479 Gear Shift Test Adapter Cable
1U-9480 Gear Shift Test Adapter Cable
9U-7498 Extension Cable,
9U-7495 Test Cable (Wheel Loaders)
1U-9483 Test Cable (Challenger)
1U-9484 Programming Cable ID: ph2, C66959T1-E; 9U-7499
1U-9482 Test Cable (ICM)

FT2640 Test Cable (D6M)
Service Parts
1U-6141 Connector (Service Repair)
1U-9458 Connector (Service Repair)
TSPG 2002 2-65

Diagnostic Tools Diagnostic and Repair Tools
Power Train Tools
FT2640 Test Cable

SMCS Code: 3030
Model: D6R Track-Type Tractor
Warranty: None
• Used to shift transmission and measure speed sensor signals during a bench test
• Used with 9U-7500 Transmission Analyzer II Group
• One end plugs directly into transmission control connector
• Speed sensor connectors plug directly into multimeter
• Use Caterpillar parts and other locally obtained parts
ID: il3, C79756T1; Assembly drawing

Connector (1) 1U-9458
Connector (2) 108-6259
ID: il2, C79757T1; Wiring diagram
Ground clip (3) P/N 46-C BK, Mueller Electric
Speed sensor plugs (4) P/N 90504 Model 1330, Pomona Electronics
1U-9100 Adapter Cable (Challenger to PC)

SMCS Code: 7490-035
Model: Challenger 35, 45, and 55
Warranty: One Year
• Used to connect a personal computer into the Challenger’s on-board electronic system
• Used with personal computer
• Cable connects RS232 port on computer to Diagnostic and Maintenance (D.A.M.) connector
on Challenger
• Cable allows Electronic Technician (ET) software to read fault codes, delete fault codes
(where allowed), and change vehicle parameters
• Cable comes complete with communication adapter which allows computer to communicate
with Challenger’s electronic system
• Cable length: 2.1 m (7.00 ft)
• Computer connection: 9 pin serial ID: ph2, C66845T1; 1U-9100
4C-4068 Extension Cable

SMCS Code: 3000-035
Model: 621E, 623E, 627E, 631E, 637E, 651E, 657E
Warranty: One Year
• 14-foot long extension cable that enables serviceman to position ICM control box in cab while troubleshooting transmissions
• Make troubleshooting safer and easier
2-66 TSPG 2002

Power Train Tools
139-5210 Extension Cable Assembly (ARC/EPTC II)

SMCS Code: 0740, 0779
Model: See List Below
Warranty: One Year
• Extension cable for Automatic Retarder Control (ARC) used on 769D, 771D, 773D, 775D, 776D,
777D, 785B, 789B, 793B, and 793C Off-Highway Trucks; and Electronically Programmable
Transmission Control (EPTC II) used on 769D, 771D, 773D, 775D, 776D, 777D, 785B, 789B, 793B,
and 793C Off-Highway Trucks; D250E, D300E, D350E, and D400E Articulated Trucks; and 621F,
623F, 627F, 631E, 633E, 637E, and 657E Wheel Tractor Scrapers
• Connects to 10-pin sure seal connector on ARC or EPTC II
• Two additional connectors allow 4C-8195 Control Service Tool and 7X-1700 Communication
Adapter to be connected ID: ph2, C66569T1; 139-5210
• Allows serviceman to position ARC and EPTC II in cab while troubleshooting
• Overall length: 4.3 m (14 ft)
198-1758 Calibration Group

SMCS Code: 5084-524
Model: 621G, 623G, 627G, 631G, and 637G Scaper
Essential Tool
Service Parts
• Used to calibrate electro-hydraulic implement control system 3J-7354 Seal
• Used with Caterpillar Electronic Technician (ET) software 3K-0360 Seal
• Ensures efficient operation of implement system 8C-7325 Adapter
• Overall length: 650 mm (25.6 in) 9X-4455 Switch Assembly
202-4995 Harness Assembly
Reference 142-2763 Coupler Assembly
RENR1528, RENR1534, and RENR1593 Service Manual Modules
198-6593 Calibration Instructions
4C-5974 Adapter Cable

SMCS Code: 0785
Model: Machines with military-type connectors
Warranty: One Year
• Used to adapt military-type connector, previously used on majority of Caterpillar machines,

to Sure Seal connector
• Standard harness with military-type connectors can now be used with the serviceable
replacements that use Sure Seal connectors without any modification of wiring harness.
• Testing and analysis equipment can be used on hardware with new Sure Seal connectors.
ID: ph2, C27266T1; 4C-5974
TSPG 2002 2-67

Power Train Tools / Speed Measuring Tools
FT2796 Breakout Harness

Model: 700 Series Articulated Truck 5,6,7
Warranty: None 200 Green
Black
Note B
1 2
• Used to connect a signal generator to transmission output speed sensor 50
• Made from 8T-8666 Connector Kit and other miscellaneous parts Orange Black
1 Note A 2X Shrink Wrap
• Simulates ground speed Approx 165 mm Long
3
Orange Note C 5,6,7
A NC
200.00 2 Green
Green
Black
Black 50
B 1 4 1 2
Green 3E-3664
2 200
C
Note A: Tape down unused Orange wire to harness assembly.
Note B: Splice 16GA Black wire to Black wire of harness assembly.
1 Cover splice with shrink wrap.
3E-3664 Note C: Splice 16GA Green wire to Green wire of harness assembly.
2 Cover splice with shrink wrap.
ID: il3, D00254T1
ID: il2, D00260T1
Parts Required for Assembly Assembly Instructions
1. Obtain 8T-8666 Connector Kit.
Item Part No. Description Quantity
1 8T-8666 Connector Kit 1 2. Cut 50 mm off Green wire to make the same length as Black wire.
2 — 16 GA Green Wire 250 mm long 1 3. Splice 16GA Black wire to Black wire of 8T-8666 Harness.
3 — 16 GA Black Wire 250 mm long 1 4. Splice 16GA Green wire to Green wire of 8T-8666 Harness.
4 — Shrink Wrap 1 5. Crimp 186-3735 Pins to Green and Black wires.
5 3E-3364 Receptacle Assembly 2
6. Cover splices with heat shrink wrap.
6 3E-3365 Wedge 2
7 186-3735 Connector Pin 4
7. Insert pins into 3C-3364 Receptacles, Black to 1 and Green to 2.
8. Insert 3C-3365 Wedges into receptacles. Tape unused Orange wire
to harness.
Speed Measuring Tools
9U-7400 Multitach II Group

9U-7401 Multitach II
9U-7402 Multitach II Photo Group
SMCS Code: 1250-025
Model: All Caterpillar Products
Warranty: One Year
• Used to measure rpm, frequency, and engine set point — combines three
instruments into one
• Engine set point indicator captures and displays set point rpm
• Hz frequency meter measures gen set or other signal frequency
• Easy to use photo pickup for fast RPM measurement
• Two digital displays show Input 1 and Input 2 values simultaneously —
ID: ph2, C66677T1; 9U-7401
eliminates switching screens
• Displays minimum, maximum, and difference values of inputs RPM measurement range 1-9999 rpm
• Displays difference between Input 1 and Input 2 Measurement accuracy ±1 rpm
• Backlit display for operation in low light conditions Pulses per revolution 0.1 to 256 PPR (selectable)
• Optional RS232 output available for sending data directly to printer Frequency measurement range 0-9999 Hz
• Adjustable pulses per revolution Frequency measurement accuracy:
• Operated by rechargeable battery — designed with low battery indicator 0-999.9 Hz ±0.5 Hz
and internal battery voltmeter 1000-9999 Hz ±1.0 Hz
• Accepts many different types of pickups (including most pickups used with Set point measurement set point — 20 rpm = full load rpm
former Multitach II) Overrun indicator 0 to 10% rack contact
• Program each input separately with different PPR (Pulses Per Revolution) Set point rpm 11% rack contact (RPM held on display)
values for each — different pickups can be used simultaneously Overrun and lug off 11 to 74% rack contact
• Stays pre-programmed to values last used — displays values when turned on Lug indicator 75 to 100% rack contact
• CE compliant
2-68 TSPG 2002

Item Part No. Description

1 9U-7505 High Voltage (600 Volt Max.) Input Adapter
2 4C-3024 Battery Charger
3 Storage for three spare AA size batteries
4 9U-5140 LED Photo Pickup (also storage for additional photo pickup)
5 9U-7401 Multitach II
6 6V-6045 Accessories Case
NEEG2061 Accessories Case Decal
7 1U-6605 Retro-Reflective Tape 12 mm x 1.5 m (.5 in x 5.0 ft) roll
8 6V-3138 Extension Rod for Magnetic Base
9 9U-7506 Magnetic Adapter Cable
10 8T-5111 Rack Adapter Cable
11 5P-7360 Tachometer Generator
12 Storage for additional Tachometer Generator
13 Storage for additional Tachometer Drive Group
14 5P-1759 Tachometer Drive Group (additional parts in accessory case)
15 9U-7508 Foam Insert
16 6V-2198 Extension Cable 5.5 m (18.0 ft)
17 6V-7145 Carrying Case
NEEG2573 Group Label on lid of 9U-7400 Group
ID: il3, C66650T1 18 6V-7072 Test Lead Set (for use with high Voltage adapter)
19 1P-7446 Rack Cable 5.5 m (18.0 ft)
20 Storage for additional photo pickup magnetic base
21 6V-3137 Photo Pickup Magnetic Base
22 Storage for two spare AA size batteries
23 NEEG2593 Inside Lid Decal
24 NEHS0605 Operating Instructions

1 Storage for five spare AA size batteries
2 9U-5140 LED Photo Pickup
3 9U-7401 Multitach II
NEEG2061 Accessories Case Decal
5 1U-6605 Retro-Reflective Tape 12.5 mm x 1.5 m (.5 in x 5.0 ft)
6 6V-3138 Extension Rod for Magnetic Base
NEEG2574 Group Decal on lid (9U-7402 Group)
8 6V-2198 Extension Cable 5.5 m (18.0 ft)
9 9U-7507 Foam Insert
10 6V-3137 Magnetic Base for Photo Pickup
12 NEEG2594 Inside Lid Decal
13 NEHS0605 Operating Instructions
ID: il3, C66664T1
TSPG 2002 2-69

ID: ph2, C66638T1

Optional accessories for 9U-7401
1 4C-9499 RS232 Output Adapter
2 155-5175 AC Clamp-on Probe (use with 9U-7505 High Voltage Adapter or 9U-5265 Banana Plug Adapter to measure Hz)
3 155-5176 AC/DC Clamp-on Current Probe (use with 9U-7505 High Voltage Adapter or 9U-5265 Banana Plug Adapter to measure Hz)
4 9U-5215 Diagnostic Tool Soft Case (not as shown)
5 8T-5297 Extension Cable 0.9 m (3.0 ft)
6 9U-5265 Adapter (connects two banana plugs to 9U-7506 magnetic adapter cable)
7 6V-0093 Retro Reflective Tape, 12 mm (.5 in) wide x 15 m (50.0 ft) long roll
8 4C-6919 Retro Reflective Tape, 25 mm (1.0 in) wide x 2.5 m (100.0 in) long roll, with honeycomb pattern design
9 and 10 4C-6821 Injection Line Speed Pickup Group (for Multitach or Data Logger)
10 and 1 6V-4950 Injection Line Speed Pickup Group (for Multitach only)
12 1U-7445 NiCad (Nickel Cadmium) Rechargeable Battery, AA (packaged singly)1
13 1U-9533 Alkaline Non-Rechargeable Battery, AA (package of 96)1
14 8L-4171 Magnetic Pickup (general purpose)
15 8T-5184 Magnetic Pickup, 88.9 mm (3.50 in) long x 6.35 mm (1/4 inch)
16 6V-2197 Magnetic Pickup, 114.3 mm (4.50 in) long x 6.35 mm (1/4 inch)
17 8T-5185 Magnetic Pickup, 177.8 mm (7.00 in) long x 6.35 mm (1/4 inch)
18 6V-2199 Pickup Adapter, 6.35 mm (.250 in) dia. x 1/8 inch NPT
19 6V-3093 Pickup Adapter, 6.35 mm (.250 in) dia. x 1/4 inch NPT
Not shown 1U-6605 12.2 mm (1/2 in) Retro Reflective Tape, 1 - 1524 mm (5 ft) long roll.
1 Five batteries are required to power Multitach II.
Reference
NEHS0605 Operating Manual
5P-1759 Tachometer Drive Group

SMCS Code: 1250-25
Model: All Models
• Used on engines with ENM Service Meters including engines with Sleeve Metering Fuel Systems
• Replaced 9S-5609 Drive Group
• To use 5P-1759 Drive Group, service meter is removed and drive group installed.
• On 5.4 inch bore engines not equipped with tachometer drive group, 5P-1758 Shaft Assembly must be used.
ID: ph2, A69888-2T1
Item Part No. Description Use

1 1W-2316 Adapter Assembly (former 9N-3018) For all engines with ENM Service Meters
4M-8308 Seal (outside)
2 5P-1758 Shaft Assembly With 1W-2316 or former 9N-3018 for 5.4 inch bore V—engines
3 4N-0538 Coupling With 1W-2316 or former 9N-3018 and 5P-0537 for engines with Sleeve Metering Fuel Systems
4 5P-0537 Washer (discontinued) Between former 9N-3018 and 4N-0538 (5P-0537 Washer, discontinued, is not needed with later
1W-2316 Adapter Assembly)
5 9S-3032 Clamp (two)
6 9S-0211 Clamp (two)
2-70 TSPG 2002

168-7727 Battery Cover Group

SMCS Code: 1250-25
Warranty: One Year 3 4
• Replacement battery cover kit for the following hand held diagnostic tools
which have external battery access:
9U-7401 Multitach II Item Description 2
168-7721 Ultrasonic Wear Indicator III 1 Battery Screw Cover
2 O-Ring Seal 1
3 Battery Cover
4 Gasket
Not Shown
Battery Clip, Single (2)
Battery Clip, Dual (4)
ID: il2, D00248T1
211-1773 Drive Motor Speed Pickup Breakout-T

211-1774 Engine Speed Sensor Breakout-T
Model: D3G, D4G, D5G Track-Type Tractor
Warranty: One Year
• Used to monitor drive motor speed pickup and engine speed sensor
• Used with DataView
• 211-1773 connects between machine harness and engine speed sensor (magnetic pickup)
• 211-1774 connects between machine harness and drive motor speed pickup (Hall-effect sensor)
ID: ph2, C80493T1
FT1808 Magnetic Input Adapter Cable

SMCS Code: 1250-025
Model: All Models
Warranty: None
• Permits easier use of 6V-2100 Multitach or 9U-7400 Multitach II to check engine or alternator RPM
• Used on engines equipped with magnetic pickup which is used as RPM signal for electronic overspeed switch or electronic governor
Operating Instructions
To measure engine RPM on the multitach, connect the lug end of the cable to the magnetic pickup output signal lead for the magnetic pickup.
Connect the plug end of the cable to the 5P-7362 Magnetic Input Cable on the multitach. No ground connection is needed if the engine battery
is used as the power source for the multitach. Use the number of flywheel teeth as the P/REV (pulses per revolution) number on the multitach.
To measure alternator RPM, connect the lug end of the cable to the “R” terminal on the alternator. Connect the plug end of the FT1808 Cable to the
5P-7362 Mag Input Cable that is connected to the multitach mag input. This method gives the alternator RPM which is a ratio of the engine RPM.
See the chart for the P/REV numbers for the specific alternator to be checked.
Reference
SENR2945 Electronic Monitoring System (EMS) Service Manual contains additional information to check alternator “R” terminal output.
Alternator Type Multitach P/Rev

Caterpillar 6
DELCO 10-20 DI 7
DELCO 25-30 SI 8
TSPG 2002 2-71

7M-6001 Drive Adapter Group

SMCS Code: 1000-025
Model: All Models
• Some engines are equipped with service meters that have no means of attaching a tachometer drive.
Installation of the 7M-6001 Adapter Group is accomplished by removing the Service Meter and installing the drive assembly with the
7M-6010 Bushing using two 1B-2713 Bolts through the swivel mounting plate. On other engines, the drive assembly is installed in place
of the service meter cover and the 7M-6011 Bushing is used instead of the 7M-6010 Bushing. Two 1B-7182 Bolts are used to secure the
drive assembly to the service meter cover mounting boss and the swivel mounting plate is not used.
D2 Tractors, early 933 Traxcavators, and D311 Engines (prior to series H) require a 4F-4246 Shaft and a 7B-1075 Spacer in addition to
the 7M-6001 Tachometer Drive Adapter Group.
• On engines equipped with the ENM Service Meter (manufactured in England) either the 7M-6001 or the 5P-1759 Drive Group may be
used. On engines with Sleeve Metering Fuel Systems, the 4N-0538 Coupling must be used. If the 7M-6001 Adapter Group is used, the
Service Meter must also be removed. The 8S-7165 Bushings and a 5S-6106 Adapter are used for mounting the 7M-6001 Adapter Group.
1 6B-3127 Cable
2 7M-6003 Adapter
3 Tachometer Drive Group includes three Bushings:
7M-6010, 7M-6011, 8S-7165
4 7M-6004 Fitting
5 1B-2713 Bolt (two)
3B-4504 Washer (two)
6 1B-7182 Bolt (two)
3B-4505 Washer (two)
ID: ph2, C05359T1; 7M-6001
Service Parts for Tachometer Drive Group

1 9B-2232 Cap
2 1F-3257 Shaft
3 7M-6007 Housing Assembly
4 2B-4602 Plug
5 7M-6010 Bushing
6 7M-6009 Shaft
7 7B-9002 Washer
8 1F-3275 Screw Assembly
9 7M-6011 Bushing
ID: il2, C54535T1
10 8S-7165 Bushing
5P-0935 Tachometer Drive Adapter Group

SMCS Code: 1000-025
Model: 910. 931, D3, 3204
Warranty: One Year
• Used with Tachometer Drive Group for checking engine speed on 3204 Engine in
D3 Tractors, 910 Wheel Loaders, and 931 Track Loaders (7M-6006 Group must be
modified by removing plate and machining housing to dimension shown)

1 5P-0933 Adapter (Part of 5P-0935)
2 5P-0934 Shaft (Part of 5P-0935) ID: ph2, 74071T1
3 7M-6006 Drive Group
2-72 TSPG 2002

8N-5945 Adapter Assembly

SMCS Code: 1250-025, 3224-025, 5050-038, 7106-011
Model: 943, 953, 3204
• Used for measuring engine speed on 3204 Engines, 10X1-2935, in 943 and 953 Loaders
• 90° drive adapter assembly installed on engine timing gear cover
• Used with 5P-7360 Tachometer Generator; 4M-8303 Seal and two 9S-3032 Clamps
also required for installation of adapter assembly
ID: ph2, B11770-1T1; 8N-5945
5P-6560 Tachometer Adapter

SMCS Code: 1000-025
Model: 627B
Warranty: One Year
• Used to connect tachometer drive cables (with SAE No. 12 heavy duty input fitting and SAE No. 10 Marine
output fitting) to 9S-3047 Generator Assembly
• Desirable arrangement on machines, such as 627B Tractors, where engine tachometer drive is not accessible
• 5P-7360 Generator Assembly included with 5P-3600 Flowmeter, 5P-2160 Engine Horsepower Meter and 1P-5500 Phototach Group
ID: ph2, A36336-1T1; 5P-6560
6N-1345 Tachometer Drive Adapter

SMCS Code: 1000-025
Model: 943, 953, 215, 3204
• Used for measuring engine speed on later 3204 Engines, 10X-2396-Up, in 943 and 953 Loaders
and 215 Excavators (different adapter needed for later engines because of change to camshaft)
• Also required for adapter installation: 4M-8303 Seal, 5P-1758 Shaft Assembly, two 9S-3032 Clamps,
two 0S-1617 Bolts and two 9M-1974 Washers
ID: ph2, B39042T1; 6N-1345
7N-8929 Cable Connector

SMCS Code: 1000-025
Model: All Models
• Used to connect tachometer drive cable to 9S-3047 Tachometer Generator (included in 1P-5500 Phototach Group)
on engine applications where access to tachometer drive is difficult; disconnect tachometer drive cable at
tachometer and use this fitting
ID: ph2, A24450T1; 7N-8929
1U-5550 Oil Pressure Adapter Group

SMCS Code: 1300-036
Model: XNIP Peugeot Engines
• Used to measure oil pressure on XNIP Peugeot Engines. These engines are found on several models of Caterpillar lift trucks. The 1U-5550 is installed
in place of the oil pressure solenoid in the oil filter base. The 1U-5550 provides a 9/16 inch 18-2B (SAE No. 6) port for pressure measurement purposes.
TSPG 2002 2-73

FT0907 Adapter
SMCS Code: 3224-081
Model: D342, D343, D346, D348, D349, D353, D379B, D398B, D399
Warranty: None
• Used with reversible variable speed drill and tachometer to bench set mechanical
overspeed controls.
ID: il2, C05356T1; FT0907
4C-6821 Pickup Group, Injection Line Speed for Data Logger

Discontinued — Service Parts Available
Service Parts
1 1U-9139 Pickup
2 4C-6812 Amplifier
Reference
SMHS7504-01 Special Instruction
SEHS7807 Special Instruction
ID: ph2, C44356T1; 4C-6821
1U-9139 Universal Fuel Line Pickup

SMCS Code: 1000-025
Model: All non-unit-injected Caterpillar diesel engines
Warranty: One Year
• Used with 6V-2100 Multitach (as accessory part for 6V-4950 Pickup Group) to measure
diesel engine speed
• Works on Perkins fuel lines as well as on those with remote unit pump group, on all
precombustion chamber fuel systems and on some smaller direct injection fuel systems
• Not applicable to unit injected 3500 and 3600 Engines
• Adaptable to different fuel line sizes from 5.5mm Perkins to 7.0mm size range
Reference Item Part No, Description

SEHS8029 Special Instruction 1 1U-9139 Universal Fuel Line Pickup
SEHS7807-03 Special Instruction
2 6V-6113 Amplifier
ID: ph2, B83852T1; 1U-9139, 6V-6113
2-74 TSPG 2002

1U-9710 Adapter Cable

SMCS Code: 1250-025
Model: Most Caterpillar Spark-Ignited Engines
Warranty: One Year
• Used with 6V-2100 Multitach to measure RPM on most Caterpillar spark-ignited engines
• Used with 6V-9060 Spark Timing Adapter Group and 6V-2100 Multitach or 6V-3121 Multitach Group
• Multitach owners have method of measuring RPM of spark-ignited engines.
• 6V-2100 Multitach has digital LCD display.
ID: ph2, C27156T1; 1U-9710
1U-6602 Photo-Tach Group

SMCS Code: 1000-025
Model: All Models
Warranty: One Year
• Measures RPM by directing laser light beam onto piece of reflective tape and counting reflected light pulses; reflective tape can be affixed to any rotating component
• RPM can be measured to and is accurate within 1 RPM
• LCD viewed simultaneously while aiming the instrument
• Provides low cost tachometer for general use; does not replace 6V-3121 Multitach Group. The 1U-6602 is a phototach only and reads only the basic input frequency
(1 pulse per revolution per piece of reflective tape). The more versatile 6V-3121 accommodates multiple RPM pickup devices (e.g., photo, magnetic, fuel lines)
and can be programmed to divide by any number up to 256. This allows the RPM to be displayed directly.
Measurement range 5 to 100,000 RPM

Accuracy ±1 RPM
LCD size 6 digit 12.7 mm (.50 in) high
Range 0 to 3 m (0 to 10 ft) from reflective tape
Angle up to 45° from perpendicular to target (Best results at angles from 5° to 20°)
Last measurement memory displays last measurement approximately 1 min. after trigger release
Power-on switch pistol grip trigger; may be locked on with latching push-button for longer duration measurements
Optical system linear reflective laser - 3mW
Recommended size of reflective tape 13 mm (1/2 in) square
Size 83 mm x 45 mm x 156 mm (3.25 in x 1.75 in x 6.13 in)
Weight approx. 0.57 kg (1.25 lbs.)
Power 1U-9533 “AA” size batteries (4) (Can operate instrument for 8 continuous hours)
or optional, rechargeable 1U-7445 Nickel Cadium Batteries

1 6V-3073 Case
2 1U-7771 Tachometer
3 1U-9533 Battery (4)
4 1U-6605 Reflective Tape
5 4C-3024 or 161-8384 Recharger, 110/220 VAC. 4C-3024 (older units) photo-tach has 2.54 mm (.10 in)
hole for charger connection. 161-8384 (newer units) photo-tach has 6.35 mm
(0.25 in) hole with center pin for charging connection.
Optional
Not shown 1U-7445 Nickel Cadmium Batteries (4)
Not shown 1U-7772 Foam Block
Reference
ID: phod 19p6,14p0, B96709T1; 1U-6602
TSPG 2002 2-75

Speed Measuring Tools / Temperature Measuring Tools
161-8384 Battery Charger

SMCS Code: 1900-038, 0781 Charger connector barrel type
Model: All Models
Connector OD 5.6 mm (.22 in)
Warranty: One Year
Connector ID 2.5 mm (.10 in)
• Used to recharge nickel cadmium batteries on newer hand-held Photo-Tach Center pin (ID) polarity negative
• Used with 1U-7771 Photo-Tach, part of 1U-6602 Photo-Tach Group
Reference
SEHS8854 Special Instruction, Using the 1U-6602 Photo-Tach Group
Temperature Measuring Tools
4C-6500 Digital Thermometer Group

SMCS Code: 1000-082, 3000-082, 4000-082, 5000-082, 7000-082, 0776
Model: All Models
Warranty: One Year
• Fast and accurate method of measuring temperature • Compatibility with probes for 131-5050 Data View offers greater flexibility
• Backlit, digital LCD display for use in low light conditions in solving temperature problems. Probes designed to be used with Cat’s
• Larger liquid crystal display for easier viewing probe seal adapters
• Does not need to be calibrated every time it is used • Temperature readings can be sent to serial printer (requires optional,
user-installed 4C-9499 RS-232 Output Adapter Group
• Provides user with differential temperature calculated from any
2 of the 5 channels • CE compliant
• Records minimum and maximum temperatures for each channel
Reference
• Has battery saver features
Operating Manual NEHS0554
4C-6800 Datalogger Tool Operating Manual NEHS0549
Inputs 5, 4-wire PRTD (Platinum Resistance Temperature Detector)

Output Optional, RS-232 level 300 or 1200 Baud rate
Power Internal rechargeable batteries or 110/220 VAC, 50/60 Hz line power using 4C-3024 Battery Charger
Range -50°C to 850°C (-58°F to 1582°F)
Resolution ± 0.1°C or F
Accuracy -50°C to 260°C, ± 0.5°C (-58°F to 500°F, ± 1°F); 261°C to 850°C, ± 1.1°C (501°F to 1562°F, ± 2°F)
Operating temperature -18°C to 60°C (0°F to 140°F)
Weight 4.95 kg (11 lbs.)

2 4C-4545 Probe Seal Adapter, 3/4 inch O-ring
4C-4547 Probe Seal Adapter, 1/2 inch O-ring
5P-2720 Probe Seal Adapter, 1/8 inch NPT
5P-2725 Probe Seal Adapter, 1/4 inch NPT
5P-3591 Probe Seal Adapter, 9/16 inch O-ring
3 4C-6264 Probe, 1 inch RTD
4C-6265 Probe, 1.5 inch RTD
4C-6268 Exhaust Probe RTD
4 6V-2198 Extension Cable, 20 ft
5 4C-6501 Digital Thermometer
8T-0844 Front Cover
4C-6355 Back Cover
4C-6499 Front Panel Switch
4C-6356 Transflective Display
6 6V-6045 Accessory Case
4C-6498 Foam Insert
Not Shown
4C-6496 Immersion Probe, Handheld
ID: ph3, C26990T1
4C-6497 Surface Probe, Handheld
4C-9499 Adapter, RS-232
2-76 TSPG 2002

164-3310 Infrared Thermometer (Standard, Battery Power Only)

164-3320 Infrared Thermometer (Enhanced, 110 VAC) or Battery
166-9030 Infrared Thermometer (Enhanced, 220 VAC) or Battery
SMCS Code: 0776-082
Model: All
Warranty: One Year
• Has 16-point laser circle spot (know exactly what area is covered) not available
on former 123-6700
• Used to measure temperature (without contact) in hard to reach places, around
moving machinery, or without stopping production
• Measures component temperatures on engine, transmission, power train,
hydraulic, electrical, and mechanical systems, axles, and bearings
• Measure equipment, electrical panel, circuit breaker, generator, and gearbox
temperatures in production plants; piece part temperatures in manufacturing
facilities; or component and system temperatures in field applications
• Monitor temperatures in commercial applications such as supply and return
registers, air stratification, and duct leakage; monitor temperatures of gasoline
and diesel engine cylinders; check food preparation and storage temperatures
• Small light-weight units—extremely portable ID: il2, C79623T1
164-3310 Target Specifications

Temperature measurements can be taken at any distance as long as the target size
• Replaces discontinued 123-6700 Thermometer II
is larger than the target spot. The chart measures target distance in meters (feet)
• Unit is lower priced and spot size in millimeters (inches). If the target distance is greater than 3 meters
• Designed with adjustable emissivity, audible/visible high alarm, (10 ft), divide the target distance by 24 to figure the spot size.
maximum/minimum temperature, and bar graph display
• Battery powered only (x 2 AA Cells)
Former 50:1 New 60:1
164-3320 Target Distance Spot Size Spot Size
• Designed with easily adjustable emissivity, on-board emissivity table, 16-point mm (ft) mm (in) mm(in)
laser circle spot (know exactly what area is covered), audible/visible high alarm, 0.3 (1) 20 (.8) 20 (.8)
audible/visible low alarm, maximum/minimum temperature, DIF and AVG 0.6 (2) 20 (.8) 20 (.8)
temperature, bar graph display, RS232 data output port, 100 point data logging,
0.9 (3) 23 (.9) 20 (.8)
Windows-compatible Data Graphing Software, and 110 VAC power supply
• Hand held thermistor probe included 1.2 (4) 25 (1.0) 20 (.8)
• Can be powered by battery or AC power access 1.5 (5) 30 (1.2) 25 (1.0)
1.8 (6) 38 (1.5) 30 (1.2)
166-9030 2.1 (7) 43 (1.7) 36 (1.4)
• Can be powered by battery or AC power access
2.4 (8) 51 (2.0) 41 (1.6)
• This unit is 220 VAC version of the 164-3320.
2.7 (9) 58 (2.3) 46 (1.8)
Graphic Display 3.0 (10) 69 (2.7) 51 (2.0)
• Allows more information to be displayed at a glance ID: il2, C79621T1
• Automatically creates a graphic display of last 10 temperature points measured
using maximum and minimum temperature values to establish range Temperature reading range -30 to 900°C (-25 to 1600°F)
Accuracy ±1% of reading or ±1°C (±2°F), whichever is greater
Repeatability ±0.5% of reading or ±1°C (±2°F), whichever is greater
Response time (95%) 250 mSec
Spectral response 8 to 14 um, thermopile detector
Display resolution tenth degree reading up to 900°C (.2 to 999.8°F)
Ambient operating range 0 to 50°C (32 to 120°F)
Relative humidity 10 to 95% RH noncondensing @ up to 30°C (86°F)
Storage temperature -20 to 50°C (-4 to 120°F) without battery
Power source two 1.5 volt alkaline batteries
Power direct current
Operating time without laser 25 hours
Operating time with laser 10 hours
Tripod mount 1/4-20 UNC
ID: il2, C79624T1 Dimensions 200 mm x 170 mm x 50 mm (7.9 in x 6.7 in x 2 in)
Laser Targeting Feature Weight 480 g (1 lb. 6 oz)
• Laser targeting accuracy is greatly increased (60:1 ratio of distance versus spot
size as compared to former 50:1 ratio).
• Increased accuracy when several heat sources are present (16 percent smaller
target spot over former spot size at same distance)
• Factory aligned laser circle accurately pinpoints target, even when viewed at
different angles.
• Compact, solid-state laser is mounted inside thermometer and is manufactured
for rugged use.
• Laser targeting can be turned off when not required.
TSPG 2002 2-77
192-3750 Infrared Temperature Tool (single point)

192-3755 Infrared Temperature Tool (circular point)
SMCS Code: 1800-082, 0776
Warranty: One Year
192-3750
• Used to measure surface temperatures without having to contact surface
THERMOMETER WITH LASER

192-3750 COMPACT IR
• Used to find restrictions in hydraulic lines or radiators, perform cooling checks,
measure cylinder temperatures, measure air stratification, etc.
• Backlit LCD display
LASER CIRCLE
®
192-3755 COMPACT IR
THERMOMETER WITH
• Laser target marker can be turned on or off.
192-3755
192-3750 (single point)
• Single point laser shows user where target area temperature is being measured. ID: il2, C79997T1; 192-3750, 192-3755
Accuracy 1%, ±1°C (2°F) which ever is greater at 18 to 28°C
• Economically priced for general temperature measurement (64 to 82°F ambient temperature
• Measures temperatures from -32 to 400°C (-25 to 750°F) Response time 500 milliseconds
Spectral response 7 to 18 microns nominal
192-3755 (circular point)
• Provides circular laser pattern on surface area being measured Display resolution 1°C or 1°F
• Much better definition of the target area eliminates guesswork of single point Ambient operating range 0 to 50°C (32 to 120°F)
laser (only objects inside circular pattern are measured). Relative humidity 10 to 95% non-condensing, at up to 30°C (86°F)
• Measures temperature of any engine or machine component up to 600°C (1100°F) Storage temperature -25 to 70°C (-13 to 158°F) without battery installed
[in some cases turbocharger temperatures can exceed 600°C (1100°F)] Battery 1U-9534 Battery, 9 volt alkaline
• Measures temperatures from -32 to 600°C (-25 to 1100°F); for applications Dimensions 260 x 200 x 75 mm (10 x 8 x 3 in)
up to 900°C (1600°F), use 164-3310 Infrared Thermometer or 164-3320 Infrared Weight 270 gm (9.5 oz)
Thermometer
• Adjustable high and low temperature alarms (works well when taking repetitive
temperature measurements; alarm(s) is activated if temperature is outside of
Repair Information
alarm settings) United States Repair Center European Repair Center
• Calculates maximum, minimum, and average temperatures Raytek UPS and Normal Post:
1201 Shaffer Road Raytek Sensorik GmbH
Santa Cruz, CA 95061 Borkumstrasse 2
Attn: Instrument Repair 1 - 1100 Berlin, Germany
Phone: (800) 227-8074 Air Freight:
(408) 458-1110 Airport Berlin Tegel (BLN TXL)
Fax: (408) 458-1239 Raytek Sensorik GmbH
Telex: 171890 Borkumstrasse 2
Phone: 37-2-4725126
49-30-4632070
Fax: 37-2-4710251
213-4310 Infrared Thermometer

SMCS Code: 1800-082, 0776
Model: All Models
Warranty: Manufacturer’s
• Used to measure surface temperatures without surface contact

• Single point laser shows user where target area temperature is being measured
• Economically priced for general temperature measurement
• Applications include testing engine cooling systems, checking brakes and bearings, inspecting
undercarriage components, verifying heating and air conditioning systems and inspecting defroster grids
• CE compliant
Temperature measurement range -20 to 260°C (0 to 500°F)

Accuracy 1 percent or 1°C (2°F) which ever is greater at
18 to 28°C (64 to 82°F) ambient temperature Warranty
ID: il2, C80581T1
Response time 500 milliseconds One year from purchase date

Spectral response 7 to 18 microns nominal Raytek Corporation Raytek GMBH
Displace resolution 1°C to 1°F 1201 Shaffer Road Arkonastrasse 45-49
Santa Cruz, CA 95060, USA D-13189 Berlin, Germany
Ambient operating range 0 to 50°C (32 to 120°F)
Relative humidity 10 to 95 percent non-condensing at up to 30°C (86°F) Phone: (800) 866-5478 Phone: 49 30 478 0080
Storage temperature -25 to 70°C (-13 to 158°F)
Raytek China Company Raytek Japan Inc.
Battery 1U-9534 Battery, 9 volt alkaline Beijing, China Tokyo, Japan
Dimensions 190 x 45 x 45 mm (7.5 x 1.75 x 1.75 in)
Phone: 86 10 6437 0284 Phone: 81 3 5976 1531
Weight 160 gm (5.6 oz) Web site: http://www.rayteck.com
2-78 TSPG 2002

1U-6236 Non-Contact Temperature Probe

SMCS Code: 0776
Model: All Models
Warranty: One Year
• Measures surface temperatures without touching object

• Same measurement method as 1U-8865 and 9U-5828 Infrared Thermometers
• Used with 6V-7070 Digital Multimeter or 9U-7330 Digital Multimeter
• Easy to use — provides fast, accurate, and reliable measurements
• Enhances use of technician’s digital multimeter — provides low cost optional attachment for
measuring temperature
• Uses 1U-9534 Battery, 9 Volt
Reference ID: ph2, C66687T1; 1U-6236
NEHS0618 Tool Operating Manual
Output 1mV DC per C or F

Temperature range -18 to 260 °C (0 to 500 °F)
Ambient operating temperature 0 to 65 °C (32 to 150 °F)
Output accuracy (the greater of the two) ±2% of reading or ±2 °C (±3 °F) at 23 °C (73 °F) ambient operating temperature
Repeatability ±1% of reading or ±1 °C (±2 °F)
Typical response time 1 second
Spectral response 8 to 14 microns nominal
Emissivity 0.95 preset
Relative humidity 10 to 95% relative humidity at up to 30 °C (86 °F) under noncondensing conditions
Storage temperature (without battery) -25 to 70 °C (-13 to 158 °F)
Power 9 volt battery (1U-9534)
Battery life 50 hours at 23 °C (73 °F)
Low battery indication display flashes -60 °C (-76 °F)
Dimensions (LxWxH) 180 x 30 x 50 mm (7.1 x 1.2 x 2.0 in)
Weight 80 grams (6.4 oz)
4C-6090 Multichannel Temperature Selector

SMCS Code: 0785
Model: 3500 Captive Engines
Warranty: One Year
• Saves time and money by allowing serviceman to read individual cylinder exhaust
temperatures to quickly locate faulty fuel injector
• Measures 16 exhaust temperatures individually
• Supplied with 8-channel cable pack stored in lid; optional 4C-6097 Cable Pack,
8-Channel, available to provide 16 channel capability
• Uses 6V-7070 and 6V-9129 Temperature Adapter to digitally display temperatures
• Connected to thermocouples installed in engine at assembly, starting with the following
engine serial number and product designation:
99W-2034 — D11N and 777
96Z552 — 785
54Z404 — 789 ID: ph2, C27261T1; 4C-6090
• Input: 16 channels, type K thermocouple, miniature connector Item Part No. Description
• Output: switch selectable, one of 16 inputs, miniature connector 1 4C-6096 Adapter Cable
2 4C-6089 Foam Insert
Reference 3 4C-6093 Cable Pack, Ch. 1 - 8
NEHS0537 Special Instruction
TSPG 2002 2-79

4C-9030 Mini TC-K Jack

SMCS Code: 0702-038, 0707-038, 0708-038, 0776-038
Model: All Models
• Used with 7X-7481 Cable and 4C-6095 Mini Plug to make extension cables
• More uses for 4C-6090 Multichannel Temperature Selector, with extension cables
and 8T-0933, 8T-0934, 8T-0935, 8T-0936, 8T-0458 and 6V-9055 Thermocouple Probes
• Industry standard, miniature yellow type K thermocouple jack
Reference
NEHS0537-02 Operating Manual
NEHS0544 Installation Instructions
ID: ph2, C26983T1
Temperature rating 204° C (400° F)
1 4C-9030 Mini TC-K Jack
Connector dimensions 27 x 16 x 8 mm (1.06 x 0.624 x 0.312 in)
2 7X-7481 Cable
Thermocouple connections “-” red wire, “+” yellow wire
3 4C-6095 Mini Plug
6V-9130 Temperature Adapter Group

SMCS Code: 1000-038, 1050-038, 5050-038
Model: 0785
Warranty: One Year
• Used with any Caterpillar high impedance digital multimeter to measure oil, coolant or air temperatures
from -50°C to 900°C (-58°F to 1652°F)
• 6V-9129 Temperature Adapter converts input from a K-type thermocouple to 1mV/°C or 1mV/°F output,
for use with Caterpillar 6V-3030 or 6V-7070; if adapter (with the 6V-9131 K-type Thermocouple attached)
is plugged into VOLT and COMMON inputs of a multimeter, temperature will be displayed on multimeter
• 8T-0458 Thermocouple Wire can be used to take temperature measurements in areas where probe is not
necessary. Because thermocouple wire has less mass, response time is faster than with 6V-9131
Thermocouple Probe
• 6V-3073 Carrying Case, SEES5666 Decal, 8T-0485 Foam Block, and 6V-4094 Foam Top available to store
6V-9129 Temperature Adapter, 6V-9131 Thermocouple Probe, 8T-0458 Thermocouple Wire, and
6V-3030, 6V-7070 or 6V-7800 Digital Multimeter and Probes ID: ph2, C80337T1; 6V-9129, 6V-9131
• 6V-9129 Power source: 1U-9534 Battery, 9V Item Part No. Description

• CE compliant 1 6V-9129 Temperature Adapter
NOTE: Use with 5P-2720, 5P-2725, 5P-3591, 4C-4545 and 4C-4547 Self-Sealing Probe Adapter Groups 2 6V-9131 Thermocouple Probe, Type K
(Diagnostic Tools Section of Tool Guide, Speed Measuring Tools)
Reference
SEHS8382 Special Instruction Probes
Part No. Length Diameter Application
8T-0936 3.5 in 1/8 in Probe seals
6V-9055 1 6 in 1/4 in Exhaust (bent)
6V-9131 6 in 1/8 in Hand held
8T-5334 Surface Hand held
1 For 6V-9055 Probe replaceable fitting, see FT1046
in Engine Section of Tool Guide.
2-80 TSPG 2002

8T-2844 Temperature Recorder Group

SMCS Code: 1000-082
Model: All Models
• Used for checking operating temperatures of the cooling system, engine oil system, hydraulic system and brake system
• Quick, easy, inexpensive method to determine component’s surface temperature
• 6 silver-colored temperature sensitive indicator windows on each recorder; each window turns permanently black when
temperature for that window is reached or exceeded.
• 5 different temperature recorders for 5 different ranges
• Adhesive back — attach to any clean dry surface; remove and keep as permanent record.
• Withstands repeated temperature changes, solvents, and water
• Consist: 3 each of temperature recorders listed in chart Temperature Recorder (Range)
ID: ph2, B97626T1
• Response time: approximately 1 sec. °C °C °C °C °C °C
Part No. (°F) (°F) (°F) (°F) (°F) (°F)
8T-2820 60 66 71 77 82 88
(140) (150) (160) (170) (180) (190)
8T-2821 82 88 93 99 104 110
(180) (190) (200) (210) (220) (230)
8T-2822 104 110 116 121 127 132
(220) (230) (240) (250) (260) (270)
8T-2823 127 132 138 143 149 154
(260) (270) (280) (290) (300) (310)
8T-2824 149 154 160 166 171 177
(300) (310) (320) (330) (340) (350)
Thermometers
Warranty: One Year
• Used to check:
- General temperature measuring applications.
- Coolant temperature.
- Heat indicator accuracy.
• 9U-5324 measures in Centigrade, 9U-5323 in Fahrenheit
(both include a 1.5V silver oxide battery).
ID: ph2, C80306T1

Item Part No. Temperature Length Type Readout Accuracy
1 2F-7112 -1.11°C to 116°C (30° to 240°F) 226.1 mm (8.9 in) Mercury with 6.4 mm (1/4 in) pipe connect Linear ±1%
2 6H-3050 10°C to 204°C (50° to 400°F) 171.45 mm (6.75 in) Mercury Linear ±1%
3 9U-5324 40° to 110°C 177.8 mm (7 in) Electronic Digital ±1%
4 9U-5323 40° to 230°F 177.8 mm (7 in) Electronic Digital ±1%
Self-Sealing Probe Adapter Groups

SMCS Code: 5050-038
Model: All Models
Warranty: One Year
• Provide method for checking pressure or temperature in fluid-filled
compartments without cooling down machine and draining fluid
• Can be installed in any prime product
• Seal permits probe insertion through center and seals automatically
when the probe is removed
• All temperature probes included with thermistor thermometer and
164-2192 Pressure Probe can be used in these probe adapters. ID: ph2, A92067T1
• 9F-2247 Plug (1/8 in) installed in adapter groups to serve as protective Item Part No. Descrption
cover when tests are concluded 1 5P-2720 Self-Sealing Probe Adapter Group (1/8 inch pipe thread)
• Oil can be checked at temperatures less than 132°C (270°F) and pressures 2 5P-2725 Self-Sealing Probe Adapter Group (1/4 inch pipe thread)
less than 3100 kPa (450 psi).
3 5P-3591 Self-Sealing Probe Adapter Group (9/16 inch standard thread)
• Coolant and fuel can be checked at temperatures less than
4 9F-2247 Plug (Part of 5P-2720, 5P-2725 and 5P-3591)
121°C (250°F) and pressures less than 690 kPa (100 psi).
TSPG 2002 2-81

Temperature Measuring Tools / General Diagnostic Tools
Self-Sealing Probe Adapter Groups 3

SMCS Code: 0785
Model: 1.1 Liter Engine 3
Warranty: One Year 4 1
• Used with 6V-9130 Temperature Adapter Group, 4C-6500 Digital Thermometer Group,
and 131-5050 Data View Temperature Sensors
5
WARNING 2
ID: il2, C79669T1
Using the probe seal at pressures and temperatures higher than those
indicated can result in injury to personnel or damage to the machine. Item Part No. Description Port Size
1 4C-4545 Self-Sealing Probe Adapter Group #8 3/4 inch x 16 Thd
Maximum oil temperature 132°C (270°F) at 3100 kPa (450 PSI) 2 3K-0360 Seal O-Ring
Maximum fuel/coolant temperature 120°C (250°F) at 690 kPa (100 PSI) 3 9F-2247 Plug
4 4C-4547 Self-Sealing Probe Adapter Group #5 1/2 inch x 20 Thd
5 1J-9671 Seal O-Ring
General Diagnostic Tools

4C-8195 Control Service Tool, CMS II Reference
SMCS Code: 7490-038, 0785 NEHS0586 Tool Operating Manual
Model: All Models with CMS Panels NEEG2741 Switch Positions for H-Series Motor Grader
Warranty: One Year
• Replaces discontinued 9U-6665 CMS Service Tool
• Used to access diagnostic modes on CMS panels (allows service technician
to easily enter diagnostic modes)
• Used with available adapter cables to diagnose Wheel Loader
transmission controls; also used on countershaft transmission controls
• Allows technician to scroll through active and logged faults
• Allows logged faults to be cleared
• 138-7795 replaces discontinued 134-2576 Countershaft Transmission Cable Assembly
ID: ph2, C66938T1; 4C-8195
Size 190 x 120 x 40 mm (7.5 x 4.7 x 1.5 in)
1 4C-8196 Cable, CMS II
Weight 0.2 kg (.44 lbs)
2 4C-8197 Wheel Loader Transmission Control Cable
Cable length 2.4 m (8 ft)
3 138-7795 Countershaft Transmission Control Cable (for H-Series Motor Grader)
217-7202 Interface Kit (Standard 520) PC Requirements

217-7203 Interface Kit (Premium 550) Processor 486, 66 Mhz minimum
Operating system Windows 95, 98, 2000 or NT
SMCS Code: 0734, 0779, 0785
Model: 3054 and 3056 Marine Generator Sets Ram 16 Mb
Warranty: One Year Display resolution 640 x 480
Fixed disk 10 Mb free, 80 Mb minimum
• Used to access configuration stored within control module on 3054 and 3056
Marine Generator Sets: CHN1-UP, TCN1-UP, SNX1-UP Disk drive CD Rom
• Allows user to view diagnostic display from control module Communication port RS-232
• Kit contains one 25 to 9 pin Adapter Cable, one FCC-68 Interconnecting Cable, Operating Environment
and one Windows-based CD Temperature -15 to 55° (5 to 131°F)
• CE compliant Power Requirements
Power DC (powered from control module)
217-7202
217-7203
ID: il2, D00164T1

ID: il2, D00158T1
2-82 TSPG 2002

218-2944 Data Transfer Cable 146-8488 RS-232 Cable

Model: Power Module Models PM3512, PM3516, and PMG3516 Model: Power Module Models PS003, PS004, PS005, and PS010
Warranty: One Year Warranty: One Year
• Used to connect a computer to touchscreen display for downloading • Used to connect a computer to power module protective relays for download
configuration files of configuration files
• Requires a RS-232 (DB-9) port • Used to connect 146-4080 Cat Digital Multimeter to 131-5050 DataView
• Standard 9 pin DB9 RS232 cable
and socket to pin adapter included
ID: il2, D00302T1

ID: il2, D00308T1
148-9610 PC Cart, 110-125 VAC, 60 Hz
SMCS Code: 7600-052
Model: All Models
Used to hold PC, monitor, printer and data view hardware in one Printer and Monitor Features
portable workstation • Accommodates most dot matrix or laser printers
• Universal printer securement strap (maximum printer weight 12.2 kg, 27 lbs)
• Universal monitor mounting system will hold diagonal screen size monitors
up to 431 mm (17 in)
Overall dimensions (H x W x D) 1263.7 x 958.9 x 749.3 mm

(49.75 x 37.75 x 29.50 in)
Internal equipment area 546.1 x 781 x 565.2 mm (21.5 x 30.7 x 22.25 in)
Two internal storage compartments 235 x 381 x 546.1 mm (9.25 x 15 x 21.5 in)
Cart weight, empty 84 kg (185 lb)
Shipping weight 104.4 kg (230 lb)
Casters (four swivel) 127 x 50.8 mm (5 x 2 in) two with brake
Color base is dark grey; top platform is medium grey
Capacities and Other Dimensions
Largest monitor screen (diagonal measure) 431 mm (17 in)
Largest monitor base (W x D) 317.5 x 285.7 mm (12.5 x 11.25 in)
Maximum monitor column width 184.1 mm (7.25 in)
Maximum printer dimensions (W x D) 438.2 x 400.1 mm (17.25 x 15.75 in)
Maximum printer weight 12.2 kg (27 lbs)
CD storage capacity (in door) 90 disks
Largest keyboard (W x D) 609.6 x 216.9 mm (24.0 x 8.50 in)
ID: il3, C66969T1; 148-9610
Mouse pad (largest recommended): (W x D) 279.4 x 215.9 mm (11.0 x 8.50 in)
General Features Power 148-9610
• Durable corrosion resistant baked on powder coat finish on steel body Rated voltage 125 VAC
• Protective bumper wraps around top of PC cart
Rated amperage 15 Amps
• Large 127 x 50.8 mm (5 x 2 in) casters which are customer installed
Rated frequency 60 Hz
• Two lower compartments for paper and supplies
Power cord 4572 mm (15 ft)
• CD storage with self closing door holds up to 30 CD’s
• Retractable cup holder Power Strip
• Four position communication and data port blank panel Outlets 4
• Five cable hangers Surge Suppressor
• Care and use maintenance guide Electrical rating 125 VAC, 15 Amps
• One year limited manufacturer’s warranty Maximum surge voltage 6 KV
Maximum surge dissipation 75 Joules
Protection Features Maximum spike current 4500 Amps, at 25°C (77°F)
• Fan and filter system provides added protection for computer components
Maximum clamping ratio 1.2:1
• Locking cabinet door protects computer components
Clamping volts 330 Volts
• CPU securement system
Clamping response time < 1 Nanosecond
Power Management Features Temperature range -40 to +80°C (-40 to +176°F)
• Master on/off switch (lighted) that will turn on all components at one time Outlets 6
• 381 mm (15 ft) power cord
• NEMA power block with two outlets
• “Quick release” power cord wrap system
TSPG 2002 2-83

Borescopes
SMCS Code: 0777-000
Model: All Models
Warranty: One Year
• Caterpillar’s line of borescopes are used to make visual inspections of internal 1U-5268, 9U-6940 and 186-0180 Rigid Tube Borescopes
surfaces where normal viewing is not possible.
• 1U-5268 Borescope provides straight viewing of internal surfaces.
• In most cases, inspection and analysis can be done without disassembling a
product, significantly reducing inspection time. • 1U-5269 Mirror Tube Adapter slides over shaft of 1U-5268 Borescope for right
angle viewing.
• Use a borescope as a first means of component inspection.
• 9U-6940 Fixed Right-Angle Borescope provides a more durable right-angle
• An adjustable focus under the eyepiece allows clear viewing of internal surfaces viewing borescope.
and objects.
• 186-0180 Borescope with Adjustable Angle of View is typically used for larger
• Borescopes can be used to inspect internal engine surfaces through fuel nozzle (3500 and 3600) engine applications to check cylinders, etc.
holes on engines using “pencil style” injectors.
• Used with either a 1U-5266 and 1U-5267 Light Source or a 1U-5265 Battery
• Other applications include checking turbochargers for cracked or missing blades, Light Source
checking valve bodies for internal damage or blockage, and checking cylinder
walls for scratching or scouring. • A 6V-9459 Fiber Optic Light Cable can be used with 1U-5268, 9U-6940, and
186-0180 Borescopes.
• A 6V-9461 Right Angle (90 degree) Viewing Adapter allows operator to view
into borescope from a 90 degree direction (use with 1U-5268 Borescope).
Probe Working Direction Total adjustable

Part No. Description diameter length of view Field of view Focus range view coverage Magnification Resolution Used with
1U-5268 Borescope 6.50 mm 580 mm 0 degrees 60 degrees 4.8 mm (.19 in) — — — —
(.256 in) (23.0 in) to infinity
1U-5269 Mirror Tube Adapter 7.24 mm 580 mm 90 degrees 60 degrees 4.8 mm (.19 in) — — — 1U-5268
(.285 in) (23.0 in) to infinity Borescope
9U-6940 Fixed Right-Angle 6.50 mm 570 mm 90 degrees 60 degrees 4.8 mm (.19 in) — — — —
Borescope (.256 in) (22.5 in) to infinity
186-0180 Borescope with 14.00 mm 940 mm 95 degrees 45 degrees 6.35 mm (.25 in) 140 degrees 1:1 at 76.2 mm 4 LPMM —
Adjustable Angle (.551 in) (37.0 in) to infinity viewing distance (3.00 in) minimum
of View
Basic Borescope Inspection System

(items shown in photo must be ordered separately)
1 1U-5268 Direct View Borescope
2 1U-5269 Mirror Tube, 90 degree direction of view)
3 6V-9459 Fiber Optic Light Cable 1830 mm (72.0 in)
4 6V-9461 Right Angle (90 degree) Viewing Adapter
5 1U-6345 Instrument Case, 355 x 832 x 115 mm (14.0 x 32.8 x 4.5 in)
6 1U-5265 Battery Light Source
Not Shown
6V-9465 Replacement Rubber Eye Piece (1U-5268 and 9U-6940)
1U-6346 Foam Packing for use with 1U-6345
9U-5118 Lamp, 6 Volt, for use with 1U-5265
ID: ph2, C80075T1
ID: ph1, C80087T1; 1U-5268, 1U-5269
ID: ph2, C80077T1; 186-0180
Item Part No Description

ID: ph2, C80088T1; 9U-6940
1 6V-9459 Fiber Optic Light Cable
2 4C-9664 Heavy-Duty Case
2-84 TSPG 2002

8T-9290 and 146-1738 Battery-Operated Borescopes

• Provides a compact, battery-powered borescope
• 8T-9290 battery handle can be attached directly or using an extension cable.
• 146-1738 battery handle attaches directly to viewing tube.
• 146-1738 provides 90 degree viewing.
Part No. Description Probe diameter Length Direction of view Field of view Focus range
8T-9290 Battery-Powered Borescope 8.0 mm (.32 in) 240 mm (9.5 in) 90 degrees 60 degrees 6.4 mm (.25 in) to infinity
146-1738 Borescope 6.4 mm (.25 in) 305 mm (12.0 in) 0 degrees 40 degrees 10 to 317 mm (.4 to 12.5 in)
Borescope Mirror Tube 8.0 mm (.32 in) 305 mm (12.0 in) 1.0 (.03 in) to infinity 90 degrees 40 degrees
Service Parts
1U-6862 Bulb
4C-6493 Bulb
See NEHS0504 for correct replacement bulb.
ID: ph2, C80084T1; 8T-9290
1
146-1738
Item Description
2 1 Borescope Case
2 Precision Borescope
3 3 90 Degree Viewing Adapter
4 Flashlight (light source)
4
ID: il2, C80085T1; 146-1738
186-0170 Flexible Shaft Borescope

• Allows viewing in areas where rigid-shaft borescopes cannot reach
• Articulated tip can be steered around or through obstructions.
• Provides 0 degree and 90 degree directional view
Diameter 6.00 mm (.236 in)

Length 600 mm (24.0 in)
Direction of view 0 degrees
Field of view 50 degrees
Focus range 5.0 to 304.8 mm (.20 to 12.0 in)
Light cable built-in
Mirror head (90 degree side view)
Direction of view 90 degrees ID: ph2, C80086T1; 186-0170
Field of view 50 degrees Item Part No. Description

1 186-0185 Mirror Head (90 Degree Side View)
2 4C-9662 Heavy-Duty Case
TSPG 2002 2-85

Optional Parts/Equipment
110 VAC (1U-5266) and 220 VAC (190-8160) Light Sources
• Compact, lightweight units provide illumination with a 150 watt bulb
• Can be used with 1U-5268, 9U-6940, 186-0170, and 186-0180 Borescopes
• Light intensity is adjustable and is controlled by varying Voltage output of solid state dimmer
• Light cable plugs into a 12.7 mm (.25 in) receptacle
• A cooling fan keeps units from overheating
• Bulb circuit is protected with a 2 Amp fuse or
circuit breaker which is replaceable (resetable)
ID: ph2, C80083T1; 190-8160
ID: ph2, C80082T1; 1U-5266

Replacement
Part No Descriptiion Voltage Hertz Output lamp (21 V) Compatibility Unit weight Dimensions Warranty
1U-5266 Light Source 120 V 50 to 60 Hz 150 Watts 1U-5792 — — — —
(110 VAC)
190-8160 1 Light Source 220 to 230 V 50 to 60 Hz 150 watts 1U-5792 CE 4 kg (8 lbs) 222.3 mm (8.75 in) x Manufacturer’s
(220 VAC) 120.7 mm (4.75 in) x
158.8 mm (6.25 in)
1 Contact CSTG for more information on this light source.
1U-5265 Battery Light Source 207-8837 Light Source Adapter

• Rechargeable from 110 VAC power source • Used to connect 1U-5268, 9U-6940, and
• Used with 1U-5268, 9U-6940 and 186-0180 Borescopes 186-0170 Borescopes to 1U-5265 Battery Light Source
• Makes borescopes more portable
• Allows use in areas where a 110 VAC
or 220 VAC power source is not available
ID: il2, C80116T1; 207-8837
ID: ph2, C80089T1; 1U-5265
Camera Adapters
A variety of camera adapters are available for 1U-5868 and 9U-6940 Borescopes. Refer to NEHSO5O4 for a complete listing.
Repair Information
All borescope systems are warranted to be free from defects in material and workmanship for a period of 12 months from original purchase date
from Caterpillar Inc. If repair is necessary, contact Lenox Instrument Company Inc., for information on obtaining required service. Borescopes less
than one year old will be repaired under warranty (EXCEPT FOR ABUSE). Cost of out-of-warranty repairs will be charged to the owner.
Lenox Instrument Company Inc.
265 Andrews Road
Scottsville Industrial Park
Trevose, Pa. 19053-3427
Phone: (215) 322-9990 or (800) 356-1104
Fax: (215) 322-6126
Reference
NEHSO838 Tool Operating Manual, Using the 8T-9290, 1U-5268, 9U-6940, 146-1738, 186-0170, and 186-0180 Inspection Borescopes
2-86 TSPG 2002

131-5050 DataView Group

131-5051 DataView Portable TechStation Group
SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038, 0788
Model: All Models
Warranty: One Year
• PC-based diagnostic tool that accepts up to nine standard Caterpillar sensors • Calculated channels for displaying sum, difference, and hydraulic horsepower
for measurements on any engine or machine—data is displayed on a • Automatic sensor identification of “Analog” sensors for automatic set-up
personal computer (PC) using Auto ID cables (optional)
• Includes Data Logger using 2 Mbyte PC Memory Card for storage. Data • RS232 input connector for future Digital Multimeter (DMM)
Logger has Auto Triggering and Pre-Trigger information settings.
• Portable TechStation carrying case holds DataView and a portable PC.
• Measures pressure, temperature, blowby, position, RPM, Hz, duty cycle
• Internal battery operates for up to eight hours.
(PWM), hydraulic flow, and fuel flow
• Operates and charges on 110/220 VAC, 11 to 40 VDC, or 12V Automotive
• DataView hardware unit connects to standard PC parallel (printer) port.
Cigarette Lighter
DataView software program runs on PC using Microsoft Windows™ or IBM
OS/2™ operating system. • CE certified for European use
• Allows many current hand-held diagnostic tools to be replaced with a single
diagnostic unit.
• Includes digital and analog measurements, bar graphs, charts, and
histograms in real time or Data Logged data
• Can provide test/diagnostic data for test facilities such as dynamometer
rooms, transmission test centers, or any other application where diagnostic
measurements are required.
• Future versions of DataView software will interface with other programs such
as SIS and ET via Service Technician Workbench (STW).
• Six “Analog” inputs for measuring any combination of pressure, temperature,
blowby, and position
• Three “Frequency” inputs for measuring RPM, Hz, duty cycle (PWM),
hydraulic flow, and fuel flow
• Two “Engine Set Point” inputs
ID: ph2, C78428T1; 131-5050

Minimum PC Requirements
Connection to PC standard parallel (printer) port
Computer IBM PC compatible with 486, 33 Mhz SL or SXL processor or greater
RAM 8 Mb
Available hard disc space 10 Mb
Diskette drive (internal or external add-on) 3.5 Inch, 1.44 Mb
Monitor VGA
DOS version 5.0 or greater
Operating system Microsoft Windows™ version 3.1 or Windows 95, OS2 version 2.11, or Warp 3.0
Printer port parallel
General Hardware Specifications
Internal power source rechargeable internal nickel metal hydride battery (Varta C526F, 7.2 Volt 2400 mAh)
AC external power 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz
External power connector 11 to 40 VDC machine power or cigarette lighter adapter
Power consumption 2 amp max at 15 VDC
Low battery indicator flashing ON light
Battery life 10 hours nominal (dependent upon sensors being used)
Battery charge time 6 hours
Battery charge indicator light off - not charging, light on solid - fast charge, light flashing - trickle charge
Operating temperature -17 to +60°C (0 to 140°F)
Storage temperature -40 to +100°C (-40 to +212°F)
Size 297 x 229 x 45.7 mm (1.7 x 9.0 x 1.8 in)
Weight DataView hardware (enclosure only) 1.8 kg (4 lbs)
Data Logger Specifications
Channels data can be logged from all nine input channels
Memory 2 Mbyte PC PCMCIA flash memory card is standard
Sample rate adjustable up to 1000 samples per second
Recording time varies depending on sample rate and number of channels in use
Maximum log size At first release of software, logs will be limited to 8000 samples.
A later software version will provide larger size logs.
Pre-trigger allows logging of events which happen before the log trigger point
Auto trigger logging can be triggered from an event or change in any channel
Manual trigger logging can be manually started from the PC or from the hardware
TSPG 2002 2-87

Analog Channel Specifications

Connector type 5 pin DIN connectors (female)
Analog channel sensor types analog inputs are automatically reconfigured with relays to accept voltage, milliamp,
RTD, or resistance-type output sensors.
Analog channel input ranges 0 to 5 VDC; Milliamp: 4 to 20 mA; RTD: 100 Ohm, PRTD; Resistance: 15K Ohm nominal
Sensor power supply ranges 5, 8, 12, or 15 VDC available, firmware selectable
Input impedance 500K Ohms minimum
A/D resolution 12 bit
A/D Access time 10 microseconds
Channel scan rate 50 microseconds per channel (10 channels scanned in 500 microseconds)
Frequency response DC to 300 Hz (2000 samples per second)
A/D input voltage range 0 to 5 VDC
Max input voltage protected to 40V RMS or peak
Frequency Channel Input Specifications
Frequency sensor types waveform or pulse inputs
Input voltage range 0.1 to 40 VAC or VDC peak
Allowable signal offset +0.040 VDC
Input impedance 50K Ohms minimum
Frequency response 3 Hz to 15K Hz
Frequency accuracy ±1 Hz
RPM measurement range 1 to 9999 RPM
RPM accuracy ±1 RPM in selected RPM/PPR ranges
Pulses per revolution 0.1 to 256 pulses per revolution;
Hz fixed at 60 pulses per revolution
Pulse width measurement 1 to 100% duty cycle for 40 Hz to 15K Hz
Cat PWM sensor measurement special adapter cable required because of DC offset on output signal
Pulse width accuracy ±1% for signals above 1V peak
Photo pickup power provided for 9U-5140 Photo Pickup
Photo pickup range 3 to 30 inches from retro-reflective tape target
Engine Set Point Specifications
Set point inputs 2 inputs provided for use with 2 frequency channels
Rack contact voltage 12 VDC
Rack contact current 5.5 mA
Overrun indication 0 to 10% rack contact closure
Set point indication 11% rack contact stores engine rpm
Lug indication 75 to 100% rack contact closure
131-5050 Basic Cat DataView Group

• Very basic group which includes only DataView hardware unit and accessories
necessary to power it and connect it to the PC
• No sensor or adapter cables are included.
• The memory card for data logging is not supplied but can be purchased separately.

1 JERD2163 DataView Software
2 131-5050 DataView Hardware
3 137-0172 DataView Mounting Kit
4 137-0169 DataView Front Flash Programming Cable
5 131-5059 DataView Rear Flash Programming Cable
6 131-5053 DataView to PC Parallel port cable (short)
7 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz
8 131-5047 AC Power Cable, 110 VAC (USA Plug)
9 137-0171 European Power Adapter
10 NEHS0662 Tool Operating Manual
ID: ph2, C78297T1; 131-5050 Not shown 142-2415 Test Connector (for parallel port test)
2-88 TSPG 2002

131-5051 DataView Portable TechStation Group Item Part No. Description

• Contains all accessories, excluding sensors, needed to operate DataView 1 JERD2163 DataView Software
on a PC. 2 133-6976 Memory Card for DataView (2 MB Capacity)
• Includes carrying case which holds DataView unit and PC (not included). 3 131-5050 DataView Hardware
4 137-0173 DataView Carrying Case
5 131-5058 Foam Insert for Universal PC
6 137-0172 DataView Mounting Kit
7 6V-2198 Extension Cable 5.5 m (18 ft), (4 provided)
8 8T-5111 Rack Adapter Cable
9 1P-7446 Rack Cable
10 131-5054 Adapter Cable for Caterpillar Pressure Sensors
11 131-5055 Adapter Cable for Blowby/Airflow Pickups
12 9U-7506 Magnetic Adapter Cable
13 131-5056 Adapter Cable for Caterpillar Hydraulic Flowmeters
14 131-5065 Auto ID Cable for Caterpillar Electronic Position Probe
15 NEHS0662 Hardware Operating Instructions
16 JEBD3004 Software Program Operating Instructions
17 9U-7505 High Voltage Adapter
ID: ph2, C78298T1
18 6V-7072 Test Lead Set
19 131-5053 DataView to PC Parallel port cable (short)
20 137-0169 Flash Programming Cable, DataView Front
21 131-5047 AC Power Cable, 110 VAC (USA Plug)
22 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz (NEEG2740 label)
23 137-0171 European Power Plug Adapter
24 131-5059 DataView Rear Flash Programming Cable
Not shown NEEG2723 Group Label on lid of 131-5051 DataView Group
Not shown 142-2415 Test Connector (for parallel port test)
Optional Equipment
ID: ph2, C78299T1

1 131-5058 Generic Foam Insert Fits in 137-0173 Case and has locations for DataView and a square hole for almost any laptop
PC, plus a location for Caterpillar communications adapter
2 137-0173 DataView Carrying Case Has access door in front to allow DataView to be used without removing it from case. Foam
inserts must be ordered separately, depending on configuration
3 138-8779 Top Foam Insert Replaces generic PC foam in DataView case to allow Cat Portable PC (Itronix) with CD ROM
drive and Cat Communications adapter to be used with 131-5051 DataView Portable
TechStation
4 137-0174 Cat Portable PC Foam Insert (4 pcs) Fits 137-0173 Case and has location for DataView on lower level and Cat Portable PC (Itronix)
with CD ROM and Cat Communications adapter on upper level. Also includes a DataView
blank foam and lid foam
5 137-0168 External Power Cable, 11 to 40 VDC, 5 m (18 ft) long
6 133-6975 European DataView Power Cable (220 VAC) European-style connector to fit 131-5052 AC Power Adapter
7 137-0170 Cigarette Lighter Power Cable (12 VDC)
Not shown 142-2415 Parallel Port Test Connector
TSPG 2002 2-89

Optional Cables and Sensors to Use with DataView Frequency Channel Sensors
Part No Description
Analog Channel Sensors Photo Pickup Speed Sensor
Part No Description 9U-5140 LED Photo Pickup
Pressure Sensors for Analog Channels 6V-3137 Magnetic Mounting Base for 9U-5140
A 131-5054 Adapter Cable or Auto ID Cable is always required to use the following sensors: 6V-3138 Extension Rod for 6V-3137
213-3274 Auto-ID Pressure Sensor (0 to 100 psi) 1U-6605 Retro-Reflective Tape, 12 mm (.5 in) x 15 m (5.0 ft) long
213-3275 Auto-ID Pressure Sensor (0 to 1000 psi) 6V-0093 Retro-Reflective Tape, 12 mm (.5 in) x 47.5 m (50 ft) long
213-3276 Auto-ID Pressure Sensor (0 to 7500 psi) 4C-6919 Retro-Reflective Tape, 25 mm (1.0 in) x 2.5 m (100 in) long
4C-6816 Pressure Sensor (0 to 60 psi) Injection Line Speed Sensor
131-5060 Auto ID Cable (for 4C-6816 Sensor) 6V-4950 Injection Line Pickup Group (from Multitach Group)
4C-6817 Pressure Sensor (0 to 100 psi) 4C-6821 Injection Line Pickup Group (from Data Logger Group)
131-5061 Auto ID Cable (for 4C-6817 Sensor) Tach Generator Speed Sensor
4C-6818 Pressure Sensor (0 to 500 psi) 9U-7506 Magnetic Adapter Cable
131-5062 Auto ID Cable (for 4C-6818 Sensor) 5P-7360 Tach Generator (20 tooth internal gear)
4C-6819 Pressure Sensor (0 to 1000 psi) 5P-1759 Tachometer Drive Group
131-5063 Auto ID Cable (for 4C-6819 Sensor) Flywheel TDC Magnetic Speed Sensors
4C-6820 Pressure Sensor (0 to 7500 psi) 9U-7506 Magnetic Adapter Cable
131-5064 Auto ID Cable (for 4C-6820 Sensor) 8T-5184 Magnetic TDC Pickup 89 mm (3.5 in) long
Probe Type RTD Temperature Sensors 6V-2197 Magnetic TDC Pickup 114 mm (4.5 in) long
4C-6264 RTD Temperature Sensor, 25.4 mm (1.0 in) long, 3.2 mm (.125 in) diameter 8T-5185 Magnetic TDC Pickup 178 mm (7.0 in) long
4C-6265 RTD Temperature Sensor, 38.1 mm (1.5 in) long, 3.2 mm (.125 in) diameter 9U-7506 Magnetic Adapter Cable (required for TDC Sensors)
4C-6266 RTD Temperature Sensor, 63.5 mm (2.5 in) long, 3.2 mm (.125 in) diameter 6V-2199 Sensor Mounting Adapter, 1/8 in NPTF
4C-6267 RTD Temperature Sensor, 88.9 mm (3.5 in) long, 3.2 mm (.125 in) diameter 6V-3093 Sensor Mounting Adapter, 1/4 in NPTF
Exhaust RTD Temperature Sensor 7X-1171 Sensor Mounting Adapter, 7/16-20 Straight Thread
4C-6268 Exhaust RTD Temperature Sensor Magnetic Pickup Speed Sensors
Hand Held RTD Temperature Probes 8L-4171 General Purpose Magnetic Speed Sensor, 91 mm (3.5 in) long,
4C-6496 Immersion Hand Held RTD Temperature Probe, 3.18 mm (.125 in) diameter 5/8-18 Thread
9G-6724 Magnetic Speed Sensor, 76 mm (3.0 in) long, 3/4-16 Thread
4C-6497 Surface Hand Held RTD Temperature Probe, 6.35 mm (.25 in) diameter
6V-4156 Adapter Cable (required for above sensors), Amphenol to Phono Jack
Blowby Sensors for Analog Channels
9U-7506 Magnetic Adapter Cable (required for above sensors) Phono Jack
8T-2685 Small Blowby/Air Flow Pickup (Part of 8T-2700 Blowby Group)
to Data View
131-5066 Auto ID Cable for Small Blowby Pickup
Fuel Flowmeters and Fuel Flow Communicator
1U-8860 Large Engine Blowby/Air Flow Pickup Group (For 3500 and 3600 Engines)
1U-9500 Fuel Flow Communicator
131-5067 Auto ID Cable for Small Blowby Pickup
1U-5450 Complete Engine Fuel Flow Monitor Arrangement
Position Sensor for Analog Channels
4C-9764 Fuel Flow Monitor Group
8T-1002 Position Sensor 0 to 25 mm (0 to 1.0 in) range
4C-9758 Supply Fuel Flowmeter Group, Small
131-5065 Auto ID Cable for 8T-1002 Position Sensor
4C-9759 Return Fuel Flowmeter Group, Small
6V-6042 Contact Point Group
4C-9760 Supply Fuel Flowmeter Group, Large
5P-4814 Fuel Setting Collet
4C-9761 Return Fuel Flowmeter Group, Large
9U-6909 Extended Fuel Setting Collet (for 3500 engines)
1U-5305 Hose Adapter Group, Small
1U-5306 Hose Adapter Group, Large
1U-5420 Hose Adapter Group, 3600 Engine
1U-5299 Case Assembly
1U-5430 Small to Medium Engine Fuel Flow Monitor Arrangement
1U-5440 Medium to Large Engine Fuel Flow Monitor Arrangement
Hydraulic Flowmeters for Frequency Channels
The 131-5056 Adapter Cable is required to use the following flowmeters:
4C-9911 Hydraulic Flowmeter, 8 to 50 Lpm (2 to 12 gpm)
Hydraulic Flowmeters with Load Valves for Frequency Channels
160-2513 Tester Flowmeter, 5-50 gpm
Reference
NEHS0662 Tool Operating Manual, Using the Caterpillar Data View
NEHP5622 Data View Marketing Brochure
2-90 TSPG 2002

153-9630 Sensor Test Group

SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038
Model: Electronically Controlled Cat® Equipment
Warranty: One Year
• Recommended for testing CAT PWM and analog sensors on or off the machine
• Used with 131-5050 DataView and DataView 2.0 software
• DataView 2.0 software lists common sensors for easy setup
• Internal power supply powers active sensors while removed from equipment
• CE certified for European use
Reference
ID: ph2, C79438T1; 153-9630
Input impedance 120 kΩ
1 153-9629 Insert Foam
Input voltage 5 VDC (from DataView) 148-5675 Case
Output voltage 9.4 VDC (sensor power) 6V-6096 Foam
Maximum sensor current 40 mA maximum at 9.4 VDC NEEG2813 Decal
Operating temperature -17 to 60°C (0 to 140°F) 2 153-9625 PWM Sensor Adapter
Size 85 x 56 x 35 mm (3.3 x 2.2 x 1.4 in) 3 153-9627 Cable Assembly, DT
Weight (153-9625) 0.23 kg (.5 lb) 4 153-9626 Cable Assembly, HD
DataView Auto ID Pressure Sensors

SMCS Code: 1000-038, 4000-038, 5000-038, 6000-038, 0788
Warranty: One Year
• Low cost pressure sensors

• Used with 131-5050 DataView (sensors are not designed for use with
4C-6800 Data Logger and will not give correct readings if used)
• Built-in auto ID
• Plugs directly into DataView Analog Channels
• Accuracy of ±1%
• Replaces discontinued 143-4062, 143-4065 , and 143-4066 Pressure Sensors
• CE compliant
ID: il2, C80595T1

Pressure ranges 0 to 689 kPa (0 to 100 psi)
0 to 6890 kPa (0 to 1000 psi)
0 to 51675 kPa (0 to 7500 psi)
Accuracy ±1% of full scale or ±1% of reading typical
213-3274 DataView Auto ID Pressure Sensor, 689 kPa (100 psi)
Proof pressure two times rated range
Burst pressure five times rated range
Connection male, 1/4 inch NPT thread
Connector male, 5-pin DIN
Operating temperature range -40 to 100°C (-40 to 212°F)
Maximum diameter 26.0 mm (1.02 inches)
Sensor length 84 mm (3.3 inches)
Cable length 305 mm (12 inches)
Weight 0.13 kg (.28 lbs)
DataView Auto ID resistor built-in
TSPG 2002 2-91

177-8910 Power Link Group

SMCS Code: 7100-038, 0759, 0769, 0599
Model: Challenger 35, 45, 55, 65, 75, 85, and 95
Warranty: One Year
• Used to measure actual drawbar horsepower of Ag Tractors

• Allows side-by-side comparison between Caterpillar Challenger and competitive
equipment or any tractor equipped with a traditional drawbar
• Complete portable system ideal for field use
• Quick and easy installation and set-up
• Measures true ground speed and draft load
• All measurements are shown on power link display screen.
• Designed to accommodate a wide range of tractors and implements,
complete with drawbar pins for row crop and tillage machines
• Measures tractors with up to 18,160 kg (40,000 lbs) drawbar pull and 36,320 kg
(80,000 lbs) maximum rating
177-8910 Power Link Group

Storage case 560 x 480 x 230 mm (22.0 x 19.0 x 9.0 in), 2 required
Weight (power link case) 27.7 kg (61 lbs)
Weight (accessory case) 17.7 kg (39 lbs)
Operating temperature range 0 to 40°C (32 to 104°F)
Accuracy ±5%
177-8905 Power Link Display
Provides readout device for user
Size 290 x 178 x 92 mm (12.0 x 7.0 x 4.0 in)
Weight 2.25 kg (5 lbs)
Power requirements 0.5 to 2 Amps
Output (data) RS232
Operating voltage 10.5 to 29 Volts DC ID: ph2, C80350; 177-8905
Fuse 3 Amp slow blow, 2 required
177-8902 Power Link - provides drawbar pull information
Size 380 x 150 x 100 mm (15.0 x 6.0 x 4.0 in)
Nominal impedance 350 Ohms
Operating voltage 5 Volts DC
Pull capacity (continuous) 16,160 kg (40,000 lbs)
Pull capacity (maximum) 36,320 kg (80,000 lbs)
Vertical load capacity 2,725 kg (6,000 lbs)
Power requirements 15 mA ID: ph2, C80475; 177-8902
Output DC milli-volt
177-8906 Radar - provides ground speed information
Size 220 x 110 x 115 mm (8.5 x 4.3 x 4.5 in)
Weight 1.6 kg (3.5 lbs)
Power requirements 150 mA
Velocity range 0.161 to 48 km/h (0.1 to 30 mph)
Beam width 7 degrees
Mounting height 460 to 1070 mm (18 to 42 in)
Input voltage 11 to 26 Volts DC
Output (data) RS232
Operating temperature range 0 to 40°C (32 to 104°F)
Accuracy 0.161 kmp (0.1 mph) ID: ph2, C80477; 177-8906
2-92 TSPG 2002

Item Part No. Description Repair Information

1 4C-9660 Equipment Case, 2 required
2 177-8904 Radar Foam Insert
177-8906 Radar Sensor
O’Conner Engineering
3 177-8906 Radar Sensor 1060 Grant Street 1B
4 177-8908 Radar Sensor Bracket Benicia, California 94510
5 9U-5061 Velcro Strap Phone: 270-838-1000
6 162-7120 Hitch Lock Pin Fax: 707-745-3191
7 177-8919 Angle Indicator A Return Material Authorization
8 177-9455 Radar Mount Tie Down Number is required
9 NEEG2868 Decal
10 177-8907 Power Link Power Cable 177-8902 Power Link
11 177-8905 Power Link Display 177-8905 Power Link Display
12 NEHS0768 Tool Operating Manual Stress-Tek, Inc.
13 177-8920 Radar Cable 5920 South 194th Street
14 113-5518 Hitch Pin (1 3/8 inch)
Kent, Washington 98032
15 FT2686 Extension Hoses (not included) Phone: 253-872-1910
16 NEEG2867 Decal
Fax: 253-872-9626
ID: ph3, C79890T1; 177-8910 17 177-8909 Power Link Cable A Return Material Authorization
18 135-4730 Hitch Pin (2 inch)
Number is required
19 177-8902 Power Link
20 177-8903 Foam Insert, Power Link
Reference
4C-9024 Battery Pack Group

4C-9031 Battery Cable
SMCS Code: 0785
Model: All Models
Warranty: One Year
• Portable, rechargeable power supply for use with all Caterpillar diagnostic tools
that require 12-Volt DC power, e.g., 4C-9021 Torsional Vibration Signal
Conditioner Group
• Recharged from self-storing 4C-9026 Charger from standard 110 Volt wall outlet
• Provides quick power for short diagnostic tests — no need to open vehicle
battery compartment
4C-9025 Rechargeable Battery
• 4C-9031 Cable required to connect to diagnostic tools
4C-9026 Battery Charger
ID: ph2, C26988T1; 4C-9024
Reference
NEHS0562 Operating Manual, 4C-9021 Torsional Vibration Measuring Group
4C-9024 Battery Pack Group

Volts 12 VDC
Capacity 6 amp hrs. at 20 hr. rating (25° C, 77° F)
Internal resistance 25 milliohms
Self discharge 2-3% per month
Size 210 mm L x 73 mm W x 165 mm H
(8.25 in L x 2.875 in W x 6.5 in H)
Weight 7 lbs.(3.18 kg)
Charge/discharge cycles up to 500 typical
Operating temperature -60 to +60 ° C (-76 to +140° F)
Charging temperature -16 to +50 ° C (+4 to +122° F)
ID: ph2, C26989T1; 4C-9031
Recharge time 16-20 hrs.
4C-9031 Cable, Battery to Tool
Length 182 cm (6 ft.)
Typical operating times
Weight .113 kg (.25 lbs)
Current drain (amps) 0.25 0.5 1.0 2
Connectors:
Power drain (watts) 3 6 12 24 Plug standard cigarette lighter plug with integral 1 Amp fuse
Operating time (hours) 20 11 5 2 Receptable standard MS, 2-pin connector used on diagnostic tools
TSPG 2002 2-93

9U-7560 Field Soldering Iron Group

9U-7561 Field Soldering Iron
SMCS Code: 0709
Model: All Models
Warranty: One Year
• Used to solder electrical connections in the field — light-weight and easy to use
• Used with 4C-9024 Battery Pack Group
• Tip is temperature regulated (provides better control for outdoor usage).
• In-line fuse prevents damage and/or overload.
• Plugs into any 12V vehicle cigarette lighter plug
• The optional 4C-9024 Portable Battery Pack will power 9U-7561 for three hours continuously.
Reference ID: ph2, C66644T1; 9U-7560

Voltage requirement 12 VDC Item Part No. Description

Wattage 42 Watts 1 9U-7561 Soldering Iron
Tip temperature 370°C (700°F) 2 9U-7562 Solder, 0.5 kg (1 lb.) Spool
Length 190 mm (7.5 in) 3 6V-3073 Case
Cord length 3.5 m (11.50 ft.) Service Parts
9U-7563 Tip, Soldering Iron Replacement
6V-4094 Foam Block
2S-6024 Fuse or 333672 Fuse, 5 Amp
NEEG2588 Soldering Iron Label
NEEG2587 Case Label\
4C-5607 Combustible Gas Detector

SMCS Code: 1250-034
Model: Spark Ignited Engines
Warranty: One Year
• Portable, battery operated, solid-state Power supply 2 (2.4V) Ni-Cad batteries

• Approved for use in Class-1 Hazardous Atmospheres Battery life 4 hours
• Provides “geiger-counter” ticking signal which increases in frequency Sensitivity 50 - 1000 PPM
as source of combustion gas or vapor is approached
Warm-up time automatic, approx. 15 sec.
• Excellent for instantly pin-pointing gas leaks in Class-1 Atmospheres,
Response time instantaneous
as minute as 50 PPM
Weight 439 grams (15.5 oz.)
• Includes flexible probe, sturdy carrying case,
rechargeable batteries, and recharger adapter Dimensions 20.32 cm x 7.62 cm x 4.57 cm (8 in x 3 in x 1.8 in)
Duty cycle continuous, no limitations
Materials the 4C-5607 will respond to: Operating temp. range 0°C to 38°C (33°F to 100°F)
Hydrocarbons Probe length 38.1 cm (15 in.)
• Methane (Natural Gas) • N-Butane
• Ethane • Isobutane
• Propane • Pentane Service Part
• Benzene • Hexane
• Acetylene • Gasoline Part No. Description
• Butane • Diesel Fuel 4C-5611 Sensing Tip
Halogenated Hydrocarbons
• Methyl Chloride • Trichloroethane
• Methylene Chloride • Vinyl Chloride
ID: phod 19p6,19p0, C33391T1; 4C-5607
2-94 TSPG 2002

4C-5608 Vacuum Leak Detector/Transmitter

SMCS Code: 7300-034
Model: All Models
Warranty: One Year
• Designed to detect high pressure and/or vacuum leaks through use of

ultrasonics (All pneumatic and vacuum leaks emit high-frequency sound in
range far above that audible to human ear.)
• Transmitter (included in 4C-5608) to be used with Vacuum Leak Detector
when checking system that does not generate a high frequency tone
• Excellent for finding door seal leaks in cabs.
Service Part
4C-5609 Replacement Transmitter for 4C-5608
Power supply 1U-9534 Battery, 9V

Battery life 40 hrs for carbon-zinc, 80 hrs for alkaline
Sensitivity automatic
Response time instantaneous
Reset time 1/4 second
Set time 1 second
Warm-up time instantaneous
Weight 14.5 oz. with battery
Dimensions 20.32 cm x 7.62 cm x 4.57 cm (8 in x 3 in x 1.8 in)
Probe length 31.75 cm (12.5 in.) ID: ph3, C33390T1; 4C-5608
8T-9295 Diagnostic Tool Holder

SMCS Code: 0785
Model: All Models
Warranty: One Year
• Frees serviceman’s hands while performing critical diagnostic tests

• Magnetized, adjustable device holds multimeter, multitach, electronic position indicator
or any diagnostic tool.
• Especially helpful while checking or adjusting fuel systems
ID: ph2, C44352T1; 8T-9295
9U-5215 Tool Case, Soft

SMCS Code: 0785
Model: All Models
• Universal soft case for most Caterpillar hand-held “green box” diagnostic tools
• Foam insert used to hold standard-size tool; without foam, will hold 4C-6500 Digital thermometer
• Resistant to coolant, diesel fuel, and oil
• Adjustable/removable strap
• Clear vinyl front for excellent instrument visiblity; provides extra protection
• Opening in top for easy access to all connections of instrument
ID: ph2, C27065T1; 9U-5215
TSPG 2002 2-95

156-1060 Emission Analyzer Group (Gas Engines Only)

156-1070 Emission Analyzer Group (Gas and Diesel Engines)
SMCS Code: 1088-036, 0781
Model: All Models of Gas and Diesel Engines
NOTE: Manufacturer’s one year warranty from date of purchase on all parts except
the 156-1061 Oxygen Sensor which has a two year warranty.
156-1060 Input exhaust from engine under test

• Replaces discontinued 4C-8710 Emissions Analyzer 156-1067 length 305 mm (12.0 in)
• Used for fast, easy set-up and servicing of lean burn and stoichometric engines 156-1068 length 4572 cm (15 ft)
• Measures exhaust concentrations of oxygen (O2), carbon monozide (CO), low Power cord length 4572 cm (15 ft)
nitricoxide (NO), and nitric oxide (NO2)
Power
156-1070 Internal sealed lead acid battery, 12VDC, 2.2 AH rechargeable
• Used for fast, easy set-up and servicing of lean burn, stoichometric, and diesel engines External selected 110/220 VAC, 50/60 Hz
• Measures exhaust concentrations of oxygen (O2), carbon monoxide (CO), nitric oxide External converter 12VDC, battery cables and cigarette lighter plug
(NO), nitric dioxide (NO2), and combustibles (CxHx) (available separately)
156-1060 and 156-1070 Operating Temperatures
• Measures exhaust and ambient temperatures, stack draft, and smoke test Analyzer 6.7 to 50.0°C (20 to 122°F)
• Calculates carbon dioxide, excess air, efficiency, and losses Probe -17.8 to 982.2°C (0 to 1800°F)
• Display shows all parameters at once and has two levels of zoom Storage temperature -40.0 to 60.0°C (-40 to 140°F)
• Housed in a durable aluminum reinforced case Measurements
• Durable pistol grip probe (one foot in length) External dimensions 48.3 x 40.6 x 16.5 cm (19 x 16 x 6.50 in)
• Built-in thermal printer
• Automatic water dump
Reference
NEHS0713 Tool Operating Manual Part No. Description
NEHS0714 Tool Operating Tips Pocket Card
Sensors provided with 156-1060 Analyzer Group (installed in analyzer)
156-1061 Sensor, Oxygen
156-1062 Sensor, Carbon Monoxide (CO) Low
156-1064 Sensor, Nitric Oxide (NO)
156-1065 Sensor, Nitric Dioxide (NO2)
Sensors provided with 156-1070 Analyzer Group (installed in analyzer)
156-1061 Sensor, Oxygen
156-1062 Sensor, Carbon Monoxide (CO) Low
156-1063 Sensor, Carbon Monoxide (CO) High
156-1064 Sensor, Nitric Oxide (NO)
156-1065 Sensor, Nitric Dioxide (NO2)
156-1066 Sensor, Combustibles (CxHx)
Service Parts (available separately)
156-1078 Printer Paper
156-1074 Smoke Test Paper
156-1073 Filter Media (purple beads)
ID: ph3, C79262T1 156-1072 Water Trap Filter
Components included with 156-1060 or 156-1070 Emission Analyzer Group Replacement Parts (available separately)
Item Part No. Description 156-1069 Inlet O-Ring (draft)
1 156-1067 Probe 156-1076 Inlet O-Ring (gas)
2 156-1068 Sample Line 156-1071 Printer Head
3 Two rolls of printer paper 156-1067 Probe
4 Package of smoke test paper and comparison chart 156-1068 Sample Line
5 Single water trap assembly 156-1061 Sensor, Oxygen
6 Ambient thermocouple with magnet 156-1062 Sensor, Carbon Monoxide (CO) Low
7 Shoulder strap 156-1063 Sensor, Carbon Monoxide (CO) High
8 Calibration certificate and magnet 156-1064 Sensor, Nitric Oxide (NO)
9 AC power cord 156-1065 Sensor, Nitric Dioxide (NO2)
10 NEHS0713 Tool Operating Manual 156-1066 Sensor, Combustibles (CxHx)
11 Package of water trap filters Optional (available separately)
12 Drain hose 156-1077 Power Inverter - 12VDC, includes battery cables
13 Emission Analyzer and cigarette lighter adapter
14 NEHS0714 Tool Operating Tips Pocket Card 156-1075 Remote Display - includes a cable 76.2 cm (30 ft) in length
Not shown Two keys for case latches Data Acquisition Software (contact CSTG)
2-96 TSPG 2002

Measurement Measurement Measurement

Range Resolution Accuracy Sensor Life
Oxygen (O2) 0 to 21% 0.1% ±2% of reading 2 years
Carbon monoxide (CO) low 0 to 4000 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Carbon monoxide (CO) high 0 to 40,000 ppm 5 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Nitric oxide (NO) 0 to 4000 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Nitrogen dioxide (NO2) 0 to 500 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Combustibles (CxHx) 0 to 6% 0.01% ±2% of reading 3 years
Ambient temperature -17.8 to 121.1°C (0 to 250°F) 0.6°C (1°F) -16.1°C (3°F) 10 years
Exhaust temperature -17.8 to 982.2°C (0 to 1800°F) 1.7°C (1°F) -16.1°C (3°F) 10 years
Stack draft 0 to 40.00 inches H20 0.01 inch H20 2% of reading 10 years
Smoke test 0 to 9 spot method — — —
209-5545 Oxygen Analyzer

SMCS Code:0781,1088
Warranty:Manufacturer’s
• Battery operated—will operate more than 4 hours on 4 AA-size alkaline batteries

• Can be operated from AC power with optional power supply/recharger when
optional NiCad batteries are used in place of alkaline batteries
• Measures oxygen content and temperature of exhaust gases of natural gas,
diesel, oil, and propane powered engines
• Updates quickly to easily track adjustments
• Magnet-backed case provides ease of mounting
• CE compliant
Temperature
Measurement range -40 to 600°C (-40 to +1112°F)
Accuracy ±0.5°C (0 to +99.9°C)
±0.5% (from +100°C)
Resolution 0.1°C
ID: ph2, C80590T1
Sensor Thermocouple Type K
(NiCr-Ni) to DIN IEC 584 Part 2, Class 1
Draft/Pressure Measurement Part No. Description
Measurement range ±40 mbar (±0.6 psi) Oxygen Analyzer
Resolution 0.01 mbar 1U-7538 AA Non-rechargeable Alkaline Batteries
Accuracy 0.03 mbar 209-5551 Protective Rubber Boot with magnetic back
Maximum overload 1000 mbar (14.5 psi) 209-5552 Gas Probe/Hose Assembly
Gross/ Net Efficiency Reference Guide
Measurement range 0 to 100 % Calibration Information
Resolution 0.1 % Instruction Manual
Oxygen Measurement 6V-7145 Carrying Case
Measurement range 0 to 21 volume % 209-5574 Foam Insert
Accuracy ±0.2 volume % Service Parts
Resolution 0.01 volume % 209-5554 Particle Filter (10 per pack)
Carbon Dioxide Measurement 209-5555 Oxygen Sensor
Display range 0 to CO2 maximum Optional Parts (order separately)
Accuracy ±0.2 volume % 209-5556 Environmental Case (for instrument)
Resolution 0.01 volume percent 209-5558 Power Supply/Recharger (120 VAC) for use with NiCad batteries
Measurement Digital calculation from O2 209-5560 Power Supply/Recharger (240 VAC) for use with NiCad batteries
General Technical Data 1U-7445 Rechargeable NiCad Battery, AA-size
Power supply AA-size batteries (4), rechargeable AA-size batteries (4), 209-5561 In-line Water/Particulate Trap (for high water content)
or power supply/recharger 209-5563 Replacement Filter for 209-5561 Water/Particulate Trap
205-8335 Monitor Extension Cable

SMCS Code: 1901-038, 0781
Model: 320C Excavator
Warranty: One Year
• Used to connect in-cab system monitor to a remote monitor

• Provides ground-level system monitoring to instructors and training students
TSPG 2002 2-97

ID: ph2, C80406T1; 205-8335
206-2933 ProLink Printer (220 VAC / 12 VDC) Repair Information

SMCS Code: 1900-036, 0779 NEXIQ Technologies
Model: On-Highway Trucks 6839 Caminito Sueno
Warranty: Manufacturer's Carlsbad, CA 92009
• Used to print active diagnostic codes, logged fault event codes, data lists, Phone: 800-639-6774
trip recorder, customer specified parameters, engine rating specifications, Fax: 810-731-3348
snap shot data, and maintenance data
• Provides printed copy for permanent history folder
• Helps troubleshoot intermittent engine problems (allows comparison
between properly running engine and an engine with problems)
Reference Power source input 220 VAC

STG00-15 Manual
Power output to printer 12 VDC
ID: ph2, C80409T1; 206-2933
22 Wiring Harnesses for 320 SCM Excavators 192-8734 Harness Group (320 C)
SMCS Code: 1901-038, 0781 • Used to check operation of engine/pump controller by measuring a voltage
Model: 320 B and C SCM Hydraulic Excavators signal across different connections of controller
Warranty: One Year • 197-3832 Test Harness used for CONNECTOR 1
• Used to check a variety of electrical connections including: continuity between • 197-3833 Test Harness used for CONNECTOR 2
terminals, terminals and ground, or terminals and battery; measuring voltage
between terminals; and checking reducing valve, governor actuator, engine/pump
192-8735 Harness Group (320 C)
controller signal, engine/pump controller, and engine/pump attachment controller • Used to check operation of engine/pump attachment controller by measuring
a voltage signal across different connections of controller
• 197-3834 Test Harness used for CONNECTOR 3
192-8731 Harness Group (320 B and C)
• Used to check continuity between terminals, terminals and ground, or terminals
and battery
• 190-0150 Harness Type 1 used on clip-type terminal 190-0150 190-0159
• 190-0152 Harness Type 2 used on terminals of Yazaki female type
• 190-0154 Harness Type 3 used to connect between Yazaki male and female type 190-0152
• 190-0155 Harness Type 4 used on terminals of Yazaki female 190-0160
• 190-0156 Harness Type 5 used to connect between Deutsch female and clip-type
terminal 190-0154
• 190-0157 Harness Type 6 used on Deutsch female terminals 190-0162
• 190-0158 Harness Type 7 used on Deutsch 2-pin type plug
190-0155
192-8732 Harness Group (320 B) 190-0163
• Used to check continuity between terminals, or measure voltage between
190-0156
terminals, terminals and ground, or terminals and battery
• 190-0159 Harness Type 8 used on AMP female terminals
190-0165
• 190-0160 Harness Type 9 used on AMP female terminals 190-0157
• 190-0162 Harness Type 10 used to connect AMP female and clip-type terminal
• 190-0163 Harness Type 11 used on Deutsch 2-pin type receptacle
190-0158 190-0166
192-8733 Harness Group (320 C)
• Used to check continuity between terminals, or measure voltage between
terminals, terminals and ground, or terminals and battery 190-0167
• 190-0165 Harness Type 12 used on AMP female terminals
• 190-0166 Harness Type 13 used on AMP female and clip-type terminal
188-8588
• 190-0167 Harness Type 14 used to connect Deutsch 2-pin type receptacle
and clip-type terminal
188-8588 Valve Test Harness (320 B and C)

• Used to check operation of reducing valve by measuring a current signal (Sweep Test)
188-8589 Governor Test Harness (320 C) 197-3837

• Used to check operation of governor actuator by measuring a voltage signal across 197-3836
different connections (Sweep Test)
188-8589
190-0169 Harness Group (320 B)
• Used to check operation of engine/pump controller signal by measuring a voltage
signal across different connections of controller
197-3832
197-3833
197-3834
197-3835
2-98 TSPG 2002 ID: il6, C80505T1; 190-0150, 190-0152, 190-0154
8T-5200 Signal Generator/Counter Group

SMCS Code: 0785
Model: All Models
Warranty: One Year
• Small handheld square-wave generator
• Used mainly to simulate speed in place of magnetic speed pickup for
troubleshooting transmission electronic control units; 8-Volt (Peak to Peak)
square wave OUT PUT provided
Other functions:
• Electronic diagnostic tool calibration in number of applications that currently
use 5P-9698 Calibrator; 3-Volt (Peak to Peak) square wave CAL OUT provided;
ID: ph2, C06286T1
frequency (Hz) range approximately 3 Hz (cycles per second) to 7000 Hz, Item Part No. Description
infinitely variable by turning Hz adjustment knob, and displayed by 4-1/2 digit LCD
• Frequency (Hz) counter when input is pulsating DC or AC signal within following
2 8T-5267 Foam Block
parameters: 10 cycles per second (Hz) to 19,999 cycles per second (Hz) then signal
level must be 0.1 to 50 Volts peak 3 8T-5201 Signal Generator/Counter
4 6V-2198 Extension Cable
Reference 5 8T-5198 Transmission Adapter Cable
SEHS8579 Special Instruction 6 8T-5197 Calibrator Cable and Adapters
4C-6534 Harness in Tool Guide (setting electronic speed switches) 7 8T-5112 Signal Input Cable
196-1900 MAC14 Frequency Input Adapter

SMCS Code: 0785 ®
Model: Off-Highway Trucks and Wheel Tractor Scrapers

Warranty: One Year 196-1900
MAC14
FREQUENCY ADAPTER
• Used to simulate a transmission output speed (TOS) to allow service technician to observe transmission
shifting through all gears
• Used with 8T-5201 Signal Generator Counter Group
• Enables signal generator to input a frequency signal into a MAC14 control (multiple application control
14 outputs)
WARNING
ID: il2, C79993T1; 196-1900
Using the signal generator to simulate transmission output speed could cause the
machine to move. To prevent possible injury, refer to the procedure in the Service
Manual for the correct installation and operating instructions.
4C-6534 Harness
SMCS Code: 7427-036
Model: All Models
Warranty: One Year
• Replaces discontinued 9W-6370 Harness

• Used with 8T-5201 Signal Generator/Counter to test and adjust all engine electronic speed
switches, whether 2-, 3- or 4-element (9W-6370 checks only 2- and 3-element speed switches;
4C-6534 Harness provides higher voltage signal which will operate 4-element speed switches.) Reference
• Length: 1524 mm (60 in) SEHS8657 Special Instruction
ID: ph2, C26937T1; 4C-6534
Hook and Loop Fastener

• Fast — lets you secure and release cables quickly and easily Part No. Description Size (W x L)
with the combinations of Velcro strap and nylon tie 9U-5061 Closed Loop 25.4 mm x 177.8 mm (1 in x 7 in)
• Easy — mounts to cables permanently; installs in seconds 9U-5062 Open loop 25.4 mm x 177.8 mm (1 in x 7 in)
• Reuseable 9U-5063 Open loop 38.1 mm x 457 mm (1 1/2 in x 18 in)
• Tidy — keeps cables neat and safe
• A great way to coil them for storage — a better way to keep
harnessed cables organized
ID: ph2, C44268T1

TSPG 2002 2-99
6V-2196 Microscope
6V-7894 Microlite
6V-2196
• This 20X microscope is a general usage instrument, but is specifically recommended
for checking crankshaft bearing surfaces after magnetic inspection.
• Accurate measurement is provided by a scale reading in 0.1 mm increments.
6V-7894
• Provides a light source for the 6V-2196 Inspection Microscope; clip included to attach the light to the microscope
ID: ph2, B62607-1T1; 6V-2196. 6V-7894
• Uses a standard 222 bulb with a screw-type base and focus lens (can also use 6V-3061 as replacement bulb);
two standard 1.5 Volt “AAA” size batteries are required, but not included with the microlite.
• For longer service life 1U-9535 Alkaline Batteries are recommended.
Dual Scale Pressure Gauges Connection Range Range

Part No. Location (psi) (kPa)
• Dual scale, liquid-filled pressure gauge in a brass case 8T-0846 1 Back 0 to 145 0 to 1000
• Inside scale is kilopascals (kPa) identified by a yellow band. 8T-0847 Back -15 to 0 to 72 -100 to 0 to +500
• Outside scale is pounds per square inch (psi) 8T-0848 1 Back 0 to 58 0 to 400
8T-0849 1 Back 0 to 290 0 to 2000
8T-0850 1 Back 0 to 580 0 to 4000
Gauge diameter 2.50 in (63.5 mm)
8T-0851 1 Back 0 to 2300 0 to 16 000
Accuracy 1.6%
8T-0852 1 Back 0 to 5800 0 to 40 000
Connector 1/4-18 NPTF
8T-0853 Stem 0 to 58 0 to 400
8T-0854 Stem 0 to 145 0 to 1000
8T-0855 Stem 0 to 580 0 to 4000
8T-0856 Stem 0 to 870 0 to 6000
8T-0857 Stem 0 to 1450 0 to 10 000
8T-0858 Stem 0 to 2300 0 to 16 000
8T-0859 Stem 0 to 3600 0 to 25 000
8T-0860 Stem 0 to 5800 0 to 40 000
8T-0861 Stem 0 to 8700 0 to 60 000
8T-0862 Stem -15 to 0 to 72 -100 to 0 to +500
8T-0863 Stem 0 to 36 0 to 250
1 Can be used in 1U-5481 Transmission Test Group
Standard and Certified Pressure Gauges

Dual Scale Pressure Gauges (Stem Connector) 2.50 in
• Dual scale, liquid-filled pressure gauge in a brass case Certified Standard Range
• Inside scale is kilopascals (kPa) identified by a yellow band. Part No Part No kPa (psi)
• Outside scale is pounds per square inch (psi) 186-2601 8T-0853 0 to 400 (0 to 58)
• Certified gauge has a serial number and Accuracy 1.6% 186-2602 8T-0854 0 to 1,000 (0 to 145)
certificate of accuracy from the manufacturer. 186-2604 8T-0855 0 to 4,000 (0 to 580)
Connector 1/4-18 NPTF
Gauge diameter 63.5 mm (2.50 in) — 212-7043 0 to 700 (0 to 100)
Gauge diameter of 186-2613 101.6 mm (4.0 in) 186-2605 8T-0856 0 to 6,000 (0 to 870)
186-2606 8T-0857 0 to 10,000 (0 to 1,450)
186-2607 8T-0858 0 to 16,000 (0 to 2,300)
Dual Scale Pressure Gauges (Back Connector) 2.50 in 186-2608 8T-0859 0 to 25,000 (0 to 3,600)
Certified Standard Range 186-2609 8T-0860 0 to 40,000 (0 to 5,800)
Part No Part No kPa (psi)
186-2610 8T-0861 0 to 60,000 (0 to 8,700)
186-2592 8T-0846 1 0 to 1,000 (0 to 145)
186-2611 8T-0862 -100 to 0 to 500 (-15 to 0 to 72)
186-2593 8T-0847 -100 to 0 to 50 (-15 to 0 to 72)
186-2612 8T-0863 0 to 250 (0 to 36)
186-2594 8T-0848 1 0 to 400 (0 to 58)
186-2595 8T-0849 1 0 to 2,000 (0 to 290)
Dual Scale Pressure Gauges (Stem Connector) 4.00 in
186-2596 8T-0850 1 0 to 4,000 (0 to 580)
Certified Standard Range
186-2597 8T-0851 1 0 to 16,000 (0 to 2,300) Part No Part No kPa (psi)
186-2598 8T-0852 1 0 to 40,000 (0 to 5,800) 186-2613 8T-0820 0 to 70,000 (0 to 10,000)
ID: ph2, C80258T1
1 Can be used in 1U-5481 Transmission Test Group
2-100 TSPG 2002

8T-0820 Standard Pressure Gauge 8T-5342 and 8T-5343 Pressure Gauge

186-2613 Certified Pressure Gauge
• Liquid-filled pressure gauges designed for use with the most popular series
of hydraulic pullers and rams
• Grade “A” liquid-filled dual scale (kPa range 0-70,000, • 8T-5343 Gauge is a bottom mount pressure gauge having 1/4 inch NPT threads.
PSI range 0-10,000), 101.6 mm (4.0 in) diameter
• 8T-5342 Gauge is a lower back-mounted pressure gauge.
with 1/4 inch NPT thread and stem mounted
• Both gauges have a 101,6 mm (4.00 in) liquid filled housing
• General purpose gauge;
can be used with all Caterpillar • Provide Grade A accuracy with a pressure range of 0-70,000 kPa (0-10,000 psi)
electric hydraulic pumps • Tonnage scales are provided for 30, 50, 70, 100 and 150 ton cylinders (27T,
• Certified gauge has serial number 45T, 63.5T, 91T and 136T).
and certificate of accuracy
from the manufacturer.
ID: ph2, C80258T1; 8T-0820, 186-2613
218-8445 Differential Pressure Gauge

Model: 201-8131 Heavy Duty Filter Cart
• Used to monitor pressure drop across filter element

• Used with 201-8131 Heavy-Duty Filter Cart
• Easily mounts anywhere
• 1/4 inch NPT hose connections Maximum temperature 80°C (175°F)
Maximum pressure 200 bar (3000 psi)
Full range scale 5 to 80 psi
Accuracy FSD ± 2% 60
40
Dial size 63.5 mm (2.50 inches) 80
20
Hose connections 1/4 FNTP PSID
0
Line connections in-line dp
Lens glass
Body material stainless steel 316
Units of measure pounds per square inch (psi)
Seals Buna-N
Red zone from 65 psi and higher
ID: il2, C80596T1
1U-5809 Grommet
• Provides protection to gauges during field operations

• Fits stem or back-mounted gauges with 63 mm (2 1/2 in) face diameters
and thicknesses of 28 mm (1 1/8 in)
ID: ph2, B96658T1; 1U-5809
TSPG 2002 2-101

5P-8558 Calibrating Group Pressure Gauge

• 3 gauges of 1/2% accuracy with pressure ranges of 1100 kPa (160 psi), 4150 kPa
(600 psi), and 34 500 kPa (5000 psi)
• Two lower pressure gauges protected from excessive pressure by two sensor
valves which shut off the pressure signal to the gauges at a preset value
• A separate source of pressure such as the 1U-5230 Hand Pump is required
to actuate the calibrating group.
Components Used for Testing

with the 5P-8558 Calibrating Group
ID: ph2, A66421-1T1; 5P-8558
1 1U-5230 Pump Group
1 5P-0946 Box
2 1P-2375 Coupler Assembly
2 1P-2375 Coupler Assembly
3 1P-2376 Coupler (two)
3 8S-4600 Nipple (two)1
4 8F-0024 Hose Assembly
4 8S-4599 Coupling Assembly
5 1S-8937 Valve 1 Othernipples available for gauge attachment
6 5P-8998 Nipple are: 2S-5244, 1/4 inch NPT External Thread
ID: ph2, A66422-1T1; 5P-8558
204-7393 Gauge Comparator
• Used to compare accuracy of analog and/or digital gauges (compares gauge in question to a precise
master gauge)
• Used with 204-7394 7000 kPa Precision Gauge, 204-7395 35000 kPa Precision Gauge, and 198-9257
70000 kPa Precision Gauge (not part of 204-7393)
• Can also be used to check accuracy of 198-4240 Digital Pressure Indicator Group
• Quick-sealing, threaded gauge adapters allow quick and easy gauge changes
• Works in stationary or portable applications (can be bench mounted or mounted to a rolling cart)
• Hand wheel allows minute pressure changes to be made
• Large diameter master gauges for easy pressure reading
• Master gauges have dual scale pressure readings [inside (kPa) and outside (psi)]
Range 0 to 68900 kPa (0 to 10000 psi) ID: ph2, C80576T1

Pressure medium water, animal/vegetable oil, or alcohol
Mounting 4 holes
Dimensions (w x h x d) 275 x 200 x 270 mm (10.8 x 7.9 x 10.6 in)
Connections 1/4-18 NPTF female
Accuracy ±0.25% of span
8T-5135 Gauge Mounting Group

• Used to mount fluid-filled, 63.5 mm (2.50 in) diameter gauges, both kPa and psi
back-mounted, in the discontinued 6V-4160 Transmission Test Case. Some U-shaped
mounting panels may need to be modified by brazing a piece of sheet metal to the
U-shaped mounting panel to make it 4.8 mm (.188 in) deeper.
• Use for transmission test cases without a U-shaped mounting panel.
ID: ph2, C44063T1; 8T-5135
2-102 TSPG 2002

6V-7830 Tetragauge
• Functions as a general purpose pressure measuring device
• Capable of measuring hydraulic or air pressure from -100 kPa (-14.5 psi) to 40 000 kPa (+5800 psi)
• The two lower pressure gauges are protected from over-pressurization by two sensor valves which shift and prevent
pressure from increasing past a pre-set value which is less than the full-scale range of the gauges. The highest
pressure gauge is not protected by a shutoff valve.
• Background of the kPa scale is highlighted Item Part No. Description
in yellow to indicate metric units.
1 6V-3081 Hose Assembly
• Repair Kit: 8T-5324 Repair Kit
2 8T-0862 Gauge, -100 kPa (-14.5 psi) to +500 kPa (+72.5 psi)
3 8T-0860 Gauge, 40 000 kPa (0 kPa to 5800 psi)
4 8T-0855 Gauge, 4000 kPa (0 kPa to 580 psi)
5 6V-4144 Coupler Assembly ID: ph2, B97290T1; 6V-7830
6 4S-6399 Connector
Hose Assemblies
• Can be used when pressure testing hydraulic systems with pressures up to 41,500 kPa
(6,000 PSI)
• The new hose assemblies have the same end connections and hose lengths as the existing
hoses, but have a smaller inside diameter, 2 mm (.080 in) versus 3.18 mm (.125 in).
• The smaller inside (and outside) diameter makes the hose lighter, more flexible,
able to be bundled in a tighter coil, stored in a smaller area, and easier to handle.
• The end connections allow the hose to be used with various existing adapters,
fittings, and quick disconnects. ID: ph2, C26899T1; 1U-5754ST, 1U-5755, 1U-5756
End
Part No. Desc. I.D. Length Connections
177-7860 Hose Assembly 2 mm 3050 mm 1/8 NPT
.080 in 10 ft Both Ends
1U-5757 Hose Assembly 2 mm 1830 mm 1/8 NPT By
.080 in 6 ft 7/16—20 X
37° JIC
4C-5623 Smoke Candle Ordering Information

SMCS Code: 7301-034, 7325-034 U.S. and Canadian dealers — This product is a direct shipped item from our
Model: All Models supplier to anywhere in the U.S. and Canada. Order this part number on the DTS
(Dealer Terminal System) as a class 3A order.(There is no emergency charge for
• Easy, inexpensive way to find air leaks in vehicle cabs by pressurizing this product.)
cab and watching for leaks identified by escaping white smoke Do not order this product on a stock order. The system will not accept it. This
• Does not leave residue direct shipped product is not stocked in Caterpillar Parts Departments. The stock
• Contains no explosive materials check procedure always shows “no stock” and therefore will reject the order.
• Blends readily with air; stays in suspension for 10-15 minutes All dealers outside the U.S. and Canada — Order as a class 3A order with your
• Smoke is generated as a mist that contains a large amount of atmospheric moisture subsidiary parts department. (There is no emergency charge for this product.) After
as opposed to solids being generated as a by-product of burning. These smoke placement of your order you should notify your subsidiary parts department that this
candles have a rating of 2100 total obscuring power (T.O.P.), compared to 200 T.O.P. is a direct shipped item from the U.S. (Do not order this product on a stock order.
for crude oil. T.O.P. is the scientific method of determining the quantity The system will not accept it.) Your order will be direct shipped from the supplier
of smoke generated by a given unit of smoke composition. through a freight forwarder in the U.S. to your subsidiary parts department.
Smoke duration 30 seconds Reference

Smoke color white to gray depending Material Safety Data Sheets (MSDS) for all chemical products are required by
upon density and lighting law. All of Caterpillar Material Safety Data Sheets are on file at the Rocky
Volume generated 4000 cubic feet Mountain Poison Center in Denver, Colorado. In addition, Caterpillar now has a
dedicated “Safety Hotline” to the Center. This toll free number (1-800-458-5924)
Quantity 12 candles per box
is staffed by trauma specialists 24 hours per day all year round and is available
to U.S. and Canadian dealers.
ID: ph2, C27233T1; 4C-5623
TSPG 2002 2-103

9X-3075 Cable Assembly

SMCS Code: 0781
Model: Off-Highway Trucks
Warranty: One Year
• Used to download information from TPMS (Truck Payload

Measurement System) to a user’s laptop computer
• Setup functions, diagnostics, and productivity reports are available using
TPMS, this cable, and TPM software package (available separately).
• Truck cab connector: 5 pin MS
• Computer connector: 9 pin serial port
ID: ph2, C79231T1; 9X-3075
127-9797 Cable, TPMS, VIMS, WLP to PC

SMCS Code: 7494-038, 0779
Model: All Off-Highway Trucks
Warranty: One Year
• Replaces discontinued 9X-3393 Cable Group

• Used to download data from off-highway trucks
• Used with Truck Payload Measurement System (TPMS)
software package and IBM compatible personal computer
Service Parts
• Cable connects to 5-pin circular connector on TMPS and 9-pin
“D” connector on computer.
8C-6313 Connector
• New cable allows data to be downloaded from ground level
(eliminates need to turn keyswitch inside cab). 8C-4797 Socket
ID: il2, C66799T1; 127-9797
9U-6386 Extension Cable

SMCS Code: 5050-082, 5050-036
Model: 320, 330, and 325 Hydraulic Excavators
Warranty: One Year
• Used to extend reach of 7Y-5500 Control Group into cab —

allows technician to adjust hydraulic system from inside cab
• Efficient and cost effective way to diagnose hydraulic system problems Service Parts
• Length: 6 meter (20 feet) Part No. Description
ID: il2, C66601T1; 9U-6386
7N-8204 Housing Plug
7N-8205 Receptacle Housing
7N-7779 Connector Socket
7N-7780 Connector Pin
218-3363 Breakout T-Adapter 209-1969 Training Harness

Model: Lexion Combine SMCS Code: 0115
Warranty: One Year Model: C-15 Engines
Warranty: One Year
• Used to check voltage at solenoid while it is in use (verifies if solenoid
is not working or there is no power to solenoid) • Used to connect between C-15 Electronic Training Aid and 70 pin ECM
• Fits all standard DIN 43650 type connectors connector
• Connects between machine • Simulates six-cylinder industrial engine
harness and solenoid
ID: ph2, D00128T1
ID: il2, D00228T1

2-104 TSPG 2002
114-0904 Electronic Engine Training Aid without PC

114-0905 Electronic Engine Training Aid
118-3381 Electronic Transmission Training Aid
129-3906 VIMS Training Aid
SMCS Code: 0315
Model: D11 and Off-Highway Trucks with 3500 Electronic Engines, 3176 Marine Engines, 3500B Engines, EPTC II Transmission Control
Warranty: One Year
• Used to train personnel in diagnosing problems with electronic control systems Service Parts
• Reduces or replaces the need for a machine to be present during the training course Part No. Description
• Facilitates electronic unit injector (EUI) training in classroom environment 109-9842 Electronic Control System Simulator
• Allows ECAP screen projection without an engine or machine 109-9843 Parallel Expansion Board
• Provides realistic pre-programmed diagnostic training with faults 109-9844 Analog to Digital Module
• 114-0905 includes engine component panel, simulation computer, and reusable 109-9845 Digital to Analog Module
shipping crate.
109-9846 Timer/Counter Module
• 114-0904 includes engine component panel, I/O boards for use in existing simulation
110-0313 Harness, EPTC II Panel to Simulator
computer, and reusable shipping crate.
110-0314 Engine Component Panel
110-0315 Harness, Engine Panel to Simulator
110-4541 Harness, Engine Panel to 9X-9972 ECM
110-4542 Engine Care Simulation Software
110-4543 TTT Application Software
111-7842 Shipping Crate
112-6225 Parallel Expansion Board
125-4326 Harness, Engine Panel to 9X-9971 ECM|
(allows simulation of large off-highway trucks)
117-5280 Harness (allows simulation of 777C Tractor)
124-2451 Harness (allows simulation of D11N Track-Type Tractor)
126-7437 Harness (allows simulation of marine engine applications)
128-1171 Harness (allows simulation of 3500B Engines)
ID: il2, C66654T1
169-0720 Vibration Analyzer Group

Discontinued—Service Parts Available
169-0717 Vibration Analyzer, discontinued
169-0716 Leather Case
169-0718 Clear Plastic Sheath
169-0719 Break Away Strap
169-0733 Isolator
4C-3032 Accelerometer Pickup
169-0711 Battery Charger
169-0712 Battery Pack
9U-6955 Current Adapter (Trickle)
169-0725 Software Kit1
169-0726 Routes Disk1
217-6422 Software Group (Virtual Printer)1
169-0735 Balance Group1
4C-3036 Sensor Extension Cable
169-0721 Communication Cable Assembly
4C-3039 Accelerometer / Velometer Adapter
4C-5629 Velometer Pickup
9U-5087 Velometer Cable Assembly
4C-3042 Magnetic Base
9T-5505 Plate (Magnet Keeper)
9U-5933 Probe
— NEHS0850 Manual
ID: ph3, C80464T1
1 Contact CSTG Hotline for ordering instructions.
TSPG 2002 2-105

Field Balance Attachment for 169-0720

1 169-0734 Software Group
2 4C-6918 Photohead
3 4C-6921 Adapter Cable Assembly
4 6V-2198 Cable Assembly
5 4C-6919 Reflective Tape
ID: ph3, C80465T1
189-2231 Harness
203-0202 Harness
SMCS Code: 0315
Model: 3500B EPG and Marine Engines
Warranty: One Year
• Used to connect engines’ ECM to front panel connectors on Electronic Control System
Simulator (wire colors and wire codes match production machines)
• Engine wire harness colors are identical to the training
aid wire harness colors
• Used with 114-0904 or 114-0905 Electronic Engine
ID: ph2, C80420T1; 189-2231
Training Aid
• 189-2231 Harness used for 3500B EPG Engine
applications
• 203-0202 Harness used for 3500B Marine
Engine applications
ID: ph2, C80410T1; 203-0202
4C-3030 Vibration Analyzer Group

Discontinued — Service Parts Available 1 4C-3026 Plastic Sheath
2 4C-3027 Barrel Connector
3 4C-3031 Vibration Analyzer (not available)
4 4C-3035 Cloth Carry Case
5 4C-3036 Extension Cable
6 4C-3037 Communication Cable
7 4C-3039 Adapter, Acc./Vel.
8 4C-3042 Magnetic Base
9 4C-3040 Printer Adapter
10 4C-4085 Slide Rule
11 4C-5629 Velometer
12 9T-5505 Plate
13 9U-5087 Velometer Cable
14 9U-5605 Battery Charger
ID: ph2, C44351T1; 4C-3030 15 9U-5834 Linear Routes Loader Software Disk
16 9U-5835 Analyzer Functions Loader Software Disk
Reference 17 9U-5933 Probe
NEEG2536, 4C-3030 Quick Reference Guide
18 NEHS0568 Operating Manual, 4C-3030 Vibration Analyzer
19 NEHS0569 Operating Manual, Route Documentation
20 NEHS0570 Operating Manual, Balancing, Application Guide
Not Shown
Battery
4C-3038 Adapter Cable
4C-9658 Case
9U-5090 Foam Block
2-106 TSPG 2002
9U-6745 Board Group

SMCS Code: 0781
Model: All Models
Warranty: One Year
• Used for upgrading previous analyzers to current standards

• Used with 4C-3030 Vibration Analyzer Group
• Over three times more memory for data storage
• Upgrades storage memory for routes and programs from 128k to 320k
• 9U-6699 Memory Board: 256 KB of DRAM
• Vibration Analyzer: 320K Part No. Description
9U-6699 Memory Board
Reference 6V-6045 Case
NEHS0568 Tool Operating Manual ID: ph2, C54917T1; 9U-6745
4C-6920 Field Balance Group

Discontinued — Service Parts Available
1 4C-3021 Balance Software Disks (2) (not serviced)
2 4C-6918 Photo Head
NEEG2455 Decal
3 4C-6921 Adapter Cable Assembly
4 6V-2198 Cable Assembly
5 4C-6916 Magnetic Base Group
8D-6894 Washer
6V-3137 Magnetic Base
4C-6917 Adapter Assembly, Photo Head
2S-6251 Machine Screw
7 NEHS0539 Operating Manual
Not Shown
6V-3072 Plastic Case
NEEG2381 Decal
4C-6915 Foam Insert
ID: ph2, C27001T1; 4C-6920
Reference
NEHS0539 Operating Manual, 4C-6920 Field Balance Group
NEHS0570 Operating Manual, 4C-3030 Vibration Analyzer Group, Application Guide
Vibration Analyzer Replacement Batteries

SMCS Code: 0781, 0783
Model: All Models
Warranty: Manufacturer's
Part No. Description Voltage Dimensions Weight Use

4C-6729 1 Battery Pack ±12/24 Volts, 600 mAh 32 x 146 x 51 mm (1.3 x 5.8 x 2.0 in) 0.5 kg (1 lb) Used to replace battery in 4C-4031 Vibration Analyzer
169-0712 Battery Pack 7.2 Volts, 3.0 AH 26 x 153 x 51 mm (1.0 x 6.0 x 2.0 in) Used to replace battery in 2117 Vibration Analyzer
206-2689 Battery Pack ±12 Volts, 1200 mAh 35 x 172 x 51 mm (1.4 x 6.8 x 2.0 in) Used to replace battery in 2115 SX and 2115 SU Vibration Analyzer
1 Reference: NEHS0568 Tool Operating Manual
TSPG 2002 2-107

4C-9021 Torsional Vibration Measure. Group

SMCS Code: 0781, 0783 4C-9022 Torsional Vibration Signal Conditioner
Model: 3600 Family Engines Weight 15.5 oz.
Warranty: One Year Dimensions 1.6 x 4.4 x 8.0 in.
Input ±30 MV to ±100 V magnetic pickup
• Used with 4C-3030 Vibration Analyzer Group to measure torsional vibration
Torsional amplitude range 0.1-10°
at front and rear of crankshaft of 3600 Family Engines
Power requirement 12 VDC (4C-9024 battery gp. included)
• Permits torsional vibration audits of new installation, evaluation of engine
damper condition and diagnosis of torsional vibration problems Temperature 32-140°F
• Case has space for 4C-3030 Vibration Analyzer Group and 4C-6920 Field
Balance Group. Item Part No. Description
• Includes photo head pickup for monitoring RPM 1 4C-9022 Torsional Vibration Signal Conditioner
• With proper gear and magnetic pickup, can measure torsional vibration of 2 4C-9024 Battery Group
other engines and driven equipment 4C-9025 Charger
4C-9026 Battery
8D-8113 Fuse
3 4C-9023 Volts Adapter
4 4C-6918 Photo Head Pickup
NEEG2455 Decal (Not Shown)
5 4C-6916 Magnetic Base Group
8D-6894 Washer
4C-6917 Adapter Assembly, Photo Head
2S-6251 Machine Screw
7 6V-2198 Cable Assembly (photo head ext.)
8 4C-6921 Adapter Cable Assembly (photo head to analyzer)
9 4C-9028 Adapter Cable Assembly (sure seal-BNC)
10 5N-9292 Magnetic Pickup
11 4C-3023 Cable Assembly (4 ft. BNC-BNC)
12 4C-3036 Cable Assembly (10 ft. BNC-BNC)
ID: ph2, C27067T1; 4C-9021 13 NEHS0562 Tool Operating Manual
Reference 14 4C-9027 Cable Assembly (Power)
7T-0037 Fuse (Not Shown)
NEHS0562 Tool Operating Manual, 4C-9021 Torsional Vibration Measurement Group
NEHS0558 Special Instruction, 4C-9024 Battery Group 15 9U-5091 Torsional Vibration Software Diskettes
NETG5006 Decal (5.25 in.)
NETG5007 Decal (3.50 in.)
Not Shown
9U-5090 Foam Group
4C-9658 Case
NEEG2471 Decal
NEEG2503 Decal
Accessories for 4C-3030 Vibration Analyzer Group

SMCS Code: 0781, 0783
Model: All Models 9U-6955 Adapter, Charger to Analyzer
Warranty: One Year • Used with 4C-3030 Vibration Analyzer Group to prevent damage to 4C-3031
Analyzer batteries caused by overcharging
• Connects standard 4C-3033, 9U-5606 and 9U-5605 Battery Chargers and
4C-3032 Accelerometer 4C-3031 Vibration Analyzer
• Useful for higher frequency measurements where acceleration units are
needed 9U-5606 Battery Charger
• Response is flat between 6 and 6000 Hz (±5%, 3-10000 Hz).
• Same as 9U-5605 except it is for 220-240 VAC
• Has U.S. 110-120 VAC household-type plug
Model Wilcoxon Research Model 762S
Weight 80 grams
Dimensions 43.2 x 21.6 dia. (1.7 x .85 in.)
Sensitivity 10 mV/G
Frequency response ±5% 3.0-10000 Hz, ±10% 2.0-12000 Hz, ±3 dB 1.0-15000 Hz
Temperature range -50 - 120°C
Attachment 1/4-28 thread
ID: ph2, C54530T1; 9U-5606

2-108 TSPG 2002
4C-9023 Volts Adapter 9U-5836 Adapter Cable

• Used with 4C-3031 Vibration Analyzer to perform frequency analysis of any • Permits connecting 4C-3031 Analyzer to battery charger while using speed
voltage signal (±10 Volts) pickup in 4C-6920 Balance Group
• Used to calibrate 4C-3031 Analyzer (signal generator required for calibration)
9U-5616 Adapter Cable

• Permits charging spare 4C-6729 Battery Pack outside of 4C-3031 Analyzer
ID: ph2, C54532T1; 9U-5836
ID: ph2, C54531T1; 9U-5616
163-0097 Spare Battery

SMCS Code: 0785
• For discontinued 163-0096 Process Calibrator
210-5530 S·O·S Quick Disconnect Coupler Assembly

SMCS Code: 5050-036
Model: All
Warranty: One Year
• Replaces discontinued 170-8505 Quick Disconnect S·O·S valve (new quick disconnect works with all
fittings and analyzers that former quick disconnect used)
• Used with 8C-3446 S·O·S Sampling Valve; 183-7264 and 183-8652 Dual Purpose S·O·S Sampling Valves
• Used to quickly take samples for testing
• 210-5530 valve is specifically designed for use with portable particle analyzers
• Easily snaps onto S·O·S sampling valves for continuous oil flow sampling
NOTICE
Using discontinued 170-8505 Quick Disconnect Coupler will cause
damage to 183-7264 and 183-8652 S·O·S Sampling Valves. Only use new ID: il2, C80543T1
210-5530 Quick Disconnect Coupler on these valves. Operating pressure 41397 kPa (6000 psi)
Burst pressure 165517 kPa (24000 psi)
Maximum operating temperature 104°C (220°F)
Seal material nitrile/buna
TSPG 2002 2-109

188-0645 Portable S2 Particle Analyzer

SMCS Code: 5050-082
Model: All models with hydraulic systems
Warranty: One Year
• Used to analyze particle contamination on pressurized and non-pressurized NOTE: This analyzer compliments S·O·S lab to detect contamination problems, but
hydraulic systems may not determine the source of the problem. If a problem is detected, fluid can be
• Analyzer is manufactured for Caterpillar® by PAMAS sent to the S·O·S lab for further analysis to determine if the debris is the result of
leaking cylinder wipers, pump debris, or airborne particles leaking through the
• Portable self-contained system uses red laser sensor technology to count
reservoir breather. Particle analyzers, such as the S2, play just one role in the overall
and size particles in fluids (same sensor technology as particle analyzers
contamination assessment process.
used in S·O·S lab and other Caterpillar® factory applications
• Performs fluid analysis in 90 seconds
• Internal nickel cadmium battery pack capable of performing 60 tests per charge Measurement capability pressurized and non-pressurized systems
• Self-contained digital display and printer shows test results Flow regulation automatic 25 ml flow
• Meets CE requirements Viscosity capability up to 300 centistokes
Packaging self-contained
On-board data storage 555 tests
Software (for PC viewing of test results) included
Service Parts
210-5530 S·O·S Connector
184-7679 Printer Paper
188-0639 Hose Assembly
9U-6794 Adapter, Minimess to 1/4 in NPTF
9U-6795 Hose Assembly, 914 mm (3 ft) Minimess
6V-4144 Pressure Tap Connector
ID: ph2, C79333T1
170-8500 S40 Particle Analyzer Group

SMCS Code: 0784, 5050-082 Operating voltages
Warranty: Manufacturer's Internal battery 100-240 VAC 50/60 Hz
External battery 12-24 VDC
Weight 9 kg (20 lbs)
• Used to analyze particle contamination on pressurized and non-pressurized
hydraulic systems Measurements 300 x 140 x 300 mm
(11.8 x 5.5 x 11.8 in)
• Portable self-contained system uses red laser sensor technology to count
and size particles in fluids (same sensor technology as particle analyzers Ambient temperature 5 to 40°C (40 to 104°F)
used in S·O·S lab and other Caterpillar factory applications) Relative humidity maximum 70%
• Performs fluid analysis in 90 seconds Size range 4-30 mm (certified ISO-11171)
• Internal battery pack capable of performing 60 tests per charge Maximum viscosity 300 cSt
• Self-contained digital display and printer shows test results
• Equipped with keypad and graphical, back-lit LCD (Liquid Crystal Display)
with resistive touch screen
Repair Information
The unit is warranted by the manufacturer for 1 year
• CE compliant from date of receipt. If the unit needs servicing, contact
Service Parts
Part No. Description one of the following manufacturer's repair facilities:
Reference
184-7679 Paper Roll C & J International Inc.
131-5047 Power Cable 6721 E. 106th St.
Tulsa, OK 74133, USA
6V-4144 Coupler Assembly
9U-6754 Adapter Tel: 0 01 91 82 99 40 19
Fax: 0 01 91 82 99 74 10
170-8506 Hose Assembly
188-0639 Hose Assembly Sintech Scientific (SEA) Pet Ltd.
No. 196 Pandan Loop # 02-18
Pantech Industrial Complex
Singapore 128384
Tel: 0 06 57 79 00 07
Fax: 0 06 58 72 23 92
PAMAS GmbH
Dieselstrabe 10
D-71277 Rutesheim
Postfach 162
Germany
Tel: + 49 7152 9 96 30
ID: ph2, C80423T1 Fax: + 49 7152 5 48 62
2-110 TSPG 2002

169-4371 Portable Contamination Instructional Kit

• Used to estimate amount and type of solid contamination in hydraulic fluid or
lubrication oil (cannot determine exact particle counts)
• Conduct on-the-spot visual field evaluations of system fluid contamination
• Can be used by trained technicians to compare actual patches (25 ml fluid volume) to examples
shown in NEHS0729 to generally classify amount and type of contamination in a fluid sample
• All items are serviced separately (some items must be obtained from OEM).
Reference
NEHS0729 Portable Contamination Instructional Kit (The examples shown in this brochure are
typical of the type of contamination found using the portable contamination instructional kit. The
examples are shown for reference only. Instructions on obtaining, preparing and viewing samples
are also provided in this brochure.)
ID: ph2, C79734T1; 169-4371
1 HPCA 2-Bolt, Stand (Pall)
2 4204-PCA, Filter Base and Funnel (Pall)
3 169-5738 Sample Bottles (qty 6) (Cat)
4 MXA 339945, Rinse Bottle (Whatman)
5 1U-5718 Vacuum Pump (Cat)
6 08-757-20A, Petri Dishes (qty 10) (Fisher Scientific)
7 03894-00, Microscope (Cole-Farmer)
8 192-4524 Filter Patches (5 micron)
9 10-280, Forceps/Tweezers (Fisher Scientific)
10 141-1655 Penlight (Cat)
11 13-380-15A, Grease Pencil (Fisher Scientific)
12 4C-9658 Carrying Case1 (Cat)
1 Replacement cases will have pick-and-pluck foam inserts
8C-8456 Sealed Cap

• Used to seal the valved and non-valved nipples listed below. The nipples are used on machines, tool groups, and dealer shop equipment.
• A heavy-duty, pressure-tight cap that provides both positive sealing and added protection for the nipples
Dust Cap Ref.
Adaptable to these Pressure Diagnostic Quick Disconnect Nipples
Part No. Description Color 8C-8456
Sealed Cap
6V-3965 Nipple, 9/16 inch-18 thd. SAE external (for #6 Port) Buna-N® Seal zinc chromate
6V-3966 Nipple, 1/4 inch-NPTF external thd. Buna-N® Seal zinc chromate
6V-3989 Nipple, 1/4 inch-NPTF internal thd. non-valved zinc chromate
6V-4142 Nipple, 1/8 inch-NPTF internal thd. non-valved zinc chromate
6V-4433 Nipple, 9/16 inch-18 thd. external (for #6 Port) Viton Seal green chromate
6V-7691 Nipple, 1/4 inch-NPTF external thd. Ethylene Propylene Seal red chromate
8T-3613 Nipple, 1/8 inch-NPTF external thd. Buna-N® Seal zinc chromate
8T-3614 Nipple, 1/8 inch-NPTF external thd. Ethylene Propylene Seal red chromate Mating Valve Ref.
ID: il2, C26876T1; 8C-8456
Operating pressure 42,000 kPa (6100 psi)

Minimum burst pressure 168,000 kPa (24,000 psi)
Operating temperature -34° - 107°C (-29° - 225°F)
Seal material High Temp. (Buna-N®)
TSPG 2002 2-111

9U-5155 O-Ring Measuring Cone

Warranty: Manufacturer’s Cross Section Diameter or Width
Dash Series -0 1.78 mm (0.070 in)
Find the correct O-ring replacement faster and easier. Dash Series -1 2.62 mm (0.103 in)
• An O-Ring Measuring Cone designed to measure SAE industry standard O-ring Dash Series -2 3.53 mm (0.139 in)
dimensions (cross section and dash size). These dimensions are published by the Dash Series -3 5.33 mm (0.210 in)
Society of Automotive Engineers (SAE).
Dash Series -4 6.99 mm (0.275 in)
• 457.2 mm (18 in) tall, cone shaped, made of high-impact, yellow plastic
• Round base with five industry standard O-ring cross section diameters (widths)
cut into the edge The second two digits of the dash size give an indication of the size of the O-ring’s
• Cone has 65 steps indicating varying inside diameters. inside diameter, but do not give the exact dimensions. As the inside diameter of the
O-ring becomes larger, so do these two digits.
The dash size consists of a three-digit number in which the first digit indicates the To determine the cross section diameter (width) of an O-ring:
dash series. These SAE industry standard O-ring dash series are: -0, -1, -2, -3 and -4. Insert the O-ring into the slots located around the base of the cone.
Every O-ring in a dash series has the same cross section diameter (width).
The O-ring will fit snugly into one of the five slots, and its dash series can be
identified by looking at the first digit of the numbers imprinted on the cone directly
above the slot in which the O-ring fits.
Drop the O-ring over the peak of the cone, ensuring that it sits level
on one of the cone’s steps. The O-ring should not overlap any part
of the step’s edge; a snug fit is required.
ID: il2, C54426T1
ID: il2, C54425T1
Determine the dash size by:

Reading the dash size column located above the slot identifying the O-ring’s
cross section dia. or width. The number imprinted on the face of the step on
which the O-ring rests identifies the three-digit dash size (you may have to
move the O-ring to read the number).
Determine the Cat O-ring part number by:

Refer to the Special Instruction NEHS0571 Cross-Reference List.
This list will identify the proper Caterpillar O-ring part number.
ID: il2, C54427T1
ID: il2, C54428T1
Fluid Sampling Supplies

We offer a complete assortment of fluid extraction tools to service pressurized vehicle compartments such as engine, transmission, and hydraulic
systems, as well as non-pressurized vehicle compartments such as final drives, differential, transfer case, and axle housings. Get extra protection
and maximum performance by using Cat fluids, filters, and regular oil analysis through scheduled oil sampling (S·O·S).
2-112 TSPG 2002

Fluid Sampling Extraction Tools for Pressurized Compartments

169-8373 Bottle Group (Package Qty. — 300)
• Valve locations provide oil sample confidence and continuity — Comparative data This bottle group is sealed in a plastic bag with sampling instructions included.
of pressurized oil samples is more reliable because the sample is taken from a The bottle group is ready to use when it is removed from the bag after the valve
continuous flow of oil at a known location. has been purged and the sample is ready to be taken. The bottle included in this
• A probe is provided that allows the valve to be quickly flushed prior to taking the group (169-7372) has the capacity to provide a 114 g (4 oz) sample. The 169-7372
oil sample. can also be ordered by itself, 200 per case.
• The sample bottle group is packaged, and sealed in a plastic bag to insure After the sample is obtained, the probe and tube are removed from the bottle
cleanliness. cap and holder, and discarded, and the cap-cover seals the bottle. Labels for
• Pressurized oil sampling is a fast, economical and clean method of obtaining oil identifying the sample (obtained locally) can then be attached to the bottle for
samples from pressurized systems. identification purposes. The 4C-4600 mail tube is available to send the oil
sample to the laboratory. The laboratory also provides the mailing label.
• Better represents oil condition because the oil is continually mixed and circulated
• 10 to 20 times faster than sampling oil from non-pressurized systems
• Mailing container is available so the oil sample can be conveniently mailed to the
testing laboratory. 177-9343 Probe and Cap Group (Package Qty. — 500)
The probe and cap group provides the same probe and cap that are used in the
169-8373 Bottle Group, however, without the bottle. This group is also sealed in
a plastic bag with sampling instructions included. This group allows the dealer
the flexibility to use other bottles such as the smaller 71 g (2 1/2oz) 169-7373
bottle assembly (which must be ordered separately). (The cap requires that the
bottles have a 38 M thread.)
169-7373 Bottle Assembly (Package Qty. — 200)

This smaller bottle assembly (169-7373) can be used with the 177-9343 Probe
and Cap Group and reduces mailing expense by approximately one-half for
dealers whose oil sample labs can provide effective full service analysis with
71 g (2 1/2 oz) or less of oil. These bottles can be used for engine samples since
particle count is not used for engine samples. This bottle can also be used with
the 1U-5718 Vacuum Pump used for non-pressurized oil sampling.
ID: ph2, C80305T1

1 169-8373 Bottle Group, 300 per box
8T-9208 Probe Assembly (Package Qty. — 1)
The 8T-9208 Probe Assembly can be attached to a 6.35 mm (1/4 in) I.D. rubber
2 162-8873 Probe, Holder
hose (6K-0713 Hose — 228.6 mm (9 in) long or any desired length cut from bulk
3 177-9343 Cap and Probe Group, 500 per box 5P-6442 Hose or equivalent 100R6 type high temperature — low pressure hose).
4 4C-4600 Mailer Container — reusable The 8T-9208 Probe and hose connected to a locally obtained waste container
Tube — 30.5 m rolls (100 ft) provide a method to purge or flush the 8C-3446, 8C-3345, or 7X-3387 sample
5 1U-8757 6.35 mm O.D. x 30.5 m rolls valves prior to obtaining the desired oil sample using either the 169-8373 Bottle
(1/4 in x 100 ft) (5 rolls per box) Group or 177-9343 Probe and Cap Group with the desired bottle. Approximately
6 4C-4056 7.9 mm O.D. x 30.5 m rolls (5/16 in x 100 ft) 14.8 cm3 to 29.6 cm3 (1/2 to 1 ounce) of expelled fluid purges the valves.
(5 rolls per box) (not pictured) Pressurized systems on many Caterpillar products are factory equipped with
7 169-7373 Clear Bottle, 71g (2 1/2oz), 200 per box sampling valves to quickly extract oil samples with the above tools. Special
8 169-7372 Clear Bottle, 114g (4 oz), 200 per box Instruction SEHS9043 details retrofitting some earlier models with oil sampling
9 1U-5718 Vacuum Pump valves, as well as pointing out the respective valve locations on models currently
1U-5719 Seal Kit for 1U-5718 Pump (not pictured) factory equipped with the oil sample valves
10 8T-9208 Probe, purging
11 1U-7648 Tube Cutter The following valves, fittings and adapters are required or are commonly used
1U-8589 Replacement Blades (not pictured) for retrofitting the sampling valves to pressurized systems:
12 8C-8456 Sealed Cap
13 8C-3446 Oil Sampling Valve (7/16 inch-20 — ext. thread) Oil Sampling Valves and O-Ring Seals
3J-7354 O-Ring Seal for 8C-3446 (not pictured)
14 7X-3387 Oil Sampling Valve (1/4 inch-18 NPTF— ext. thread)
8C-3446 Oil Sampling Valve (7/16 inch-20 ext. thread)
15 8C-3345 Oil Sampling Valve (M10 x 1 — ext thread)
3J-7354 O-Ring Seal for 8C-3446
8T-7876 O-Ring Seal for 8C-3345 (not pictured)
8C-3345 Oil Dampling Valve (Mid X1 ext. thread)
16 8C-3445 Dust Cap (Engine)
8C-3447 Dust Cap (Transmission) (not pictured) 8T-7876 O-Ring Seal Form 8C-3345
8C-3451 Dust Cap (not pictured) 7X-3387 Oil Sampling Valve (1/4 inch-18 NPTF ext. thread)
6V-0852 Dust Cap (Blank) (not pictured)
Protective Dust Caps for Oil Sampling Valves
Not Shown (These are rubber caps with embossed symbols to indicate system being sampled.)
Tube, 2.1 m (7 ft) pieces 8C-3445 Dust Cap (Engine)
4C-4055 6.35 mm O.D. x 2.1 m (1/4 in x 7 ft), 250 pieces per box 8C-3447 Dust Cap (Transmission)
4C-4057 7.9 mm O.D. X 2.1 m (5/16 in x 7 ft), 240 pieces per box 8C-3451 Dust Cap (Hydraulic)
4C-3602 Frosted Bottle, 57g (2 oz), 700 per box 6V-0852 Dust Cap (Blank)
8C-8456 Sealed Cap
TSPG 2002 2-113

The 8C-8456 Sealed Cap can be applied to the valves with the Miscellaneous fittings and adapters commonly used for oil sampling valve retrofit installations
valve dust cap retention ring left in place. This cap enables the
user to quickly seal a leaking valve and prevents the need to
immediately deadline (or stop) the machine or compartment. 3B-7722 Reducer 3/8 inch-18 NPTF to 1/4 inch-18 NPTF
The leaking valve can then be repaired (flushed) or replaced 8C-6427 Adapter 1/4 inch-18 NPTF external to 7/16 inch-20 SAE internal
during the scheduled maintenance period. 6V-7529 Adapter 1/8 inch-27 NPTF external to 7/16 inch-20 SAE internal
Some retrofit applications of the various valves may require 7J-8611 Adapter 90° street elbow 1/4 inch-18 NPTF
the 8C-8456 Sealed Cap to provide maximum protection for 5P-9617 Adapter Reducer 9/16 inch-18 SAE external to 7/16 inch-20 SAE internal
both sealing and environmental contamination, such a brake and 3J-1907 O-Ring Seal for 5P-9617 Adapter
hydraulic system exposed to severe elements. This cap serves
ONLY as a temporary solution to a leaking sampling valve. 3J-5390 Adapter Reducer 3/8 inch-18 NPTF external to 1/8 inch-27 NPTFinternal
9T-6865 Adapter Plug 5/8 inch-12 SAE external to 7/16 inch-20 SAE internal
2S-4078 O-Ring Seal for 9T-6865 Adapter Plug
5P-3501 Adapter 9/16 inch-18 SAE external to 1/4 inch-18 NPTF internal
3J-1907 O-Ring Seal for 5P-3501 Adapter
3L-6521 Adapter Tee 1/4 inch-18 NPT(two internal and one external)
1P-9369 Adapter Tee 1/8 inch-27 NPT (two internal and one external)
6V-3966 Pressure Test Valve 1/4 inch-18 NPTF external
7M-8489 Adapter 90° elbow 9/16 inch-18 SAE external to 1/4 inch-18 internal
5P-3413 Pipe Sealant 12/3 oz (85 g) tube.
Fluid Sampling Extraction Tools for Non-Pressurized Compartments

Fluid sampling extraction tools are used to obtain fluid samples from non-pressurized Part No. Description
vehicle compartments such as final drives, differential compartments, transfer cases,
4C-4056 Tube, 7.9 mm (5/16 inch) O.D. by 30.5 m (100 ft) lengths (5 rolls per box)
axle housings, etc.
4C-4057 Tube, 7.9 mm (5/16 inch) O.D. by 2.1 m (7 ft) length (250 per box)
The 1U-5718 Vacuum Pump is capable of pulling 25 inch (7.62 mm) Mercury
4C-4055 Tube, 6.35 mm (1/4 inch) O.D. by 2.1 m (7 ft) length (250 per box)
(vacuum). The pump is compact and accepts the 169-7372, 114 g (4 oz), and
169-7373 Bottle Assembly, 71 g (2 1/2 oz), bottles, or any 38 M threaded plastic 177-9343 Probe and Cap Group
bottle, and 6.35 mm (1/4 inch) O.D. and/or 7.9 mm (5/16 inch) O.D. plastic tube. 8C-3345 Oil Sampling Valve
The 1U-5719 Kit provides replacement seals for the vacuum pump. 8C-3446 Oil Sampling Valve
8C-3445 Dust Cap (Engine)
The 169-7372 Bottle has 4 oz (114 g) capacity. The bottle is marked showing fluid
fill range at 3/4 capacity. The fill range provides a reminder to not overfill the bottle. 8C-3447 Dust Cap (Transmission)
Partially filling the bottle satisfies both mailing and lab requirements. Full bottles 8C-3451 Dust Cap (Hydraulic)
expand because of temperature changes that can possibly rupture within the mailing 8C-8456 Sealed Cap
container. The partially filled bottle also allows the lab to shake the fluid sample 3J-7354 O-Ring Seal for 8C-3446 Valve
prior to extracting fluid for testing. Labels identifying the fluid are obtained locally.
8T-7876 O-Ring Seal for 8C-3345 Valve
The label is processed locally and attached to the sample bottle.
169-8373 Bottle Group
The 169-7373 Bottle is the same as the 169-7372 bottle except the capacity is 71 g
8T-9208 Purging Probe, brass
(2 1/2 oz) rather than 114 g (4 oz). Both are clear high performance plastic rated at
91°C (195°F). 1U-5718 Vacuum Pump
1U-5719 Seal Kit for 1U-5718 Vacuum Pump
The 1U-8757 Tubing consists of five 30.5 m (100 ft) rolls of 6.35 mm (1/4 inch) O.D.
plastic tubing. Random lengths of tubing can be easily dispensed from the tubing 169-7372 Bottle, 114 g (4 oz)
package. The tubing connects the vacuum pump to the fluid in the compartment. 169-7373 Bottle, 71 g (2 1/2 oz)
The tubing is discarded after each sample extracted. 4C-4600 Mail Tube
The 4C-4056 Tubing consists of five 30.5 m (100 ft) rolls of 7.9 mm (5/16 inch) O.D. 1U-7648 Tube Cutter
plastic tubing. Again, random lengths of tubing can be easily dispensed from the 1U-8589 Replacement Blades
tubing package. This tubing permits extraction of heavier oils when using the
1U-8757 Tube, 6.35 mm (1/4 inch) O.D. by 30.5 m (100 ft) length (5 rolls per box)
vacuum pump.
6V-0852 Dust Cap (Blank)
Both tubing sizes are also available in pre-cut 2.1 m (7 ft) lengths that are packaged
7X-3387 Oil Sampling Valve
250 pieces per box. This eliminates cutting the tube for each sample.
The 4C-4055 Tubing contains 250 pieces of 6.35 mm (1/4 inch) O.D. tubing each
2.1 m (7 ft) long.
The 1U-7648 Tube cutter is a convenient tool that easily cuts the desirable length of
either 6.35 mm (1/4 inch) or 7.9 mm (5/16 inch) plastic tubing. The cutter can cut the
tubing at 90° or at a bias. The 1U-8589 blades are available as replacement blades
for the cutter.
The following summarizes various sampling tools available through the Caterpillar
Parts Distribution System:
2-114 TSPG 2002

Diagnostic and Repair Tools Engine Tools
Air Induction
Air Induction
FT1984 Pressurizing Group

SMCS Code: 1063-025, 1063-031, 1063-081
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 sourcing information
Reference
ID: illus WIDE 42p0,24p0, C54547T1
152-2067 Differential Pressure Gauge

SMCS Code: 1063-036
Model: Multiple Engine Models
W
AT
ER
40
Accuracy ±2% of full scale
S
OF 30
IN
C HE
20 Weight 18 oz
• Used to monitor aftercooler pressure drop in applications with crankcase 10 Range (inches of water) 0-40
IC
fumes recirculation 0
ELR
AEHD FOION Minor divisions 1.0
GIBNRATPOSIT5 PSIG
• Minimize risk of engine reliability problems MACRALTICASLURE 1
VE RES
Temperature range 20°-140°F
P
X.
• Helps eliminate premature plugging of aftercooler cores MA
Maximum pressure 80 psi
• Increase service life of air cleaner
• Eliminates need for using two gauges
• Installs easily across air side of aftercooler core
• Measures differential pressure continuously, regardless of fluctuation in system
ID: il2,pressure
C66987T1
• For maximum accuracy, calibrate gauge in position used

• Magnahelic gauge with high pressure option
TSPG 2002 2-115

Engine Tools Diagnostic and Repair Tools
Air Induction
Turbocharging Reconditioning Tools

SMCS Code: 1052-017
Warranty: 9S-6343 Fixture Assembly and Turbine Holders—One Year
9S-6363 Turbocharger Fixture Group—Six Months
The tools needed to service a particular turbocharger can be determined from the following charts. Most of the tools can be fabricated from the dimensional drawings
included in this section. Others can be ordered by part number in the normal manner.
4 Manufacturer: AIResearch
4A 4B V4HD 4MD F Part No Description T6 T12 T114 T18 T24 T3019 T04 TV81 TW81
Part No. Description 3LK 4C 4D V4MD 4ME 4HD E
3
FT0165 3 Fixture (Modified) X X X X X X X X X
FT0165 Fixture (Modified) X X X X X X X
FT0165 Fixture X X X X X X
FT0165 Fixture X X X X X X
FT0168 Adapter X X
FT0168 Adapter X X
FT0170 Support Screw X X X X X
FT0170 Support Screw X X X X X
FT0174 Driver Tool X X X X X X X X
FT0174 Driver Tool X X X X X
FT0745 Pliers, Modified X X X X X X
FT0175 Expander Sleeve X X X X X
FT0808 Adapter X
FT0623 Removal Tool X X
FT1354 Adapter X X
FT0626 Spacer Block X X X X X
9S-6363 1 Fixture Group X X X
FT0745 Pliers, Modified X X X X X X
9S-6343 2 Cartridge Fixture X X X
FT0808 Adapter X X X
8S-9943 Turbine Holder X
9S-6363 1 Fixture Group X X X
9S-6343 2 Cartridge Fixture X X X
1
9S-6363 replaced FT0621
2
8S-9946 Turbine Holder X X X
9S-6343 replaced FT0622
1 9S-6363 replaced FT0621
3 FT0165 (Modified) replaces FT0165 Turbo Fixture
2 9S-6343 replaced FT0622
3 FT0165 (Modified) replaces FT0165 Turbo Fixture
Reference
SMHS6854 Special Instruction
9S-6343 Fixture Assembly and Turbine Holders

• Used to disassemble turbocharger rotating assemblies by positioning
turbine wheel in 9S-6343 Fixture Assembly for removal of shaft nut 1 9S-6343 Fixture Assembly
• Contains sockets required to hold Schwitzer turbine wheels Turbine Holders (one shown):
• Set of 4 turbine holders available to hold AiResearch turbine wheels 2 8S-9943 T-6
8S-9944 T-12
• Frame of fixture retains holder in place 8S-9945 T-14
8S-9946 T-18
ID: ph2, B22568
9S-6363 Turbocharger Fixture Group FT0175 Ring Expander Sleeve

• Used for disassembly and assembly of current and non-current turbochargers • Used to service turbocharger (see chart)
• Mounting plate tilts 90° so turbochargers can be positioned vertically or horizontally.
• In either position, mounting plate can be
rotated to 8 fixed positions in 360°.
ID: il2, C09507T1
ID: ph2, C09503T1
2-116 TSPG 2002

Air Induction
FT0170 Support Screw FT0808 Fixture Adapter

• Used to service turbocharger (see chart) • Used to service turbocharger (see chart)
ID: il2, C09506T1
FT0165 Modified Fixture ID: il2, X1721T1

• Existing FT0165 Fixture can be modified according to boxed dimensions so that
only one adapter is needed for disassembly and assembly of all turbochargers. FT1354 Turbocharger Fixture Adapter
• Used with FT0165 Fixture for disassembly of AiResearch TV81 and TW81
Turbochargers
ID: il2, C09357T1
FT0168 Fixture Adapter

• Used to service turbocharger (see chart)
ID: il4, A46298
FT0626 Spacer Block

ID: il2, C09358T1
FT0174 Driver Tool

ID: il2, C09359T1
ID: il2, C09501T1

TSPG 2002 2-117
Air Induction
FT0623 Insert Removal Tool

ID: illus WIDE 42p0,28p0, C09504T1
1U-5429 Snap Ring Pliers 155-3046 Hex Socket, 10 mm

SMCS Code: 1256-015, 1256-016, 3071-015, 3071-016, 3167-015, 3167-017, SMCS Code: 1056-010
4120-015, 4120-016, 4120-017 Model: G3606B and G3612B Engines
• Used to remove and install turbocharger band clamps

• Used to remove snap rings from deep bores in turbocharger housings • Fits limited clearance within bearing cartridge housing
and other components • Manufactured to meet torque specifications of band clamp
• Plier tips slightly off center to improve visibility • Makes removal and installation faster and easier
• Pins made from 1.04 mm dia. (0.041 inch) piano wire • Hex size: 10 mm
• Drive: 3/8 inch
ID: il2, C66988T1
ID: ph2, C27081T1
2-118 TSPG 2002

Air Induction
215-2592 Wastegate Tool Kit

SMCS Code: 1050-036, 1081-036
Model: C-15 Engine
• Used to test and adjust wastegate setting
Service Parts
1 213-4269 Adapter
2 8C-3996 Setscrew
3 — Hose, .25 in inside dia. (not included)
4 214-0788 Regulator
5 215-2648 Toggle Valve
6 215-2649 Connector
ID: ph2, C80495T1
7 7B-0192 Cross Fitting
8 214-0787 Pressure Gauge
9S-9143 Gauge Group

SMCS Code: 1052-016, 1052-017
• Used to recheck end housing positions of compressor and turbine housings or when
new housings are installed
• Required to convert new or exchange turbocharger assembly to another assembly number
Reference
SBFY0609, Technical Parts-gram [interchangeability of parts and angular settings
(rotation codes)]
GMG00579, Special Instruction
ID: ph2, C09505T1
Fabricated Tools for Installing Turbine Shaft Seal Rings in Turbochargers

SMCS Code: 1077-012
Warranty: None
Part No Description Turbocharger Model
FT1785 Installer T12, 61, 81
• Special tools designed to assist serviceman when
FT1786 Installer T51
installing shaft seal rings in turbochargers
FT1787 Installer T18
• Eliminate possibility of ring damage
resulting from overexpansion FT1788 Installer T91
FT1789 Installer 4LE, LF, MF
FT1790 Installer 4 MD, HD, HF, ME, 5MF
ID: ph1, B67209T1
180-5286 Turbine Shaft TPS57 Turbocharger Socket

SMCS Code: 1052-017, 0714
Model: G3606 and G3612 Engines
Essential Tool
• Used to remove and install turbocharger shaft bearings

• Used with FT2685 Mounting Plate
• Socket threads onto shaft and pulls or pushes bearing
• Heat-treated for added durability
• Thread: M24 x 2 Reference
REHS0556 Special Instruction, Disassembly and Assembly
• Square drive: 1/2 inch
of the Water Cooled TPS57 Turbocharger
ID: il2, C79892T1
TSPG 2002 2-119

Air Induction
FT2299 Turbine Holder

SMCS Code: 1053ÿ2D017; 0702
Warranty: None
• Used for disassembly and assembly of turbocharger on 621E and 627E Scrapers
• Convenient tool for holding turbine wheel during removal and installation of impeller nut
Reference
621E and 627E Service Manuals
ID: il2, C44390T1
FT2685 Turbocharger Cartridge (TPS57) Mounting Plate Assembly

SMCS Code: 1052-017, 0714
Model: G3606 and G3612 Engines
Warranty: None
• Used to hold ABB TPS57 turbocharger cartridge for disassembly and assembly 406.4
Ø 19.05 ± 0.10 THRU STK TOL
• Used with 180-5286 Socket for maintenance of turbine bearing
52 ± 1 14.66 ± 1.00
• Permits one-man operation while applying sockets to each end of turbine shaft
63.5 ± 2.0 120.7 ± 1.0

25.4
336.6 ± 2.0 STK TOL
457.2 ± 2.0
NO WELD
WELD
THIS SIDE 12
2 PLACES
8F-4225 Bolt
Plate
ID: il2, C79859T1 ID: il3, C79860T1
3S-2128 Rivet Nut Header Tool

SMCS Code: 1051-012
• Required to install 3S-2127 Rivnuts, 5/16 inch, in two-stage dry-type air cleaners
ID: ph2, C09502T1
102-9720 Air Filter Cleaning Kit

SMCS Code: 1054-070, 0680
Model: 3406, 3408, and 3412, Heavy-Duty Marine Engines Air filter oil 0.227 L (8 oz)
Air filter cleaner 0.946 L (32 oz)
• Used to clean air filter elements

• Kit includes cleaner, spray nozzle, and air filter oil
• Cleaner is specially formulated for removing dirt from cotton gauze
elements — prevents shrinkage or other damage to filter element
when used according to manufacturer’s directions
• Air filter oil greatly increases effectiveness of filter — oil is added
to filter after cleaning
Reference
SEHS9541 Special Instruction ID: ph2, C66640T1
2-120 TSPG 2002

Air Induction
Differential Pressure Regulator Testing and Reconditioning Apparatus

SMCS Code: 1051-036
• Required to test and calibrate differential pressure regulators

• Basic test apparatus required for fuel operated pressure ratio controls and exhaust bypass valves
• Additional parts required for pneumatic pressure ratio control
Reference 1 Basic Apparatus
FE035027 and FE034610 Special Instructions
2 4L-9555 Cover
3 3B-7722 Bushing
4 3B-7276 Nipple
5 5L-3252 Cover
6 Calibration Plate
7 Rod ID: ph2, D00107T1
8 9M-0428 Gauge (or manometer)
9 3B-7263 Nipple
10 3B-7719 Coupling
6V-7060 Gauge Group

SMCS Code: 1051-036
• Used to measure seal ring grooves on turbocharger components

• Precision ground to maximum permissible width for seal ring grooves on turbine shaft
and when assemblies, flinger sleeves and thrust collars
• Gauge held perpendicular to groove when measurements made; if gauge will enter
groove, part must be reconditioned or scrapped; if gauge will not enter, part is reusable
Part No. Description Size

6V-6045 Case
6V-7012 Foam Insert
6V-7016 Gauge 3,302 (.1300 inch) ID: ph2, B67057T1
6V-7017 Gauge 2,591 (.1020 inch)
6V-7018 Gauge 1,765 (.0695 inch)
6V-7019 Gauge 1,740 (.0685 inch)
6V-7021 Gauge 1,689 (.0665 inch)
6V-7022 Gauge 1,676 (.0600 inch)
6V-7023 Gauge 1,659 (.0653 inch)
6V-7024 Gauge 1,651 (.0650 inch)
FT1781 Cartridge Checking Fixture

SMCS Code: 1056-036
Warranty: None
• Used to check reconditioned cartridge assemblies in turbocharger for correct end play movement
• Increases service life by early detection of end play movement not within correct tolerances
(End clearance problems can result in turbocharger failure, which could result in engine failure.)
ID: ph2, B80397T1
TSPG 2002 2-121

Air Induction
FT1782 Turbocharger Test Stand

SMCS Code: 1052-036
Warranty: None
• Used to test all current turbochargers that are used on Caterpillar engines
• Used to test seal ring leakage, end housing clearance and shaft rotation
• Can also give break-in before installation—uses air and oil pressure to provide
conditions that are similar to normal operation
• Has oil heater to raise temperature of oil to normal engine oil temperature
ID: ph2, B82435T1
5P-6518 Parts Reusability Fixture Group

SMCS Code: 1052-015, 1052-017
1 5P-6517 Dial Indicator
2 5P-6516 Angle Plate
• Used to measure turbocharger shaft straightness and engine valve
lip thickness
• Parts securely positioned on V-blocks while measurements are taken
with metric dial indicator
Reference
ID: ph2, A39325-1T1
2P-2333 High Temperature Sealer

SMCS Code: 1052-012
• Used on all exhaust manifold joints, either flat or cylindrical

• Retains sealing characteristics at temperatures up to 980°C (2000°F)
ID: ph2, C79520T1
9U-5794 Tap
SMCS Code: 0671, 1050-012
Model: 3306C and 3406B Diesel Truck Engine
Warranty: One Year
• Used to tap hole for 6I-3553 and 102-3599 Air Inlet Heater in air intake elbow Reference
• Plug-type SEHS9551, Special Instruction (3300 Engines)
• Size: M20 x 1.5 mm
PS4826 (3300 Engines)
SEHS9444, Special Instruction (3400 Engines)
ID: ph1, C27050T1 PS588, PS658 (3400 Engines)
2-122 TSPG 2002

Air Induction / Cooling System
143-9730 Wrench (30 mm throat)

143-9731 Wrench (122 mm throat)
SMCS Code: 1052-079, 0602, 0702
Model: 3176, 3176B, C-10, C-12, 3114, 3116, 3126 Engines 143-9730
• Used to properly tighten hard-to-reach 15 mm nuts 143-9731

• Used with 1/2 inch square drive torque wrench
• Helps prevent turbocharger gasket failures
• Two wrenches fit almost all turbocharger installations
Distance between
Part No. Description Size Drive wrench faces
143-9730 Wrench (30 mm throat) 15 mm, 12 point 12 in, square 266.7 mm (10.50 in)
ID: il2, C79638T1
143-9731 Wrench (122 mm throat) 15 mm, 12 point 12 in, square 200.0 mm (8.87 in)
Cooling System
5P-7381 Lifting Bracket

SMCS Code: 1353-017
• Bolts to pressure relief valve boss for removal of radiator units on 776 and 777 Trucks
• Has 2 sets of holes in bracket for positioning over center of gravity for either group
• Safe working load: 450 kg (1000 lbs)
ID: il2, A49237T1
178-3704 Lift Bracket Assembly

SMCS Code: 1353-010
Essential Tool Lift capacity 45.4 kg (100 lbs)
• Used to remove AMOCs radiator cores on 950 through 994 Wheel Loaders, all Wheel Tractors,
and any vehicle using AMOC Radiator Cores
• Allows one-person removal and installation of radiator cores
• To install: place bale in “down position” and attach bracket over top of radiator core with center
hole over core protrusion to restrict side movement
• To lift: push bracket down to properly position spring-loaded wings and raise bale to “up position”
• To remove: place radiator core on ground (remove weight) and place bale in “down position”
ID: ph2, C79880T1
8T-9275 Radiator Fin Comb

SMCS Code: 1353-023
• Multi-head tool which handles 8, 9, 10, 12, 14, and 15 fins/inch

• Breaks down easily for tool box storage
ID: ph2, C27195T1
TSPG 2002 2-123

Cooling System
212-8144 Socket FT1377 Installer

SMCS Code: 1372-012 SMCS Code: 1353-012
Model: 3304, 3306 Model: Multiple Engine Models
Warranty: None
• Used to loosen and tighten radiator drain • Used when installing side channels
valve on 3304 and 3306 Engines on radiator cores on D10 Tractors
• 1/2 inch drive • Compresses resilient strips so that bolts
ID: ph2, D00359T1 and holes can be aligned
ID: ph2, A79680-1T1
9U-6737 Radiator Test Kit

SMCS Code: 1350-081
Model: 3176, 3306, and 3406 Engines
Warranty: One Year
• Low cost kit for testing radiators for excessive gases (Gas buildup leads to costly
fluid discharge and overheating problems.)
• Simple, quick test to identify problems early that require more detailed diagnosis
• Plastic bottle is graduated and marked for easy reading
Reference
NEHS0581 Special Instruction
ID: ph2, C54929T1
2S-9528 Blade Reversing Tool

SMCS Code: 1356-025
• Used to change fan blade pitch on machines equipped with reversible fan blades ID: ph1, C09510T1
Tooling for Variable Speed Fan Clutch on Trucks

SMCS Code: 1359-017
Warranty: None
• Provides tooling needed to disassemble and assemble variable speed fan clutch on 768C,
769C, 771C, 772B, 773B, 775B, 784B, 785B, 789B, and 793B Trucks Part No. Description
• FT2461 and FT2467 used to disassemble and assemble 6I-4427 and 123-6968 Fan Clutches FT2461 Pressing Bar
• FT2464 and FT2465 Plates used to disassemble and assemble 100-8105 and 129-9494 Fan FT2462 Pressing Tube
Clutches which are both replaced by 133-5969 Fan Clutch
FT2463 Ring
• Material used for FT2461 through FT2465: SAE 4140 steel
FT2464 Plate
• Material used for FT2466: SAE 1020 steel
FT2465 Plate
FT2466 Mounting Plate
Reference
SENR8603-01 Variable Speed Fan Clutch FT2467 Rotating Plate
A F FT2461 Pressing Bar

Item Dimension
B C E A 41.72 ± 0.06 mm (1.643 ± .002 in)
B 37.88 ± 0.01 mm (1.491 ± .001 in)
C 25 ± 1 mm (1.0 ± .04 in)
D D 37.53 ± 0.06 mm (1.478 ± .002 in)
E 13 ± 1 mm (.5 ± .04 in)
F 140 ± 1 mm (5.5 ± .04 in)
H G G 1.0 mm (.04 in) x 45° chamfer, two places
FT2461 H 0.5 (.02 in) maximum radius
ID: il2, C78513T1
2-124 TSPG 2002

Cooling System
F FT2462 Pressing Tube

G Item Dimension
E A 87.12 ± 0.25 mm (3.430 ± .010 in)
A
D H B 66.95 ± 0.02 mm (2.636 ± .001 in)
C 60.26 ± 0.06 mm (2.372 ± .002 in)
D 9.40 ± 0.13 mm (.370 ± .005 in)
B C I J E 31.62 ± 0.13 mm (1.245 ± .005 in)
F 178 ± 1 mm (7.0 ± .04 in)
G 119.0 ± 1 mm (4.69 ± .04 in)
L L K H 3.0 ± 0.5 mm (.12 ± .02 in)

M I 38.20 ± 0.02 mm (1.504 ± .008 in)
FT2462 J 76 ± 1 mm (3.0 ± .04 in)
K 30 ± 1° chamfer
ID: il2, C78514T1
L 0.5 mm (.02 in) maximum radius
A FT2463 Ring
B M 1.0 mm (.04 in) x 45° chamfer, 4 places
Item Dimension
A 86.87 ± 0.25 mm (3.420 ± .010 in)
B 64.90 ± 0.13 mm (2.555 ± .005 in) A
C 13 ± 1 mm (.5 ± .04 in)
D 1.0 mm (.40 in) x 45° chamfer, 4 places
FT2464 Plate
D Item Dimension
C A 57.15 mm (2.250 in) C
B 13 ± 1 mm (.5 ± .02 in)
FT2463
C 1.0 mm (.40 in) x 45° chamfer, 4 places B
ID: il2, C78515T1
FT2464
A FT2465 Plate ID: il2, C78516T1
Item Dimension
A 93.98 ± 0.1 mm (3.700 ± .004 in)
B 13 ± 1 mm (.5 ± .002 in)
C 1.0 mm (.04 in) x 45° chamfer, two places
C
FT2466 Mounting Plate
Item Dimension D
C A 58.38 ± 0.04 mm (2.298 ± .002 in) B
B 89 ± 1 mm (3.5 ± .04 in)
B
C 22 ± 1 mm (.9 ± .04 in) 6
FT2465 D 20.6 ± 0.5 mm (.81 ± .02 in)
ID: il2, C78517T1 E 20.6 ± 0.5 mm (.81 ± .02 in) A E
FT2466 6
A FT2467 Rotating Plate ID: il2, C78518T1
B
C Item Dimension
D A 216 ± 1 mm (8.5 ± .04 in)
E B 197 ± 1 mm (7.7 ± .04 in)
F
C 140 ± 1 mm (5.5 ± .04 in)
D 108 mm (4.3 in)
L G E 76 mm ± 1 mm (3.0 ± .04 in)
H F 19 ± 1 mm (0.7 ± .04 in)

J I G 76 ± 1 mm (3.0 ± .04 in)
K H 45 ± 0.5 mm (1.8 ± .02 on)
M I 38 mm (1.5 in)
J 31 ± 0.5 mm (1.2 ± .02 in)
K 25.4 mm (1.00 in) minimum
6 L 19.19 mm (.755 in)
N
O M 38.1 ± 0.5 mm (1.50 ± .02 in)
N 43 ± 2 mm (1.7 ± .08 in)
FT2467 O 15.88 mm (.625 in)
ID: il3, C78519T1
TSPG 2002 2-125

Cooling System
Disassembly and Assembly Tooling for 200 Rockford Fan Clutch

SMCS Code: 1359-017
2X R O.25 MAX
Warranty: None Ø57.15 ± 0.25
Ø41.986 ± 0.025
Ø37.973 ± 0.025
• Used to disassemble and assemble 183-5116 (200 Series Rockford) Variable Speed Fan
Clutch on D9R (s/n ABK and ACL) and D10R (s/n 3KR and AKT) Track-Type Tractors
• Heat treat FT2814 through FT2820 to RC 38 to 42
• Material: SAE 4140 steel (FT2814 through FT2820)
• Material: SAE 1020 steel (FT2821 and FT2822) 25.4 ± 0.25
82.55 ± 0.25
2X 1.5 ± 0.5 X 45˚
165.1 ± 0.5
FT2814
FT2814 Bearing Remover
ID: il2, C80448T1
FT2815 Bearing Installer
FT2817 Bearing Remover 2X R O.25 MAX
Ø41.986 ± 0.025 Ø57.15 ± 0.25
FT2818 Installation Ring Plate
FT2819 Fan Hub and Shaft Assembly Removal Plate Ø37.973 ± 0.025
FT2820 Bearing and Seal Removal and Installation Plate
FT2821 Clutch Body Hold Fixture Assembly
FT2822 Fan Mounting Hub Removal and Installation Fixture Assembly
25.4 ± 0.25 2.921 ± 0.064

2X R O.25 MAX Ø57.15 ± 0.25 2X 1.5 ± 0.5 X 45˚
Ø41.986 ± 0.025 85.73 ± 0.5
Ø37.973 ± 0.025
FT2815
ID: il2, C80449T1
119 ± 0.25
R 0.25 31.62 ± 0.13
25.4 ± 0.25 3.05 ± 0.25 9.4 ± 0.13
10.41 ± 0.13
2X 1.5 ± 0.5 X 45˚ 30˚

92.08 ± 0.5 2X R 0.13 MAX
Ø76.2 ± 0.025
FT2816
ID: il2, C80450T1
0.13 A 0.13 B
Ø86.87 ± 0.25 12.7 STK TOL
177.8 ± 0.5
Ø64.9 ± 0.13 Ø66.954 ± 0.025
Ø38.202 ± 0.025 Ø87.122 ± 0.025
Ø0.13 A
A B
FT2817
ID: il3, C80451T1
FT2818
ID: il2, C80452T1
Ø93.98 ± 0.25 12.7 STK TOL
12.7 STK TOL
Ø57.15 ± 0.25
FT2819 FT2820
ID: il2, C80453T1 ID: il2, C80454T1
2-126 TSPG 2002

Cooling System
20.64 STK TOL 57.2 ± 0.5

57.2 ± 0.5 76.2 STK TOL
14.2 ± 0.5
88.9 ± 0.5
Ø 58.38 ± 0.5 22.23 STK TOL
31 ± 0.5
19.05 ± 0.5
19.05 ± 0.5 215.9 ± 1 15.88 STK TOL
FT2822 Plate Drawing

ID: il2, C80462T1
FT2821 Parts Drawing
ID: il2, C80455T1
(44.45)
38.1 ± 0.5
108 ± 0.5
214 - 6562
18.87 ± 0.5 FT2821
Assembly Drawing 6 WELD
15.26 ± 0.5
FT2822 Assembly Drawing

WELD ID: il2, C80463T1
6
2 PLACES References
ID: il2, C80456T1 SENR8603-01 Variable Speed Fan Clutch
Tooling for Variable Speed Fan Clutch on Off-Highway Trucks

SMCS Code: 1359-017
E Stamp FT2749 Bearing Installer
Warranty: None H Part No.
F Min Size 3 Item Dimension
A
G A 44.5 ± 1 mm (1.75 ± .04 in)
B 74.498 ± 0.025 mm (2.9330 ± .0010 in)
A C 69.723 ± 0.025 mm (2.7450 ± .0010 in)
FT2750 Bearing Installer B
C D D 82.6 ± 0.5 mm (3.25 ± .02 in)
FT2751 Bearing Remover
E 114.3 ± 0.5 mm (4.50 ± .02 in)
FT2752 Seal Installer Assembly
F 5.08 ± 0.06 mm (.200 ± .002 in)
G 50.8 ± 0.5 mm (2.00 ± .02 in)
0.8 H 50.8 ± 1 mm (2.00 ± .04 in)
FT2755 End Cap Remover J I
K Medium I 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
FT2756 Sensor Installer I Knurl
Material: SAE4140 Steel J 0.13 mm (.005 in)
FT2757 Sensor Installer
ID: il2, D00239T1 K 1 ± 0.5 mm (.04 ± .02 in) x 45°
• Used to disassemble and assemble

variable speed fan clutch on 784C, 785C, E Stamp
F Part No.
785CHAA, 789C, and 793C Off-Highway G Min Size 3 Item Dimension
A H
Trucks
A 44.5 ± 1 mm (1.75 ± .04 in)
• Ensures proper positioning and
B 74.498 ± 0.025 mm (2.9330 ± .0010 in)
installation of clutch parts A
C 69.723 ± 0.025 mm (2.7450 ± .0010 in)
• Material (all parts): SAE4140 steel C
D 92.1 ± 0.5 mm (3.63 ± .02 in)
B D
E 88.9± 0.5 mm (3.50 ± .02 in)
F 50.8 ± 1 mm (2.00 ± .04 in)
G 7.21 ± 0.06 mm (.28 ± .002 in)
0.8 H 25.4 ± 0.5 mm (1.0 ± .02 in)
I
J I 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
I K Medium
Material: SAE4140 Steel Knurl J 0.13 mm (0.005 in)
ID: il2, D00233T1 K 1.0 ± 0.5 mm (.04 ± .02 in) x 45°
TSPG 2002 2-127

Cooling System
E Stamp FT2751 Bearing Remover

Part No.
H Min Size 3 Item Dimension
F
A 44.5 ± 1 mm (1.75 ± .04 in)
A G
B 74.498 ± 0.025 mm (2.9330 ± .0010 in)
C 69.723 ± 0.025 mm (2.7450 ± .0010 in)
B A
D D 82.6 ± 0.5 mm (3.25 ± .02 in)
C
E 177.8 ± 0.5 mm (7.00 ± .02 in)
F 127.0 ± 0.5 mm (5.00 ± .02 in)
0.8 J G 25.40 ± 0.25 mm (1.000 ± .010 in)
I I K H 44.5 ± 1 mm (1.75 ± .04 in)
J Medium Knurl I 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
Material: SAE4140 Steel J 0.13 mm (.005 in)
ID: il2, D00227T1 K 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
T
S
R
Item Dimension Item Dimension
A 128.14 ± 1.40 mm (5.45 ± .055 in) K 95.25 ± 0.5 mm (3.750 ± .02 in) 3.2
Q
B 105.28 ± 0.13 mm (4.145 ± .005 in) L 2 x 2.5 ± 0.5 mm (.10 ± .02 in)
C 95.38 ± 0.13 mm (3.755 ± .005 in) M 0.13 mm (.005 in)
D 70.23 ± 0.13 mm (2.765 ± .005 in) N 3.0 ± 0.5 mm (.12 ± .02 in) x 45°
E
E 95.25 ± 0.50 mm (3.750 ± .02 in) O 45° ± 1° F
A B
F 108.0 ± 1 mm (4.25 ± .04 in) P R1.5 ± 0.5 mm (.06 ± .02 in) D
C
G 14.122 ± 0.025 mm (.5560 ± .0010 in) Q 26.12 ± 0.5 mm (1.028 ± .02 in) L O
H 60.325 ± 0.025 mm (2.3750 ± .0010 in) R R3.56 ± 0.25 mm (.140 ± .01 in)
I 111.76 ± 0.25 mm (4.400 ±.0010 in) S 7.12 ± 0.5 mm (.280 ± .02 in) L 3.2
M N 3.2 P
J 228.6 ± 0.5 mm (9.00 ± .02 in) T 3.56 ± 0.25 mm (.140 ± .01 in) M
G
H
I K
J
Material: SAE4140 Steel
ID: il3, D00221T1
3 15-120˚
1
2
F A
C
E Stamp Part No. Stamp Part No.
B Min Size 3
Min Size 3
ID: il2, D00215T1T1
B
Item Dimension
A 144.0 ± 0.5 mm (5.67 ± .02 in)
A C
D B 12.7 mm (.5 in)
Item 2 C 2 x 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
ID: il3, D00185T1
Item Dimension
A 108 ± 1 mm (4.3 ± .04 in)
B 94.0 ± 1 mm (3.70 ± .04 in)
C 9.53 ± 0.05 mm (.375 ± .002 in)
D 6.35 ± 0.50 mm (.25 ± .020 in)
E 0.13 mm (.005 in)
F 235 mm (9.3 in) reference
2-128 TSPG 2002

Cooling System

Item Dimension
A 168.9 ± 0.5 mm (6.65 ± .02 in)
B 12.7 mm (.5 in)
C 2 x 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
C A
Stamp Part No.
B Min Size 3
ID: il2, D00209T1
FT2755 End Cap Remover

Item Dimension
A 61 ± 2 mm (2.4 ± .08 in)
B 130 ± 2 mm (5.1 ± .08 in)
C 2 x 1.5 ± 0.5 mm (.06 ± .04 in) x 45° A
Stamp Part No. C
Min Size 3
ID: il2, D00203T1
FT2756 Sensor Installer

Item Dimension
A 108.0 ± 0.5 mm (4.25 ± .02 in)
Medium G
Knurl H B 88.9 ± 1.0 mm (3.50 ± .04 in)
I
J K C 50.8 ± 1.0 mm (2.00 ± .04 in)
A D 1.5 ± 0.5 mm (.06 ± .02 in)
E 60 ± 1.0 mm (2.36 ± .04 in)
A F 12.7 ± 1.0 mm (.50 ± .04 in)
M
G 146.0 ± 0.5 mm (5.75 ± .02 in)
D N H 22.0 ± 4 mm (0.87 ± .16 in)
C L I 25.4 ± 0.5 mm (1.0 ± .02 in)
B J 19.05 ± 0.05 mm (.75 ± .001 in)
Stamp Part No.
Min Size 3 K 0.13 mm (.005 in)
F
L 25.4 ± 1.0 mm (1.00 ± .04 in)
Material: SAE4140 Steel E
M 70.218 ± 0.013 mm (2.7645 ± .0005 in)
ID: il2, D00197T1
N 74.511 ± 0.013 mm (2.9335 ± .0005 in)
C FT2757 Sensor Installer

Item Dimension
D A 9.5 ± 0.5 mm (.37 ± .02 in)
B
B 25.4 mm (1.00 in)
C 127 ± 1 mm (5.0 ± .04 in)
D 88.9 ± 1.0 mm (3.50 ± .04 in)
E 1.5 ± 0.5 mm (.06 ± .02 in)
A F 0.5 mm (.02 in)
Stamp Part No. F G
G 1.5 ± 0.5 mm (.06 ± .02 in) x 45°
E Min Size 3
ID: il2, CD00191T1
Reference
RENR2634 Service Manual, Variable Speed Fan Clutch
TSPG 2002 2-129

Cooling System
5P-3518 Fan Pulley Spanner Wrench FT0203 Spring Compressor

Model: 3208 Model: Multiple Engine Models
Warranty: Lifetime Warranty: None
• Used with a 9S-7353 Torque Wrench to tighten fan pulley nut on 3208 • Water temperature regulators can be disassembled by fabricating a short
Engines equipped with a fan drive length of pipe as illustrated.
ID: ph2, A23429-1T1
ID: il2, C09362T1
FT0161 Thermometer Adapter

SMCS Code: 1355-036
Model: D8H Engine
Warranty: None
• Used to mount the 2F-7112 Thermometer to D8H Engine
ID: il2, C09364T1
9S-8140 Pressurizing Pump

SMCS Code: 1350-036, 1350-038, 1350-081
• Used to pressurize cooling systems to detect leaks

• Can also test dash gauges, relief valves, and pressure caps

1 6V-7775 Gauge 0-205 kPa (0-30 psi)
2 2P-2331 Release Valve (Not included in earlier pump groups; to permit testing
of automotive-type cooling systems, ordered and install on earlier pumps)
3 3R-3810 Hose
4 2P-2329 Adapter
6V-2001 Bushing ID: ph2, A69886-1T1
5 9S-8139 Packing (Internal)

6 6V-0117 Bushing Reference
Not shown 4M-5317 Adapter, 1/8-1/4 inch npt
Not shown 6V-9068 Valve Kit
1S-0578 Wrench
SMCS Code: 1361-017
Model: 1673 Engines
• Used to disassemble and assemble water pump
ID: ph2, C54548T1
2-130 TSPG 2002

Cooling System
5P-7361 Water Pump Tool Group

SMCS Code: 1361-016, 1361-017 Item Part No Description
Model: 1100, 3100, and 3200 Engines 1 5P-7348 Spacer
2 5P-7347 Spacer
3 5P-7346 Plate
• Used with other tools to disassemble and assemble water pumps 4 5P-7349 Plate
• 9N-3139 Rebuild Kit available 5 5P-7355 Plate
6 5P-7353 Spacer
Reference 7 5P-7352 Spacer
8 5P-7351 Spacer
9 5P-7350 Spacer
ID: ph2, A46434T1
10 5P-7354 Pin
11 5P-7356 Spacer
FT0200 Seal Case Removal Tool 5P-7385 Insert

SMCS Code: 1361-010, 1361-017 SMCS Code: 1361-012
Model: Multiple Engine Models Model: 3400
Warranty: None
• Used to remove brass case on any water pump equipped with carbon thrust • When water pump bearing seat becomes worn on 3400 Family Engines,
washer and bellows-type seal on D9H, 776, 777, 777B housing can be machined for installation of 5P-7385 Insert.
• Slot must be aligned with oil passage in housing.
ID: ph2, A92069
Reference
Service Magazine, March 7, 1977 (machining instructions)
ID: il3, T98403T1
4A-0334 Water Pump Packing Wrench 5P-2686 Installation Tool

Model: Multiple Engine Models Model: 3406 Engines
• Used to adjust water pump packing nut on early pumps • Used to install water pump seal
ID: ph2, 97711T1
ID: ph2, C13426T1
TSPG 2002 2-131

Cooling System
5P-9722 Seal Driver 9U-6944 Pump Seal Installer

SMCS Code: 1361-016, 1361-017 SMCS Code: 1361-012, 0708
Model: 3208 Engines Model: 3046 Diesel Engine
• Used to install the 9N-3141 Water Pump Seal Assembly (9N-3075 Water • Used to install water pump seal
Pump and 9N-3898 Water Pump)
• Required to compress seal spring pre-determined distance
ID: ph1, C66686T1

Reference
SENR3910, 3176 Service Manual Reference
SEHS9120 Special Instruction, operation SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engines
ID: ph2, A66402T1
6V-6158 Adapter 9S-8096 Seal Installer Sleeve

SMCS Code: 1361-016, 1361-017
6V-6159 Seal Guide Model: Multiple Engine Models
SMCS Code: 1361-016
Model: 3204 Engines
• Used to press in 9H-8839 Oil Seal and 4S-6413 Water Seal
on 5S-6684 Water Pump
• Used for assembly of 1W-6446 Water Pump and 2W-1223 Water Pump for 4.75 inch bore engines
• 6V-6158 Adapter required to install roller bearings without damaging them
• 6V-6159 Seal Guide prevents shaft seal from rolling when shaft is installed
in water pump housing.
ID: ph2, A92588T1
ID: ph2, B54471-1T1
FT1783 Fixture
SMCS Code: 1361-023
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)
ID: ph2, B76453T1
8T-3142 Impeller Installer

8T-0457 Impeller Installer
SMCS Code: 1361-012
Model: 3204, 3208
Warranty:
• Used with an arbor press to position impeller to specified clearance from water pump body
• Designed to bottom on water pump body when impeller is in correct position on shaft
• 8T-3142 Impeller Installer for all 3204 Family Engine water pumps
• 8T-0457 Impeller Installer for all 3208 Family Engine water pumps
ID: ph2, B96367T1
2-132 TSPG 2002

Cooling System
Fabricated Tools for Reconditioning and Testing 3400 Series Engine Water Pumps
SMCS Code: 1361-036
Model: 3400
Warranty: None
ID: ph2, B60698T1

1 FT1760 Driver Used with hammer to drive shaft from pump assembly
2 FT1762 Test Driver Used with V1-A Vacuum Tester to test water seal after assembly
ID: ph2, B64321T1
Fabricated Tools for Reconditioning and Testing 3208 Engine Water Pumps
SMCS Code: 1361-036
Model: 3208
Warranty: None

1 FT1700 Fixture Used to hold water pump shaft during pump assembly
2 FT1706 Installer Used with arbor press to install bearings into housing
3 FT1705 Installer Used with arbor press to install seal into housing
4 FT1704 Installer Used with arbor press to install impeller on shaft
5 FT1752 Test Fixture Used with V1-A Vacuum Tester to test water seal after assembly
ID: ph2, B60700-1T1

6 FT1708 Fixture Used with FT1707 Ram Adapter and hydraulic press
to remove impeller and seal from shaft
7 FT1707 Ram Adapter Used with FT1708 Fixture and hydraulic press to remove
impeller and seal from shaft
8 FT1702 Driver Used with hammer to drive rear bearing from pump housing
9 FT1703 Driver Used with hammer to drive front bearing from pump housing
10 FT1701 Fixture Used to hold pump housing during disassembly
ID: ph2, B60699-1T1

11 FT1733 Fixture Used with Zero automated glass bead machine
to clean pump housings, pulleys and impellers
ID: ph2, B60701-1T1

12 FT1732 Salvage Fixture Used with 17/64 inch drill and drill press to drill holes
in pump housing flanges that have been rebuilt with weld
ID: ph2, B60702T1
TSPG 2002 2-133

Cooling System
Water Pump Seal Installation Tools

SMCS Code: 1361-012
• Water pump seal installation tool has been removed from 6N-9312, 6N-9313
and 4W-3864 Water Pump Seal Groups.
• 7N-7843 and 7N-8268 Water Pump Seal Installation Tools used to install seal
groups
in respective water pumps (see chart)
Engine Seal Group Installation Tool

ID: il2, C07630T1
3400 Series 6N-9312 7N-7843
3300 Series and 3406B 4W-3864 —
Reference
6 1/4 Bore Vee 6N-9313 7N-8268
172-5711 Seal Installer

SMCS Code: 1000-016, 0700, 0701, 0708
Model: 3306 Engines
Outside diameter 47.4 mm (1.87 in)
Inside diameter 19.54 mm (.769 in)
• Used to install 154-9291 and 169-1750 Water Pump Seals Counterbore diameter 36.50 mm (1.437 in)
• Makes installation quick and easy Material steel
ID: il2, C79365T1
193-8094 Spline Wrench (14 Teeth)

193-8094
193-8100 Impeller Nut Spanner
SMCS Code: 1361-010
Model: All 3500 Marine Engines with 148-8000 Seawater Pump
• Used to disassemble and assemble pump during rebuild

• 193-8094 used to hold spline
• 193-8100 used to remove locknut
Reference 193-8100
SENR6564 Service Manual, 3500B Engines Disassembly and Assembly
ID: il2, C80097T1
138-9299 Oil Seal Tool 2

147-6521 Seal/Shaft Installer
SMCS Code: 1361-016
Model: 3400 Engines
• Used to install water pump seals

• Both 139-0088 and 138-9299 tools work on 3406C Engines with serial numbers 3
8PN10279-UP and 3406E Engines with serial numbers 5EK85240-UP 1
ID: il2, C66998T1
Item Part No. Description Outside Diameter Inside Diameter Counterbore Diameter Material Installs
1 138-9299 Oil Seal Tool 35.42 mm (1.394 in) 19.25 mm (.757 in) — aluminum Pump shaft through 136-1152 Oil Seal in pump housing
or plastic
2 139-0088 Seal Installer 43.9 mm (1.73 in) 19.31 mm (.760 in) 37.6 mm (1.48 in) steel 128-0317 Coolant Seal and support ring in housing
3 147-6521 Seal/Shaft Installer — — — — shaft/oil seal assembly into early pump housing
2-134 TSPG 2002

Cooling System
135-7629 Water Pump Seal Installer

SMCS Code: 1361-016
Model: 3406 Engines
• Used to correctly and quickly install the 118-9163 Seal Group in water pumps
• Replaces discontinued 2W-9102 Installation Tool (Water Pump Seal) and 125-9622 Seal
Installer (Water Pump)
• Seal fits into counterbore of seal installer
• Seal installer slips over pump shaft (seal is installed using hand force)
• Overall length: 22.4 mm (.88 inch)
• Diameter: 31.75 mm (1.25 inch)
Reference ID: il2, C66887T1

SEHS8449 Special Instruction, Installation of Water Pump Seal Group

SMCS Code: 1000-012, 0700, 0701, 0708
Model: 3176, C-10, C-12, and 3196 Engines
Essential Tool
• Used to install 147-5088 Pump Seal into 153-8053 Pump

• Provides quick, easy installation
ID: il2, C79849T1
1U-9582 Seal Guide 9U-5103 Slotted Socket

SMCS Code: 1361-012 SMCS Code: 1906-017, 0708
Model: 3304 and 3306 Series Engines Model: 3406E, C-15, and C-16 Engines
Warranty:
• Used in repair of water pumps on 3304 and 3306 Series Engines • Used to remove and install coolant temperature sensor
• Prevents damage to 8C-5210 Seal while installing impeller shaft • Deep well design easily reaches sensor
• Seal installed into housing first, and shaft installed through seal • Slotted side for sensor wire clearance
• Square drive: 1/2 inch
• Socket type: 6 point, 1 1/16 inch
ID: ph1, C27138T1

ID: il2, C80019T1
9U-6627 Seal Installer

9U-6626 Lock Nut Spanner Wrench
2P-2317 Lock Nut Spanner Wrench
SMCS Code: 1361-012, 0708
Model: 3400 Marine Engines
• Used to disassemble and assemble 6I-1928 and 105-0268 Raw Water

Pumps — used on 5N-6054 Seal Group
• Spanner sockets reduce removal time of shaft locknuts — easier removal ID: ph2, C66646T1
and less chance of damage Item Part No. Description
• Dual purpose 9U-6627 Seal Driver installs seal — ring is used with driver 1 9U-6627 Seal Installer
to remove old seal 2 Seal Remover (part of 9U-6627)
3 9U-6626 Lock Nut Spanner Wrench
4 2P-2317 Lock Nut Spanner Wrench
TSPG 2002 2-135

Cooling System
FT2229 Puller Plate

SMCS Code: 1316-011
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 spacing on 3406B impellers
ID: il3, B83912T1
FT2800 Puller Plate 2X Ø14.0

SMCS Code: 1316-011 +0.40 Ø152.4±1.0
Model: 3524B Engine in 797 Off-Highway Truck 70.71 ± 0.5 -0.15
Ø12.20
Warranty: None
Ø9.00 35.36 ± 0.5 25.4 STOCK TOL
+0.40
+0.40 -0.15
• Used to remove impeller from 199-5590 Water Pump -0.15 Ø27.00
• Used with 1P-0820 Hydraulic Puller Group 76.2 +0.40
• Material: SAE1020 steel ±0.5 -0.15 17.68 ± 0.25
2X Ø14.00
38.1
+0.20-0.10
±0.25
5/8-11-2B THD
34.75± 17.68 ± 0.25 2X 1.5±0.5X45˚
0.25
35.36 ± 0.5
57.15 ± 0.25 34.75 ± 0.25
114.3 ± 0.5 70.71 ± 0.5
ID: il3, C80560T1
164-2192 Pressure Probe

SMCS Code: 1350-036
Warranty: One Year
• Replaces discontinued 5P-2718 Pressure Probe

• Used with pressure gauge to check pressure of fluid-filled compartments
• Fits 1/8 inch pipe plug threads ID: ph2, A23418
• Can be used alone or with 5P-2720 Probe Adapter Group, 5P-2725 Probe Adapter Group, or 5P-3591 Probe Adapter Group
• Can be used in applications up to 2750 kPa (400 psi)
2-136 TSPG 2002

Cooling System
9S-6090 Belt Tightener Tool Group

SMCS Code: 1358-010
Model: D9 Engine
Item Part No. Descriptionn
1 Nut
• Used to assist in removal and installation of D9 fan belt tightener spring 2 1B-4203 Nut
3 4B-4278 Washer
4 Plate Assembly
5 Clamp Assembly
6 Hook Assembly
ID: ph2, 13427T1
6V-7860 Removal Tool Group, Water Sleeve

SMCS Code: 1362-011
Model: 1100, 3100, and 3200 Family Engines
Item Part No. Descriptionn

• Used to remove water sleeves 1 6V-7857 Slide Hammer
• Provides sufficient strength to break sleeves loose 2 6V-7859 Forcing Ring
even when there’s corrosion buildup
3 6V-7858 Wedge
• Replaces discontinued 6V-0116 Removal Tool
ID: ph2, B75363
9U-6956 Water Pump Seal Installer

SMCS Code: 1371-010, 0708
Model: 3408 and 3412 Marine Engines
• 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-piece design eliminates need for second tool
• Large end of driver installs seals — greatly reduces chances of damage
• Handle end of driver removes old ceramic seal
• Overall length: 180 mm (7.1 inch)
ID: il2, C66666T1
• Large diameter: 70.0 mm (2.75 inch)
Temporary Strainers
SMCS Code: 1350-046
Model: 3400, 3500, 3600 Family Engines
Warranty: Six Months
• Convenient to install in coolant lines on 3600, 3500 and some 3400 Family Engines
• Filter particles larger than 1/16 inch diameter
• Used during initial startups and after overhauls
• Meant to be removed from cooling system before engine returned to service ID: ph2, C26952T1
Composition stainless steel

Perforations 1/16 inch diameter
Pipe size 4C-9045 Temporary Strainer, 4 inch
4C-9046 Temporary Strainer, 5 inch
4C-9047 Temporary Strainer, 6 inch
TSPG 2002 2-137

Cooling System / Crankshaft, Main Bearing and Flywheel
125-5597 Mounting Bar

SMCS Code: 1379-017
Model: 3406E Marine Engine
• Used to hold heat exchanger plates in alignment during disassembly and assembly
• Makes repair work faster and easier
Hex end 3/4 inch

Outside diameter 29.75 mm (1.171 in)
Threaded end 1/2-13
ID: il2, C66986T1
169-4309 Mounting Bar

SMCS Code: 1000-016, 0700, 0701, 0708
Model: 3412 HEUI Marine Engines
• Used to align heat exchanger plates during disassembly and assembly

• Makes heat exchanger repair work easier and faster
• Two guides are typically used per heat exchanger
Hex end 3/4 inch
Reference Outside diameter 29.75 mm (1.171 in)
SENR5031 Disassembly and Assembly Manual Threaded end 5/8-11
ID: il2, C66986T1
Crankshaft, Main Bearings and Flywheel
Crankshaft Gear Installation Tools

SMCS Code: 1204-012
Model: Caterpillar Engines
• Used to install crankshaft gears on most engines with tool setup illustrated
ID: il2, C05369T1
Item Part No. Description Thread sizes of adapters (5) are as follows:
1 5H-1275 Stud Part No Thread Size
2 1B-4206 Nut 5F-7339 3/4 inch NF — Male x 5/8 inch NF — Female
3 4D-3704 Washer 5F-7342 1 inch NF — Male x 5/8 inch NF — Female
4 6V-3160 Hydraulic Puller 5H-1274 1 1/4 inch NF — Male x 5/8 inch NF — Female
5 Adapter (5F-7339, 5F-7342, 5H-0124, 5H-1276, or 5H-1277) 5H-1276 7/8 inch NF — Male x 5/8 inch NF — Female
6 5H-1273 1 Sleeve 5H-1277 1 1 3/8 inch NF — Male x 5/8 inch NF — Female
FT1410 Sleeve 1 Discontinued
1 Discontinued
2-138 TSPG 2002

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Diagnostic and Repair Tools Diagnostic Tools

Power Train Tools

Power Train Tools

9U-7500 Transmission Analyzer II Group

Size 393 x 311 x 171 mm (15.5 x 12.3 x 6.7 in)

Part No. Description

1U-9482 Test Cable (ICM)

TSPG 2002 2-65

FT2640 Test Cable

ID: il3, C79756T1; Assembly drawing

1U-9100 Adapter Cable (Challenger to PC)

4C-4068 Extension Cable

2-66 TSPG 2002

139-5210 Extension Cable Assembly (ARC/EPTC II)

198-1758 Calibration Group

4C-5974 Adapter Cable

• Used to adapt military-type connector, previously used on majority of Caterpillar machines,

TSPG 2002 2-67

FT2796 Breakout Harness

Speed Measuring Tools

9U-7400 Multitach II Group

2-68 TSPG 2002

Item Part No. Description

Item Part No. Description

ID: il3, C66664T1

TSPG 2002 2-69

ID: ph2, C66638T1

5P-1759 Tachometer Drive Group

ID: ph2, A69888-2T1

Item Part No. Description Use

2-70 TSPG 2002

168-7727 Battery Cover Group

211-1773 Drive Motor Speed Pickup Breakout-T

ID: ph2, C80493T1

FT1808 Magnetic Input Adapter Cable

Alternator Type Multitach P/Rev

TSPG 2002 2-71

7M-6001 Drive Adapter Group

ID: ph2, C05359T1; 7M-6001

Service Parts for Tachometer Drive Group

5P-0935 Tachometer Drive Adapter Group

Item Part No. Description

2-72 TSPG 2002

8N-5945 Adapter Assembly

ID: ph2, B11770-1T1; 8N-5945

5P-6560 Tachometer Adapter

ID: ph2, A36336-1T1; 5P-6560

6N-1345 Tachometer Drive Adapter

7N-8929 Cable Connector

ID: ph2, A24450T1; 7N-8929

1U-5550 Oil Pressure Adapter Group

TSPG 2002 2-73

ID: il2, C05356T1; FT0907

4C-6821 Pickup Group, Injection Line Speed for Data Logger

1U-9139 Universal Fuel Line Pickup

Reference Item Part No, Description

ID: ph2, B83852T1; 1U-9139, 6V-6113

2-74 TSPG 2002

1U-9710 Adapter Cable