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Engine Tools

Air Induction 9U-7994 Flywheel Guide Pin ................................................................... 3-14

152-2067 Differential Pressure Gauge ..................................................... 3-1 5P-3022 Wear Sleeve and Seal Installer ................................................ 3-14
Turbocharging Reconditioning Tools ........................................................ 3-1 Crankshaft Seal and Wear Sleeve Installation Tools
9S-6343 Fixture Assembly and Turbine Holders ................................. 3-1 (Silicone and Hydrodynamic) .............................................................. 3-15
9S-6363 Turbocharger Fixture Group ................................................... 3-2 193-0233 PTO Oil Seal Installer .............................................................. 3-17
1U-5429 Snap Ring Pliers ......................................................................... 3-2 Wear Sleeve Installers ............................................................................ 3-17
155-3046 Hex Socket, 10 mm ................................................................... 3-2 9U-6170 Installer Group .......................................................................... 3-18
215-2592 Wastegate Tool Kit ................................................................... 3-2 5P-7318 Wear Sleeve Distorter Group ................................................... 3-18
9S-9143 Gauge Group ............................................................................... 3-2 4C-4869 Distorter Ring ............................................................................ 3-18
180-5286 Turbine Shaft TPS57 Turbocharger Socket ............................... 3-3 155-8795 Crankshaft Distortion Gauge .................................................. 3-18
102-9720 Air Filter Cleaning Kit ................................................................ 3-3 5P-7409 Distorter .................................................................................... 3-19
Differential Pressure Regulator Testing and Reconditioning Apparatus . 3-3 1U-8585 Installer ..................................................................................... 3-19
6V-7060 Gauge Group ............................................................................... 3-4 1U-7325 Distorter Adapter ...................................................................... 3-19
5P-6518 Parts Reusability Fixture Group .................................................. 3-4 6V-3143 Distorter Adapter ...................................................................... 3-19
2P-2333 High Temperature Sealer ............................................................ 3-4 4C-5501 Alignment Tool ......................................................................... 3-19
9U-5794 Tap .............................................................................................. 3-4 9U-6200 Alignment Group ...................................................................... 3-19
143-9730 Wrench (30 mm throat) ............................................................. 3-5 9U-5114 Seal and Wear Sleeve Installer ............................................... 3-20
143-9731 Wrench (122 mm throat) ........................................................... 3-5 Crankshaft Oil Seal Installers ................................................................. 3-20
1U-7430 Front Seal Installer ................................................................... 3-20
Cooling System 1U-7598 Rear Seal Installer Group ......................................................... 3-20
5P-7381 Lifting Bracket ............................................................................. 3-5 9U-6180 Front Seal Installer Group ........................................................ 3-20
178-3704 Lift Bracket Assembly ............................................................... 3-5 9U-6210 Installer Group .......................................................................... 3-21
208-1350 Radiator Fin Comb ..................................................................... 3-6 9U-6205 Rear Seal Installer Group ......................................................... 3-21
212-8144 Socket ....................................................................................... 3-6 4C-6375 Locator ...................................................................................... 3-21
9U-6737 Radiator Test Kit ......................................................................... 3-6 127-1591 Rear Oil Seal Installer ............................................................. 3-21
2S-9528 Blade Reversing Tool .................................................................. 3-6 Seal Installer Tools ................................................................................. 3-22
5P-3518 Fan Pulley Spanner Wrench ........................................................ 3-6 5P-4725 Step Plate .................................................................................. 3-22
243-6532 Spanner Wrench Assembly ...................................................... 3-6 5P-4726 Step Plate .................................................................................. 3-22
9S-8140 Pressurizing Pump ....................................................................... 3-7 Thread Repair Kits ................................................................................... 3-22
5P-7361 Water Pump Tool Group ............................................................. 3-7 Bearing Cap Tools ................................................................................... 3-23
5P-7385 Insert ........................................................................................... 3-7 3500 Engine Main Bearing Cap Removal/Installation Tool .................... 3-23
4A-0334 Water Pump Packing Wrench .................................................... 3-7 9U-6942 Socket ....................................................................................... 3-23
5P-2686 Installation Tool .......................................................................... 3-7 9U-6282 Torque Extension ...................................................................... 3-24
5P-9722 Seal Driver .................................................................................. 3-8 Bearing Removal and Installation Tools ................................................. 3-24
9U-6944 Pump Seal Installer .................................................................... 3-8 Plastic Gauges for Checking Clearance ................................................. 3-24
6V-6158 Adapter ....................................................................................... 3-8 Wear Sleeves and Drivers ...................................................................... 3-25
6V-6159 Seal Guide .................................................................................. 3-8 171-7212 Repair Sleeve .......................................................................... 3-25
9S-8096 Seal Installer Sleeve ................................................................... 3-8 6V-3044 Polishing Belt ............................................................................ 3-26
Impeller Installers ..................................................................................... 3-8 4C-9765 Standard Centering Ring .......................................................... 3-26
Water Pump Seal Installation Tools ......................................................... 3-8 4C-9766 Oversized Centering Ring ......................................................... 3-26
172-5711 Seal Installer ............................................................................. 3-9
248-3310 Spanner Wrench ....................................................................... 3-9 Cylinder Block and Liners
248-3311 Holding Fixture .......................................................................... 3-9 9U-6274 Compression Test Kit ............................................................... 3-26
193-8094 Spline Wrench (14 Teeth) ......................................................... 3-9 193-5859 Cylinder Pressure Tool Kit (Gas Engines) ................................ 3-27
193-8100 Impeller Nut Spanner ................................................................ 3-9 Cylinder Block Cleaning Brushes ............................................................ 3-27
Water Pump Seal Installers ...................................................................... 3-9 1P-3565 Chamfering Group ..................................................................... 3-27
135-7629 Water Pump Seal Installer ...................................................... 3-10 Tools for Cleaning Cylinder Bores for Reuse .......................................... 3-28
183-4028 Seal Installer ........................................................................... 3-10 8S-2269 Ridge Reamer ........................................................................... 3-28
1U-9582 Seal Guide ................................................................................ 3-10 6V-2194 Puller Plate ................................................................................ 3-28
9U-5103 Slotted Socket .......................................................................... 3-10 129-9196 Puller Plate (lower) .................................................................. 3-29
9U-6627 Seal Installer ............................................................................ 3-10 129-9197 Puller Plate (upper) .................................................................. 3-29
9U-6626 Lock Nut Spanner Wrench ....................................................... 3-10 9U-6008 Plate Puller ............................................................................... 3-29
2P-2317 Lock Nut Spanner Wrench ........................................................ 3-10 9U-6007 Plate Puller ............................................................................... 3-29
164-2192 Pressure Probe ........................................................................ 3-11 9U-6142 Puller Plate ............................................................................... 3-29
9S-6090 Belt Tightener Tool Group ........................................................ 3-11 4C-4377 Stress Plate Group .................................................................... 3-29
6V-7860 Removal Tool Group, Water Sleeve ......................................... 3-11 142-2285 Cylinder Head Stress Plate ..................................................... 3-29
9U-6956 Water Pump Seal Installer ....................................................... 3-11 Cylinder Head Stress Plates .................................................................... 3-30
221-8647 Seal Installer ........................................................................... 3-11 Tools for Reconditioning Cylinder Block Counterbores .......................... 3-30
Temporary Strainers ................................................................................ 3-12 8S-3140 Counterboring Tool Group ........................................................ 3-32
125-5597 Mounting Bar .......................................................................... 3-12 9U-7988 Riser Plate Group ...................................................................... 3-33
237-9608 Mounting Bar .......................................................................... 3-12 9U-7990 Counterbore Tool Group ........................................................... 3-33
169-4309 Mounting Bar .......................................................................... 3-12 159-9404 Counterbore Tool Group .......................................................... 3-34
9U-7993 Depth Gauge Assembly ............................................................ 3-34
Crankshaft, Main Bearings and Flywheel 1P-4000 Line Boring Tool Group ............................................................. 3-35
Crankshaft Gear Installation Tools ......................................................... 3-13 Tools for Repairing Cylinder Liner Lower Bores in the Cylinder Block ... 3-36
137-7293 Crank Gear Puller .................................................................... 3-13 5P-6512 Valve Lifter Guide Bore Sleeving Tool Group ........................... 3-36
5P-3546 Puller Plate ................................................................................ 3-13 6V-7840 Deck Checking Tool Assembly .................................................. 3-36
6V-6035 Hardness Tester ........................................................................ 3-13 5P-8665 Cylinder Liner Puller .................................................................. 3-37
5P-8637 Crankshaft Support Group ........................................................ 3-14 5P-3570 Cylinder Liner Puller Group ....................................................... 3-37
5P-8718 BrakeSaver Rotor Support ........................................................ 3-14 7F-1857 Liner Puller ................................................................................ 3-37
8F-4423 Flywheel Lifter ........................................................................... 3-14 Adapter Plates for 7F-1857 Puller ........................................................... 3-38
8T-0455 Liner Projection Tool Group ...................................................... 3-38

Home Dealer Service Tools 2004

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2P-8260 Cylinder Liner Installer Group ................................................... 3-38 Valve Seat Driver .................................................................................... 3-58
Cylinder Pack Pullers ............................................................................... 3-38 Valve Seat Drivers ................................................................................... 3-58
129-6675 Cylinder Pack Puller Group ...................................................... 3-39 157-3717 Valve Seat Driver (Intake) ....................................................... 3-58
Cylinder Liner Puller Plates and Leg ....................................................... 3-39 157-3716 Valve Seat Driver (Exhaust) .................................................... 3-58
5P-8709 Piston Cooling Jet Alignment Tool Group ................................ 3-40 9U-6897 Valve Seat Driver (Inlet) ........................................................... 3-58
1U-9593 Cylinder Pack Puller .................................................................. 3-40 9U-6898 Valve Seat Driver (Exhaust) ...................................................... 3-58
1U-9897 Bridge Group ............................................................................. 3-40 Valve Seat Depth Gauges ....................................................................... 3-59
1U-6319 Socket ....................................................................................... 3-40 6V-0087 Valve Stem Gauge .................................................................... 3-59
6V-7772 Driver ........................................................................................ 3-41 155-1536 Valve Recession Tool Kit ........................................................ 3-59
6V-4840 Water Ferrule Tool Group ......................................................... 3-41 213-9285 Valve Recession Tool Kit ........................................................ 3-60
6V-4841 Fixture Assembly ...................................................................... 3-41 148-2997 Valve Recession Tool Kit ........................................................ 3-60
6V-6021 Fixture Assembly ...................................................................... 3-41 Dowel Drivers .......................................................................................... 3-60
4C-9645 Bottoming Tap .......................................................................... 3-41 5P-7333 Bridge Dowel Repair Tool Group .............................................. 3-60
Drivers ..................................................................................................... 3-42 3P-2243 Installer Group .......................................................................... 3-61
5P-0944 Dowel Puller Group ................................................................... 3-42 8H-8501 Tappet Wrench ......................................................................... 3-61
6V-7912 Bearing Driver ........................................................................... 3-42 5P-7433 Cam Follower Tool Group ......................................................... 3-61
Thread Repair Tools ................................................................................ 3-42 5P-8690 Fixture Group ............................................................................. 3-61
198-9113 Seal Installer ........................................................................... 3-43 5P-8691 Spline Socket ............................................................................ 3-61
5P-8595 Honing Tool Group .................................................................... 3-43 5P-6512 Valve Lifter Guide Bore Sleeving Tool Group ........................... 3-61
Valve Lash Setting Tools ......................................................................... 3-62
Cylinder Head, Valves and Cam Followers 146-2597 Push Rod Holder ...................................................................... 3-62
Thread Insert Installation Tools .............................................................. 3-44 194-2062 Tool Group ............................................................................... 3-63
Valve Guide Drivers and Bushings .......................................................... 3-45 125-2742 Base Assembly (for 3500) ....................................................... 3-63
124-9057 Guide Collar (Swirl) ................................................................. 3-45 125-2743 Collar Group ............................................................................ 3-63
9U-6954 Guide Collar .............................................................................. 3-45 4C-8246 Indicator .................................................................................... 3-63
149-4008 Valve Guide Collar .................................................................. 3-45 124-2946 Lifting Bracket Assembly (3406E Rocker Arm) ....................... 3-63
9U-6220 Stop Collar ................................................................................ 3-46 8S-6691 Cylinder Head Stand Group ...................................................... 3-64
157-3722 Valve Guide Driver .................................................................. 3-46 9U-6238 Guide Bolt ................................................................................. 3-64
Puller Fingers for 7H-1970 Puller Group ................................................. 3-46 185-5321 Cylinder Head Lifting Hook Assembly .................................... 3-64
6V-7770 Valve Guide Tool Kit ................................................................. 3-46 199-1418 Hook Assembly ....................................................................... 3-64
6V-7755 Spring Seat Guide ..................................................................... 3-46 5P-3021 Lifting Bracket ........................................................................... 3-64
1U-6685 Guide and Insert Tool Group .................................................... 3-46 5P-8700 Lifting Bracket ........................................................................... 3-64
149-6115 Valve Seat Installer ................................................................. 3-47 165-4638 Guide Manifold ....................................................................... 3-65
1U-9654 Tool Group ................................................................................ 3-47 1U-8264 Head Lifting Bracket ................................................................. 3-65
132-4379 Valve Seat Driver (HEUI) ......................................................... 3-47 209-1368 Head Lifting Bracket ............................................................... 3-65
9U-6460 Guide Collar .............................................................................. 3-47 185-3145 Lifting Bracket Assembly ........................................................ 3-65
9U-6137 Installation Guide Collar ........................................................... 3-47 Sleeve Replacement Tools ...................................................................... 3-66
4C-6366 Valve Guide Driver .................................................................... 3-48 139-0692 Sleeve Jaw ............................................................................. 3-67
4C-6370 Guide Collar .............................................................................. 3-48 131-8362 Reamer Head .......................................................................... 3-67
4C-8134 Valve Guide Seal Remover ...................................................... 3-48 121-2920 Roller Expander ....................................................................... 3-67
Valve Guide Ream and Hone Tools ......................................................... 3-48 151-4832 Sleeve Remover Assembly ..................................................... 3-67
1P-7451 Valve Guide Honing Group ........................................................ 3-48 173-1530 Injector Seating Tool Group .................................................... 3-68
5P-5170 Valve Guide Knurling Group ...................................................... 3-49 170-9227 Reamer Shims ......................................................................... 3-68
5P-3536 Valve Guide Gauge Group ......................................................... 3-49 131-3921 Puller Group (HEUI) ................................................................. 3-69
4C-9734 Valve Guide Gauge, 3114, 3116 ............................................... 3-49 111-5051 Injector Wrench (3408 and 3412 HEUI) .................................. 3-69
Gauges .................................................................................................... 3-50 164-5924 Injector Bore Gauge ................................................................ 3-69
5S-1330 Pneumatic Valve Spring Compressor ....................................... 3-50 164-5927 Tube Brush .............................................................................. 3-69
1P-3527 Valve Spring Compressor .......................................................... 3-50 4C-8714 Guide Bushing (Large) ............................................................... 3-69
9U-5300 Unit Injector Spring Compressor Group ................................... 3-50 4C-8715 Guide Bushing (Small) .............................................................. 3-69
7F-4292 Valve Spring Compressor Group ............................................... 3-51 9U-5671 Reaction Sleeve ........................................................................ 3-69
9U-6144 Adapter Assembly .................................................................... 3-51 4C-6591 Bottom Swage .......................................................................... 3-70
9U-6145 Air Connector ............................................................................ 3-51 9U-6891 Injector Tool Group ................................................................... 3-70
1U-9347 Valve Spring Compressor Group .............................................. 3-51 Bore Cleaning Brushes ............................................................................ 3-70
Service Tools for Jacobs Vehicle Systems (Jake Brake®) .................... 3-52 9U-6860 Tool Group ................................................................................ 3-70
228-3610 Feeler Gauge (C15) .................................................................. 3-53 169-3374 Injector Sleeves Tool Group .................................................... 3-71
235-0032 Lash Gauge (C13) .................................................................... 3-53 150-3152 Sleeve Installer ....................................................................... 3-71
241-0124 Spring Compressor Group ....................................................... 3-53 Screw-In Precombustion Chamber Tools ................................................ 3-71
4C-6726 Valve Spring Compressor Group ............................................... 3-53 Drive-In Precombustion Chamber Tools .................................................. 3-71
9U-7241 Valve Spring Compressor Group .............................................. 3-53 5F-9217 Precombustion Chamber Tool Group ........................................ 3-72
9U-6195 Valve Spring Compressor Group .............................................. 3-54 8S-0225 Precombustion Chamber Wrench ............................................. 3-72
8T-2660 Compressor Group .................................................................... 3-54 5P-0125 Precombustion Chamber Wrench ............................................. 3-72
8S-2263 Valve Spring Tester .................................................................. 3-54 5P-0961 Fuel Valve Adapter Wrench ...................................................... 3-72
5S-1322 Valve Keeper Inserter ............................................................... 3-55 5S-0276 Glow Plug Wrench .................................................................... 3-72
166-7441 Valve Seat Extractor Tool Group ............................................. 3-55 1P-0550 Glow Plug Tool Group ............................................................... 3-72
Valve Seat Extractors .............................................................................. 3-55 Glow Plug Tools ...................................................................................... 3-73
4C-6371 Valve Seat Driver, Inlet ............................................................ 3-56 5P-0127 Socket ....................................................................................... 3-73
4C-6372 Valve Seat Driver, Exhaust ...................................................... 3-56 9S-2573 Socket ....................................................................................... 3-73
9S-3080 Valve Seat Insert Puller Group ................................................. 3-56 161-3440 Socket ..................................................................................... 3-73
130-1449 Valve Seat Puller Group .......................................................... 3-56 124-0662 Impact Socket ......................................................................... 3-73
8S-7170 Valve Seat Puller Group ............................................................ 3-57 5P-7275 Glow Plug Wire Installer ........................................................... 3-73
125-6185 Swirl Valve Seat Driver ........................................................... 3-57 6V-3049 Glow Plug Wire Remover ......................................................... 3-74
125-6186 Swirl Valve Seat Driver Guide ................................................ 3-57 9U-7511 Spark Plug Seat Cleaner ........................................................... 3-74

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Engine Tools

154-9521 Spark Plug Seat Cleaner ......................................................... 3-74 9U-6705 Master Nozzle Group ................................................................ 3-93
5P-1762 Support Bracket ........................................................................ 3-74 1P-1795 Valve Group ............................................................................... 3-93
6V-2033 Brush ......................................................................................... 3-74 Storage Bags ........................................................................................... 3-93
6V-2032 Adapter ..................................................................................... 3-74 NEHS0594 Using TMI for Finding Injection Pump
Inserts ...................................................................................................... 3-75 Off Engine Test Specifications ........................................................... 3-93
5P-8699 Tool Group ................................................................................. 3-75 Calibration Fluid ...................................................................................... 3-93
6V-9050 Stud Removal Tool Group ......................................................... 3-75 4C-8192 Heavy Duty Drive Group ........................................................... 3-94
188-3922 Exhaust Stud and Bolt Removal Tool Group ........................... 3-75 Pressure Gauges ..................................................................................... 3-94
6V-7028 Spring Seat Enlarger ................................................................. 3-76 9U-7840 Calibration Fluid and Diesel Fuel Test Kit ................................ 3-95
227-4397 Socket, 1-1/8 inch ................................................................... 3-76 136-8330 Basic Mounting/Setup Group ................................................. 3-95
4C-6373 Valve Seal Installer ................................................................... 3-76 6V-3116 Sleeve Metering Adapter Group .............................................. 3-97
Cylinder Condition Analysis Tools .......................................................... 3-76 6V-2009 Adapter Group .......................................................................... 3-98
9U-7995 Head Guide Pin ......................................................................... 3-76 135-2916 Mounting Drive Group ............................................................ 3-99
152-1058 Head Bolt Socket .................................................................... 3-77 6V-6046 Adapter Group ........................................................................ 3-101
4C-8200 Mounting and Drive Group ..................................................... 3-102
Electrical and Ignition Tools Zexel and Nippondenso Fuel Pump and Governor Disassemble
6V-7913 Expansion Rod .......................................................................... 3-77 and Assemble Tools ......................................................................... 3-104
6V-7914 Collet ......................................................................................... 3-77 Zexel and Nippondenso Fuel Pump and Governor Test
9U-7226 Installer Group .......................................................................... 3-77 and Adjust Tools .............................................................................. 3-105
6V-3025 Battery Cable Repair Kit ........................................................... 3-78 Injection Pump Off-Engine Disassembly, Assembly, and Bench Test .. 3-107
Ferrule Crimp Tools ................................................................................. 3-78 6V-6090 Adapter Group ........................................................................ 3-109
6V-3000 Sure Seal Repair Kit ................................................................. 3-78 2P-5510 Adapter Group ......................................................................... 3-109
4C-3406 Deutsch Connector Repair Kit .................................................. 3-79 5P-5237 Pump Adapter ......................................................................... 3-109
1U-9710 Adapter Cable ........................................................................... 3-79 5P-9737 Adapter Group ......................................................................... 3-110
1P-2977 Alternator Pulley Tool Group .................................................... 3-79 5P-5240 Adapter Group ......................................................................... 3-111
8S-7227 Spark Plug Adapter Wrench ..................................................... 3-79 5P-5241 Adapter Group ......................................................................... 3-112
1P-5559 Spark Plug Adapter Wrench ..................................................... 3-80 6V-9441 Fuel Pump Adapter Group ....................................................... 3-112
2P-5481 Spark Plug Wrench ................................................................... 3-80 4C-6907 Governor Drive Group ............................................................. 3-112
176-7129 Terminal Removal and Installation Tool Assembly ................ 3-80 4C-8980 Test and Adjust Group ............................................................ 3-112
132-8263 Terminal Spanner Wrench ...................................................... 3-80 4C-8740 Air Supply and Test Group ...................................................... 3-112
4C-4601 Spark Plug Socket ..................................................................... 3-80 4C-6100 Tool Group, 3161 Governor Torque Control ............................ 3-114
216-1685 Spark Plug Socket ................................................................... 3-80 1U-9361 Governor Torque Arm ............................................................. 3-114
235-9751 Spark Plug Driver Adapter Assembly ...................................... 3-81 1U-6661 Tester ...................................................................................... 3-115
9U-7516 Spark Plug Gauge ..................................................................... 3-81 1U-6662 Block Group ............................................................................ 3-115
192-7039 Driver Assembly ...................................................................... 3-81 1U-6663 Holding Block Group ............................................................... 3-115
6V-4960 AC Current Probe ...................................................................... 3-81 4C-6566 Holding Block Group ............................................................... 3-115
225-8266 Clamp On Ammeter ................................................................. 3-82 1U-6665 Power Supply .......................................................................... 3-115
Carrying Case and Accessories 9U-6143 Power Supply Adapter ............................................................ 3-115
for Discontinued 8T-0900 Clamp-on Ammeter .................................. 3-82 6V-4172 Injector Sleeve ........................................................................ 3-116
4C-9279 Plate ........................................................................................ 3-116
Lube System 5P-4150 Nozzle Tester Group ................................................................ 3-116
175-7546 Oil Filter Cutter Group ............................................................. 3-82 1U-9578 Repair Kit ................................................................................ 3-117
4C-5084 Spin-on Oil Filter Cutter ............................................................ 3-83 5P-7448 Adapter ................................................................................... 3-117
4C-6780 Bushing Removal Tool Group ................................................... 3-83 8S-2270 Fuel Collector .......................................................................... 3-117
9S-9273 Coupler ...................................................................................... 3-83 1U-8857 Extension Tube ....................................................................... 3-117
9S-9274 Plug ........................................................................................... 3-83 Tube Assemblies ................................................................................... 3-117
246-4268 Coupler Rework Fixture Group ................................................ 3-84 1U-7326 Governor Calibration Bench ................................................... 3-118
201-2592 Bit ............................................................................................ 3-84 1U-9087 Governor Adjust Tool Group ................................................... 3-118
126-7538 Transmission Oil Nozzle Assembly ......................................... 3-84 1U-9088 Governor Disassembly and Assembly Tool Group ................. 3-118
126-7539 Crankcase Oil Nozzle Assembly .............................................. 3-84 159-1783 Fuel Ratio Control Adjusting and Synchronizing Wrench ..... 3-119
148-3605 Wrench .................................................................................. 3-119
Engine Test Tools 4C-8996 Hex Ball Driver, 4 mm Standard ............................................. 3-120
Dynamometer Testing Facilities ............................................................. 3-84 4C-9309 Adapter ................................................................................... 3-120
4C-3502 Engine Repair Indicator Kit ....................................................... 3-85
1U-8835 Scale ......................................................................................... 3-85 Fuel System Repair and Adjust
196-3165 Tool Kit, C-9 Engine ................................................................ 3-86 6V-2023 Flow Checking Adapter Group ................................................ 3-120
173-5533 Repair Stand Bracket .............................................................. 3-86 4C-8180 Timing Tool Group .................................................................. 3-121
9U-7530 Tool Kit, 3406E Engine ............................................................. 3-86 1P-0540 Flow Checking Tool Group ...................................................... 3-121
195-0875 Marine Tool Kit ....................................................................... 3-87 3P-2239 Timing Plate ............................................................................ 3-121
5P-0294 Crowfoot Wrench .................................................................... 3-121
Fuel System Test Tools Timing Fixture Plates ............................................................................. 3-121
Hartridge AVM 20-12C Fuel Injection Test Benches — ......................... 3-87 8T-5246 Engine Timing Indicator Group ............................................... 3-122
132-9753 Fuel Injection Test Bench (480 Volt, 60 Hz) ............................ 3-87 6V-6175 Torque Adapter ....................................................................... 3-122
139-1437 Fuel Injection Test Bench (480 Volt, 50 Hz) ............................ 3-87 4C-9874 Torque Adapter ....................................................................... 3-122
158-2262 AVM 2-PC Fuel Injection Equipment Test Stand .................... 3-88 2P-8256 Timing Decal ........................................................................... 3-122
Hartridge Fuel Injection Equipment Test Stands— ................................ 3-90 7F-8748 Timing Fixture .......................................................................... 3-123
6V-7900 Test Stand, 208/240 V .............................................................. 3-90 5P-0950 Timing Plate ............................................................................ 3-123
1U-8212 Test Stand, 440/480 V .............................................................. 3-90 6V-9145 Adapter Group ........................................................................ 3-123
1U-8213 Test Stand, 380/420 V .............................................................. 3-90 4C-9287 Timing Advance Holding Tool ................................................. 3-123
FIETS Nozzle Block and Lines .................................................................. 3-91 127-1069 Timing Pin ............................................................................. 3-123
6V-7904 Diagnostic Unit ......................................................................... 3-92 Timing Setting Tools ............................................................................. 3-124
Fuel Injection Tube Assemblies .............................................................. 3-92 136-4632 Timing Pin ............................................................................. 3-124

Home Dealer Service Tools 2004

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220-2793 Timing Pin ............................................................................. 3-124 Special Taps .......................................................................................... 3-140

208-9387 Timing Pin ............................................................................. 3-124 5P-6217 Fixture ..................................................................................... 3-141
208-9388 Adapter ................................................................................. 3-124 5P-6218 Bearing Driver ......................................................................... 3-141
9U-6188 Timing Fixture Group .............................................................. 3-125 6V-4824 Driver ...................................................................................... 3-141
157-3719 Fuel Spanner ......................................................................... 3-125 6V-4825 Plate ........................................................................................ 3-141
192-3331 Timing Gauge ........................................................................ 3-125 7S-7113 Rack Setting Gauge ................................................................ 3-141
238-9586 Engine Turning Pinion Assembly .......................................... 3-125 3H-1690 Fuel Rack Setting Gauge ........................................................ 3-141
5.4 inch Bore, 6 Cylinder Vehicle Engine Lifter Setting Tools .............. 3-125 1F-7944 Rack Setting Fixture ................................................................ 3-141
Tools for Rotating Crankshaft ............................................................... 3-126 1H-6471 Rack Setting Gauge ................................................................ 3-142
9U-6198 Crankshaft Turning Tool ......................................................... 3-126 5P-0130 Gauge, “O” Set ....................................................................... 3-142
208-0888 Engine Turning Tool .............................................................. 3-126 6V-7941 Overfueling Spring Compressor .............................................. 3-142
178-8615 Socket ................................................................................... 3-126 6V-7942 Hook ........................................................................................ 3-142
5P-7306 Gear Shaft Housing Assembly ................................................ 3-127 158-8665 Rack Set Tool ........................................................................ 3-142
5P-7305 Engine Turning Gear ............................................................... 3-127 9U-5296 Rack Positioning Assembly .................................................... 3-142
5F-2807 Cap .......................................................................................... 3-127 6V-9128 Rack Position Tool Group ........................................................ 3-143
2F-2990 Plug .......................................................................................... 3-127 9S-0228 Rack Position Tool Group ........................................................ 3-144
9S-1743 Ferrule Nut Wrench ................................................................ 3-127 6V-6070 Tool Group .............................................................................. 3-144
5P-0166 Crowfoot Wrench, 3/8 inch Square Drive .............................. 3-127 6V-4069 Body Group ............................................................................. 3-144
5P-5195 Fuel Line Wrench .................................................................... 3-127 5P-4203 Sleeve Metering Field Service Tool Group ............................. 3-145
5P-7260 Socket ..................................................................................... 3-127 3P-2200 Sleeve Metering Calibration Tool Group ................................ 3-146
5P-0144 Socket ..................................................................................... 3-127 5P-3516 Reaming Tool Group ............................................................... 3-146
6V-4089 Reamer Assembly ................................................................... 3-128 6V-4164 Driver ...................................................................................... 3-146
5B-1401 Fuel Injection Valve Orifice Cleaning Tool Group ................... 3-128 6V-4163 Bit ............................................................................................ 3-146
8S-2245 Cleaning Tool Group ............................................................... 3-128 5P-6577 Fuel Setting Tool Group .......................................................... 3-146
5P-6229 Extractor .................................................................................. 3-128 Calibration Tools ................................................................................... 3-147
Fuel Injection Valve Nut Removal Tools ............................................... 3-129 5P-7253 Socket Assembly ..................................................................... 3-147
6V-4061 Nozzle Puller Group ................................................................ 3-129 6V-4068 Cutter Tool Group ................................................................... 3-148
6V-4054 Nozzle Puller Group ................................................................ 3-129 6V-4141 Sleeve Metering Calibration Tool Group ................................ 3-148
6V-6026 Pump Group, 230V, 50Hz ........................................................ 3-129 Tools for Reconditioning 3208 Engine Fuel Systems ............................ 3-148
6V-6027 Pump Group, 110V, 60Hz ........................................................ 3-129 6V-4830 Fixture Group .......................................................................... 3-149
8T-2854 Nozzle Retainer Handle .......................................................... 3-129 Ultrasonic Cleaner Group ...................................................................... 3-149
6V-6980 Nozzle Puller Group ................................................................ 3-130 6V-6188 Cleaning Tray .......................................................................... 3-149
6V-6976 Puller Group ............................................................................ 3-130 6V-4822 Tip Driver ................................................................................ 3-149
6V-7020 Nozzle Puller Group ................................................................ 3-130 149-2955 Seal Protector ....................................................................... 3-149
6V-6981 Nozzle Puller Group ................................................................ 3-131 149-2956 Backup Ring Installer ............................................................ 3-149
9U-6278 Injector Puller Connector ........................................................ 3-131 192-5092 Removal Tool ........................................................................ 3-150
Tools for 3406B Engine Fuel Nozzle and Fuel Nozzle Adapter ............. 3-131 180-0186 Removal Tool ........................................................................ 3-150
4C-8175 Nozzle Puller Assembly .......................................................... 3-131 250-6092 Removal Tool ........................................................................ 3-150
134-2570 Nozzle Retainer Spanner Wrench ......................................... 3-131 185-3213 Seal Positioner ...................................................................... 3-150
1U-9725 Wrench ................................................................................... 3-132 187-5523 Seal Protector ....................................................................... 3-150
6V-4980 Torque Screwdriver Tool Group .............................................. 3-132 187-5524 Seal Installer Group .............................................................. 3-150
9U-7227 Injector Height Setting Gauge ................................................ 3-132 152-1057 Injector Installer .................................................................... 3-151
187-0482 Spacer Sleeve ....................................................................... 3-132 6V-4808 Tip Tester Adapter Group ....................................................... 3-151
9U-7227 Injector Height Gauge ............................................................ 3-133 6V-4809 Rack Weight Cup .................................................................... 3-151
1U-5895 Bit Linehead ............................................................................ 3-133 9U-5132 Timing Tool Group .................................................................. 3-151
1U-8780 Nozzle Puller Group ................................................................ 3-133 Collet Extensions ................................................................................... 3-152
6V-7025 Guide ....................................................................................... 3-133 6V-6999 Lapping Plates ........................................................................ 3-152
9U-5127 Tool Group, 3408 PEEC, and 3412 PEEC ................................. 3-133 6V-7151 Lapping Compound ................................................................. 3-153
9U-5219 Tool Group 3406 PEEC Engines .............................................. 3-134 1U-9395 Plate ........................................................................................ 3-153
9U-5292 Rack Preload Assembly (3400 PEEC) ...................................... 3-134 1U-8701 Socket ..................................................................................... 3-153
9U-5295 Rack Position Group (3400 PEEC) ........................................... 3-134 223-2454 Fuel System and Governor Tool Group, 3114-3116 .............. 3-153
8T-5160 Gas Regulator Setting Tool Group .......................................... 3-135 1U-6680 Governor and Fuel Injection Adjusting Tool Group ................ 3-155
Fuel Injection Pump Extractors .............................................................. 3-135 1U-9563 Offset Wrench ........................................................................ 3-155
5P-2682 Bleeder Valve Socket .............................................................. 3-136 9U-5129 Seal Remover ......................................................................... 3-155
8T-0833 Fuel Pump Wrench .................................................................. 3-136 5P-2413 Air Regulator Assembly .......................................................... 3-155
6V-7050 Compressor Group .................................................................. 3-136 195-0761 Pressure/Vacuum Pump Group ............................................. 3-156
6V-4180 Off-Engine Lifter Setting Tool Group ...................................... 3-136 6V-9052 Piston Seal Guide ................................................................... 3-156
6V-7870 Fixture Group .......................................................................... 3-138 6V-9072 Piston Seal Guide ................................................................... 3-156
Tools for Accessory Drive Gear ............................................................. 3-138 159-0271 Solenoid Spanner Wrench .................................................... 3-156
8S-2271 Timing Fixture Group .............................................................. 3-138 1P-0087 Adjusting Wrench ................................................................... 3-156
1P-5550 Fuel Cam Locking Group ......................................................... 3-138 6V-0022 Governor Spring Guide Tool Group ......................................... 3-157
9S-8520 Puller Group ............................................................................ 3-138 5P-7285 Adjusting Bracket .................................................................... 3-157
8S-4618 Timing Gauge .......................................................................... 3-139 8T-3226 Ring Expander ......................................................................... 3-157
8S-4620 Timing Gauge .......................................................................... 3-139 8T-5223 Reamer .................................................................................... 3-158
Sockets for Special Applications .......................................................... 3-139 8T-5107 Fixture Assembly ..................................................................... 3-158
Timing Pins ............................................................................................ 3-139 8T-3222 Governor Adjusting Tool Group .............................................. 3-158
Timing Pins ............................................................................................ 3-139 4C-4354 Applicator ............................................................................... 3-158
Decal for 1P-7410 Degree Wheel ......................................................... 3-139 9S-8100 Fuel Transfer Pump Tool Group .............................................. 3-158
9U-5692 Spring Compressor ................................................................. 3-140 Fuel Transfer Pump Assembly Tools ..................................................... 3-158
9S-6326 Rack Bearing Installation Tool Group ..................................... 3-140 6V-6169 Check ValveInstaller ............................................................... 3-159
5P-1665 Alignment Plate ...................................................................... 3-140 5P-7345 Gauge ...................................................................................... 3-159
6V-0094 Universal Joint ........................................................................ 3-140 1P-2385 Protractor Assembly ................................................................ 3-159

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Engine Tools

2P-8278 Fuel Flow Tube ........................................................................ 3-159 132-3904 Camshaft Retainer ................................................................ 3-178
9U-6872 In-line Flow Sight ................................................................... 3-159 8F-3671 Gear Installation Group ........................................................... 3-179
185-3630 Filter Strap Wrench ............................................................... 3-159 Gear Installation Tools .......................................................................... 3-179
Special Sockets for Fast Fill Fuel System Adapters ............................. 3-160 173-2021 Puller Group .......................................................................... 3-179
5P-7339 Lifting Plug Assembly ............................................................. 3-160 193-9199 Socket Assembly ................................................................... 3-179
1U-8869 Digital Dial Indicator .............................................................. 3-160 8F-3672 Gear Removal Plate ................................................................. 3-179
Toolmaker’s Ink and Ink Remover ......................................................... 3-161 167-3834 Puller Group .......................................................................... 3-180
171-1085 Bolt Remover Kit ................................................................... 3-161 9U-6896 Guide Bolt ............................................................................... 3-180
171-1088 Torque Screw Locknut Wrench ............................................. 3-161 8S-2264 Puller Group ............................................................................ 3-180
171-1089 Idle Adjustment Locknut Wrench ......................................... 3-161 8S-8375 Sleeve ..................................................................................... 3-180
173-9774 Bolt Remover ......................................................................... 3-161 4C-5613 Puller Group ............................................................................ 3-181
132-5451 Air Compressor Gear Holder ................................................. 3-181
Pistons, Rings and Connecting Rods 4C-9991 Idler Shaft Retrofit Tool Group ............................................... 3-181
5P-3519 Piston Ring Groove Gauge ...................................................... 3-162 9U-7255 Adjustable Idler Assembly ..................................................... 3-182
1U-6431 Gauge Group ........................................................................... 3-162 9U-6148 Idler Shaft Removal Group .................................................... 3-182
9U-5931 Piston Ring Groove Gauge ...................................................... 3-163 195-7503 Shaft Installer Group ............................................................. 3-182
Piston Ring Groove Gauge Groups ........................................................ 3-163 6V-0098 Socket, 9/16 inch Extention Hex Drive ................................... 3-182
1U-7616 Compressor Group .................................................................. 3-163 9U-7324 Indicator Bracket .................................................................... 3-182
6V-4020 Expander Group ...................................................................... 3-164
Piston Ring Expanders ........................................................................... 3-164 Starting Systems
Piston Ring Compressors ...................................................................... 3-164 2H-8581 Clutch Adjusting Wrench ....................................................... 3-183
1U-6683 Expander ................................................................................. 3-165 6V-4058 Universal Extension ................................................................ 3-183
4C-3601 Ring Expander ......................................................................... 3-165
1U-6684 Compressor ............................................................................. 3-165 Engine Lifting and Positioning
7F-9303 Connecting Rod Wrench ......................................................... 3-165 6V-0097 Engine Rebuild Stand ............................................................. 3-183
5P-3550 Connecting Rod Boring Machine ............................................ 3-165 4C-9832 Large Engine Roll-Over Stand ................................................. 3-184
5P-4777 Torsion Bracket ....................................................................... 3-166 171-4660 Engine Stand Adapter Assembly .......................................... 3-185
5P-4778 Feed Cylinder .......................................................................... 3-166 1U-6238 Mount Bracket Group ............................................................. 3-185
9U-5945 Rod Locating Group ................................................................ 3-166 1U-7502 Repair Stand, Heavy-Duty, 2000 lb. ....................................... 3-185
9U-5948 Expanding Segment Group (1.1) ............................................. 3-166 1U-9352 Engine Stand, 1000 lb. ........................................................... 3-185
9U-5949 Expander Segments Group ..................................................... 3-166 1U-5750 Diesel Engine Repair Stand, 6000 lbs. ................................... 3-186
5P-2050 Connecting Rod Checking Fixture ........................................... 3-167 206-0030 Foot Plate .............................................................................. 3-187
9U-5917 Pin Mandrel, Bushing Out ...................................................... 3-168 173-5533 Repair Bracket Assembly ...................................................... 3-187
9U-5918 Pin Mandrel, Bushing In ......................................................... 3-168 180-2877 Adapter Group ....................................................................... 3-187
Tools for Connecting Rod Pin Bearing Removal and Installation ......... 3-168 179-9561 Mounting Bracket Group ....................................................... 3-188
Tools for Removing and Installing Tapered Connecting Rod Bearings 3-169 179-9562 Mount Bracket Assembly ...................................................... 3-188
1U-6242 Pin Bushing Adapter ............................................................... 3-170 6V-7762 Dual Hook Hoist ...................................................................... 3-188
1U-6244 Spacer ..................................................................................... 3-170 9U-7847 Bolt ......................................................................................... 3-189
1U-6243 Push Adapter .......................................................................... 3-170 1U-8763 Lifting Bracket Assembly ........................................................ 3-189
1U-9032 Pin Bushing Adapter ............................................................... 3-170 8F-2550 Engine Tilting Group ................................................................ 3-189
1U-9033 Spacer ..................................................................................... 3-170 Motor Grader Rear Engine Support Groups .......................................... 3-190
1U-9034 Push Adapter .......................................................................... 3-170
Reconditioning Connecting Rod Tools .................................................. 3-170 3600 Engine Tools
139-9039 Snap Ring Pliers .................................................................... 3-171 8T-9209 Turbocharger Blocking Tool .................................................... 3-191
4C-8725 Pin Bushing Adapter ............................................................... 3-171 137-7024 Turbocharger Wash Group .................................................... 3-191
4C-8726 Spacer ..................................................................................... 3-171 4C-8769 Valve Seat Driver .................................................................... 3-191
4C-8727 Push Adapter .......................................................................... 3-171 200-5958 Wear Sleeve Installer ........................................................... 3-192
4C-9749 Pushing Adapter ..................................................................... 3-171 121-7705 Stud Assembly ...................................................................... 3-192
4C-9750 Bushing Adapter ..................................................................... 3-171 121-7700 Distorter Block ...................................................................... 3-192
4C-9751 Spacer ..................................................................................... 3-171 4C-6593 Valve Lash Tool ....................................................................... 3-192
8T-7748 Polishing Wheel ...................................................................... 3-171 4C-6585 Cylinder Pressure Measuring Indicator Group, 3000 PSI ....... 3-192
Parts Baskets for Handling Pistons and Piston Pins ............................. 3-172 4C-6987 Socket ..................................................................................... 3-193
Induction Bearing Heaters and Ring Heater ......................................... 3-172 184-3131 Cylinder Head Stud Socket Assembly .................................. 3-193
4C-9839 Safety Retainer Group ............................................................ 3-193
Camshaft and Timing Gear Tools 130-6993 Injector Seat Cleaning Brush ................................................ 3-193
131-1525 Camshaft Alignment Pilot Assembly .................................... 3-173 130-2534 Bridge Dowel Gauge ............................................................. 3-193
Camshaft Installation Tools .................................................................. 3-174 Valve Guide Gauges .............................................................................. 3-194
125-0200 Camshaft Pilot ....................................................................... 3-174 4C-2980 Valve Projection Group ........................................................... 3-194
125-0201 Camshaft Guide Assembly .................................................... 3-175 4C-6506 Vibration Damper Repair Group ............................................. 3-194
Camshaft Removal and Installation Tools ............................................ 3-175 1U-9570 Dowel Puller Group ................................................................ 3-195
177-8003 Cam Tool Group .................................................................... 3-175 229-3639 Overhaul Protection Kit ......................................................... 3-195
8S-2241 Camshaft Bearing Installation and Removal Group ............... 3-176 128-5113 Thread Repair Insert ............................................................. 3-195
5P-1666 Puller Plate .............................................................................. 3-176 Ring Groove Gauges .............................................................................. 3-195
5P-1667 Spacer Tube ............................................................................ 3-176 133-1531 Threaded Insert ..................................................................... 3-196
1P-5545 Adapter Group ......................................................................... 3-176 4C-6713 Spark Ignited Combination Tool Group .................................. 3-196
6V-4869 Adapter ................................................................................... 3-176 4C-8568 Liner Puller Group (part of 9U-5107 Group) ....................... 3-196
6V-6174 Plug ......................................................................................... 3-176 4C-8995 Ring Expander Group (part of 9U-5107 Group) .................. 3-197
Camshaft Bearing Remove/Install Tools .............................................. 3-177 4C-9043 Piston Ring Compressor Group (part of 9U-5107 Group) .. 3-197
6V-4077 Camshaft Bearing Tool Group ................................................ 3-177 9U-5156 Cleaning Tool Group (part of 9U-5107 Group) .................. 3-197
Camshaft Bearing Remove/Install Tools .............................................. 3-177 9U-5105 Basic Tool Group .................................................................... 3-197
Camshaft Plates, Pilots, and Sleeves ................................................... 3-178 Miscellaneous Tools ................................................................... 3-198
Camshaft Bearing Removal and Installation Tools ............................... 3-178 8T-3034 Water Pump Seal Driver (Part of 9U-5105 Group) ............. 3-198

Home Dealer Service Tools 2004

Search

1U-9824 Oil Drain Tool Group (Part of 9U-5105 Group) .................. 3-198 143-8995 Leak Down Check Tool .......................................................... 3-209
4C-6173 Fuel Drain Tray Assembly (Part of 9U-5105 Group) .......... 3-198 143-8997 Check Valve (Dummy) ........................................................... 3-209
4C-9451 and 4C-9452 Idler Gear Wrench (Part of 9U-5105 Group) 3-199 4C-6583 Governor Calibration Tool ....................................................... 3-209
9U-6461 Phoenix Screwdriver (Part of 9U-5105 Group) .................. 3-199 9U-5102 Main Bearing Journal Cover Assembly .................................. 3-209
8T-0890 Puller Group (Part of 9U-5105 Group) ................................ 3-199 147-2285 Diesel Valve Seat Group ....................................................... 3-209
Cylinder Head ................................................................................ 3-199 207-5034 Stud Tensioner Tool Group ................................................... 3-210
8T-0960 Handling Tool Group (Part of 9U-5105 Group) ................... 3-199 156-7159 Camshaft Separation Assembly ........................................... 3-210
8T-0820 Pressure Gauge (Part of 9U-5105 Group) .......................... 3-200 156-7160 Piston Support ....................................................................... 3-211
8T-3035 Lines Group (Part of 9U-5105 Group) ................................. 3-200 178-5063 Rod Cap Guide (3618) ........................................................... 3-211
126-6918 Head Lifting Bracket (3600 Vee) ...................................... 3-201 145-0316 Cleaning Kit ........................................................................... 3-211
126-6919 Head Lifting Bracket (3600 In-line) .................................. 3-201 187-6273 Prechamber Machining Tool Group (G3600) ......................... 3-211
126-6920 Handle Rod (Part of 9U-5105 Group) ............................... 3-201 151-8689 Template Seal ....................................................................... 3-212
Crankshaft and Camshaft ............................................................ 3-201 156-7162 Wrench Assembly - Isolator Stop Adjusting Tool (3618) ..... 3-212
8T-3029 Camshaft Segment Support Group 9U-7522 Head Repair Tool Group ......................................................... 3-212
(Part of 9U-5105 Group) .............................................................. 3-201 148-9704 Seal Installer Group .............................................................. 3-213
9U-5932 Camshaft Torque Extension (Part of 9U-5105 Exhaust Manifold Wrenches ................................................................. 3-213
and 9U-5106 Groups) .................................................................. 3-201 194-4944 Ratchet, 3/8 inch Drive ......................................................... 3-213
8T-0970 Camshaft Bearing Tool Group, 3600 Engines 9U-6249 Cylinder Tool Group ................................................................ 3-213
(Part of 9U-5105 Group) .............................................................. 3-202 9U-6250 Pump Tool Group .................................................................... 3-213
156-7155 Camshaft Bearing Tool Group, 3618 Engines 195-8104 ABB Turbocharger Tool Kit (TPL61) ....................................... 3-214
(Not Part of 9U-5105 Group) ....................................................... 3-202 187-3703 Tool Group (NA297) .............................................................. 3-214
134-0932 Main Bearing Driver (Part of 9U-5105 Group) ................. 3-202 179-1904 Stud Tensioner Tool Group ................................................... 3-215
Piston and Connecting Rod Assembly ...................................... 3-203 191-5320 Stud Tensioner Tool Group ................................................... 3-216
145-5190 Piston Support Group, (Part of 9U-5105) ......................... 3-203 229-9453 Pump Accessory Group ......................................................... 3-216
8T-3022 Rod Guide Group (Part of 9U-5105 Group) ........................ 3-203 Hydraulic Pumps .................................................................................... 3-216
4C-6357 Guide Group (Part of 9U-5105 Group) ............................... 3-203 160-0475 Support Tray .......................................................................... 3-218
1U-8692 Guide, Piston Pin (Part of 9U-5105 Group) ........................ 3-203 160-4901 Support Tray Rail .................................................................. 3-218
136-1452 Internal Pliers Assembly (Part of 9U-5105 Group) ........... 3-204
9U-5981 Snap Ring Retainer (Part of 9U-5105 Group) .................... 3-204
Block ............................................................................................... 3-204
235-0632 Cylinder Installation Tool Group
(Part of 9U-5105 Group) .............................................................. 3-204
4C-9818 Shank-Hex (Part of 9U-5105 Group) .................................. 3-204
4C-9819 Universal Joint (Part of 9U-5105 Group) ........................... 3-204
191-1135 Cylinder Liner Spacer Assembly
(Part of 9U-5105 Group) .............................................................. 3-205
Vibration Damper and Flywheel ................................................ 3-205
4C-9426 Damper Guide Pin (Part of 9U-5105 Group) ...................... 3-205
1U-9393 Damper Guide Pin (Part of 9U-5105 Group) ...................... 3-205
1U-9392 Damper Guide Pin (Part of 9U-5105 Group) ...................... 3-205
8T-0914 Flywheel Guide Pin (Part of 9U-5105 Group) ..................... 3-205
9U-5106 Diesel Tool Group .............................................................. 3-206
6V-7073 Liner Puller Group (Part of 9U-5106 Group) ....................... 3-206
8T-3268 Bolt (Part of 9U-5106 Group) .............................................. 3-206
8T-3033 Ring Expander Group (Part of 9U-5106 Group) .................. 3-207
4C-6594 Timing and Fuel Setting Tool Group
(Part of 9U-5106 Group) .............................................................. 3-207
1U-8795 Governor Torque Arm (Part of 9U-5106 Group) ................. 3-207
9U-5932 Camshaft Torque Extension (Part of 9U-5105
and 9U-5106 Groups) .................................................................. 3-207
146-2727 G3600 Operator Tool Group .................................................. 3-208
191-1135 Cylinder Liner Spacer Assembly ........................................... 3-208
146-2726 Maintenance Tool Group ...................................................... 3-208

Caterpillar Inc. warrants all products sold, against defects in workmanship

or materials under normal use, for Six Months after date of purchase,
unless otherwise stated.

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Caterpillar Inc. warrants all products sold, against defects in workmanship

or materials under normal use, for Six Months after date of purchase,
unless otherwise stated.

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Engine Tools Search Air Induction

Air Induction

152-2067 Differential Pressure Gauge

SMCS Code: 1063-036
Model: Multiple Engine Models
ER
AT
W 40
OF 30
IN
ES
CH 20 Accuracy ±2% of full scale
• Used to monitor aftercooler pressure drop in applications with crankcase 10 Weight 18 oz
IC
ELR
fumes recirculation 0 AEHD FOION Range (inches of water) 0-40
A GIBNRALTPOSIT15 PSIG
• Minimize risk of engine reliability problems M A L A
C TIC U
R
VE R ES
P
S
R E
Minor divisions 1.0
X.
MA
• Helps eliminate premature plugging of aftercooler cores Temperature range 20°-140°F
• Increase service life of air cleaner Maximum pressure 80 PSI
• Eliminates need for using two gauges
• Installs easily across air side of aftercooler core
ID: C66987T1
• Measures differential pressure continuously, regardless of fluctuation in system pressure
• For maximum accuracy, calibrate gauge in position used
• Magnahelic gauge with high pressure option

Turbocharging Reconditioning Tools

SMCS Code: 1052-017
Model: Multiple Engine Models
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.

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
FT0165 3 Fixture (Modified) X X X X X X X X X
FT0165 3 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
8S-9944 Turbine Holder X
9S-6343 2 Cartridge Fixture X X X
1
8S-9945 Turbine Holder X
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
Item Part No. Description
9S-6343 Fixture Assembly and Turbine Holders 1 9S-6343 Fixture Assembly
• Used to disassemble turbocharger rotating assemblies by positioning Turbine Holders (one shown):
turbine wheel in 9S-6343 Fixture Assembly for removal of shaft nut 2 8S-9943 T-6
• Contains sockets required to hold Schwitzer turbine wheels 8S-9944 T-12
8S-9945 T-14
• Set of 4 turbine holders available to hold AiResearch turbine wheels 8S-9946 T-18
• Frame of fixture retains holder in place

ID: B22568T1

Home Dealer Service Tools 2004 3-1

Air Induction Search Engine Tools

9S-6363 Turbocharger Fixture Group

• Used for disassembly and assembly of current and non-current turbochargers
• 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°.

1U-5429 Snap Ring Pliers 155-3046

ID: C09503T1
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
Model: Multiple Engine Models

• Used to remove and install turbocharger band clamps

• Used to remove snap rings from deep bores in turbocharger housings and • Fits limited clearance within bearing cartridge housing
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. • Hex size: 10 mm
(0.041 inch) piano wire
• Drive: 3/8 inch

ID: C66988T1

ID: C27081T1

215-2592 Wastegate Tool Kit

SMCS Code: 1050-036, 1081-036
Model: C-15 Engine Service Parts
Item Part No. Description
1 213-4269 Adapter
• Used to test and adjust wastegate setting
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
7 7B-0192 Cross Fitting
8 214-0787 Pressure Gauge

ID: C80495T1

9S-9143 Gauge Group

SMCS Code: 1052-016, 1052-017
Model: Multiple Engine Models

• 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: C09505T1
3-2 Dealer Service Tools 2004 Home
Engine Tools Search Air Induction

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
• Square drive: 1/2 inch Reference
REHS0556 Special Instruction, Disassembly and Assembly
of the Water Cooled TPS57 Turbocharger

ID: C79892T1

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)

• Used to clean air filter elements
Air filter cleaner 0.946 l (32 oz)
• 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 Reference
filter after cleaning SEHS9541 Special Instruction

ID: C66640T1

Differential Pressure Regulator Testing and Reconditioning Apparatus

SMCS Code: 1051-036
Model: Multiple Engine Models

• 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 Item Part No. Description
1 Basic Apparatus
2 4L-9555 Cover
Reference 3 3B-7722 Bushing
FE035027 and FE034610 Special Instructions
4 3B-7276 Nipple
5 5L-3252 Cover
6 Calibration Plate
7 Rod
8 9M-0428 Gauge (or manometer)
9 3B-7263 Nipple
10 3B-7719 Coupling
ID: D00107T1

Home Dealer Service Tools 2004 3-3

Air Induction Search Engine Tools

6V-7060 Gauge Group

SMCS Code: 1051-036
Model: Multiple Engine Models

• 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)
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) ID: B67057T1
6V-7022 Gauge 1,676 (.0600 inch)
6V-7023 Gauge 1,659 (.0653 inch)
6V-7024 Gauge 1,651 (.0650 inch)

5P-6518 Parts Reusability Fixture Group Item Part No. Description

SMCS Code: 1052-015, 1052-017 1 5P-6517 Dial Indicator
Model: Multiple Engine Models
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
SMHS6998 Special Instruction

ID: A39325-1T1

2P-2333 High Temperature Sealer

SMCS Code: 1052-012
Model: Multiple Engine Models

• Used on all exhaust manifold joints, either flat or cylindrical

• Retains sealing characteristics at temperatures up to 980°C (2000°F)

ID: C79520T1

9U-5794 Tap
SMCS Code: 0671, 1050-012 Reference
Model: 3306C and 3406B Diesel Truck Engine SEHS9551, Special Instruction (3300 Engines)
Warranty: One Year
PS4826 (3300 Engines)
• Used to tap hole for 6I-3553 and 102-3599 Air Inlet Heater in air intake elbow SEHS9444, Special Instruction (3400 Engines)
• Plug-type PS588, PS658 (3400 Engines)
• Size: M20 x 1.5 mm

ID: C27050T1

3-4 Dealer Service Tools 2004 Home

Engine Tools Search Air Induction / Cooling System

143-9730 Wrench (30 mm throat)

143-9731 Wrench (122 mm throat)
SMCS Code: 1052-079, 0602, 0702
143-9730
Model: 3176, 3176B, C-10, C-12, 3114, 3116, 3126 Engines

143-9731
• Used to properly tighten hard-to-reach 15 mm nuts
• Used with 1/2 inch square drive torque wrench
• Helps prevent turbocharger gasket failures
• Two wrenches fit almost all turbocharger installations

Part No. Description Size Drive Distance between wrench faces

143-9730 Wrench (30 mm throat) 15 mm, 12 point 12 in, square 266.7 mm (10.50 in)
ID: 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
Model: Multiple Engine Models

• 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: A49237T1

178-3704 Lift Bracket Assembly

SMCS Code: 1353-010
Model: Multiple Engine Models Lift capacity 45.4 kg (100 lbs)
Essential Tool

Compliant
• 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: C79880T1

Home Dealer Service Tools 2004 3-5

Cooling System Search Engine Tools

208-1350 Radiator Fin Comb 212-8144 Socket

SMCS Code: 1353-023 SMCS Code: 1372-012
Model: Multiple Engine Models Model: 3304, 3306

• Multi-head tool which handles 8, 9, 10, 12, 14, and 15 fins/inch • Used to loosen and tighten radiator drain
• Breaks down easily for tool box storage valve on 3304 and 3306 Engines
• 1/2 inch drive

ID: D00359T1

ID: C27195T1

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: C54929T1

2S-9528 Blade Reversing Tool 5P-3518 Fan Pulley Spanner Wrench

SMCS Code: 1356-025 SMCS Code: 1359-025
Model: Multiple Engine Models Model: 3208
Warranty: Lifetime

• Used to change fan blade pitch on machines equipped with reversible fan • Used with a 9S-7353 Torque Wrench to tighten fan pulley nut on 3208
blades Engines equipped with a fan drive

ID: C09510T1

ID: A23429-1T1

243-6532 Spanner Wrench Assembly

SMCS Code: 1359-025
Model: C-9 Engines in Timber King Feller Buncher
Square drive 1/2 inch
Number of teeth 4, equally spaced
Tooth width 6.1 mm (24 in)
• Used to disassemble and assemble Flexxaire engine fans
Inside diameter 64.0 mm (2.5 in)
• Used with 1/2 inch square drive ratchet
Outside diameter 76.2 mm (3 in)

ID: D00716T1

3-6 Dealer Service Tools 2004 Home

Engine Tools Search Cooling System

9S-8140 Pressurizing Pump

SMCS Code: 1350-036, 1350-038, 1350-081
Model: Multiple Engine Models

• Used to pressurize cooling systems to detect leaks

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

Item Part No. Description

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 ID: A69886-1T1
6V-2001 Bushing
5 9S-8139 Packing (Internal)
Reference
6 6V-0117 Bushing
SMHS8303 Special Instruction
Not shown 4M-5317 Adapter, 1/8-1/4 inch npt
Not shown 6V-9068 Valve Kit

5P-7361 Water Pump Tool Group

Item Part No Description
SMCS Code: 1361-016, 1361-017
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
7 5P-7352 Spacer
Reference
8 5P-7351 Spacer
SMHS7090 Special Instruction
9 5P-7350 Spacer
10 5P-7354 Pin
ID: A46434T1 11 5P-7356 Spacer

5P-7385 Insert 4A-0334 Water Pump Packing Wrench

SMCS Code: 1361-012 SMCS Code: 1361-025
Model: 3400 Model: Multiple Engine Models

• When water pump bearing seat becomes worn on 3400 Family Engines, • Used to adjust water pump packing nut on early pumps
housing can be machined for installation of 5P-7385 Insert.
• Slot must be aligned with oil passage in housing.

ID: C13426T1

5P-2686 Installation Tool

SMCS Code: 1361-012
Model: 3406 Engines
ID: A92069T1

• Used to install water pump seal

Reference
Service Magazine, March 7, 1977 (machining instructions)

ID: 97711T1

Home Dealer Service Tools 2004 3-7

Cooling System Search Engine Tools

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 • Used to install water pump seal
(9N-3075 Water Pump and 9N-3898 Water Pump)
• Required to compress seal spring pre- Reference ID: C66686T1
determined distance SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engines

Reference
SENR3910, 3176 Service Manual
SEHS9120 Special Instruction, operation
ID: A66402T1

6V-6158 Adapter
6V-6159 Seal Guide
SMCS Code: 1361-016
Model: 3204 Engines

• Used for assembly of 1W-6446 Water Pump and 2W-1223 Water Pump
• 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: B54471-1T1

9S-8096 Seal Installer Sleeve Impeller Installers

SMCS Code: 1361-016, 1361-017 SMCS Code: 1361-012
Model: Multiple Engine Models Model: 3204, 3208
Warranty:

• Used to press in 9H-8839 Oil Seal and 4S-6413 Water Seal • Used with an arbor press
on 5S-6684 Water Pump for 4.75 inch bore engines 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
ID: B96367T1
• 8T-3142 Impeller Installer for all 3204 Family Engine water pumps
• 8T-0457 Impeller Installer for all 3208 Family Engine water pumps

ID: A92588T1

Water Pump Seal Installation Tools

SMCS Code: 1361-012
Model: Multiple Engine Models

• 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)

ID: C07630T1
Engine Seal Group Installation Tool
3400 Series 6N-9312 7N-7843 Reference
3300 Series and 3406B 4W-3864 — SEHS8449 Special Instruction
6 1/4 Bore Vee 6N-9313 7N-8268

3-8 Dealer Service Tools 2004 Home

Engine Tools Search Cooling System

172-5711 Seal Installer

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

ID: C79365T1

248-3310 Spanner Wrench 193-8094 Spline Wrench (14 Teeth)

248-3311 Holding Fixture 193-8100 Impeller Nut Spanner
Model: G3520B and G3520C Engines in Large Mining Trucks SMCS Code: 1361-010
Model: All 3500 Marine Engines with 148-8000 Seawater Pump

• Used to disassemble and assemble jacket water (JW) pumps and separate
circuit aftercooler (SCAC) water pumps • Used to disassemble and assemble pump during rebuild
• Used with a bench vise and 1/2 inch square drive ratchet • 193-8094 used to hold spline
• Special repair tools allow pump repair instead of pump replacement • 193-8100 used to remove locknut
• Holding fixture is placed in a bench vise to hold pump spline
• Spanner wrench fits innermost locknut inside pump housing
193-8094

248-3311

248-3310
193-8100

Reference
ID: C80097T1

SENR6564 Service Manual, 3500B Engines Disassembly and Assembly

ID: D00747T1

Water Pump Seal Installers 2

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
8PN10279-UP and 3406E Engines with serial numbers 5EK85240-UP

3
1
ID: 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

Home Dealer Service Tools 2004 3-9

Cooling System Search Engine Tools

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
SEHS8449 Special Instruction, Installation of Water Pump Seal Group

ID: C66887T1

183-4028 Seal Installer

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: 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: C27138T1

ID: 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 and less chance of damage
ID: C66646T1
• Dual purpose 9U-6627 Seal Driver installs seal — ring is used with driver to remove old seal Item Part No. Description
1 9U-6627 Seal Installer
2 Seal Remover (part of 9U-6627)
3 9U-6626 Lock Nut Spanner Wrench
4 2P-2317 Lock Nut Spanner Wrench

3-10 Dealer Service Tools 2004 Home

Engine Tools Search Cooling System

164-2192 Pressure Probe

SMCS Code: 1350-036
Model: Multiple Engine Models
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: A23418T1

• 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)

9S-6090 Belt Tightener Tool Group

SMCS Code: 1358-010
Model: D9 Engine Item Part No. Descriptionn
1 Nut
2 1B-4203 Nut
• Used to assist in removal and installation of D9 fan belt tightener spring 3 4B-4278 Washer
4 Plate Assembly
5 Clamp Assembly
6 Hook Assembly

ID: 13427T1

6V-7860 Removal Tool Group, Water 9U-6956 Water Pump Seal Installer
Sleeve SMCS Code: 1371-010, 0708
Model: 3408 and 3412 Marine Engines
Discontinued—Service Parts Available
• 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)
• Large diameter: 70.0 mm (2.75 inch)
ID: B75363T1
Item Part No. Descriptionn
1 6V-7857 Slide Hammer
2 6V-7859 Forcing Ring
3 6V-7858 Wedge

ID: C66666T1

221-8647 Seal Installer

SMCS Code: 1355-012, 0708
Model: Most Caterpillar Engines

• Used to install thermostat seal in housing

• Top portion of installer fits into housing and acts as a guide
• Lower portion slides through guide portion to install seals accurately and efficiently
• Lower portion bolts to handle using a 2D-4534 Bolt (3/8-16)
• Knurled handle makes installer easier to hold

ID: D00291T1
Home Dealer Service Tools 2004 3-11
Cooling System Search Engine Tools

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: 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

125-5597 Mounting Bar 237-9608 Mounting Bar

SMCS Code: 1379-017 SMCS Code: 1000-016, 0700, 0701, 0708
Model: 3406E Marine Engine Model: C-18

• Used to hold heat exchanger plates in alignment during • Used to preload aftercooler plates for assembly
disassembly and assembly • Makes repair work easier and faster
• Makes repair work faster and easier • Two bars are typically used per aftercooler

Hex end 3/4 inch

Outside diameter 29.75 mm (1.171 in)
ID: C66986T1 Threaded end 1/2-13

ID: D00717T1

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

Reference Hex end 3/4 inch

SENR5031 Disassembly and Assembly Manual Outside diameter 29.75 mm (1.171 in)
Threaded end 5/8-11

ID: C66986T1

3-12 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

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

Thread sizes of adapters (5) are as follows:

ID: C05369T1
Part No Thread Size
Item Part No. Description
5F-7339 3/4 inch NF — Male x 5/8 inch NF — Female
1 5H-1275 Stud
5F-7342 1 inch NF — Male x 5/8 inch NF — Female
2 1B-4206 Nut
5H-1274 1 1/4 inch NF — Male x 5/8 inch NF — Female
3 4D-3704 Washer
5H-1276 7/8 inch NF — Male x 5/8 inch NF — Female
1 4 6V-3160 Hydraulic Puller
5H-1277 1 3/8 inch NF — Male x 5/8 inch NF — Female
1 Discontinued 5 Adapter (5F-7339, 5F-7342, 5H-0124, 5H-1276, or 5H-1277)
6 5H-1273 1 Sleeve
FT1410 Sleeve
1 Discontinued

137-7293 Crank Gear Puller

SMCS Code: 1204-011
Model: 3116 and 3126 Engines

• Used to remove 2W-8147 Gear from crankshaft

• Saves time by allowing crankshaft gear to be removed without removing crankshaft
from engine or engine from frame
• Especially useful on 3126 Engines in motor home applications
• Weight: 3 kg (7 lbs)

ID: C55054T1

5P-3546 Puller Plate 6V-6035 Hardness Tester

SMCS Code: 3100-017, 5068-017, 3268-017, 3271-017 SMCS Code: 1202-040
Model: D10, D11N, 245B, 992C Model: Caterpillar Engines

• Used to remove 9S-3013 Crankshaft Gear on D343 and 1693 Engines • Used to check crankshaft journal hardness before and after journals are
• Used with 6V-3160 Hydraulic Puller, 9M-6592 Guide, three 6F-4991 Bolts, reground
and three 7F-1926 Bolts • Hardened steel ball that strikes tested surface will not damage journal
surface; height of bounce read as Shore scleroscope reading
• Can be used on any Caterpillar crankshaft if journal diameter is at least 38 mm
(1.5 inch) and smooth; surface finish must be 0,8 micrometers (20 microinches)
or smoother and have minimum surface thickness of 25 mm (1 inch)

NOTE: Do not use any hardness tester which can damage the journal. Some
testers use a hardened tip which can dent the journal surface. The 6V-6035
Tester uses a large ball which will not damage the journal surface.

ID: A16275T1

Reference
SEBF8041 Guideline for Reusable Parts
ID: B46825-1T1

Home Dealer Service Tools 2004 3-13

Crankshaft, Main Bearings and Flywheel Search Engine Tools

5P-8637 Crankshaft Support Group

SMCS Code: 1202-040
Model: Caterpillar Engines
Part No. Description Quantity
7F-7836 Screw 4
• V-block-type supports used to inspect crankshafts for bend (two support groups required)
5P-8636 Pad 2
• Replaceable plastic bearing pads will not damage crankshaft
2H-6120 Screw 3
0S-0509 Bolt 2
Reference
SEBF8054 Guideline for Reusable Parts

ID: A63387-1T1

5P-8718 BrakeSaver Rotor Support 8F-4423 Flywheel Lifter

SMCS Code: 1155-010, 1155-017 SMCS Code: 1156-010
Model: 3406, 3406B, 3408, 3408B Model: Caterpillar Engines

• Used to prevent damage to seals during BrakeSaver removal and installation • Used for flywheel removal and installation
on 3400 Series Engines • Two lifters can be used for removal and installation of some crankshafts
• Attached to engine with four 0S-1594 Bolts • Maximum lifting capacity: 454 kg (1000 lbs)
• Replaces 9N-0046 design changes

ID: T97406T1

ID: A73571T1

9U-7994 Flywheel Guide Pin

SMCS Code: 1156-010, 0714
Model: 3046 Diesel Engine

• Used to remove and install flywheel (two required)

• Supports weight and aligns flywheel during engine assembly
• Simple to use (threaded guide pin has screwdriver slot for easy installation)
• Thread: M12 x 1.25
ID: C66684T1
• Overall length: 190 mm (7.5 inch)
Reference
SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engines

5P-3022 Wear Sleeve and Seal Installer

SMCS Code: 1160-012, 1161-012
Model: Caterpillar Engines

• Used to install both front and rear seals and wear sleeves on 6.25 inch bore V-engines
• Also included with 3N-8008 Crankshaft Seal Conversion Group, Front, and 3N-8000
Crankshaft Seal Conversion Group, Rear, for replacing former piston ring-type seal,
thrower, and baffle

ID: A08838T1

3-14 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

Crankshaft Seal and Wear Sleeve Installation Tools (Silicone and Hydrodynamic)
SMCS Code: 1160-012, 1161-012
Model: 1100, 3100, 3200, 3300, 3400

• Typical tools for installing silicone and hydrodynamic-type oil seals and wear sleeves

Reference
SMHS7100-02, SMHS8508, SMHS8301 and SMHS6959-01 Special Instructions

ID: C54533T1

Crankshaft Seal and Wear Sleeve Installation Tools

CURRENT ENGINES
Location (1) (2) (3) (4) (5) (6) Qty Distorter Distorter
Locator Installer Other Parts Nut Bolts Ring/Adapter
1100 and 3100 Engines — Silicon Seals — SMHS7100
Front — 9S-6030 6V-7777 — — — — —
Rear 5P-0290 5P-7293 — 9S-8858 1P-5515 2 5P-7312 5P-7338
3034
Front — 159-9074 159-9076 — — — — —
Rear — 159-9071 159-9076 — — — — —
3054
Front 9U-6208 9U-6211 9U-6206 — 089-7989 — — —
Group 9U-6210 9U-6207
9U-6209
Rear — 9U-6203 9U-6202 — — — — —
9U-6204
3056
Front 9U-6208 9U-6211 9U-6206 — 089-7989 — — —
Group 9U-6210 9U-6207
9U-6209
Rear — 9U-6203 9U-6202 — — — — —
9U-6204
3064
Front — 9U-6181 9U-6178 — — — — —
Group 9U-6180 9U-6179
Rear 9U-6171 9U-6169 5P-8247 — 9U-6172 2 — —
Group 9U-6170 6V-3303
3066
Front — 9U-6181 9U-6178 — — — — —
Group 9U-6180 9U-6179
Rear 9U-6171 9U-6169 5P-8247 — 9U-6172 2 — —
Group 9U-6170 6V-3303
3046
Front — 4C-6378 4C-6376 — — — — —
4C-6377
Rear 4C-6375 127-1591 5P-8247 — 9U-6172 2 — —
6V-3303 1
3200 and 3204 Engines — Silcon Seals — SMHS7100
Front — 9S-6030 6V-7777 — — — — —
Rear 5P-0290 5P-7293 — 9S-8858 1P-5515 2 5P-7312 5P-7338
Lip Rear 5P-0290 8T-3098 — 9S-8858 1P-5515 2 5P-7312 5P-7338
3208 Engines — Silcon Seals — SMHS7100
Front — 5P-4194 5P-4230 — — — — —
Rear 5P-0290 5P-7293 — 9S-8858 1P-5515 2 5P-7312 5P-7338
3208 Engines — Hydrodynamic Seals — SMHS8508
Front — 4C-4234 1 — — — — — —
Rear 5P-0290 5P-7293 — 9S-8858 1P-5515 2 5P-7312 5P-7338
3300 Engines — Silcon Seals — SMHS7100
Front — 4C-8982 — — 7F-8022 1 5P-7312 5P-7315

Home Dealer Service Tools 2004 3-15

Crankshaft, Main Bearings and Flywheel Search Engine Tools

Crankshaft Seal and Wear Sleeve Installation Tools

CURRENT ENGINES
Location (1) (2) (3) (4) (5) (6) Qty Distorter Distorter
Locator Installer Other Parts Nut Bolts Ring/Adapter
Rear 9S-8871 5P-7298 — 9S-8858 9S-8890 3 5P-7312 5P-7313
3300 Engines — Hydrodynamic Seals — SMHS8508
Rear Gear 9S-8871 6V-7876 — 9S-8858 2P-1956 3 5P-7312 5P-7313
Train
Not Oiled
Rear Gear 9S-8871 6V-7877 — 9S-8858 2P-1956 3 5P-7312 5P-7313
Train
Oiled
Rear Train 9S-8871 1U-8585 — 9S-8858 2P-1956 3 5P-7312 5P-7313
Oiled
Double lip
7C-4297 and 7E-6159
Front 9Y-9895 — 4C-8982 — — 7F-8022 1 5P-7312 5P-7315
3114 and 3116 Engines — Hydrodynamic Seals — SMHS8508, SEHS8868
Front 1U-7430
Wear Sleeve Installer: 5P-6208
Wear Sleeve: 171-7212
Rear — 1U-7594 1U-7597 9S-8858 1U-7596 2 5P-7312 4C-4869
3114, 3116 and 3126 HEUI Engines — Hydrodynamic Seals — SMHS8508
Front 1U-7430
Wear Sleeve Installer: 5P-6208
Wear Sleeve: 171-7212
Rear 132-8772 1U-7594 1U-7597 9S-8858 1U-7596 2 5P-7312 4C-4869
3176, 3196, C-10 and C-12
Front
Wear Sleeve Installer: 145-5247
Wear Sleeve: 9Y-0821
Rear
Wear Sleeve Installer: 147-2675
Wear Sleeve: 9Y-0810
3196 Rear FT2712 FT2711 2
Gear Train (Qty 3) (Qty 2)
3400 Engines — Silcon Seals — SMHS7100
Front 5P-1733 6V-2086 — 9S-8858 5P-1737 3 5P-7312 5P-7314
Rear 5P-1733 6V-2087 — 9S-8858 5P-1737 3 5P-7312 5P-7314
Rear Gear
Train 5P-7301 6V-2087 — 9S-8858 5P-7309 2 5P-7312 5P-7314
5P-7310
3400 Engines — Hydrodynamic Seals — SMHS8508
Front 5P-1733 6V-6142 — 9S-8858 5P-1737 3 5P-7312 5P-7314
Rear 5P-1733 6V-6143 — 9S-8858 5P-1737 3 5P-7312 5P-7314
Rear
(Gear Train) 5P-7301 8T-2683 — 9S-8858 5P-7309 2 5P-7312 5P-7314
5P-7310
Rear
(Brake Saver) 5P-3594 8T-2855 8T-2856 9S-8858 1T-0720 2 5P-7409 5P-7314
3500 Engines — Hydrodynamic Seals — SMHS8508
Front and
Rear 6V-4003 6V-4977 6V-4001 9S-8858 2N-5006 2 5P-7409 6V-3143
(With Adapter Group) 6V-4002
1W-6975 and 1W-6978 1D-4716 4
Front and
Rear (without 6V-4003 8T-3099 — 9S-8858 2N-5006 2 5P-7409 1U-7325
adapter group)
3524B 192-6339 187-1841 5P-8249 9S-8858 1 5P-7409 1U-7325
Rear of Rear 2J-3505 4
Engine Only
C27/C32 Engines — Hydrodynamic Seals — SMHS8508
Front 5P-1733 6V-6142 — 9S-8858 9S-8858 3 5P-7312 5P-7314
Rear
Small Pilot
Crank Gear 5P-1733 6V-6143 — 9S-8858 9S-8858 3 5P-7312 5P-7314
Large Pilot
Crank Gear 249-2937 6V-6143 — 9S-8858 9S-8858 3 5P-7312 5P-7314

3-16 Dealer Service Tools 2004

Home
Engine Tools Search Crankshaft, Main Bearings and Flywheel

Crankshaft Seal and Wear Sleeve Installation Tools

CURRENT ENGINES
Location (1) (2) (3) (4) (5) (6) Qty Distorter Distorter
Locator Installer Other Parts Nut Bolts Ring/Adapter
D343 (5.4 inch) 6 Cylinder Engines — Silicon Seals — SMHS7100
Front 9S-8876 5P-7295 — 9S-8858 9S-8889 2 5P-7312 5P-7316
Rear 9S-8870 5P-7294 — 9S-8858 618718 3 — —
Rear
(Brake
Saver) 9S-8870 5P-7294 — 9S-8858 2P-2346 3 — —
D348 (5.4 inch) 60° Vee Engines — Silicon Seals — SMHS7100
Front 5P-7302 5P-7297 5 — 9S-8858 9S-8889 3 5P-7312 5P-7316
Rear 9S-8874 5P-7296 6 — 9S-8858 9S-8893 3 — —
(5.4 inch) 60° Vee Engines — Hydrodynamic Seals — SMHS8508
Front 7C-7473 5P-7302 4C-5822 — 9S-8858 9S-8889 3 5P-7312 5P-7316
Rear 7C-7474 9S-8874 9U-5114 — 9S-8858 9S-8893 3 — —
D379, D398, D399, G379, G398 and G399 Engines — Hydrodynamic Seals — SMHS8301
— 6V-7829 6V-7831 6V-7833 9S-8858 6V-7834 2 — —
6V-7799 6V-9442 2
3B-1915 6
4B-5271 6
1 Use stud instead of damper bolt

Crankshaft Seal and Wear Sleeve Installation Tools

NON-CURRENT ENGINES
Location Locator(1) Installer(2) Ring(4) Nut(5) Bolts(6) Plates
D342 and 5.75 inch Bore Engines — Silicon Seals — SMHS6959-01
Front — 5P-6543 5P-3036 — 5S-8096 5P-3037
5P-6545
D334, 1674 1 and 4.75 inch Bore Engines — Silicon Seals — SMHS6959-01
Front 9S-8876 9S-8866 2 9S-8537 2 9S-8858 9S-8889 9S-8865
9S-8880 2
9S-8545 3
Rear 9S-8875 9S-8550 9S-8534 9S-8858 9S-8891 9S-8864
9S-8547
D334, 1674 4 and 4.75 inch Bore Engines — Silicon Seals — SMHS6959-01
Rear 9S-8872 9S-8867 9S-8533 9S-8858 8S-4950 9S-8864
9S-8541
D336, 1676 and 4.5 inch Bore Engines — Silicon Seals — SMHS6959-01
Front 9S-8876 9S-8866 9S-8536 9S-8858 9S-8889 9S-8865
Rear 9S-8872 9S-8867 9S-8533 9S-8858 9S-8892 9S-8864
9S-8541
1 92B322-Up, 93B292-Up, 94B675-Up or prior engines reworked with 9S-0124 or 1N-5466 Crankshaft Assemblies.
2 Not used on D334 Marine Engines.
3 Not used on D334 Industrial or 1674 Engines
4 92B1-92B331, 93B1-93B291, 94B1-94B674 with 4S-5349 and 7L-5188 Crankshaft Assemblies.
5 FT2323, made from 5P-7297
6 FT2324, made from 5P-7296

193-0233 PTO Oil Seal Installer Wear Sleeve Installers

SMCS Code: 1165-012, 0704, 0714 SMCS Code: 1202-ZV-012
Model: 3408 and 3412 Engines Model: 3176, 3176B, C-10, and C-12 Engines

• Tool must be used to install the 160-8181 • Used to quickly and easily install crankshaft wear sleeves
PTO Shaft Seal (Seal is included in the
178-2973 Seal Kit)
Part No. Description Use
• Used with nut and washer of
145-5247 Wear Sleeve Installer Front crankshaft sleeves
PTO yoke to push seal into
position 147-2675 Wear Sleeve Installer Rear sleeves
• Decreases installation time
(uses positive stop to
accurately set depth of seal)
• Made from hardened steel
for added durability

ID: C80068T1

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Crankshaft, Main Bearings and Flywheel Search Engine Tools

9U-6170 Installer Group

SMCS Code: 1161-012, 0714
Model: 3064 and 3066 Engines

• Used to install rear seal and wear sleeve onto crankshaft (assures seal lip will bear
uniformly around the crankshaft)
• Prevents seal damage during installation—longer seal life

Item Part No. Description

1 9U-6169 Installer
ID: C55121T1
2 9U-6171 Locator
3 9U-6172 Bolt, M12 x 1.25 x 20 mm long Reference
4 5P-8247 Washer, .625 in SENR5553 Service Manual
5 6V-3303 Bolt, M16 x 2 x 60 mm long

5P-7318 Wear Sleeve Distorter Group

SMCS Code: 1160-010, 1161-010
Model: D10, D9N, D8K, 631E, 637E

• Used to remove all 1,58 mm (.062 inch) thick Item Part No. Description
crankshaft front and rear wear sleeves 1 5P-7312 Distorter
• Prevents damage to crankshaft Distorter Rings
• Removal in-chassis takes just a few minutes 5P-7313 3300 Series, Rear
5P-7314 3400 Series, Front and Rear
5P-7315 3300 Series, Front
5P-7316 5.75 in D-Series Engines
5P-7317 5.4 in D-Series Engines
5P-7338 1100, 3100, 3200 Series, Rear
ID: A48900-1T1

4C-4869 Distorter Ring

SMCS Code: 7558-010
Model: 3114, 3116, 910E

• Used with 5P-7312 Distorter to remove rear crankshaft wear sleeve from 1.1 liter engine
• Wear sleeve removal can be difficult without use of distorter and distorter ring to expand sleeve away from crankshaft;
after wear sleeve is expanded on journal, it can easily be removed without damaging sealing surfaces

155-8795 Crankshaft Distortion Gauge

SMCS Code: 1202-082
Model: All Engines, 3500 and Up

• Used to check crankshaft bearing alignment or shaft deflection without engine disassembly
• Also used as a strain gauge on frame of running engine
• Will stay in any position for hands free operation
• Comes with ten rods (varying sizes)
• Sharp rod points hold gauge on surfaces with an angle up to 45 degrees
• Balancing attachment maintains face of indicator in any desired position
155-8795
0

• Attractive protective case

5 5

10 10

15 15
20

Dial indicator graduations 0.02 mm

Dial reading 0-50-0
Range per revolution 1 mm
Travel length 4.0 mm (.16 in) Balancing Attachment
Range 61 to 458 mm (2.4 to 18.0 in)
Balancing attachment quantity 2 ID: C79160T1

3-18 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

5P-7409 Distorter
SMCS Code: 1160-010, 1161-010, 7558-010
Model: Caterpillar Engines

• Used to remove 1,58 mm (.062 inch) thick crankshaft wear sleeves on engines equipped with BrakeSavers
ID: A48330T1
• Appropriate distorter ring must be selected from 5P-7318 Distorter Group

1U-8585 Installer 1U-7325 Distorter Adapter

SMCS Code: 1160-012, 1161-012 SMCS Code: 1160-010, 1160-011
Model: 3300 Family Engines Model: 3508, 3512, 3516, 789, 793, 994
Warranty:

• Required to install new double lip • Used with 5P-7409 Distorter to remove front and rear crankshaft wear
7C-4297 Seal Group in rear of sleeves from 3500 Series Engines with 1W-6974 Seal Group and 1W-6977
block for crankshaft Seal Group
• Positions 5P-7409 Distorter properly against flywheel and timing gear
housing for wear sleeve removal, a difficult task without the use of a
distorter and adapter to expand sleeve away from crankshaft; once expanded
on journal, wear sleeve can be easily removed

ID: C44372T1

6V-3143 Distorter Adapter 4C-5501 Alignment Tool

SMCS Code: 1160-010, 1161-010 SMCS Code: 1166-010
Model: 3500 Engines Model: 416, 426, 428, 3054

• Used with 5P-7409 Wear Sleeve Distorter to remove crankshaft wear sleeves • Used when installing front cover on 3054 Perkins engine in 416 Backhoe
Loader
• Fits around crankshaft into seal recess in cover and centers cover and seal on
crankshaft
• Helps prevent seal damage during cover installation and ensures seal lip will
bear uniformly around crankshaft to provide long seal life

ID: B14944T1

ID: C27244T1

9U-6200 Alignment Group

SMCS Code: 1151-012, 0704
Model: 3056 Engines
Warranty: Manufacturer’s

• Used to install front cover (correctly aligns it for easier installation)

• Designed to fit around crankshaft and into seal recess—centers cover on crankshaft
• Prevents seal damage during installation and helps assure uniform contact
of seal lip—two advantages that extend seal life

Reference Item Part No. Description

SENR5555 Service Manual ID: C54939T1 1 9U-6199 Cover Guide
2 9U-6201 Plate

Home Dealer Service Tools 2004 3-19

Crankshaft, Main Bearings and Flywheel Search Engine Tools

9U-5114 Seal and Wear Sleeve Installer

SMCS Code: 1000-012; 0701
Model: D346, D348, D349

• Required to locate 7C-7474 Seal and Wear Sleeve, Rear, on D346, D348 and D349 Engines, 5.4 bore, 60° Vee

ID: C27018T1

Crankshaft Oil Seal Installers

SMCS Code: 1250-010
Model: 3034 Engines 159-9076
Essential Tool

• Used to install front and rear crankshaft oil seals

• 159-9074 for front and 159-9071 for rear crank seal Part No. Description
• 159-9076 Handle used with 159-9071 159-9074 Front Seal Installer
159-9071 Rear Seal Installer
159-9076 Rear Drive Handle
Reference 159-9074
SENR5013 Engine Disassembly and Assembly Module
159-9071
ID: C79254T1

1U-7430 Front Seal Installer

1U-7598 Rear Seal Installer Group
SMCS Code: 1250-010 Part No. Description
Model: 3114, 3116 1U-7594 Rear Installer
1U-7596 Modified by Cat Bolt
1U-7597 Sleeve Ring
• Required for disassembly, assembly and adjusting of 1.1 liter engine,
9S-8858 Nut Assembly
fuel system, and governor
• 1U-7430 Front Seal Installer used to install crankshaft front seal
• 1U-7598 Rear Seal Installer Group used to install crankshaft rear seal
and its mating wear sleeve
ID: C26889T1

Reference
SENR3582, Specification Module
SENR3583, System Operation Testing and Adjusting
SENR3611, Disassembly and Assembly Manual
SEHS8868 Special Instruction, operation

ID: C26890T1

9U-6180 Front Seal Installer Group

SMCS Code: 1160-012, 0714
Model: 3064 and 3066 Engines

• Used to install crankshaft front seal without removing front cover

• Makes installation easier and prevents damage to seals
• Assures uniform contact around crankshaft (ultimately provides longer seal life) Item Part No. Description
ID: C54946T1
1 9U-6179 Washer
Reference 2 9U-6178 Installer Stud
SENR5553 Service Manual, 3066 Diesel Engines 3 9U-6181 Sleeve

3-20 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

9U-6210 Installer Group

SMCS Code: 1160-012, 0707
Model: 3054 and 3056 Engines
Warranty: Manufacturer’s
Item Part No. Description
• Used to install crankshaft front oil seal
to proper depth of 9.3 mm 1 9U-6206 Stud

• Prevents seal damage 2 9U-6207 Plate

3 9U-6208 Locator (includes 089-7989 Bolt)
4 9U-6209 Sleeve
5 9U-6211 Installer
6 089-7989 Bolt (Qty.3)

Reference ID: C80298T1

SENR5547 Service Module in SENR5555 Service Manual

9U-6205 Rear Seal Installer Group Item Part No. Description

SMCS Code: 1161-012, 0704 1 9U-6202 Plate
Model: 3054 and 3056 Engines
2 9U-6203 Installer
3 9U-6204 Seal Guide
• Used to install rear seal onto crankshafts
(assures seal lip will conform uniformly around crankshaft)
• Prevents seal damage during installation—longer seal life

1 2 3
Reference
SENR5555 Service Manual ID: C54940T1

4C-6375 Locator
127-1591
127-1591 Rear Oil Seal Installer Small seal diameter 96.0 mm (3.78 in)
SMCS Code: 1161-012, 0714 Large seal diameter 98.06 mm (3.861 in)
Model: 3046 Diesel Engine
Washer for 8T-0375 Bolt 5P-8247
Center bolt for locator 8T-0375
Crankshaft/locator bolts 9U-6172
4C-6375
• Used to install crankshaft rear seal (assures seal lip will bear uniformly
around crankshaft)
1
• Prevents seal damage during installation

127-1591
• Reversible
• Used to install 103-2835 Rear Crankshaft Oil Seal Assembly and 117-5015 Oil
Seal Assembly (when installer bottoms against crankshaft, seal assembly,
including wearsleeve, is installed in correct location)
• Used with 4C-6375 Locator, 9U-6172 Socket Head Screw (2), 8T-0375 Bolt, 3
and 5P-8247 Washer
• Installer equally distributes installation pressure on edge of seal (prevents 2
damage to edge of seal assembly during assembly, resulting in longer seal life)
4 5
• Knurled outside diameter provides better grip for mechanic during oil seal installation
• To use: bolt locator onto crankshaft, put seal assembly in installer, push seal onto ID: C79701T1
crankshaft until installer bottoms out
Item Part No. Description
1 4C-6375 Locator
2 127-1591 Rear Oil Seal Installer
Reference 3 9U-6172 Bolt, M12 x 1.25 x 20 mm long (qty 2)
SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engine 4 6V-3303 Bolt, M16 x 2 x 60 mm long
5 4B-5275 Washer (.625 inch)

Home Dealer Service Tools 2004 3-21

Crankshaft, Main Bearings and Flywheel Search Engine Tools

Seal Installer Tools

SMCS Code: 1160-012, 0714
Model: 3046 Engine

• Used to install crankshaft’s front seal without removing front cover

• Makes installation easier, faster, and prevents damage to seal
• Ensures uniform seal contact around crankshaft — ultimately provides longer seal life

Reference ID: C66701T1

SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engine Item Part No. Description
1 4C-6378 Seal Installer Sleeve
2 4C-6376 Installer Stud
3 4C-6377 Installer Washer

5P-4725 Step Plate

5P-4726 Step Plate
SMCS Code: 3107-017, 3150-017, 3258-010, 4351-016, 7117-017
Model: 768C, 769C, 920, 930, 973, 992C

• Used to install and locate positive flywheel housing seals

• 5P-4726 Step Plate used on D5 Tractor engines
• 5P-4725 Step Plate used on D4, 941, 951 and 955 Engines ID: A16272T1

Thread Repair Kits

SMCS Code: 1203-023
Model: 3406, G3406, 3408, G3408, 3508, G3508, 3512, G3512, 3516, and G3516 Engines
Essential Tool

• Used to repair main

Item Part No. Description
bearing cap bolt holes
1 178-2349 Reamer
• Repairs bolt hole threads 178-2350 Reamer
to like-new condition 178-2351 Reamer
• Groups are serviced at 178-2462 Reamer
individual tool level only. 2 178-2353 Tap (1-14 UNS)
178-2356 Tap (1-14 UNS)
178-2463 Tap (7/8-16)
178-2465 Tap (7/8-16)
3 178-2467 Insert, Sleeve
178-2468 Insert, Sleeve 2 1
4 178-2501 Threaded Insert (All 3400 Models) 3 4
178-2502 Threaded Insert (All Early 3500 Models)
178-2503 Threaded Insert (All Late 3500 Models) ID: C79877T1

Reference
SEBF8437, Main Bearing Bolt Hole Repair in 3400
and 3500 Series Engines

Main Bearing Bolt Hole Repair Tools for 3400 and 3500 Engines
Part No Description Engine Model 1st Ream 2nd Ream 3rd Ream 1st Tap 2nd Tap Insert Sleeve Insert
203-6594 Thread Repair Kit All 3400 178-2349 178-2350 178-2351 178-2353 178-2356 178-2467 178-2501
203-6597 Thread Repair Kit Early 3500 3/4 inch bolt hole 178-2462 N/A N/A 178-2463 178-2465 178-2468 178-2502
203-6598 Thread Repair Kit Late 3500 7/8 inch bolt hole 178-2351 N/A N/A 178-2353 178-2356 178-2467 178-2503

3-22 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

Bearing Cap Tools

SMCS Code: 1203-010; 0602
Model: 1100, 3100, 3208, D342, D379, D398, D399, 3512, D397, G397, D375, G375, D364, 3500

• 8S-5131 Adapter used to torque front main bearing cap when oil pump is in place
on 1100 and 3100 Series and 3208 Engines
• 1D-5343 Wrench used to remove hollow head screws from main bearing caps
on D342 Engines
• 8M-9379 Wrench used to remove main bearing caps without removing pan on D379,
D398 and D399 Engines; to apply actual torque indicated by the torque wrench dial
reading, insert torque wrench at right angle to 8M-9379 Wrench Assembly
• 7F-1709 Wrench used to remove main bearing caps without removing pan on D397,
G397, D3867, D375, G375 and D364 Engines ID: C44400T1

• 9U-5023 Main Bearing Wrench used to remove and install crankshaft main bearings
on 3500 Family Engines; fits both 1/2 inch diameter bolt and 3/4 inch diameter main Item Part No. Description
bearing bolts; can be used through crankshaft access 1 8S-5131 Adapter
opening in sides of block without removing oil pan when 2 1D-5343 Wrench
connected to short extension and 3/4 inch drive torque 9U-5023
3 9U-5023 Main Bearing Wrench
wrench; no longer fits bolts on 6-3/4 inch bore engines Socket size (left end) 1 5/16 inch
(use 8M-9379 Wrench instead) 4 7F-1709 Wrench
Socket size (right end) 1 1/8 inch
5 8M-9379 Wrench
Square drive (both ends) 3/4 inch

3500 Engine Main Bearing Cap Removal/Installation Tool

SMCS Code: 1203-010, 0602
Model: All 3500 Engines

• Used in pairs to remove and install main bearing cap (makes operation much easier)
• Allows one mechanic to remove or install a bearing cap weighing approximately 16 kg (35 lb)
• Flexible wire rope makes it easier to insert tool through engine side covers

Application Procedure
1. Loosen all (4) bolts for the main bearing cap.
2. Remove the (2) outer bolts for main bearing cap and replace with tooling.
3. Hand tighten smaller threaded end until tooling bottoms out in cylinder block.
4. Adjust nuts and washers on tooling until washers contact main bearing cap.
5. Remove the (2) remaining inner bolts for main bearing cap.
6. Loosen nuts evenly in order to lower cap. Lower cap to the end of the bolt to gain ID: D00446T1
Part No. Use
access to main bearing.
230-5843 Early 3500 Engines with 3/4 inch thd. bearing caps
7. Reverse to process for installation.
236-6688 Later 3500 Engines with 7/8 inch thd. bearing caps

9U-6942 Socket
SMCS Code: 1225-010, 1231-010
Model: 3500 Engines

• Used to remove and install crankshaft counterweight bolts and piston connecting rod bolts
• Used with an impact wrench
• 3/4 inch drive is necessary to obtain the correct bolt torque (1/2 inch drive sockets will not work in this application)
• Socket is specifically designed to provide adequate clearance

Drive 3/4 in
Size 5/8 in, 12 point
Small diameter 25 mm (1.0 in)

ID: C66797T1

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Crankshaft, Main Bearings and Flywheel Search Engine Tools

9U-6282 Torque Extension

SMCS Code: 1203-079, 0602
Model: 3054 and 3056 Engines

• Used to remove and install front main bearing bolts (conventional sockets cannot reach the bolts)
• Specially forged and heat treated for extra strength, toughness, and long service life
• Chrome plated to prevent corrosion
• Using this extension requires a calculation to determine the correct setting of the torque wrench.
Refer to SEHS7150 for torque wrench settings. 12-point socket 15/16 inch
Square drive 1/2 inch
ID: C54938T1 50 mm (2.0 inch)
Length of extension

Bearing Removal and Installation Tools

SMCS Code: 1203-010, 1219-010
Model: Caterpillar Engines

Bearing Part
Bore Model Thickness No.
• Used to remove main bearing upper halves quickly and easily in Caterpillar Engines
159 mm D353, D379, D398, D399 4.55 to 14.76 mm 2P-5517
• Shank of tool is adjustable to fit angle of crankshaft oil passage
(6.25 in) (.179 in to .581 in)
146 mm D339, D342, D364, D375, 4.55 to 14.76 mm 2P-5517
(5.75 in) D386, D379 (.179 in to .581 in)
137 mm 4 Cylinder, 90° V-8, D343, 4.55 to 14.76 mm 2P-5517
(5.40 in) D346, D348, D349, 1693 (.179 in to .581 in)
130 mm D326, D337 4.55 to 14.76 mm 2P-5517
(5.125 in) (.179 in to .581 in)
114 mm D315, D318, D336, 4.55 to 14.76 mm 2P-5517
(4.50 in) 1673 (early), 1676 (.179 in to .581 in)
102 mm D311 (early) 4.55 to 14.76 mm 2P-5517
(4.00 in) (.179 in to .581 in)
137 mm 3406 2.60 to 3.96 mm 2P-5518
(5.40 in) (.1025 in to .156 in)
ID: C05360T1
121 mm D330C, 3304, D333C, 2.60 to 3.96 mm 2P-5518
(4.75 in) 3306, D334, 1674 (.1025 in to .156 in)
114 mm D330, D333, D320, 1100 2.60 to 3.96 mm 2P-5518
(4.50 in) and 3100 Series, 3208, (.1025 in to .156 in)
1670, 1673 (Later)
102 mm D311 (Later), D320 2.60 to 3.96 mm 2P-5518
(4.00 in) (.1025 in to .156 in)

Plastic Gauges for Checking Clearance

SMCS Code: 1000-082, 0700, 0701, 0714 Typical package with one indicator
Model: All Engines or Clearance Between Any Mating Parts Part No. Description Color Clearance Range
198-9142 Plastigage Green 0.025 to 0.076 mm (.001 to .003 in)
198-9143 Plastigage Red 0.051 to 0.152 mm (.002 to .006 in)
• Used to quickly and easily check clearance between mating parts (main rod and 198-9144 Plastigage Blue 0.102 to 0.229 mm (.004 to .009 in)
bearing clearance, component side clearance, oil pump cover to gear clearance, etc.)
198-9145 Plastigage Yellow 0.230 to 0.510 mm (.009 to .020 in)
• Plastigage clearance indicator is an extruded plastic thread that crushes when
clamped between two mating parts
• Available in four color-coded sizes for easy identification
in
• Clearance thickness is determined by holding crushed indicator material against
USE HPB-1 (BLUE) F

.001
USE HPR-1 (RED)

paper packaging (see to illustration) .0015

.003 INCH

• Any plastic residue on parts can be quickly removed with component cleaner .002
.003
• One indicator per package
in
• Overall length: 30 cm (12.0 in) .001

.0015
.002
.003
.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.003
.002
.0015

.001
in

.001 TO .003 INCH CLEARANCE RANGE .001 TO .003 INCH CLE

USE HPR-1 (RED) FOR .002 TO .006 INCH USE HPR-1 (RED) FOR .002 TO .006 IN
USE HPB-1 (BLUE) FOR .004 TO .009 INCH USE HPB-1 (BLUE) FOR .004 TO .009 I

Crushed material indicates a (.001 in) clearance

ID: C80135T1
ID: C80131T1

3-24 Dealer Service Tools 2004 Home

Engine Tools Search Crankshaft, Main Bearings and Flywheel

Wear Sleeves and Drivers Wear Sleeve and Driver Application

SMCS Code: 1200-010 Shaft Sizes Wear Sleeve Width Sleeve
Model: Caterpillar Engines mm (inch) Sleeve mm (inch) Driver
19,8-19,9 (.780-.784) 5P-6158 7,95 (.313) —
22,1-22,3 (.873-.877) 5P-6159 7,95 (.313) —
Parts such as couplings, crankshafts, damper assemblies, flanges, hydraulic pump shafts,
24,9-25,0 (.982-.986) 5P-6160 7,95 (.313) 5P-6196
steering clutch shafts, transmission shafts, water pump shafts and yokes are often reusable
except for seal wear grooves. They can be salvaged with the wear sleeves and drivers listed 25,3-25,4 (.998-1.002) 5P-6161 7,95 (.313) 5P-6196
below. The chart lists the sleeve and sleeve driver required to recondition a specific size shaft. 26,9-27,0 (1.060-1.064) 5P-6162 7,95 (.313) 5P-6197
27,9-28,1 (1.100-1.104) 5P-6163 9,53 (.375) 5P-6197
28,5-28,6 (1.123-1.127) 5P-6164 7,95 (.313) 5P-6198
29,3-29,4 (1.154-1.158) 5P-6165 9,53 (.375) 5P-6198
31,7-31,8 (1.247-1.253) 5P-6166 7,95 (.313) 5P-6198
34,8-35,0 (1.372-1.378) 5P-6167 12,70 (.50) 5P-6199
34,8-35,0 (1.372-1.378) 5P-6168 7,95 (.313) 5P-6199
36,4-36,6 (1.435-1.441) 5P-6169 9,53 (.375) 5P-6200
38,0-38,2 (1.497-1.503) 5P-6170 9,53 (.375) 5P-6200
41,2-41,4 (1.622-1.628) 5P-6148 7,95 (.313) 5P-6149
41,2-41,4 (1.622-1.628) 5P-6171 14,27 (.562) 5P-6149
42,8-42,9 (1.685-1.691) 5P-6172 7,95 (.313) 5P-6150
44,4-44,5 (1.747-1.753) 5P-6173 9,53 (.375) 5P-6150

ID: A28797-1T1
48,4-48,6 (1.909-1.915) 5P-6174 9,53 (.375) 5P-6151
49,1-49,3 (1.934-1.940) 5P-6175 14,27 (.562) 5P-6151
53,9-54,1 (2.122-2.128) 5P-6176 19,82 (.781) 5P-6201
60,2-60,4 (2.372-2.378) 5P-6177 15,06 (.593) 5P-6201
61,8-62,0 (2.435-2.441) 5P-6178 12,70 (.500) 5P-6201
63,4-63,6 (2.499-2.505) 5P-6179 12,70 (.500) 5P-6201
65,0-65,2 (2.559-2.565) 5P-6180 19,82 (.781) 5P-6202
66,6-66,8 (2.622-2.628) 5P-6181 12,70 (.500) 5P-6202
69,7-69,9 (2.747-2.753) 5P-6182 19,82 (.781) 5P-6203
72,9-73,1 (2.872-2.878) 5P-6183 19,82 (.781) 5P-6204
76,1-76,3 (2.997-3.003) 5P-6184 20,62 (.812) 5P-6204
ID: A28796-1T1 79,3-79,5 (3.122-3.128) 5P-6185 20,62 (.812) 5P-6205
82,5-82,6 (3.247-3.253) 5P-6186 20,62 (.812) 5P-6206
88,9-89,1 (3.502-3.507) 5P-6187 20,62 (.812) 5P-6207
91,8-92,0 (3.617-3.623) 5P-6188 20,62 (.812) 5P-6208
Reference 93,5-93,7 (3.685-3.691) 5P-6189 20,62 (.812) 5P-6208
SMHS6915 Special Instruction, installation instructions and cross reference 101,5-101,7 (3.996-4.004) 5P-6190 12,70 (.500) 5P-6209
between repairable component part numbers and applicable wear sleeve
114,2-114,4 (4.496-4.504) 5P-6191 20,62 (.812) 5P-6210
123,7-123,9 (4.871-4.879) 5P-6192 16,13 (.625) 5P-6211
157,4-157,7 (6.198-6.208) 5P-6193 20,62 (.812) 5P-6212
189,1-189,3 (7.444-7.454) 5P-6194 20,62 (.812) 5P-6213

171-7212 Repair Sleeve

SMCS Code: 1000-023, 0701
Model: 3114, 3116, 3126, 3126B Engines

• Used to quickly and easily repair front crankshaft hub damaged by crankshaft seal
• Used with current 5P-6208 Installation Tool
• Used in place of 5P-6188 Repair Sleeve
• Provides wider surface to ensure seal is running completely on sleeve
• Sleeve width: 29.0 mm (1.14 in)

ID: C79774T1

Home Dealer Service Tools 2004 3-25

Crankshaft, Main Bearings and Flywheel / Search Engine Tools
Cylinder Block and Liners

6V-3044 Polishing Belt

SMCS Code: 1200-080
Model: Caterpillar Engines

• Used on high speed electric or air-powered polishing machine to polish bearing journals
on all Caterpillar crankshafts

Reference
SEBF8042 Guideline for Reusable Parts

ID: B11995-1T1

4C-9765 Standard Centering Ring

4C-9766 Oversized Centering Ring
SMCS Code: 1224-064, 0672
Model: 3114/3116 Engines

• Used to precision machine main bearing bores in cap and cylinder block (available for standard and oversize bearings)
• Used with 1P-4000 Line Boring Tool Group (two centering rings required for machining procedure)
• Each ring stamped with size of main bearing bore
• Diameter:
4C-9765: 95.00 mm (3.740 inch)
4C-9766: 95.50 mm (3.760 inch) Reference
REGO0867 and SMHS7606 Special Instruction ID: C66620T1

Cylinder Block and Liners

9U-6274 Compression Test Kit

SMCS Code: 1000-082, 0770 Item Part No. Description
Model: 3046, 3054, 3056, 3064, and 3066 Engines 1 9U-6279 Carrying Case
2 9U-6277 Pressure Gauge
3 9U-6389 Tee Fitting
• Used to obtain compression pressure for comparision with other cylinders
4 9U-6387 Bleed Valve
• Gauge holds reading until released by bleed-off valve
5 9U-6275 Quick Coupler
• Flexible hose provides easy viewing angle of pressure gauge
6 9U-6280 Air Connector
• Air connectors also used to put shop air into combustion chamber
7 9U-6384 Hose Assembly
while replacing valve springs
8 9U-6145 Air Connector
• Dual scales on gauge — PSI and kPa
9 9U-6390 Bushing
• Pressure range: 0-7000 kPa (0-1000 PSI)
10 9U-6276 Quick Coupler
11 9U-6391 Quick Coupler
12 5C-0249 Plug Cap
13 9U-6394 Plug Cap
14 9U-6393 Check Valve
15 7D-2746 Elbow
16 9U-6392 Quick Coupler
Not shown NEEG2538 Decal
Not shown 9U-6385 Foam Block

ID: C55199T1

3-26 Dealer Service Tools 2004 Home

Engine Tools Search Cylinder Block and Liners

193-5859 Cylinder Pressure Tool Kit (Gas Engines)

SMCS Code: 1000-082
Model: G3300, G3400, G3500, and G3600 Engines
2
1
Essential Tool
12
T
O OO
R
3
MA PER L
• Used to check cylinder compression SM
CS:
Us
(All ing

100
0
Ga the
NU ATIN
s En 19
AL G
gine3-5858
NEH
Jun S07
e 200 98
0

4
s) Cy
linde

• Low compression reading can be indication of valve guttering, broken valves,

r Co
mpr
essio
n Ga
ug
e

broken or worn piston rings, or worn cylinder liners

• Quick way to check for potential engine wear
• Can obtain compression pressure to compare with other cylinders and
pressure ratio chart
• 8T-0855 Gauge holds pressure reading until bleed-off valve is released
5
• Includes easy to use instructions
• Pressure range: 0 to 4000 kPa (0 to 680 PSI)
400

300
0
50

3000
2000
®

4000
8T0855
200

1000

kPa
Item Part No. Description

psi
0
9
100 0

1 6V-3072 Case 10
2 6V-6126 Holder Block (Foam)
11 13 7 6
3 8L-2786 O-ring (Brown) 8
4 8M-5127 O-ring (Yellow) ID: C80091T1
5 Cylinder Pressure Group (Gas Engines)
6 192-7130 Adapter Group1
7 5P-8998 Pipe Nipple1
8 6V-4144 Coupler Assembly1 Reference
9 8T-0855 Pressure Gauge1 NEHS0798 Tool Operating Manual, Using the 193-5859 Cylinder
10 4M-5317 Pipe Reducing Bushing1 Pressure Tool Kit (All Gas Engines)
11 9U-63871 Bleed Valve1
12 NEHS0798 Tool Operating Manual
13 Check Valve1
Not shown NEEG2911 Decal
1 Part of Cylinder Pressure Group (Gas Engines)

Cylinder Block Cleaning Brushes

SMCS Code: 1201-070 Brush Diameter
Models: 1100, 3100, 3208, 3204 Brush Part No mm (inch)
6V-7067 6 (.25)
1P-5580 Brush Group
6V-3182 8 (.31)
• Used during rebuild to clean oil passages and cylinder bores after honing Item Part No. Description
1P-5571 1 10 (.375)
• Circular brushes with nylon bristles and a single stem, single spiral, and carbon 1 1P-5574 Brush, 5 inch
6V-3183 11 (.44)
steel wire handle 2 1P-5573 Brush, 1 1/4 inch
6V-7091 13 (.50)
• For additional length, the larger brushes can be welded to a 1800 mm (6 feet) 3 1P-5571 Brush, 3/8 inch
length of 3,175 mm (.125 inch) diameter mild steel rod. After the brush and rod 6V-7092 16 (.625)
4 1P-5572 Brush, 3/4 inch
are welded together they can be used to clean oil passages in engine blocks. 1P-5572 1 19 (.75)
6V-7093 25 (1.0)
1P-5573 1 32 (1.25)
6V-7094 38 (1.5)
6V-7095 45 (1.75)
6V-7096 51 (2.0)
1P-5574 1 127 (5.0)
1 Included in 1P-5580 Brush Group

ID: X03918T1

1P-3565 Chamfering Group

SMCS Code: 1201-070
Model: 1100, 3100
Part No. Description Quantity
1P-3564 Abrasive Cone 6
• Used to break sharp corner at bottom of cylinder bore after
honing cylinder bores on 1100 and 3100 Series Engines

ID: C05375T1

Home Dealer Service Tools 2004 3-27

Cylinder Block and Liners Search Engine Tools

Tools for Cleaning Cylinder Bores for Reuse

SMCS Code: 1201-070 Flex-Hone Tools
Model: Multiple Engine Models
Part No. Bore Size Grit
4C-6322 4 in 180

• Flex-Hone process (superfinishing) produces controlled surface condition 4C-6323 4 1/4 in 180
that results in: 4C-6324 4 1/2 in 180
- Lowered oil consumption 1U-9787 4 3/4 in-5.00 in 180
- Less blow-by 4C-6325 5.125 in-5.4 in 180
- Less friction
4C-6326 5 3/4 in-6.00 in 180
- Plateaued finish over 50%
- Finish free from cut and folded metal 4C-6327 6 1/4 in 180
• All abrasive is silicone carbide 4C-6328 6.69 in-7.00 in 180
• Resilient, flexible, honing tool with soft cutting action 4C-6329 7 1/2 in 180
• Abrasive (points) globules each have independent suspension that assures 4C-6330 8 in 180
hone is self-centering, self-aligning to bore, and self-compensating for wear 4C-6331 9 1/2 in 180
• Low-temperature abrading process that exposes undisturbed base metal 180-3775 12 in 120
structure to produce long-wearing surface 4C-6332 2 3/8 in 240
• Method of developing surface on metal part which is optically smooth and 4C-6333 3 1/8 in 240
metallurgically free of any fragmented, amorphous, or smeared metal from 4C-6334 3 5/8 in 240
previous operations
1U-7428 4 in 240
• Accomplished at low pressure where “stones” float
4C-6335 4 1/8 in 240
• Hone crosshatch is extremely efficient in providing multiple of oil grooves
or valleys for oil retention as opposed to undirectional or uneven valleys 4C-6336 4 1/2 in 240
common to a conventional-type rigid hone 4C-6337 1/2 in 320
• After crosshatching, clean bore with cylinder washing brush 4C-6338 5/8 in 320
4C-6339 3/4 in 320
4C-6340 1 in 320
4C-6341 1 1/2 in 320
Cylinder Washing
Brushes
Part No. Size
4C-6342 3-1/2 in
4C-6343 4 in
1U-7429 4-1/2 in
1U-9788 5 in
ID: C27132T1
4C-6344 5-1/2 in
4C-6345 6 in
4C-6346 6-1/2 in
4C-6347 7 in
4C-6348 7-1/2 in
4C-6349 8 in
4C-6350 9-1/2 in
ID: C27131T1 135-7628 12 in

8S-2269 Ridge Reamer 6V-2194 Puller Plate

SMCS Code: 1214-010, 1225-011 SMCS Code: 1222-012
Model: 1100, 3100, 3204 Model: 1100, 3100, 3208, 3204

• Used to remove carbon buildup in cylinder bores • Used for installing 9N-6275 Cylinder Sleeves
• Service Part: 8S-7202 Cutter Bit, Qty. 1

Reference
ID: B19452-1T1 SMHS7638 Special Instruction
ID: T96838T1

3-28 Dealer Service Tools 2004 Home

Engine Tools Search Cylinder Block and Liners

129-9196 Puller Plate (lower)

129-9196
129-9197 Puller Plate (upper)
SMCS Code: 1222-012
Model: 3126 Engines

• Used to install 107-7604 Cylinder Sleeve in cylinder blocks with damaged cylinder walls 129-9197
• Used with 1P-0820 Hydraulic Puller Group, 6V-2183 Forcing Screw, 1P-2329 Insert, 1D-5119 Nut, 5H-1504 Washer, and hydraulic pump and hose
ID: C54977T1

Reference
SEBF8268, Installing a 107-7604 Cylinder Sleeve in 3126 Engines

9U-6008 Plate Puller

9U-6007 Plate Puller
SMCS Code: 1222-012, 0705
Model: 3114 and 3116

• Used to install 7C-6208 Cylinder Sleeve into the block

• Used with 1P-0820 Hydraulic Puller, 6V-2183 Forcing Screw, 1P-2329 Insert, 1D-5119 Nut,
5H-1504 Washer, and hydraulic pump and hose
ID: C54511T1

Reference
SEHS9047 Special Instruction, Installation of 7C-6208 Cylinder Sleeve

9U-6142 Puller Plate

SMCS Code: 1216-012, 0705
Model: 3064 and 3066 Engines

• Used to install cylinder sleeves (both mechanically and hydraulically)

• Used with 1P-0820 Hydraulic Puller Group, 1D-5119 Jam Nut, 5H-1504 Washer,
6V-2183 Forcing Screw, 1P-2392 Puller Plate, and a hydraulic pump

Reference
SENR5553 Disassembly and Assembly Manual, 3066 Diesel Engine

ID: C55197T1

4C-4377 Stress Plate Group

142-2285 Cylinder Head Stress Plate
lSMCS Code: 1223-049
Model: See below

• Used to hone cylinder bores (necessary tool to properly recondition cylinder bores)
• Allows each cylinder to be honed individually
• Must be installed on cylinder block to simulate assembled cylinder block during stress honing
and to measure finished bore dimensions
• Service Part: 200-5214 Spacer

Reference
Service Manual for 3114 and 3116 Engines ID: C78510T1
Part No. Description Model
SEHS9047 Special Instruction, 3114 and 3116 Engines
4C-4377 Stress Plate Group 3114, 3116
142-2285 Cylinder Head Stress Plate 3126B

Home Dealer Service Tools 2004 3-29

Cylinder Block and Liners Search Engine Tools

Cylinder Head Stress Plates

SMCS Code: 1223-049
Model: 3114, 3116, and 3126 Engines

• Used to properly recondition and measure cylinder bores

• Used with 8T-0362 Bolt and 8T-3282 Washer (fourteen of each required)
• Plate must be installed on cylinder block to simulate cylinder head being assembled onto block
• When plate is installed, cylinder bore is distorted as though cylinder head were installed
(plate provides adequate clearance for cylinder hone and measuring tools)
• If plate is not installed during honing, bore will not be round when cylinder head is assembled
onto block (this will reduce the life of the overhaul and could affect engine performance)
• Plate is hardened for added strength and durability
ID: C66725T1
Part No. Description Model
Overall size 789 x 215 x 50 mm (31.1 x 8.5 x 2.0 in)
125-2064 Cylinder Head Stress Plate 3126
Bore size (3126) 112 mm (4.4 in)
126-8132 Cylinder Head Stress Plate 3114/3116
Bore size (3114/3116) 107 mm (4.2 in)
Bolt specifications M20 x 2.5, 110 mm long

Tools for Reconditioning Cylinder Block Counterbores

SMCS Code: 1201-020
Model: Multiple Engine Models

Engine blocks which develop cracks in the cylinder liner counterbore area can be repaired. The repair consists of machining a new counterbore and installing a liner seat
insert. The insert is then machined to standard counterbore depth with the 5P-4175 Counterboring Tool.
The 5P-4175 Counterboring Tool along with the basic tools required for all engines are described below. Refer to the chart for additional tools and the inserts which must be
selected for individual engines.

Reference
SMHS7600 or SMHS7585 Special Instructions (use of 5P-4175 Counterboring Tool)
Other Special Instructions listed in chart
Basic Tools Required for All Engines
Item Part No. Description
1 5P-4175 Counterboring Tool Group
2 8H-3127 Bolt (Part of 5P-4175)
3 5P-1629 Drive Group (Part of 5P-4175)
5P-1628 Drive Assembly (Part of 5P-1629)
5P-1627 Sprocket Drive (Part of 5P-1629)
4B-9806 Setscrew (Part of 5P-1629)
4 5P-1631 Chain Assembly (Part of 5P-4175)
5 6V-2120 Sprocket (Part of 5P-4175)
6 5P-1657 Shaft
7 No longer available — use 9U-7896 Base and Micrometer Group
8 5P-1630 Drive Adapter
ID: A13947-1T1 9 5P-1656 Hook
10 5P-1769 Washer (four)
Additional Tools Required for Individual Engines (Refer to Chart for Part Numbers):
11 Installer Assembly Includes:
5F-9871 Nut
4M-6013 Washer
12 Depth Master Gauge
13 Cutter Assembly
14 Cutter Setting Gauge
15 Holder Group
6V-4985 Holder Plate (Part of Holder Group)
6V-4984 Screw (Part of Holder Group)
16 5P-1626 Setscrew (Part of Holder Group)
17 Mounting Bolts
18 Liner Seat Insert

3-30 Dealer Service Tools 2004 Home

Engine Tools Search Cylinder Block and Liners

Application Chart for Counterboring Tools

(18) (11) (12) (13) (14) (15) (17)
Liner Master Cutter Water
Engine Seat Depth Cutter Setting Holder Mounting Ferrule Water Special
Model Insert Installer Gauge Assembly Gauge Group Bolts Tools Ferrule Instruction
D353 D379 5P-0936 5P-1655 5P-1646 5P-1619 5P-1644 5P-1632 1D-4614 GMG02442-01
D398 D399
D353 D379 1W-6265 5,7 6V-0165 6V-0156 5P-8606 5P-8603 5P-1632 1D-4614 6V-4840 5N-8868 SMHS7221-01
D398 D399 1W-6266 5,3 6V-4983 6V-0157 5P-8604 6V-6021 5N-8869 SMHS7982|
1W-6267 5,4 6V-4986 5P-8605
4M-6013
5F-9871
D339 D342 5P-1625 5P-1654 5P-1647 5P-1619 5P-1643 5P-1633 1D-4614
D364 D375 9S-1354
D386 D397
D339 D342 5P-6595 5 6V-0164 6V-0156 5P-1619 5P-6593 5P-1633 1D-4614 6V-4840 1 5N-8869 1 SMHS7049-01
6V-4987 6V-0157 5P-6594 6V-6021 1 SMHS7982 1
6V-4983
4M-6013
5F-9871
5.4-90°V8 5P-0937 5P-1653 5P-1646 5P-1658 5P-1642 1D-4614 GMGO2442-01
D343 1693 5P-1624 5P-1653 5P-1646 5P-1658 5P-1641 1D-4614 GMGO2442-01
D337 5P-1623 5P-1652 5P-1647 5P-1658 5P-1640 5P-1636 2H-6488 GMGO2442-01
D330C D333C 5P-1622 5P-1651 5P-1648 5P-1659 5P-2409 5P-1637 1A-5405 GMGO2442-01
1673C 3304 1A-5405
3306
D315 D318 5P-1620 5P-1650 5P-1649 5P-1659 5P-1639 5P-1635 1A-5405 GMGO2442-01
D330 D333 5P-1621 5P-1650 5P-1648 5P-1659 5P-2409 5P-1638 8S-4740 GMGO2442-01
1670 1673
Spacer Plate Engines
D353 8N-6938 (.06 in) 6V-0118 (.06 in) 6V-2025 6V-2051 5P-1632 1D-4614 SMHS7600
8N-6939 (.12 in) 6V-0191 (.12 in)
D342 8N-6150 (.06 in) 6V-0118 (.06 in) 6V-2025 6V-2024 5P-1633 9S-1351 SMHS7585
8N-6742 (.12 in) 6V-0191 (.12 in)
D334 1674 6 5P-4174 5P-1651 5P-4176 5P-1659 5P-2409 5P-1637 1D-4588 GMGO2442-01
3304 3306
D343 1693 4 5P-4173 5P-1653 5P-4176 5P-1658 5P-1641 1D-4614 GMGO2442-01
D346 D348
D349
3400 Series 2W-3815 6V-0118 (.06 in) 6V-6191 6V-6189 7B-5163 SMHS8222
5N-0093 8T-0843 (.10 in)
3500 Series 7W-5949 6V-0191 6V-2025 8T-5113 8T-2682 1D-3419 SMHS7600
1 D342 only
2 D353

3 D353 Cylinders 1 and 4

4 Except 5S-9500 Block
5 Use in case of excessive counterbore cracking
6 Except 5S-6200 Block
7 D379-D398 and D399

Home Dealer Service Tools 2004 3-31

Cylinder Block and Liners Search Engine Tools

8S-3140 Counterboring Tool Group

SMCS Code: 1201-083, 1216-010
Model: Multiple Engine Models
Warranty: Manufacturer’s

• Used for resurfacing cylinder block counterbores on Caterpillar engines

equipped with cylinder liners (D25C, D8H, D8K, 3406B, 3408, 651E, 920);
counterbore is then shimmed to produce specified liner projection ID: A03012T1

• Adapter plates and holder groups as indicated in chart available

Part No. Description Quantity
separately for individual engines
Adapter Plate, Refer to chart column (1) 4
5P-3507 Case (Not shown)
Reference Holder Group, Refer to chart column (2) 9
FMO55228 Special Instruction
1P-5566 Basic Tool Group (Part of 8S-3140 Tool Group)
8S-3160 Driver Unit Group
8S-3180 Tool Bit Gauge Group
8S-3170 Depth Gauge Group
Tool Holder Service Parts 8S-3166 Extension
Item Part No. Description 8S-3165 Tool Bit 3
1 8S-3172 Spring 5P-8626 Carbide Tool Bit
(for counterboring 5P-8607 and 5P-6595 Liner Seat Inserts)
2 8S-3159 ScrewID: T96355T1
(two) (See note below)
8S-5577 Spacer, 12.7 mm (.50 in) 4
8S-5579 Spacer, 22.2 mm (.88 in) 4
NOTE: An additional 8S-3159 Screw is required
only for the 1P-5501, 1P-7399 and 5P-3018 Tool 8S-3168 Spacer, 44.4 mm (1.75 in) 4
Holders. 8S-5578 Spacer, 76.2 mm (3.00 in) 4
8S-7219 Spacer, 114.3 mm (4.50 in) 4

New New
Former Former Adapter Holder
Engine Adapter Holder Plate Group
Model Plate Group (1) (2)
D353, D379, D398, D399 8S-3174 8S-3175 5P-3016 8S-3175
D339, D342, D364,
D375, D386, D397 8S-3178 1 8S-3179 1 5P-3014 5P-3018 3
3400’s, D346, D348, D349 1P-7398 2 1P-7399 5P-3017 1P-7399
D343, 1693, 90°V-8
4 Cyl. (619C & 824A) 8S-3181 1P-7399 5P-3017 1P-7399
ID: C09344T1
D326, D337 8S-3176 8S-3177 5P-3016 8S-3177
8S-3160 Driver Unit Group Service Parts D330C, D333C, D334
Item Part No. Description Item Part No. Description 1673C, 1674, 3304, 3306 8S-3183 1P-5501 5P-3015 1P-5501
4 0L-1351 Bolt 12 8S-3147 Plunger D330, D333, 1670, 1673 8S-3185 8S-3186 5P-3015 8S-3186
5 8M-4069 Washer 13 2J-5245 Screw (four) D315, D318 5P-3014 1P-0761 5P-3014 1P-0761
6 2M-4287 Ring 14 9N-1773 Spring D311, D320 8S-3187 8S-3188 5P-3017 8S-3188
7 8S-3138 Housing 15 8S-3145 Retainer 1 Not adaptable to D364, D386 and D397
8 1B-8705 Key 16 8S-3146 Knob 2 Not adaptable to 3406
9 8S-4335 Shaft 17 8S-3164 Screw 3 The diameter of the 5P-3018 Holder is 178.77 ± 0.03 mm (7.038 ± .001 in).
10 2P-2348 Nut Assembly 18 01L509 Bolt
11 8S-3144 Handle NOTE: Counterbore diameter of 5.75 inch bore engines varies from 178.3 mm to
178.8 mm (7.021 in to 7.060 in). If the block counterbore is less than 179.3 mm
(7.039 in), it must be increased according to the procedure given in Special
Instruction FM055228.

ID: D00978T1

8S-3170 Depth Service Parts Gauge Group

ID: D00984T1 Item Part No. Description

8S-3180 Tool Bit Service Parts Gauge Group 22 8S-3158 Indicator
Item Part No. Description 23 4B-9806 Setscrew (two)
20 8S-3163 Spring 24 8S-3155 Collar
21 8S-3162 Pin 25 8S-3153 Shaft
8S-3157 Pin (two) (Part of 8S-3153)

3-32 Dealer Service Tools 2004 Home

Engine Tools Search Cylinder Block and Liners

9U-7988 Riser Plate Group

SMCS Code: 1201-023, 0672
Model: 3300 Engines with Spacer Plate

• Used during salvage operation of liner seats which are cracked or damaged
• Used with 9U-7990 Counterbore Tool Group, 9U-7989 Cutter Plate or 9U-7961 Cutter Plate, and 9U-7992 Cutter Bit
• Eliminates need to remove adjacent cylinder liners during rework procedure

Reference
NEHS0612 Tool Operating Manual
ID: C66697T1

9U-7990 Counterbore Tool Group

SMCS Code: 1201-020, 1201-023, 0672
Model: 3176, 3300 (with spacer plate), and 3406 (with spacer plate) Engines
Warranty: Manufacturer’s

• Used to machine engine block liner seats which are cracked or damaged Machining Dimensions for Cylinder Block Liner Seats
• Used with heavy duty electric drill (5/8 or 3/4 inch, 300 to 600 rpm, 8 amps Liner Inserts Bore Diameter Depth of Cut
or more), 9U-7988 Riser Plate Group (3300 Engine), 9U-7993 Depth Gauge Assembly ± 0.025 mm ± 0.013 mm
(± .001 in) (±.0005 in)
• A variety of insert thicknesses are available depending on depth of cut
3176 Engine
• Cutter plate is tapered — helps center counterbore tooling in cylinder bore
105-4203 145.85 (5.739) 0.772 (.0304)
• Each counterbore operation requires a specific cutter bit and cutter plate
(see chart for specific tooling and insert part number) 105-4204 145.85 (5.739) 0.822 (.0324)
- 3176 and 3300 Engines use 9U-7989 Cutter Plate and 9U-7992 Cutter Bit 105-4202 145.85 (5.739) 0.872 (.0343)
- 3406 Engines use 9U-7991 Cutter Plate and 6V-6191 Cutter Bit 104-7903 145.85 (5.739) 1.555 (.0612)
• Will not fit 3408 or 3412 Engines 104-7895 145.85 (5.739) 1.605 (.0632)
104-7904 145.85 (5.739) 1.655 (.0652)
104-7905 145.85 (5.739) 2.660 (.1047)
104-7896 145.85 (5.739) 2.710 (.1067)
104-7906 145.85 (5.739) 2.760 (.1087)
3300 Engine
104-5511 144.05 (5.668) 0.772 (.0304)
104-5512 144.05 (5.668) 0.822 (.0324)
104-5513 144.05 (5.668) 0.872 (.0343)
104-5515 144.05 (5.668) 1.555 (.0612)
104-5518 144.05 (5.668) 1.605 (.0632)
104-5522 144.05 (5.668) 1.655 (.0652)
104-5526 144.05 (5.668) 2.660 (.1047)
ID: C66699T1 104-5527 144.05 (5.668) 2.710 (.1067)
104-5528 144.05 (5.668) 2.760 (.1087)
104-5529 144.05 (5.668) 5.160 (.2031)
Typical Examples
104-5530 144.05 (5.668) 5.210 (.2051)
Item Part No. Description Model
104-5531 144.05 (5.668) 5.260 (.2071)
1 9U-7989 Cutter Plate 3176 and 3300 Engines
9U-7991 Cutter Plate 3406 Engines 5P-4174 147.32 (5.800) 5.210 (.2051)
2 9U-7992 Cutter Bit 3176 and 3300 Engines 3406 Engine
6V-6191 Cutter Bit 3406 Engines 6I-4361 166.05 (6.534) 0.772 (.0304)
9Y-3368 166.05 (6.534) 0.822 (.0324)
6I-4362 166.05 (6.534) 0.872 (.0343)
6I-4363 166.05 (6.534) 1.555 (.0612)
2W-3815 166.05 (6.534) 1.605 (.0634)
6I-4364 166.05 (6.534) 1.655 (.0652)
6I-4365 166.05 (6.534) 2.660 (.1047)
5N-0093 166.05 (6.534) 2.710 (.1067)
6I-4366 166.05 (6.534) 2.760 (.1087)
101-0524 166.05 (6.534) 5.160 (.2031)
101-0523 166.05 (6.534) 5.210 (.2051)
101-0525 166.05 (6.534) 5.260 (.2071)
5P-4173 169.29 (6.665) 5.080 (.2000)
108-1068 169.33 (6.666) 3.302 (.1300)

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Cylinder Block and Liners Search Engine Tools

Item Part No. Description

1 9U-7985 Basic Counterbore Tool Group
(metal case included, but not shown)
(part of 1U-6220 Counterbore Group)
2 9U-7986 Base and Micrometer Group (case included, but not shown)
(part of 1U-6220 Counterbore Group)
3 9U-7987 Master Gauge (part of 1U-6220 Counterbore Group)
4 5P-1656 Tool Remover Hook
5 9U-7984 Depth Set Collar
6 1U-7575 Allen Wrench, 1/8 in
1U-7576 Allen Wrench, 5/32 in
1U-7577 Allen Wrench, 3/16 in
7 8T-0207 Bolt M16 x 2 x 100 mm long (3 required)
8 5P-8247 Washer, 5/8 in (3 required)
ID: C66700T1 9 0S-1569 Bolt, 5/8-11 x 4 in long (3 required)
10 5P-1630 Drive Adapter
11 9U-7983 Offset Washer (3 required)
Repair and Service 12 5P-8248 Washer, 3/4 in (3 required)
Kent-Moore Phone: (800) 328-6657 (USA, Canada)
SPX Corporation Telex: 244040 KMTR UR 13 0L-1328 Bolt, 3/4-16 x 4 in long (3 required)
29784 Little Mack Fax: (313) 578-7375
Roseville, MI 48066-2298
Reference
NEHS0612 Tool Operating Manual

159-9404 Counterbore Tool Group

SMCS Code: 1000-064, 0705
Model: C-10 and C-12 Engines Item Part No. Description
1 159-9393 Basic Machine
2 159-9397 T Handle
• Used to machine cylinder bore liner seat ledge with special backcut seat design 3 159-9401 Spacer Block
• Used with 170-6555 Stylus Extension (100 mm) to measure 4 159-9402 Cutter Plate
counterbore depth (not included in group, but requires 2
5 159-9403 Cutter Bit
9U-7993 Depth Gauge and 8T-0455 Liner
11 6 170-6555 Stylus Extension 100 mm
Projection Indicator Group
7 5P-8247 5/8 Washer (Qty 4)
• Hand operated, easy to use
10 5 8 8T-0358 Bolt, M16 (Qty 4)
• Four shim thicknesses are available
to raise liner back to its original height 9 159-9395 Square Washer (Qty 4)
(can be stacked to achieve necessary 6 10 159-9400 Cutter Plate Wrench
projection) 1 11 159-9398 Hex Key
Not shown
3
168-7363 Shim 0.22 mm (.009 in)
Reference 168-7364 Shim 0.25 mm (.010 in)
NEHS0733 Tool Operating Manual, 7 9
168-7365 Shim 0.28 mm (.011 in)
159-9404 Counterbore Tool Group For
168-7366 Shim 0.50 mm (.020 in)
C-10 and C-12 Engines
159-9396 Carrying Case
SENR6593 Testing and Adjusting 4
C-10/C-12 Truck Engines

ID: C79628T1

9U-7993 Depth Gauge Assembly

SMCS Code: 1201-082, 0760
Model: 3300, 3400, and 3176 Engines

• Used to measure actual depth of liner seat counterbore — used during rework
procedure of 3176, 3300, and 3400 Engine cylinder blocks
• Used with 9U-7990 Counterbore Tool Group
• Counterbore tool does not have to be removed to measure depth of counterbore —
saves time and ensures greater accuracy over conventional means of measuring

Reference ID: C66698T1

NEHS0612 Tool Operating Manual

3-34 Dealer Service Tools 2004 Home

Engine Tools Search Cylinder Block and Liners

1P-4000 Line Boring Tool Group Centering Ring Centering Ring

SMCS Code: 1224-005, 7206-005 (2 Required) (2 Required)
Model: Multiple Engine Models Engine Bore Size Standard Oversize
4.75 in 1P-2345 6V-0137
4.50 in (1100, 3100, 3200) 1P-2344 6V-0138
• Used with the appropriate centering rings to precision bore semi-finished service 5.75 in 1P-2346 6V-0139
main bearing caps
4.50 in V8 5.40 in — 6 cyl. 1P-2347 6V-0140
• Hydraulically operated feed mechanism and power drive with a 1/2 inch drill
6.25 in — 6 cyl. 1P-2348 6V-0141
5.40 in — 3400 Series 5P-2381 6V-0142
Reference 5.40 in — 90° V8 1P-2349 6V-0143
SEBF4500 Engine and Component Reconditioning Guide 5.40 in — 60° V-Engines 1P-2350 6V-0144
SMHS7606 Special Instruction 6.25 in V-Engines 1P-2351 6V-0145
6.70 in 3500 Engine 6V-7836 4C-8564

ID: C05377T1

Item Part No. Description Quantity 17 1P-2383 Bridge Extension (L.H.) 2

1 1P-2373 Upright Bearing Assembly 2 18 1P-2360 Wrench, 3/16 in

each consisting of: 1P-2359 Wrench, 5/32 in
7M-5130 Pin 19 1P-2354 Tool Bit, 5/8 in 2
1P-2374 Oiler 1P-2355 Tool Bit, 7/8 in 2
1L-0509 Bolt 1P-2356 Tool Bit, 1 1/4 in 2
2 0S-1571 Bolt 5 1P-2357 Tool Bit, 1 1/2 in 2
1P-2358 Tool Bit, 2 in 2
3 0S-1587 Bolt 5
20 1P-2362 Holder Assembly, Larger
4. 5P-1630 Swivel Joint Universal 1P-2372 Screw
3K-4897 Pin 8H-3127 Bolt 2
5 1P-2364 Adapter — Line Bore 21 4B-9820 Hex Wrench, 1/8 in
6 1P-2352 Bar Assembly, 31 in Long 1D-5343 Hex Wrench, 1/8 in
1K-6976 Setscrew 2 1D-5343 Hex Wrench, 5/16 in
1P-2361 Hex Wrench, 3/8 in
7 5P-2981 Feed Assembly
22 1P-2366 Holder Assembly, Small
8 5M-5693 Washer 5
1P-2372 Screw
9 2S-6160 Washer 5 2H-0191 Bolt 2
10 1P-2353 Bar Assembly, 66 in Long 23 1P-2384 Bridge Extension (R.H.) 2
1K-6976 Setscrew 2
24 1P-2369 Torsion Bar Assembly
11 4D-0670 Washer 5 1P-2368 Bar
12 1B-9575 Bolt 5 5S-7003 Screw
1P-2367 Bracket
13 1B-4331 Nut 4
25 1P-2343 Bridge Assembly 2
14 4B-4283 Washer 8 2L-0041 Bolt
15 9S-8521 Rod 26 1D-4615 Bolt 4
16 1P-2370 Micrometer Bracket Assembly 27 4B-4281 Washer
6V-2122 Holder
3L-2540 Screw 28 0S-1589 Bolt
1P-2371 Micrometer Not shown Box Assembly
8H-3127 Screw
Not shown Instructions Form SMHS7606

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Cylinder Block and Liners Search Engine Tools

Tools for Repairing Cylinder Liner Lower Bores in the Cylinder Block
SMCS Code: 1223-005
Model: Multiple Engine Models

• Cylinder liner lower bores in cylinder block sometimes are damaged by erosion or pitting; blocks can be salvaged by installing sleeve in lower bore
• In bores with large gouges or severe erosion, voids can be filled with liquid metal before sleeve is installed
• Instructions are furnished; chart lists additional tools required

Engine Cylinder Adapter Chamfer Cutter Length Bushing

Block Group1 Cutter Cutter mm (inch) Sleeve
D315: 4.5 in PT-3100-001 PT-3100-009 PT-3100-006 42,9 (1.69) PT-8300
D330: 4.5 in PT-3100-001 PT-3100-009 PT-3100-006 42,9 (1.69) PT-8305
D330: 4.75 in PT-3100-002 PT-3100-009 PT-3100-006 42,9 (1.69) PT-8310
D330: 5.4 in PT-3100-003 PT-3100-010 PT-3100-007 50,8 (2.0) PT-8315
3400 Series: 5.4 in PT-3100-003 PT-3100-010 PT-3100-007 50,8 (2.0) PT-8320
3400 Series: 5.75 in PT-3100-004 PT-3100-011 PT-3100-0081 60,5 (2.38) PT-8325
6 Cyl: 6.25 in PT-3100-005 PT-3100-011 PT-2100-008 60,5 (2.38) PT-8330
V-Eng: 6.25 in PT-3100-005 PT-3100-011 PT-3100-008 60,5 (2.38) PT-8335
1 AdapterGroups consist of guide plate, drive plate, alignment ring, chamfering gauge, cutters (two), and chamfer cutters
(two). The bushings (sleeves) must be ordered separately.

5P-6512 Valve Lifter Guide Bore Sleeving Tool Group

SMCS Code: 1112-005
Model: Multiple Engine Models Item Part No. Description
1 4B-9820 Wrench
7B-7640 Wrench
• Used to restore damaged valve lifter guide bores 6B-7225 Wrench
in cylinder blocks on D342, D339 2 8L-2779 Seal
• Valve lifter guide bore quickly restored in the shop 3 5P-6511 Carbide Cutter
by reboring block and installing finished 5P-6513 Sleeve
4 5M-2894 Washer
5 0S-1588 Bolt
6 4D-3704 Washer
Reference
SMHS6982 Special Instruction
SEBF8029 Index for Salvage Parts, 3400 Family Engines bores ID: A32598-1T1

SEBF8069 Guideline for Reuseable Parts, procedure using jig mill

6V-7840 Deck Checking Tool Assembly

SMCS Code: 1216-082
Model: 518

• Provides very accurate measurements, which are Service Parts

compared to block specifications, to determine how much Part No. Description
of top surface of cylinder block has been machined (When 4B-9820 Wrench
an engine is reconditioned, it is important to know if top 7B-7640 Wrench
deck has been previously machined.)
6B-7225 Wrench

Reference
ID: B67342-1T1
SEHS8187 Special Instruction

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Engine Tools Search Cylinder Block and Liners

5P-8665 Cylinder Liner Puller

Item Part No. Description Quantity
SMCS Code: 1216-011
Model: Multiple Engine Models 1 5P-8672 Arm Assembly 2
2 5P-8666 Pin 2
3 5P-8667 Bushing
• Utilizes an impact wrench for fast removal of cylinder liners 4 131-6119 Plate Assembly, Top
• Pulls all liners, most in seconds 5 5P-8669 Bearing Assembly
• Easy to install and remove 6 5P-8668 Bolt
• 6V-4133 Wedge Bracket available separately to be 7 5P-8671 Foot 2
used with 5P-8665 Puller; always use 6V-4133 8 6V-4133 Wedge Bracket (see information above)
when removing liners from 3500 Family Engines;
9 2D-4534 Screw 2
it may be used to remove liners in horizontal position
from 5.75 inch bore and 6.25 inch bore engines; 10 8T-5103 Arm Assembly 2
wedge keeps puller feet rigidly positioned under 11 131-6118 Lifting Bar
edge of liner 12 8T-5104 Spring (Part of Item 4) 2
• 1/2 inch impact wrench adequate for job 13 8T-5105 Plunger (Part of Item 4) 2
• Applicable to all Caterpillar cylinder liners
and any other liner up to:
Diameter: 178 (7.0 in)
Length: 457 (18.0 in)

ID: A59086-1T1

5P-3570 Cylinder Liner Puller Group

Item Part No. Description
Discontinued — Service Parts Available A 5P-3570 Cylinder Liner Puller Group, Discontinued
• Discontinued and replaced by 5P-8665 Cylinder Liner Puller Includes the following Service Parts
1 5P-3571 Cam and Rod Group
2 0S-1621 Bolt (two)
1J-8499 Washer (two)
3 4B-4283 Washer (two)
4 5M-6186 Spring
5 8F-6462 Washer
6. 1P-2388 Nut
7 4B-9806 Screw
B Puller Plates
1P-2392 Puller Plate, 4 inch Bore
1P-2393 Puller Plate, 4.5 inch Bore
1P-2394 Puller Plate, 4.75 inch Bore
ID: C09307T1 1P-2395 Puller Plate, 5.125 inch Bore
1P-2396 Puller Plate, 5.4 inch Bore
1P-2397 Puller Plate, 5.75 inch Bore
Reference 1P-2398 Puller Plate, 6.25 inch Bore
GEG00631 Special Instructions C 1P-2391 Cylinder Liner Remover—5.4 inch Bore Engines Only
Includes the following Service Parts
8 2P-2347 Adapter Assembly
9 1P-2389 Screw (two)

7F-1857 Liner Puller Service Parts

Discontinued — Service Parts Available Item Part No. Description
• Discontinued and replaced by 5P-8665 Cylinder Puller liner 1 1B-4333 Nut
2 015599 Bearing
3 7F-1860 Handle
4 5F-7347 Head
5 5F-7353 Washer
6 1A-1460 Bolt (three)
7 4B-4280 Washer (three)
8 5F-7350 Block (three)
9 1B-4330 Nut
10 0S-1579 Bolt
11 5F-7349 Swivel
12 1B-4331 Nut

ID: D00936T1
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Cylinder Block and Liners Search Engine Tools

Adapter Plates for 7F-1857 Puller

SMCS Code: 1216-011 Cylinder Liner Removal — Adapter Plate Selection Cylinder Liner Removal — Adapter Plate Selection
Model: Multiple Engine Models
Engine Adapter Plate Adapter Plate Engine Adapter Plate Adapter Plate
Bore Part No. Part No. Bore Part No. Part No.
mm (inch) Current Former mm (inch) Current Former
• The hydraulic puller and the different size adapter plates 95.3 (3.75) 5F-7359 130.1 (5.12) 1P-2395 9F-9904
are not included in discontinued 7F-1857 Cylinder Liner
101.6 (4.00) 1P-2392 5F-7360 133.4 (5.25) 5F-7363
Puller Assembly. The adapter plates are ordered
separately as required. 108.0 (4.25) 5P-7361 137.2 (5.40) 1P-2396 7M-4321
114.3 (4.50) 1P-2393 5P-7362 146.1 (5.75) 1P-2397 5F-7364
120.7 (4.75) 1P-2394 8S-3611 158.8 (6.25) 1P-2398 6H-4141

8T-0455 Liner Projection Tool Group

SMCS Code: 1216-010, 1216-012, 1216-082, 1201-083
Model: Multiple Engine Models
Item Part No. Description
1 6V-6045 Case
• Provides easy, accurate way to determine 8T-0453 Block
cylinder liner projection and counterbore 2 2P-5486 Gauge Block
depth
3 1P-2402 Gauge Body
4 1P-5507 Gauge
5 1P-2403 Dial Indicator
1P-5512 Contact Point (Part of 1P-2403)
6 1P-5513 Contact Point
7 5S-2671 Bolt

Reference
SMHS7727 Special Instruction

ID: 76008-2T1

2P-8260 Cylinder Liner Installer Group

SMCS Code: 1216-010, 1216-012, 1216-082, 3159-016, 3159-017, 3159-081, 3159-082, 3256-016, 3256-017
Model: Multiple Engine Models
Item Part No. Description
1 3H-8538 Pin
• Used to install cylinder liners 2 3B-4615 Cotter Pin
• Attaches to head bolt or stud, whichever is used, and 3 2P-8258 Rod
applies firm, steady pressure, making damage to liner 4 2P-8257 Plate
seals less likely
ID: 57160-1T1

Cylinder Pack Pullers Cylinder Pack Pullers

SMCS Code: Engine
Model: See Chart 3300 3176 3400 6.25 3500
Puller 8T-0812 1U-9593 6V-9448 1, 2 8T-0811 8T-2686
Bridge — 1U-9897 1U-6317 5F-7347 FT1970
• Used to pull liner, piston and connecting rod, as an assembly, from engines
Socket 1U-6319 1U-6319 1U-6319 1U-6319 1U-6319
• Very useful when used for in-frame overhauls because it eliminates need
for ridge reaming and dirt generated
by reaming Repair Parts
• Each puller should be used with Full Nut 2J-3506 2J-3506 2J-3506 2J-3506 2J-3506
appropriate bridge (see chart) and Hard Washer 5H-1504 5H-1504 5H-1504 5H-1504 5H-1504
1U-6319 Socket which has an
Plate 4C-8738 1U-9596 4C-87343 4C-8747 4C-8751
extended body to cover length of
threaded rod and can be used with Threaded Stud 1U-9597 1U-9597 1U-9597 1U-9597 1U-9597
impact wrench Rubber Cup 4C-8736 1U-9594 4C-8741 4C-8745 4C-8749
Segment Group 4C-8739 1U-9598 4C-8744 4C-8748 4C-8752
Reference Base Cone 1U-9825 1U-9825 1U-9825 1U-9825 1U-9825
SEHS8554 Special Instruction Base Plate 4C-8737 1U-9595 4C-8742 4C-8746 4C-8750
1 6V-9448 also used for 5.5 inch engine bore size
2 Early
6V-9448 Cylinder Pack Pullers have fine thread studs. The only service parts for
ID: C27130T1
these pullers are:
1B-4207 Full Nut
5H-1504 Hard Washer
3-38 Dealer Service Tools 2004 Threaded Stud made from 6V-4832
Home
Engine Tools Search Cylinder Block and Liners

129-6675 Cylinder Pack Puller Group

SMCS Code: 1200-011
Model: C-12 Engines

Part No. Description

• Used to remove and install cylinder liner, piston, and connecting rod as an
129-6676 Rubber Cup
assembly (cylinder pack) — can also be used to remove and install liner only
129- 6677 Plate
• Used with 1U-9897 Bridge Group
129-6678 Mandrel Segment Group (not visible)
• Impact wrench can be used with 1U-6319 Socket and 129-6675 Puller Group
9U-6630 Base Cone
• Puller is very useful when used for in-frame overhauls (eliminates need for
ridge reaming and resulting debris) 1U-9597 Stud
2J-3506 Nut
ID: C27130T1 5H-1504 Washer
Reference
SENR1007 Service Manual Module: Disassembly and Assembly

Cylinder Liner Puller Plates and Leg

SMCS Code: 1216-010, 0705
Model: 3054 and 3056 Engines

• Used to remove and install cylinder liners Part No. Description Use
• 9U-6234 Puller Plate used to remove liners, 9U-6235 to install liners 9U-6234 Puller Plate remove liners
• Legs used between puller plates and additional tooling (three required) 9U-6235 Puller Plate install liners
• Liners manually or hydraulically removed (see additional tooling list)
Part No. Description
Additional tooling for hydraulic operation
1D-5119 Jam Nut
1P-2329 Insert
6V-2184 Forcing Screw Extension
9S-7346 Cylinder Assembly
1A-1460 Bolt1, 1/2-13 x 2 inch (3 required)
1U-9895 Cross Block1
5F-7347 Head1
5H-1504 Washer1
5P-8245 Washer1 (3 required)
ID: C54941T1
6V-2183 Forcing Screw1
9U-6281 Leg Additional tooling for manual operation
Overall length 330 mm (13.0 in) 2J-3507 Nut (1-8 thread)
Internal thread (one end) 1/2-13 8H-0684 Ratchet
1 These parts are used for both hydraulic and manual operation.

ID: C54943T1

ID: C54942T1

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Cylinder Block and Liners Search Engine Tools

5P-8709 Piston Cooling Jet Alignment Tool Group

SMCS Code: 1307-010, 1307-012
Model: Older Caterpillar Engines including D353, D377, D398, D899, G379, and G399 only

• Used to check the direction of cooling jet spray — used for 5S-1765, 4N-8986, 2N-4541, 4N-9881,
and 5L-4262 Piston Cooling Jets only
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Group has been updated to eliminate non-current bench tooling
• Tooling is required for off-engine testing of piston cooling jets for the engines listed above only
• Parts are serviced separately to reduce dealer cost (no need to purchase tools already in inventory)

Reference
SEHS8200 FIETS Manual and SMHS7267 Use of 5P-8709 Tool Group
ID: A68199-1T1

Item Part No. Description Quantity Where Used

1 5P-8596 Screen 1 used with all benches (FITB, FIETS, and AVM)
2 5P-8597 Spray Shield 1 used with FITB, FIETS, and AVM
3 5P-8598 Target 1 used with FITB, FIETS, and AVM
4 5P-8599 Fixture Assembly 1 used with FITB, FIETS, and AVM
5 5P-8600 Oil Return Pan 1 used with FITB bench only (Kent Moore)
6 5P-8612 Cooling Jet Adjustment Wrench 1
7 5P-8613 Cooling Jet Adjustment Wrench 1

Additional Required Hardware

The following list of hardware is required, but not included as part of the 5P-8709 Piston Cooling Jet Alignment Tool Group. This tooling can be purchased as needed.

Part No. Description Quantity Where Used

Required Hardware (not included in group)
6V-9132 Fixture Assembly 1 target/fixture assembly to bench rails
6V-9134 Screw Assembly 1 fixture assembly to clamp
6V-9138 Clamp Assembly 1 fixture assembly to rail system
0L-1138 Bolt 4 target to 6V-9132
0S-1588 Bolt 2 5P-8599 to 6V-9132
7G-7105 Hose Assembly 1 oil supply #6 (37 degree) x 965.2 mm (38.00 in) long
032-1267 Connector 1 oil supply #6 (37 degree) to 1/4-18 NPTF (external)
032-1268 Elbow, 90 degree 1 oil supply #6 (37 degree) to 1/4-18 NPTF (external)
Service Parts for 5P-8599 Fixture Assembly
3B-7614 Bolt 2
1L-8793 Bolt 1
4D-3120 Bolt 1
7S-6701 Bolt 1
8H-9208 Dowel 8

1U-9593 Cylinder Pack Puller

1U-9897 Bridge Group
1U-6319 Socket
SMCS Code: 1200-011
Model: 3176

• 1U-9593 Cylinder Pack Puller used with 1U-9897 Bridge Group to remove cylinder packs
or liner only
• 1U-6319 Socket used with 1U-9593 Cylinder Pack Puller;
allows use of impact wrench ID: C27130T1

Reference
SENR3910, 3176 Service Manual ID: C27129T1

SEHS9120 Special Instruction, operation

ID: C27128T1

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Engine Tools Search Cylinder Block and Liners

6V-7772 Driver
SMCS Code: 1307-010, 1307-012
Model: 3200

• Used to install piston cooling orifices

ID: B19813T1

6V-4840 Water Ferrule Tool Group

6V-4841 Fixture Assembly
6V-6021 Fixture Assembly
SMCS Code: 1201-005
Model: 6.25 inch Bore Engines

• Required to locate, drill and ream holes in cylinder block for ferrules
(When installing 1W-6265 Insert, 1W-6266 Insert and 1W-6267 Insert ID: B39420T1
in counterbored 6.25 inch Bore Engines, it is also necessary to install Item Part No. Description
larger 5N-8868 Water Ferrule and 5N-8869 Water Ferrule to prevent
1 6V-4842 Drill, 11,90 Dia (0.469 inch Dia)
coolant leakage.) 6V-4845 Drill, 18,26 Dia (0.719 inch Dia)
• 6V-4841 Fixture Assembly used on 6.25 inch Bore, Vee Engines D379, 2 6V-4846 Reamer, 12,19 Dia (0.480 inch Dia)
D398, D399; 6V-6021 Fixture Assembly used on 6.25 inch Bore, D353 6- 6V-4847 Reamer, 13,49 Dia (0.531 inch Dia)
Cylinder Engines 6V-4848 Reamer, 18,72 Dia (0.737 inch Dia)
6V-4849 Reamer, 19,84 Dia (0.781 inch Dia)
3 6V-4853 Bushing, 11,92 Dia (0.468 inch Dia)
6V-4854 Bushing, 12,19 Dia (0.480 inch Dia)
6V-4855 Bushing, 13,49 Dia (0.531 inch Dia)
6V-4856 Bushing, 18,26 Dia (0.719 inch Dia)|
6V-4866 Bushing, 18,72 Dia (0.737 inch Dia)
6V-4851 Bushing, 19,84 Dia (0.781 inch Dia)
4 1D-4610 Bolt (two)
5 5P-8248 Washer (two)
6 6V-4859 Case, discontinued and replaced by 6V-3072
6V-4861 Block
6V-6044 Block

ID: B39432T1
Reference
SMHS7982 Special Instruction
Item Part No. Description Quantity
1 6V-4841 Fixture Assembly, 6.25 inch Bore
5P-7330 Screw (Part of 6V-4841) 4
6V-4857 Screw (Part of 6V-4841) 8
2 6V-6021 Fixture Assembly, 5.75 inch Bore
5P-7330 Screw (Part of 6V-6021) 6
6V-4857 Screw (Part of 6V-6021) 12

4C-9645 Bottoming Tap

SMCS Code: 1201-026, 0671
Model: 3176 Engine

ID: C27050T1
• Used to recondition head bolt threads of cylinder block
• High speed, 4 flutes Size M16 x 2 x 203 mm long
• Not commonly available outside Caterpillar’s distribution system Diameter limit D6 pitch

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Cylinder Block and Liners Search Engine Tools

Drivers
SMCS Code: 1307-012
Model: 3200

• Used for installing piston cooling orifices and plugs

Item Part No. Description Model Use ID: B64033T1

1 6V-7772 Driver 3204 and 3208 Spring pin in end of driver helps hold orifice on tool until it is driven into place.
2 6D-3039 Pin
3 6V-7771 Driver 3208 Install piston cooling jet plugs

5P-0944 Dowel Puller Group

SMCS Code: 1100-010, 1102-017, 1121-011, 1202-010, 1253-017, 1202-011
Item Part No. Description
Model: 1674, D334, 3400
1 5P-0941 Extractor, 9,53mm (.375 inch)
Optional tools, not included in 5P-0944 (for 5/8 inch and 3/4 inch,
see 1U-9570; 5P-0944 and 1U-9570 parts not interchangeable):
• Used to pull .375 inch dowels
5P-0938 Extractor, 4,78 mm (.188 inch)
• Reduces time it takes for pulling the dowels and makes job much easier
5P-0939 Extractor, 6,25 mm (.250 inch)
5P-0940 Extractor, 7,92 mm (.312 inch)
5P-0942 Extractor, 11,13 mm (.438 inch)
5P-0943 Extractor, 12,70 mm (.500 inch)
PT9750 Collar (two), Porta-Tool
Slide Hammer
Shaft
Retriever

ID: 76698T1

6V-7912 Bearing Driver

SMCS Code: 1304-010, 1304-012
Model: 1100, 3100, 3200

• Used to install oil pump bearing in front cover

• Replaces discontinued 8S-2285 Driver
• Provides more depth clearance for center dowel pin than 8S-2285
ID: B85441T1

Thread Repair Tools

SMCS Code: 1221-023
Model: 3176 Engines

• Used to repair M8 x 1.25 threaded holes in aluminum 6I-4126 Spacer Deck

• Repairs stripped or damaged threads that are normally beyond range of oversized or standard inserts
• Restores original thread size, allowing original type and size fastener to be used (M8 x 1.25)
• Use 135-7631 and 135-7636 for 12.0 mm and 15.0 mm (.47 and .59 in) depth holes
• Use 140-9740 and 140-9745 on 16.0 mm (.62 in) depth holes
• All parts can be ordered separately
Part No. Description Nominal Thread
ID: Length
C54996T1
135-7631 Twinsert 12.0 mm (.47 in)
135-7636 Twinsert 12.0 mm (.47 in)
140-9740 Twinsert 16.0 mm (.62 in)
140-9745 Twinsert 16.0 mm (.62 in)
135-7637 Installation Tool
135-7638 Tang Breakoff Tool
135-7639 Special Tap

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Engine Tools Search Cylinder Block and Liners

198-9113 Seal Installer

SMCS Code: 1203-012
Model: 3034 Engine
Essential Tool

• Used to install rubber seal in front and rear main bearing cap
• Reduces risk of damage to seal's metal core

Reference
3034 Engine Service Manual
Overall length 165 mm (6.5 in)
Large end diameter 50.8 mm (2.00 in)
Small end diameter 25.4 mm (1.00 in)

ID: C80107T1

5P-8595 Honing Tool Group

SMCS Code: 1216-005
Model: 6.25 inch Bore, 6-Cylinder Diesel Engines

• Used to recondition cylinder liners on 6.25 inch bore, 6-cylinder diesel engines
(D398, D379, D399, D353)
• When later pistons with Keystone rings are installed in earlier engines, honing
operation necessary to remove liner wear ridge and produce smooth surface
• FT1371 Holding Fixture holds cylinder liners when honing; provides cradle
for 3/4 inch (375 RPM) drill

ID: A54461-1T1

Service Parts
Part No. Description
5P-8592 Stone, 4.5 inch-7.2 inch Dia (70 Grit)
5P-8593 Stone, 4.5 inch-7.2 inch Dia (600 Grit)
5P-8591 Holder
6V-7853 Stone (4.0 inch-5.6 inch Dia) (70 Grit)

Reference
SMHS7220 Special Instruction

ID: A54466T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

Cylinder Head, Valves and Cam Followers

Thread Insert Installation Tools

SMCS Code: 0676
Model: All Engines Models

• Installation of thread inserts provides relatively easy, inexpensive method of reconditioning

cylinder heads in which precombustion chamber threads have been damaged

Reference
SMHS7697 Special Instruction ID: C05386T1

Engine (1) (2) (3) (4) (5) (6) (7) (8)

Bore Size Drill Thread Tap Drill Pre- Sleeve
mm (inch) Size Size Tap Pilot Guide Winder Assembly Insert Nib
95,25 (3.75) 1.0 in 8F-5576 4H-0119 1 8F-5574 8F-5567 9F-7146 9F-7143 8F-5573 9F-7145
101,6 (4.0) 1.0 in 8F-5576 4H-0119 1 8F-5567 9F-7146 9F-7143 8F-5573 9F-7145
107,95(4.25) 1 1/8 in 8F-5577 4H-0119 1 8F-5575 8F-5568 9F-7148 9F-7143 8F-5574 9F-7147
114,3(4.5) 1 1/8 in 8F-5577 4H-0119 1 8F-5565 8F-5568 9F-7148 9F-7143 8F-5574 9F-7147
101,6 (4.0) 51/64 in 3/4 in-12 8M-8290 9M-1513 9M-1512 8M-8289 9F-7143 8M-8292 8M-8291
114.30 (4.50) 51/74 in 3/4 in-12 8M-8290 9M-1513 9M-1512 8M-8289 9F-7143 8M-8292 8M-8291
114.3 (4.50) 28/32 in 7/8 in-12 9M-6595 8S-6027 8S-6026 9M-6594 9F-7143 9M-6593 9M-6596
114.3 (4.50) 28/32 in 9M-6595 8S-6029 8S-6028 8S-6033 8S-6034 8S-6400 8S-6032
V8
120,65 (4.75) 28/32 in 7/8 in-12 9M-6595 8S-6029 8S-6028 8S-6033 8S-6034 8S-6400 8S-6032
4 Valve
120,65 (4.75) 28/32 in 7/8 in-12 9M-6595 8S-6029 8S-6028 8S-6033 8S-6034 8S-6400 8S-6032
2 Valve
130,75 (5.12) 1 1/8 in 8F-5577 5H-8148 8F-5565 8F-5568 9F-7148 9F-7143 5H-8146 5H-8147
130,75 (5.12) 1.0 in 8F-5576 4H-0119 1 8F-5564 8F-5567 9F-7146 9F-7143 8F-5573 9F-7145
Series F
137,31 (5.4) 29/32 in 7/8 in-12 9M-6595 9M-6591 9M-6592 9M-6594 9F-7143 9M-6593 9M-6596
D343, 1693
90° V8
137,31 (5.4) 29/32 in 7/8 in-12 9M-6595 5P-2417 5P-2418 9M-6594 9F-7143 8S-6400 9M-6596
3400 Series
137,31 (5.4) 29/32 in 7/8 in-12 9M-6595 7S-8739 7S-8740 9M-6594 9F-7143 9M-6593 9M-6596
60° V8,V12,V16
146,05 (5.75) 1 1/4 in 1 1/4 in-12 8F-5578 8F-5566 8F-5569 9F-7150 9F-7143 8F-5575 9F-7149
146,05 (5.75) 1 1/8 in 1 1/8 in-12 8F-5577 1P-3571 8F-5565 8F-5568 9F-7148 9F-7143 5H-8146 5H-8147
158,75 (6.25) 1.0 in 1 in-12 8F-5576 8S-6031 8S-6030 9F-7146 9F-7143 8S-6402 9F-7145
1 4H-0119 Pilot is required to locate drill guide and tap guide in later cylinder heads using the larger retainers

Special Length Heli-Coil Inserts

Thread Size Insert P/N Tap P/N Installation
and Length Cat Cat Tool P/N Cat
5/8-11 x 1.250 6V-9076 4C-9686 6V-9083
3/4-16 x 1.500 6V-9074 4C-9702 6V-9082
M8-1.25 x 16 mm 9U-5177 4C-8475 8T-2790
M16-2 x 32 mm 9U-5604 4C-9732 8T-2799

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Valve Guide Drivers and Bushings

SMCS Code: 1104-010
Valve Guide Drivers and Bushings
Model: All Caterpillar Diesel Engines, except 1100, 3100, 3208
Bore Engine and Driver Bushing
mm (inch) Engine Application Part No Part No
114 (4.5) D315, D318 4H-0445
• Piloted drivers used to remove and install valve guides
130 (5.125) D326, D337 4H-0446
• Most valve guides have flange that prevents driving them past correct depth;
guides without flange require a bushing to ensure proper depth 146 (5.75) D342 4H-0446 5P-1727
146 (5.75) D339, D364, D375, D386, D397 4H446
159 (6.25) D353, D379, D398, D399 4H-0446 5P-1726
114 (4.5) D330, 1670, D333, 1673 4H-0447
137 (5.4) 4 Cyl, D343, G343, 1693, V-8 90° 7M-3975 5P-1728
137 (5.4) 3406, 3408, 3412 — 5P-2396
137 (5.4) D346, D348, D349 7M-3975 5P-1729
with 9,53 (.375) Grooved Guides
114 (4.5) 1676 7S-5919 7S-8457
121 (4.75) D334, 1674 7S-5919 7S-8457
121 (4.75) D330C, 3304, D333C, 3306 — 7S-8858

ID: T96693T1

124-9057 Guide Collar (Swirl)

SMCS Code: 1104-010
Model: 3406C Engines with Swirl Inlet Valve Seats/Inserts
Item Part No. Description
1 121-4317 Valve Guide
• Used to quickly and accurately install 121-4317 Valve Guide to proper 2 124-9057 Guide Collar
installation height 3 9U-6895 Driver (3).
• Used with 9U-6895 Valve Guide Driver
• Install valve guide into guide collar, install 9U-6895 Valve Guide Driver
into guide collar, and drive it into place (when guide collar contacts surface
of cylinder head, valve guide is at proper height)
• Guide collar is heat-treated and plated for durability
• Size: 31.8 mm (1.25 in) hex
• Length: 44.5 mm (1.75 in)

ID: C66888T1

ID: C66876T1

9U-6954 Guide Collar 149-4008 Valve Guide Collar

SMCS Code: 1104-012, 0703 SMCS Code: 1104-012
Model: 3300 Engines Model: 3126B Engines

• Used to install stepped valve guides to correct height • Used to install exhaust valve guides to correct depth in cylinder heads
• Prevents damage to valve guide during installation • Used with 9U-6895 Driver
• Saves time by automatically controlling guide height • Installs valves guides to a consistent depth
• Height of valve guide above head: 22.23 ± 0.25 mm (.875 ± .010 in) each time (removes guess work and
time consuming measurements)
• Heat-treated for durability
• Overall length:
39.8 mm (1.57 in)
• Outside diameter:
28.5 mm (1.12 in)

ID: C66610T1
ID: C78537T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

9U-6220 Stop Collar 157-3722 Valve Guide Driver

SMCS Code: 1104-012, 0703 SMCS Code: 0703, 1104-010, 012
Model: 3054 and 3056 Engines (all SN’s) Model: 3054, 3056 Engines (serial no. 5YS, 7MS, 2PW, and 3GW)

• Used to install valve guides to proper height of 15.10 mm (.594 in) • Used to remove and install valve guides
• Used with 1U-9169 Guide Driver (7ZK, 6FK, 7AK, 1 ML) • Used with 9U-6220 Stop Collar
• Used with 157-3722 Guide Driver (5YS, 7MS, 2PW, 3GW) • Heat-treated for added durability
• Zinc coated to prevent corrosion

Small diameter 8.40 mm (.331 in)

Larger diameter 12.75 mm (.502 in)
ID: C54527T1 ID: C79226T1 Overall diameter 19.05 mm (.750 in)
Overall length 233.5 mm (9.19 in)

Puller Fingers for 7H-1970 Puller Group

Discontinued — Service Parts Available

Item Part No. Description

1 Puller Finger
7H-1981 Puller Finger for medium head assembly 1
7H-1987 Puller Finger for large head assembly

ID: A20892T1

6V-7770 Valve Guide Tool Kit

6V-7755 Spring Seat Guide Item Part No. Description

SMCS Code: 1104-012 1 6V-7770 Valve Guide Kit

Model: 1100, 3100, 3200 Service Parts in 6V-7770 Kit
5P-5176 Brush
5P-5173 Reamer, 9,47 (.373 in)
5P-5174 Reamer, 9,50 (.374 in)
• Used for installing valve guide sleeves in cylinder heads 6V-7153 Line Up Bushing
• Used with 6V-3095 Boring Fixture and 6V-3108 Boring 6V-7154 Drill Bushing
Fixture Kit 6V-7155 Core Drill|
• Valve guides in cylinder heads of 1100, 3100 and 3200 6V-7156 Reamer, 12,7 (.5 in)
6V-7157 Driver
Family Engines not replaceable; when valve guide wears 6V-7158 Pin
beyond 9,55 mm (.3760 in) diameter “Use Again” dimension, 9U-5987 Oil, 1/2 pint
ID: B66951T1
guide must be reconditioned or complete cylinder head replaced (not shown)
• 6V-7770 Tool Kit and 6V-7755 Adapter provide tools necessary to 2 6V-7755 Spring Seat Guide
bore worn valve guides for installation of 4W-3778 and 4W-3779 Reference
Valve Guide Sleeves; tool kit includes driver to install valve guide SMHS82770-01 Special Instruction
sleeves and two reamers to size inside diameter of valve guide
sleeves to correct dimension

1U-6685 Guide and Insert Tool Group Part No. Description

SMCS Code: 1250-010 1U-7791 Valve Seat Driver
Model: 3114, 3116 1U-7792 Guide Collar
1U-7793 Guide Driver
1U-7794 Shaft Assembly
• Required for disassembly, assembly, and adjusting of 1.1 liter engine,
fuel system, and governor 1U-7795 Holding Block
• Used for valve guide and valve seat removal and installation 1U-7796 Exhaust Extractor
1U-7797 Inlet Extractor
Reference 1U-7798 Slide Hammer
SENR3582, Specification Module 1U-8211 Lid Filler Block
SENR3583, System Operation Testing and Adjusting 6V-7145 Case
SENR3611, Disassembly and Assembly Manual
ID: C26886T1
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149-6115 Valve Seat Installer

SMCS Code: 1103-012
Model: 3126B Engines

• Used to install intake and exhaust valve seats

• Used with hydraulic press (valve seats should not be installed using this tool and a hammer)
• Heat-treated for added durability
• To install valve seats, place a 7N-1819 Valve Guide or a piece of suitable tubing
over the pin and press into place using hydraulic press (if tubing is used, both ends
must be machined squarely)
Length of tubing 103 mm (4.0 in) minimum
Reference Small end of driver intake seats
Engine Service Manual ID: C79208T1
Larger end of driver exhaust seats

1U-9654 Tool Group 132-4379 Valve Seat Driver (HEUI)

Discontinued — Service Parts Available SMCS Code: 1103-012
Model: 3114, 3116, and 3126 (HEUI) Engines
Part No. Description
1U-9168 Guide Collar • Used to install 126-0453 Insert (inlet) and 1W-2713 Insert (exhaust) — helps
1U-9169 Driver eliminate damage to insert which can occur when a driver is not used
1U-9170 Driver • Long pilot serves as a guide during installation
1U-9706 Plate • Tool ensures that all seats are installed uniformly and to proper depth
6V-7145 Case • Hardened for added durability — knurled handle provides better grip
1U-8211 Block
1U-7795 Block Overall tool length 212 mm (8.3 in.)
9U-6460 Guide Collar Pilot length 81 mm (3.2 in.)
Pilot diameter 7.90 mm (.311 in.)

ID: C79458T1

Reference
SENR3910, 3176 Service Manual

ID: C66926T1

9U-6460 Guide Collar

SMCS Code: 1104-010, 0703
Model: 3176 Engines

• Used to install stepped valve guide without damage to guide

• Part of 1U-9654 Tool Group
• Used with 1U-9169 Driver for valve guide removal with 1U-9654 Tool Group
• Installation height of guide is automatically set (drive guide collar down until it bottoms against top surface of cylinder head)
• Made from high strength steel and heat treated — provides a quality, long-lasting tool ID: C66610T1

• Bright nickel coating and hex shape provide easy identification from other tools in 1U-9654 Tool Group

9U-6137 Installation Guide Collar

SMCS Code: 1104-012, 0703
Model: 3064 and 3066 Engines

• Used to install valve guides to 17.00 mm (.669 in) above the top of the cylinder head
(quickly and easily installs to correct height)
• Used with 1U-7793 Guide Driver
• Zinc coated to prevent corrosion
Reference
SENR5553 Service Manual, 3066 Diesel Engines

ID: C55118T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

4C-6366 Valve Guide Driver

4C-6370 Guide Collar
SMCS Code: 1104-012, 0703
Model: 3046 Diesel Engine

• Used to remove and install valve guide

• Ensures proper height of valve guide
• Knurled handle for better handling
• Guide collar stop height: 14.00 ± 0.10 mm (.552 ± .004 in)

Reference
ID: C66694T1
SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engine

4C-8134 Valve Guide Seal Remover

SMCS Code: 1104-011, 0703
Model: 3046 Engines

• Used to remove valve guide seal

• Used with 1U-7600 Slide Hammer
• Tapped hole for slide hammer: 1/2-20
• Wrench flat: 19 mm (3/4 in)

ID: C79225T1

Valve Guide Ream and Hone Tools

SMCS Code: 1104-070
Model: Multiple Engine Models

• Used with head and driver from 1P-7451 Valve Guide Honing Group to ream and
hone 12,7 mm (.500 in) valve guides on D379, D398, D399, G379, G398, G399

Reference Part No. Description

GMGO0866 5P-7289 Mandrel
5P-7290 Sleeve
5P-7291 Stone
5P-7292 Adapter

ID: A50744-1T1

1P-7451 Valve Guide Honing Group

SMCS Code: 1104-049
Model: Multiple Engine Models

• Provides precise method for sizing grooved valve guides on D346, D348, D349
• 5P-3536 Valve Guide Gauge Group recommended for measuring all current engine valve guides;
however, 1P-7452 Valve Guide Measuring Group for .375 mm diameter guides still available

Reference
SMHS7526 Special Instruction

Item Part No. Description

1 1P-7455 Mandrel
2 1P-7454 Stone (seven)
3 1P-7457 Truing Sleeve
4 1P-7458 Driver
5 1P-7459 Reamer. 9.42 (0.371 in) ID: C05380T1
6 1P-7452 Valve Guide Measuring Group replaced by 5P-3536 Gauge Group
7 5P-8615 Honing Oil, 18.9 liter (5 gallons)

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Engine Tools Search Cylinder Head, Valves and Cam Followers

5P-5170 Valve Guide Knurling Group

SMCS Code: 1104-023
Model: 1100, 3100 and 3208

• Used to recondition cylinder heads and valve guides that are 9,4 mm to
10 mm (.371 in to .375 in) in diameter
• Among models that can be serviced are 1100, 3100 and 3208 Engines;
other arbor and reamer sizes adaptable to all current and most non-current
Caterpillar engines are available separately; arbor and reamer sizes not listed
can be obtained from K-Line Industries, Inc., 315 Garden Avenue, Holland,
Michigan 49423

Part No. Description Size Other Arbors and Reamers — Not

9U-5987 Oil 1/2 Pint Included in 5P-5170
5P-5187 Tap Wrench Part No. Description
5P-5177 Speed Reducer 5P-5188 Knurling Arbor .312 in
5P-5176 Brush 5P-5189 Knurling Arbor .406 in
5P-5175 Knurling Arbor .371 in 5P-5190 Knurling Arbor .500 in
5P-5171 Reamer .371 in 5P-5179 Reamer .310 in
5P-5172 Reamer .371 in 5P-5180 Reamer .311 in
ID: C44367T1
5P-5173 Reamer .373 in 5P-5181 Reamer .401 in
5P-5174 Reamer .374 in 5P-5182 Reamer .401 in Reference
5P-5183 Reamer .403 in SMHS6747 Special Instruction
5P-5184 Reamer .495 in
5P-5185 Reamer .496 in
5P-5186 Reamer .497 in
6V-7156 Reamer .500 in

5P-3536 Valve Guide Gauge Group

SMCS Code: 1100-017, 1104-049, 1104-082
Model: Multiple Engine Models

• Provides method for quickly and accurately measuring all current valve guides for size,
taper, and out-of-roundness on D379, D398, D399, G379, G398 and G399
• Contains 3 probes, 3 master ring gauges, and a dial bore gauge
• Probes sized to cover all current valve guides: 7,92 mm (.312 in), 9,52 mm (.375 in), and 12,7 mm (.500 in)
• Each probe long enough to reach completely through longest guide
• Gauge graduated in 0,005 (.0002 in) increments with useable range of 0,38 (.015 in) for each probe

Reference
GMGO2562 Special Instruction

ID: A11647T1

4C-9734 Valve Guide Gauge, 3114, 3116

SMCS Code: 1104-081, 1104-036, 1104-039; 0763
Model: 3114, 3116

• Used for quick, accurate checking of valve guide wear on 1.1 Liter Engines ID: C44376T1

• Double-ended for checking maximum and minimum valve guide bore dimensions
• Valve guide bore dimensions:
Maximum: 8.080 mm (.3181 in)
Minimum: 8.035 mm (.3163 in)

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Cylinder Head, Valves and Cam Followers Search Engine Tools

Gauges 5S-1330 Pneumatic Valve Spring

SMCS Code: 1100-017
Model: Caterpillar Diesel Engines
Compressor
SMCS Code: 1105-010, 1105-011, 1105-012, 1100-017, 1100-015, 1100-016,
4208-017, 4251-017
Model: All Engines except 3600
• Used for quick, accurate checking of valve guide wear limits on Caterpillar
Diesel Engines
• 6V-7058 and 6V-7068 are double-ended to permit checking maximum and • Timesaver when removing and installing
minimum valve guide bore dimensions valve keepers
• 5S-1326 Special Adapter used in place
Valve Guide Gauge Application of regular jaws for servicing D343
Engines in Which Gauge Engines in Which Gauge and 1693 Engines
(Red End) is Used to (Green End) is Used to Check
Part No Check Worn Valve Guides New or Knurled Valve Guides
6V-7058 9,550 mm (.3760 in) 9,50 mm (.3740 in)
Maximum Minimum
1673, 1693, 1100 1100 Series, 3100 Series,
Series, 3100 Series, 3204 and 3208
3204 3208, 3304, 3306,
D330C, D333C, D342, D343,
D346, D348, D349, D353,
D379, D398, D399, Item Part No. Description
5.4 inch Bore 90° V8
1 5S-1325 Frame ID: T87620T1
6V-7068 9,540 mm (.3755 in) 9,460 mm (.3725 in)
Maximum Minimum 2 5S-1323 Cylinder
3406, 3408, 3412 3304, 3306, 3406, 3 5S-1326 Special Adapter
3508, 3512 3408, 3412 4 5S-1327 Jaw (1 in — 1 3/4 in Cap)
6V-7895 12,775 mm (.5030 in) 5 5S-1328 Jaw (1 1/8 in — 2 in Cap)
Maximum
D353, D379, D398, D399 6 5S-1329 Jaw (1 1/2 in — 2 1/2 inch Cap)
4C-9734 3114, 3116 8.035 mm (.316 in)
8.080 mm (.318 in)

1P-3527 Valve Spring Compressor

SMCS: 1105-010, 011, 012, 017, 1100-015, 016
Model: 1.1, 1.2, 3126B, 3200, 3300, 3400
Warranty: Manufacturer’s

• Quick and easy way to remove valve springs

• Hand operated
• An alternative to the 5S-1330 Pnuematic Spring Compressor
when compressed air is not available
• Cylinder head must be off the engine

ID: C80143T1

9U-5300 Unit Injector Spring Compressor Group

SMCS Code: 1290-017, 0706
Model: 3176 Engine

• Used to disassemble and assemble unit injectors Item Part No. Description

• Contains compressed unit injector spring (required 1 7X-0909 Bolt

to service retainer clip) 2 5P-0541 Nut
• Can also be used to replace retainer and spring 3 9U-5321 Tube
4 9U-5322 Compressor Plate Assembly
5 9U-5320 Off-Engine Fixture

ID: C54498T1

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Engine Tools Search Cylinder Head, Valves and Cam Followers

7F-4292 Valve Spring Compressor Group

SMCS Code: 1104-010
Model: 1100, 3100, 3208

• Used to remove and install valve springs manually

• Engines with recessed valve spring chambers Part No. Description
require 7M-3976 Adapter; 1100 and 3100 Series 7F-4291 Compressor Assembly
and 3208 Engines require 8S-2277 Adapter Assembly ID: C05381T1
8S-2277 Adapter Assembly (1100, 3100 Series, 3208)
(Not part of 7F-4292)
7M-3976 Adapter (D343, 1693) (Not part of 7F-4292)
7F-4290 Adapter

9U-6144 Adapter Assembly

SMCS Code: 1108-010, 0703
Model: 3064 and 3066 Engines

• Used for manual removal of valve springs (adapts 7F-4292 Compressor Group to 3064 and 3066 Engines)
• Can also be used with 9U-6145 Air Connector to remove valve springs without removing head

Reference
SENR5553 Service Manual, 3066 Diesel Engines ID: C54948T1

9U-6145 Air Connector

SMCS Code: 1108-010, 0703
Model: 3064 and 3066 Engines

• Used to replace valve springs and guide seals without removing the head
(allows on-engine replacement)
• Air connector fits into cylinder head injector port to put shop air into combustion
chamber (prevents valve from dropping into cylinder bore)
• Used with 7F-4292 Valve Spring Compressor and 9U-6144 Compressor Adapter Overall length 153 mm (6.0 in)
• Part of 9U-6274 Compression Test Kit (connector can be ordered separately Small end diameter 7.15 mm (.281 in)
if the test kit is not needed) Body diameter 16.75 mm (.659 in)
ID: C54949T1
Air connection 1/4-18 NPTF
Reference Hex head 19.0 mm (.75 in)
SENR5553 Service Manual, 3306 Diesel Engines

1U-9347 Valve Spring Compressor Group Earlier Style Nozzle Adapters

SMCS Code: 1108-017, 0703 Item Part No. Description
Model: 3400 1 Adapter Plate
2 Stud
3 1D-4719 Nut (Qty. 2)
• Used to remove and install valve springs on
4 0S-1618 Bolt (Qty. 2)
3400 Family Engines equipped with earlier-
style fuel nozzle adapter or new-style adapter 5 Collar
• Compresses all valve springs on one cylinder 6 Spacer
at same time; safely retains them while the 7 Plate Assembl
valve locks are removed
• Can be used with cylinder head on or off engine
• Saves time, especially for on-engine applications
• Applications: replacing valve stem seals and
springs, removing springs to service the unit
injector sleeve
Reference
SEHS9032 Special Instruction

Later Style Nozzle Adapters

Item Description
1 Plate Assembly
2 Adapter Assembly
3 Adapter Assembly
ID: C26992T1

Dealer Service Tools 2004 3-51

ID: C26993T1 Home
Cylinder Head, Valves and Cam Followers Search Engine Tools

Service Tools for Jacobs Vehicle Systems (Jake Brake®)

SMCS Code: 1129-039
Model: C-10, C-12, 3176/B, 3306B/C, 3406B/C/E Truck Engines
Essential Tool

• Used to quickly and accurately install or service Jake Brake® Units on Caterpillar On-Highway Truck Engines and articulated trucks
• All tools are genuine OEM parts
• Tools can be ordered individually
• 149-6112 Trigger Upgrade Kit allows rotation of dial indicator in early trigger sets kits
• 143-6452 Fuel Line Protective Kit includes caps to seal fuel lines from contamination
during a retrofit (for 3406B and C Engines only)
• 149-6111 Oil Pressure Test Kit includes a solenoid valve o-ring pack
Item Part No. Description
(pack not available separately). Individual O-rings are available by ordering
2U-1493 Seal Ring, Lower, 2U-1492 Seal Ring, Middle, and 1 149-6108 Installation Support Tool1
143-6642 Seal Ring, Upper. 2 134-2836 Feeler Gauge, 1.70 mm (.067 in)1
149-0054 Adjusting Gauge, 0.457 mm (.018 in)1
149-6105 Adjusting Gauge, 2.03 mm (.080 in)1
149-0050 Adjusting Gauge, 2.29 mm (.090 in)1
2 3 3 149-0059 S/P Adjusting Gauge, 3.43 mm (.135 in)1
4 4 149-0053 Feeler Gauge, 1.52 mm (.060 in)1
149-0052 Feeler Gauge, 1.78 mm (.070 in)1
5 149-0055 Feeler Gauge, 0.508 mm (.020 in)1
149-6114 Feeler Gauge, 0.635 mm (.025 in)1
1 149-0056 Feeler Gauge, 1.14 mm (.045 in)1
150-7227 Feeler Gauge, 1.02 mm (.040 in)1
149-0058 Feeler Gauge, 1.27 mm (.050 in)1
KE
7B H
31 LAS
RA
T C 45

6 134-2837 Slave Piston Tool

CA .0

5
7 149-6113 Bridge Set Gauge Package1
8 149-0114 Slave Lash Gauge, 0.889 mm (.035 in)1
Jacobs
B 9 149-6110 M/P Holding Wedge2
A
10 149-0051 Feeler Gauge, 2.03 mm (.080 in)1
.035 11 149-6109 Trigger Adjusting Group with Dial Indicator
6 12 150-3618 Pressure Test Solenoid Valve3
8 13 150-3617 Pressure Test Adapter3
9 14 150-3616 C/V Pressure Test Body3
15 149-6104 Dowel Extractor1
16 150-3619 C/V Cover Removal Tool3
7 17 149-0028 Feeler Gauge, 0.686 mm (.027 in)1
149-0049 Feeler Gauge, 0.762 mm (.030 in)1
155-5238 Feeler Gauge, .838 mm (.033 in)1
90
0 155-5239 Feeler Gauge, .940 mm (.037 in)1
10
80
20
12 Not shown
70
30 149-6106 Cat Tool Kit
60 40
50
13 149-6107 Tool Box1
10
149-6111 Oil Pressure Test Kit
11
149-6112 Trigger Adjusting Group Upgrade Kit
143-6452 Fuel Line Protective Kit1
14 150-7145 Pressure Gauge 0 to 700 kPa3
17 1 Part of 149-6106 Tool Kit-Cat
2 Part of 149-6109 Trigger Adjusting Group
15 16 3 Part of 149-6111 Oil Pressure Test Kit
ID: C78598T1

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228-3610 Feeler Gauge (C15)

235-0032 Lash Gauge (C13)
SMCS Code: 1129-025
Model: C13 and C15 Engines

• Used to set variable valve actuators

• Special bent gauge allows easier access to adjustment ID: D00852T1

241-0124 Spring Compressor Group

SMCS Code: 1103-040, 1108-040, 1100-017
Model: 3500 Engines

• Functions as valve spring compressor for on-engine removal of valve springs

• Compresses all four springs simultaneously
• Functions as valve depressor when plugs are installed in bridges; depressing valves allows
borescope inspection of valve faces and seats
• Easy installation — requires removal of rocker shaft Item Part No. Description Quantity
and rocker arms only
1 0S-1587 Bolt, 1/2-13 x 1-3/4 in 2
• Operable by one person
2 241-0121 Mounting Bracket 1
• Mounting bolts included
3 4T-5657 Plug 4
ID: D00858T1
4 241-0122 Spring Compressor Bridge 2

4C-6726 Valve Spring Compressor Group

Service Parts
SMCS Code: 1108-017, 0703
Model: 3176 Engine Item Part No. Description
1 4C-6727 Plate
2 2S-0115 Washer
• Used to remove and install valve springs of 3176 Engine 3 2J-3506 Nut
• Compresses all valve springs on one cylinder at same time; 4 4C-5543 Stud
safely retains them while the valve locks are removed 5 1U-8826 Thrust Bearing
• Can be used with cylinder head on or off engine 6 9U-7548 Base
• Saves time, especially for on-engine applications
• Applications: replacing valve stem seals and springs,
removing springs to service the unit injector sleeve

ID: C26963T1

9U-7241 Valve Spring Compressor Group

Item Part No. Description
SMCS Code: 1108-017, 0703
Model: 3406E Engines 1 9U-7548 Compressor Base Assembly
2 2J-3506 Nut
3 1U-8826 Thrust Bearing
• Used to remove and install valve springs 4 5P-8248 Washer
• Saves time, especially for on-engine applications 5 9U-7242 Compressor Plate
• Compresses all valves springs on one cylinder at same time; 6 0L-1143 Bolt
retains springs while keepers are removed
• Can be used with cylinder head installed or removed

Reference
SENR5580 Service Manual; SENR6421 Service Manual Module,
ID: Disassembly
C66609T1
and Assembly 3406E Engines

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Cylinder Head, Valves and Cam Followers Search Engine Tools

9U-6195 Valve Spring Compressor Group

SMCS Code: 1108-010, 0703
Model: 3054 and 3056 Engines

• Used to manually remove and install valve springs without removing cylinder head
• Used with 9U-6280 Air Connector to hold valves in position

Reference Item Part No. Description

SENR5547 Service Module in SENR5555 Service Manual
1 9U-6193 Compressor Assembly
2 9U-6194 Stud
3 9U-6196 Nut
ID: C55200T1

8T-2660 Compressor Group

SMCS Code: 1108
Model: All 3600 Diesel Engines
Essential Tool 1

• Used to remove and install valve springs, plus prevents damage to the valve rotator
• Spring removal from HFO engines require 8T-2660 along with 167-3972 Spanner Wrench
and 167-3974 Mounting Cap Assembly

Item Part No. Description Size 3

1 167-3972 Spanner Wrench (HFO Only) (not included)
2
2 167-3974 Mounting Cap Assembly (HFO Only) (not included)
Item 3
8T-2660 Compressor Group
8F-6350 Bolt 3/8-16 x 203 mm (8.0 in) long
8T-2662 Extension Handle
9S-8752 Nut 3/8-16
8T-2664 Lever Group
6H-3956 Spring Pin 4.76 mm (.187 in) x 25.4 mm (1.0 in) long
2A-4781 Bolt 1/4-20 x 69.9 mm (2.75 in) long
8T-2661 Spring Compressor Adapter

ID: C79361T1

8S-2263 Valve Spring Tester

SMCS Code: 1105-010, 1100-017, 4250-025
Model: All Engines
Warranty: Manufacturer’s

• Provides fast, accurate testing for old valve springs which should be tested before installing in reconditioned head
• Scale graduated in newtons and has maximum capacity of 1555 N (350 lb)
• Similar to 4C-9496 Spring Tester with maximum test force of 1200 lbs. for testing larger springs

ID: T97160-1T1

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5S-1322 Valve Keeper Inserter

SMCS Code: 1105-010, 1105-012, 1100-016, 1100-017
Model: All Caterpillar Engines

• Used with the 7F-4292 Compressor to install valve keepers

ID: C79667T1

166-7441 Valve Seat Extractor Tool Group

SMCS Code: 1103-010, 1100-017
Model: All Caterpillar Engines except 3600

• Replaces discontinued 6V-4805 Valve Seat Extractor Tool Group and Item Part No. Description
discontinued 9S-3080 Valve Seat Insert Puller Group 1 6V-4801 Stone
• Used to remove valve seat inserts on all Caterpillar engines 2 6V-4802 Wheel
• Uses only 4 extractors and employs different method of insert removal 3 165-5647 Extractor, 22.23 mm (.875 in), 34.93 mm (1.375 in),
which causes less damage to the extractors 47.63 mm (1.875 in) plus swirl inserts
• Provides grinder to groove inside of insert to make insert removal easier 4 6V-4194 Extractor, 25.4 mm (1.0 in), 38.1 mm (1.500 in), 50.8 mm (2.0 in)
with extractor 5 6V-4195 Extractor, 28.58 mm (1.125 in), 41.28 mm (1.625 in) 53.98 mm (2.125 in)
• 165-5647 has “notched” (47.63 mm) diameter for easy removal of 6 6V-4196 Extractor, 31.75 mm (1.25 in), 44.45 mm (1.75 in) 57.15 mm (2.25 in)
G3500 swirl-type inserts
7 222-3074 Grinder Group, requires 4C-3689 Collar
8 6V-4199 Lifting Bracket
9 6V-4197 Base Group
10 6V-4191 Plate Assembly
11 6V-4803 Thrust Bearing (Part of 6V-4804)
12 6V-4804 Handle Assembly
13 6V-4192 Shaft Assembly

Reference
SMHS7935 Special Instruction

ID: B24957T1

Valve Seat Extractors

SMCS Code: 1103-011, 0703
Model: 3054 and 3056 Engines

• Used with 9S-3095 Handle Assembly to remove valve seat insert

Item Part No. Description Dimension (A, B) Extractor Length Use

1 9U-6396 Extractor 49.5 mm (1.95 in) 102 mm (4.0 in) Remove inlet valve seat
2 9U-6397 Extractor 44.7 mm (1.76 in) 102 mm (4.0 in) Remove exhaust valve seat

ID: C54927T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

4C-6371 Valve Seat Driver, Inlet

4C-6372 Valve Seat Driver, Exhaust
SMCS Code: 1103-012, 0703
Model: 3046 Diesel Engine

• Used to install valve seats

• Serves as a guide to properly align seat during installation — saves time and reduces chance of damage
ID: C66696T1
• Knurled handle for better handling

Reference
SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engine

9S-3080 Valve Seat Insert Puller Group

Discontinued — Service Parts Available Item Part No. Description
1 9S-3081 Extractor
9S-3082 Extractor
9S-3084 Extractor
9S-3085 Extractor
9S-3086 Extractor
9S-3087 Extractor
9S-3088 Extractor
9S-3089 Extractor
9S-3090 Extractor
2 9S-3095 Handle Assembly
3 9S-3097 Shaft (part of 9S-3095)

Reference
GMG02114 Special Instruction

ID: B14813T1

130-1449 Valve Seat Puller Group

SMCS Code: 1063-036
Model: All 3600 and G3600 Engines

• Replaces discontinued 9U-5099 Valve Seat Puller Group 3 1

• Used to remove intake and exhaust valve seat inserts
• Used with 6V-3160 Hydraulic Cylinder for faster, safer removal
• A 9U-5098 Threaded Insert, part of 130-1449, can be used to adapt 6V-7047 Hydraulic Cylinder
• Overall length: 337 mm (13.3 in)
• Overall width: 140 mm (5.5 in)

2
Reference
ID: C79207T1
SENR3594 Disassembly and Assembly, 3612 and 3616 Engines
Item Part No. Description
1 130-1449 Valve Seat Puller Group
2 9U-9058 Threaded Insert
3 157-2882 Expander Segment Set (serviced separately)

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8S-7170 Valve Seat Puller Group

SMCS Code: 1100-015, 1100-017, 4351-015, 5414-016 Item Part No. Description
Model: 1100, 3100, 3208 1 2P-2343 Extractor (Intake)
2 9S-3095 Handle Assembly
9S-3097 Shaft (Part of 9S-3095)
• Used to remove valve seat inserts 9S-3095 Handle Assembly
Hammer

The individual extractors listed below are also available for use with the 8S-7170
Puller Group. These extractors were part of the former 9S-3080 Valve Seat Puller
Group and 6V-4805 Valve Seat Extractor Tool Group both of which are
discontinued and replaced by 166-7441 Valve Seat Extractor Tool Group.

Engine Model Inlet Exhaust

1670, 1673, D330, D333 9S-3087 9S-3089
1673C, D330C, D333C, 3304, 3306 9S-3084 9S-3087
1674, D334 9S-3090 9S-3090
1693, D343, D346, D348, D349, 3400’s 9S-3081 9S-3086
D342 9S-3088 9S-3088
ID: D00930T1
D333, D379, D398, D399 9S-3082 9S-3085
Reference
GMGO2114 Special Instruction

125-6185 Swirl Valve Seat Driver

125-6186 Swirl Valve Seat Driver Guide
SMCS Code: 1103-012
Model: 3406C Engines With Swirl Valve Seat/Insert

• Used to install 115-2358 Inlet Swirl Valve Seat/Insert

• Using both tools quickly and correctly positions valve seat
• Valve seat locates on shoulder of valve seat driver (will only locate in one position)
• Valve seat driver guide correctly positions the radial location of valve seat driver
(positions the seat in the correct radial location in cylinder head)
• Valve seat driver locates in valve guide bore — valve seat driver guide locates
in valve guide bore of adjacent valve port ID: C66874T1

• Seat driver and guide are hardened and plated for durability
• Overall length of seal driver: 252 mm (9.9 in)
• Overall size of valve seat driver guide: 61 x 155 mm (2.4 x 6.1 in)

ID: C66875T1

ID: C66884T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

Valve Seat Driver

SMCS Code: 1103-012, 0703
Model: 3064 and 3066 Engines

• Used to install both intake and exhaust valve seats

• Correctly aligns insert during installation
• Knurled handle for better handling

Item Part No. Description Length Major Outside Diameter

1 9U-6176 Valve Seat Driver 207 mm (8.1 in) 45.6 mm (1.79 in)
2 9U-6177 Exhaust Driver Plate — 38.1 mm (1.50 in)
Reference
SENR5553 Service Manual, 3066 Diesel Engines ID: C55119T1

Valve Seat Drivers

SMCS Code: 1103-012, 0703 Reference
Model: 3054 and 3056 Engines (SN’s 7ZK, 6FK, 7AK, 1ML) SENR5547 Service Manual
SENR5555 Service Manual

• Used to install 30° and 45° intake and exhaust valve seats
• Helps guide seat during installation (makes correct installation easier and faster)
• 9U-6183 used for 45° intake seats, 9U-6184 for 45° exhaust seats, 9U-6185 for 30° intake seats
Part No. Description
• Knurled handle for better grip (zinc coated for corrosion resistance)
9U-6183 Valve Seat Driver
• Overall length: 203 mm (8.0 in)
9U-6184 Valve Seat Driver
• Outside major diameter: 42.4 to 51.2 mm (1.7 to 2.0 in) ID: C79257T1
9U-6185 Valve Seat Driver

157-3717 Valve Seat Driver (Intake)

157-3716 Valve Seat Driver (Exhaust)
SMCS Code: 1103-012, 0703
Model: 3054 and 3056 Engines with 5YS, 7MS, 2PW, and 3GW Serial Numbers

• Used to install valve seats in new engines with unfinished valve seats and guides
Part No. Overall Length Major Outside Diameter
• Installs both 30 and 45 degree seats
157-3717 227 mm (9.0 in) 44.9 mm (1.75 in)
• Knurled handle provides better grip
157-3716 227 mm (9.0 in) 42.8 mm (1.68 in)
ID: C79257T1

9U-6897 Valve Seat Driver (Inlet)

9U-6898 Valve Seat Driver (Exhaust)
SMCS Code: 1103-012, 0703
Model: 3406E Engines

• Used to install valve seat inserts

• Serves as guide for proper alignment of insert during installation
• Knurled handle for better handling Part No. Overall Length Major Outside Diameter
• Zinc coated to prevent corrosion 9U-6897 254 mm (10.0 in) 47.4 mm (1.86 in)
9U-6898 254 mm (10.0 in) 42.5 mm (1.67 in)
Reference
SENR6421 Special Instruction ID: C79257T1

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Valve Seat Depth Gauges

SMCS Code: 1100-017
Model: 6V-7097: IT28, 943, 953
6V-7098: 1100, 3100, 3200

• Used to quickly determine valve seat depth on cylinder heads

• During cylinder head reconditioning, valve seat faces usually grind moving face of valve seat
deeper into cylinder head; as material is removed from seat face, valve stem length on spring
side of cylinder head increases, reducing distance valve spring is compressed and at same time
reducing spring load; with use of straight edge across top of valve guide, gauges used to
determine if valve seat depth is within limits
ID: B67494T1
Part No. Description
Reference
SMHS8319 Special Instruction 6V-7097 Valve Seat Depth Gauge
6V-7098 Valve Seat Depth Gauge, discontinued and replaced by 8T-0859 Depth Gauge

6V-0087 Valve Stem Gauge

SMCS Code: 1105-082
Model: Most Caterpillar Engines

• Used to measure valve stem wear more quickly than a micrometer

• Application includes all valves on current Caterpillar engines and most non-current
engines (micrometer still needed to measure valves on D336, D334, 1674 and some
other non-current engines)
• Has 4 accurately machined slots used for the four most common valve stem diameters
• Hardened to resist wear but will not damage valve stems
• If correct gauge slot slides over valve stem, valve is worn excessively and
should not be reused
ID: A84568T1
Item Part No. Description
1 5P-4227 Holder
Reference SEHS7758 Instruction Card
SEBF8034, Guideline for Reuseable Parts, Valves and Valve Spring Specifications,
2 6V-3198 Gauge
provides minimum “use-again” stem diameters for all valves used in Caterpillar engines
Slots stamped 9,37 mm (.369 in) and 9,42 mm (.371 in)
6V-3199 Gauge
Slots stamped 9,408 mm (.3704 in) and 12,55 mm (.494 in)

155-1536 Valve Recession Tool Kit

20

10

0
30

SMCS Code: 1103-082

10
40

20
50

Model: 3500 and G3500 Engines

30
40

• Used to determine actual valve and valve seat wear 5

• Used with valve stem measuring tool to determine top end overhaul intervals
• Can be used without removing rocker arms, thereby reducing engine downtime

2
Item Part No. Description
1 158-5080 Dial Indicator (inch)1
4
2 155-1579 Base Assembly
3 155-1683 Rod Assembly
4 155-1643 Projection Gauge Block 3
5 5P-4814 Clamp Collet
1 Can use 1U-8869 Digital Dial Indicator (inches and mm)

Reference
NEHS0708 Tool Operating Manual ID: C79256T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

213-9285 Valve Recession Tool Kit

SMCS Code: 1103-082 Item Part No. Description
Model: G3400 Engine Included with 213-9285

20

10
213-9198 Valve Recession Tool Group

0
30

10
40
1

20
50

30
40
4C-3975 Case
• Used to to determine the actual valve and valve seat wear 213-9386 Foam Block
2 NEEG2946 Decal
• Valve recession can be checked without removing rocker arms—
reducing engine downtime NEHS0851 Tool Operating Manual

• Large center hole in support assembly provides clearance for spark 4 Included with 213-9198 (not serviced)
plug tube on engines with Magneto and CDIS ignition systems 3 1 158-5080 Dial Indicator
• Slots in support assembly allow access to valve rotator on 2 5P-4814 Clamp Collet
either side of rocker arm 3 213-9193 Base Assembly
5
• Small magnets in legs of base assembly hold it in place while 4 230-5826 Support Assembly
taking measurements 6 5 213-9192 Rod Assembly
6 9S-8903 Contact Point
Reference
NEHS0851 Tool Operating Manual, Operating Instructions for
ID: C80437T1
213-9285 Valve Recession Tool Group for G3400 Engines

148-2997 Valve Recession Tool Kit Dowel Drivers

SMCS Code: 1103-082 SMCS Code: 5P-2406: 1100-010, 1121-012, 5101-017
Model: 3600 and G3600 Engines 6V-4009: 1121-010, 1209-010
20

10

0
30

Model: See below

10
40

20
50

30
40

• Used to determine actual valve and 1

valve seat wear • Used to install valve train bridge dowels to correct height
• Can be used without removing rocker arms 2 • 5P-0944 Dowel Puller Group and 5P-0942 Extractor used for dowel removal
(reduces engine downtime)
Part No. Description Model
Reference 5P-2406 Dowel Driver 3400
NEHS0710 Tool Operating Manual 6V-4009 Dowel Driver 3500

Item Part No. Description 3

1 6V-3075 Dial Indicator 5
2 5P-4814 Clamp Collet
3 — Body
ID: 88527-1T1
4 146-3271 Extension Rod
5 146-3270 Base Assembly 6
6 146-2738 Projection Gauge Block

ID: D00917T1

5P-7333 Bridge Dowel Repair Tool Group

SMCS Code: 1101-023
Model: 3400
Item Part No. Description
1 5P-7330 Lock Screw
• Used to repair cylinder heads with loose bridge dowels 2 5P-7325 Driver
• Repair done by drilling and reaming larger dowel hole and installing 3 5P-7331 Reamer
5P-7324 Plug; plug then drilled and reamed for installation of new
4 5P-7332 Reamer
bridge dowel
5 5P-7326 Drill Bushing
6 5P-7328 Drill Bushing
Reference 7 5P-7327 Drill Bushing
SMHS7072 Special Instruction

ID: A48260-1T1

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3P-2243 Installer Group 8H-8501 Tappet Wrench

SMCS Code: 1209-012 SMCS Code: 5167-010, 5050-081
Model: 6.25 inch Bore V-Engines Model: Multiple Engine Models

• Used to locate and install seals between valve lifter guide brackets on later • Thin, 1/2 inch x 9/16 inch special open-end combination wrench that can be
6-1/4 inch bore V-engines (D379B, D398B, D399) used for valve adjustment on 528, 621E, 627E
• Included in 8T-0460 Serviceman’s Tool Group and 8T-0461 Serviceman’s Tool
Group, but can also be ordered separately

ID: C09516T1

Item Part No. Description

1 1P-0529 Handle
ID: 65587-1T1 0L-1404 Stud (attaches handle to installer)

5P-7433 Cam Follower Tool Group

SMCS Code: 1208-010 Item Part No. Description
Model: 3400 1 5P-2405 Compressor
2 5P-2408 Handle Assembly
3 5P-2685 Nut
• Used for removal and installation of valve lifters
4 5P-6599 Handle Assembly
5 5P-2395 Holder
6 5P-6601 Collet
7 5P-2400 Compressor

ID: C80363T1

5P-8690 Fixture Group

5P-8691 Spline Socket
SMCS Code: 1112-010
Model: D343, 1693, 5.4 inch Bore 4-cylinder and 5.4 inch Bore 90° V-8 Engines

• Used to easily disasemble and assemble 5M-4169 Cam Follower Assemblies

• Cam follower parts can be inspected to identify those which can be reused
at considerable savings
Item Part No. Description
ID: A69787-1T1
1 4B-3057 Pin
Reference
2 3B-4607 Cotter Pin
SMHS7457 Special Instruction
3 5B-0978 Spring

ID: A69788-1T1

5P-6512 Valve Lifter Guide Bore Sleeving Tool Group

SMCS Code: 1101-023
Model: Multiple Engine Models

• Used to restore damaged valve lifter guide bores in cylinder blocks on D342, D339
• Valve lifter guide bore quickly restored in the shop by reboring block and installing
finished 5P-6513 Sleeve
Item Part No. Description
Reference 1 4B-9820 Wrench
SMHS6982 Special Instruction 7B-7640 Wrench
6B-7225 Wrench
SEBF8029 Index for Salvage Parts,
2 8L-2779 Seal
3400 Family Engines bores
3 5P-6511 Carbide Cutter ID: A32598-1T1
SEBF8069 Guideline for Reuseable Parts,
4 5M-2894 Washer
procedure using jig mill
5 0S-1588 Bolt
6 4D-3704 Washer
Dealer Service Tools 2004 3-61
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Cylinder Head, Valves and Cam Followers Search Engine Tools

Valve Lash Setting Tools

SMCS Code: 0766-025
Model: 3500A and 3500B Diesel, 3500 Magneto and EIS Gas Engines
Essential Tool

• Used to accurately set engine valve lash with factory setting methods • Valve bridge adjustment can be made without removing the rocker arm. Use
• Installation of tools is quick and easy with adjustment of indicator position the 147-5536 Contact Point, 147-2058 Extension, and 148-7211 Socket to
required on initial set-up only make the adjustment.
• Removal of fuel lines not necessary to measure valve lash • A slide rule type torque computer, Form SEHS7150, is available to determine
• Adding 147-2058 Extension to indicator allows valve lash to be measured on torque wrench dial reading for different extensions
Magneto Gas engine without removing spark plug extension • This tool will not fit on some early 3500 Engines with old fuel manifolds.
• Socket and torque wrench used to torque rocker arm nuts are preset at factory to • Dial indicator is not included in group — choice of 147-2056 (in) or 147-5537
70 N·m (52 ft.lbs.) — weight of torque wrench alone sets value of valve lash (mm) is available

147-5482 Valve Lash Adjustment Group Reference

Item Part No. Description REHS0128 Special Instruction
1 145-5191 Support Assembly
2 147-5536 Contact Point
3 147-2057 Contact Point
4 147-2058 Extension
5 1 2
5 148-7211 Bridge Nut Socket 6
Not shown
6V-3073 Plastic Case
147-5535 Foam Block
3 4
Required tooling not included in 147-5482 — must be ordered separately:
6 147-2056 Dial Indicator (inch), preferred, or
147-5537 Dial Indicator (metric)
Recommended tooling not included in 147-5482 — must be ordered separately:
7 147-2060 Socket Wrench
8 147-2059 Torque Wrench ID: C80360T1

146-2597 Push Rod Holder

SMCS Code: 1208-012
Model: 3114, 3116, and 3126 Engines with MUI Fuel Systems

• Used to hold all three push rods in place while rocker arm assembly is installed to
cylinder head
• Hook design ensures tool must be removed before valve cover can be installed
• Provides faster and easier method of installing rocker arm assemblies
• Individual holder tool design will work on either 4 or 6 cylinder engines

ID: C78520T1

ID: C78522T1

ID: C78521T1

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194-2062 Tool Group

SMCS Code: 1000-025, 0701, 0766
Model: 3408 and 3412 HEUI Engines or G3500 Engines

1
3408 and 3412 HEUI Engines (194-2062 Tool Group)
• Used to make valve adjustment procedure much easier
• Used with standard screwdriver to set valve lash
• Wrench has extra deep socket to reach adjustment locknut
• Specially designed feeler gauge has both (.015 in) and (.030 in) settings required for valve lash procedure
2

G3500 Engines (194-2061 Wrench)

• Used to adjust boost pressure of 146-0758 Exhaust Bypass Valve
Item PartID:No.
C79980T1
Description
• Used with a standard 1/4 Inch Nut Driver
1 194-2060 Gauge
• To access adjustment screw, remove 9S-4205 Plug
2 194-2061 Wrench
• Wrench can also be used to adjust valve bridges
• Socket end: 9/16 inch

125-2742 Base Assembly (for 3500)

Indicator diameter 57 mm (2.25 in)
125-2743 Collar Group 20
10
0
10

20
Graduations (.001 in)
Dial reading 0-50-0
4C-8246 Indicator 4 30
40
50
40
30

Range (.250 in) total; (.100 in) per revolution

SMCS Code: 1105-025, 0766
Model: 3500 Engines 5

• Replaces discontinued 4C-8241 Valve Lash Setting Gauge 3 Assembled Valve Lash Setting Tool
• Used to provide valve lash settings on 3500 “A” Series diesel engines 2 Item Part No. Description
• Dial indicator eliminates guesswork by measuring exact valve gap 1 125-2742 Base Assembly (for 3500)
(greatly reduces time needed to accurately adjust valves) 1 2 6V-2057 Contact Point (part of 125-2743)
• Base assembly has an inner and outer sleeve: inner sleeve puts tension 3 125-2743 Collar Group
on rocker arm; outer sleeve puts pressure, in opposite direction, on valve 4 4C-8246 Indicator
bridge assembly; dial indicator measures gap to determine exact valve setting 5 9U-6272 Nylon Screw (part of 125-2743)
Not shown 6V-2030 Indicator Extension (part of 125-2743)
Reference
SEHS9261 Special Instruction
ID: C66735T1

124-2946 Lifting Bracket Assembly (3406E Rocker Arm)

SMCS Code: 1123-010
Model: 3406E Engines

• Used to lift rocker arm assembly during removal and installation (keeps the assembly aligned)
• Fingers of lifting bracket fit through bolt holes in rocker arm shaft and firmly clamp assembly together
• Using the lifting bracket greatly decreases assembly time because valve and unit injector rocker arms
are held in correct relation to one another
(using lifting bracket allows the
mechanic to have a free hand during assembly)

ID: C66885T1

ID: C66882T1

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Cylinder Head, Valves and Cam Followers Search Engine Tools

8S-6691 Cylinder Head Stand Group 9U-6238 Guide Bolt

SMCS Code: 1105-010 SMCS Code: 1100-012, 0703
Model: 3100 and 3208 Model: 3054 and 3056 Engines

• Provide simple head support and • Used to align cylinder head with block during installation (two bolts required)
clearance between head and • Screw driver slot used to easily install and remove the guide bolt
work bench when service work • Zinc coated to prevent corrosion
required on cylinder heads
• 2 stands included in group

ID: C54936T1
Overall length 127 mm (5.0 in)
Diameter 12.7 mm (.50 in)
ID: T96845T1 Thread 1/2-20 2A

185-5321 Cylinder Head Lifting Hook Assembly

SMCS Code: 1101-009, 0632, 0739
Model: 3114, 3116, 3126, 3300, and 3400 (except 3126B and 3406E) Engines

• Used to quickly and safely lift cylinder head core

• Designed for bare cylinder head “Core” handling only and not as an engine assembly tool
• Reduces potential injuries from manually handling cylinder head castings
• Easily attaches to core without bolts
• Straight leg inserts into middle bolt hole of cylinder head and hooked leg fits
Maximum lifting capacity 340 kg (750 lbs)
into breather opening on 3114, 3116, 3126 MUI/HEUI Engines or into exhaust
port on 3300, 3406, 3408, and 3412 Engines.

ID: C79895T1
199-1418 Hook Assembly
SMCS Code: 1101-009, 0632, 0739
Model: 3406E, C-15, and C-16 Engines
NOTICE
To prevent camshaft and other cylinder head component damage,
DO NOT use this hook assembly as an engine assembly tool.
• Used to quickly and easily lift cylinder head cores
(camshaft must be removed prior to using tool)
• Used with an overhead lifting device
• Attaches easily without bolts or lifting eyes
• Grabs cylinder head core below camshaft bearing saddle Maximum lifting capacity 159 kg (350 lbs)
• Designed for bare head “core” lifting only

ID: C80140T1

5P-3021 Lifting Bracket 5P-8700 Lifting Bracket

SMCS Code: 1101-010 SMCS Code: 1100-010
Model: 3406 Model: 3408, 3412 Marine Engines

• Used for cylinder head removal and installation for 3406 Truck Engines with • Used to remove and install cylinder head and exhaust manifold assemblies
little or no access to rear lifting eye on cylinder head on 3408 and 3412 Marine Engines in narrow engine compartments
• Designed to be used in pairs for
lifting cylinder head assemblies
vertically at approximately same
angle as they are positioned on
block; brackets attached to heads
between end cylinders; two
0S-1618 Bolts, 5/16 inch-18 thread,
25,4 mm (1.0 in) long required for
each bracket

ID: A28495T1

ID: A66901T1
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165-4638 Guide Manifold

SMCS Code: 1059-012, 0701, 0702
Model: 3400 Engines

• Used to install exhaust manifolds

• Threads onto manifold stud for positive retention

ID: C79318T1

1U-8264 Head Lifting Bracket Item Part No. Description

SMCS Code: 1100-010
1 6V-3668 Bolt
Model: 3176, C10, and C12 Engines
2 5P-8245 Hardened Washer

• Used to remove and install cylinder head

• Used with two 6V-3668 Bolts and 5P-8245 Hard Washers
• Use one of two lifting holes, depending on which head is being removed
• Slotted mounting holes allows mechanic to easily balance cylinder head before lifting

Working load limit 114 kg (250 lbs.)

ID: C66919T1

209-1368 Head Lifting Bracket

SMCS Code: 1000-017, 0700, 0701
Model: C-9 Engine

Compliant
• Used to lift cylinder head with or without exhaust manifold and turbocharger
• Two lifting positions allow head to remain level during lifting procedure
• Bolts to cylinder head using two 6V-2317 Bolts, one 6V-3668 Bolt, two 5M-2894 Washers,
and one 5P-8245 Washer (not part of lifting bracket)

Maximum lifting capacity 159 kg (350 lbs)

ID: C80559T1

185-3145 Lifting Bracket Assembly

SMCS Code: 1000-017, 0700, 0701
Model: 3406E, 3456, C-15, and C-16 Engines

• Used to quickly and easily lift cylinder heads

• Attaches with six 1B-7182 Bolts and 9M-1974 Hard Washers or equivalent (not included)
• Designed for a bare cylinder head, with or without camshaft
• Includes multiple hook points for proper balancing

ID: C80006T1

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Sleeve Replacement Tools

SMCS Code: 1125-011, 0703
143-2099 Sleeve Replacement Tool Group
Model: 3114, 3116 and 3126 Engines
Item Part No. Description
1 125-7060 Driver
• 143-2099 Sleeve Replacement Tool Group replaces the former 127-3458 Sleeve Replacement 2 Reamer Assembly
Tool Group 4C-8713 Shank
• The former 127-3458 Sleeve Replacement Tool Group can be UPDATED to the new configuration 4C-5564 Reamer Head
simply by purchasing the 143-2098 Sleeve Removal Tool Group. Previous tooling not listed below 4C-5502 Setscrew
is no longer needed for the new procedures. 3 4C-8714 Guide Bushing (large)
• These new improved tools are simpler and make the job faster and easier—offering the following 4 4C-8715 Guide Bushing (small)
benefits over the former 127-3458 Tool Group: 5 Swage Assembly1
- No tapping of old sleeves—means less debris, no stripped threads and no problem with loose 4C-5573 Swage (sleeve)
sleeves turning 4C-5548 Stud (3/4-10 thd x 5 1/2 in)
- Works in low-overhead applications, such as cylinders #5 and #6 in GM truck chassis, 6 125-7059 Reaction Sleeve (HEUI)
Cat machine installations, and others 7 9U-5671 Reaction Sleeve (MUI)
- Should be no need to remove the cylinder head from the engine for sleeve replacement 8 4C-5572 Plate (for reaction sleeve)
• Used on engines equipped with Mechanical Unit Injectors (MUI) or Hydraulic Actuated
9 121-2920 Roller Expander
Electronically Controlled Unit Injectors (HEUI).
10 9U-6101 Reamer Group
• Engines produced since early 1994 have had injector sleeves roller expanded at the factory.
The original 4C-4462 Tool Group will not pull these sleeves; either the 127-3458 or the 11 142-8278 Swage Tool2
143-2099 Tool Group is required. 12 142-8279 Sleeve Puller2
• All special tooling necessary to efficiently remove, install, and ream copper injector sleeves 13 142-8280 Sleeve Stud2
is included in a single custom case in the 143-2099 Group. Some additional shop supplies 14 142-8281 Plate2
are also required, as specified in the Tool Operating Manual NEHS0675.
15 143-8612 Driver2
16 3L-2415 Full Nut2, 1/2-13
2 17 7D-1649 Hard Washer2
1
18 3L-2415 Hex Bolt2 [1/2-20, 63.5 mm (2.5 in) long]
19 6V-3821 Hex Bolt2 [M8 x 1.25, 110 mm (4.3 in) long]
20 4C-5553 Sleeve Cleaning Brush (tapered)
21 126-3297 Large Bore Brush
5 7
22 4C-5570 Small Bore Brush
23 9U-6859 Pick Set
3 4
6 8 24 214-6625 Socket (11 mm, 3/8 in square drive, six point)
25 213-3530 Socket (1 1/8)
26 2J-3506 Nut (3/4-10 thd)
9 10 27 1U-8826 Thrust Bearing
28 2S-0115 Hard Washer
15 29 1B-4430 Jam Nut, 1/2-20
13 17 Not shown
19
18 6V-7145 Case
11
125-0684 Foam Insert
12 16
NEEG2748 Decal
14 29
20 NEHS0675 Tool Operating Manual, “Using
the 143-2099 Sleeve Replacement Tool
Group on 3114, 3116 and 3126 Engines”
22 26 1 Not shown
21
25 27 2 Parts in the 143-2098 Sleeve Removal Tool Group
23
24 28
ID: 143-2098 Sleeve Removal Tool Group
il4, C78481T1
Item Part No. Description
1 142-8278 Swage Tool
2 142-8279 Sleeve Puller
3 142-8280 Sleeve Stud
3
4 142-8281 Plate 4
5 143-8612 Driver 1
6 3L-2415 Full Nut, 1/2-13
7 7D-1649 Hard Washer 2
8 3L-2415 Hex Bolt, 1/2-20, 63.5 mm (2.5 in) long
9 6V-3821 Hex Bolt, M8 x 1.25, 110 mm (4.3 in) long
10 1B-4430 Jam Nut, 1/2-20
Not shown
NEEG2748 Decal 5 8
NEHS0675 Tool Operating Manual, “Using the 143-2099 Sleeve
Replacement Tool Group on 3114, 3116 and 3126 Engines”
6 7 9 10
3-66 Dealer Service Tools 2004
Home ID: C78474T1
Engine Tools Search Cylinder Head, Valves and Cam Followers

139-0692 Sleeve Jaw

SMCS Code: 1000-011, 0701, 0703, 0706
Model: 3114, 3116, 3126 Engines

1
• Used with 143-2099 Sleeve Replacement Tool Group to aid in sleeve pulling operation
• Sharp chamfer rolls top of injector sleeve over sleeve stud, reducing chance of stud pulling out

Item Part No. Description

2
1 Pulling Stud
2 139-0692 Sleeve Jaw 3
3 Sleeve Stud

ID: C80073T1

131-8362 Reamer Head 121-2920 Roller Expander

SMCS Code: 1125-011, 0703 SMCS Code: 1125-012
Model: 3114, 3116, and 3126 Engines Model: 1.1/1.2 L Engines
Essential Tool

• Included with 143-2099 Sleeve Replacement Tool Group

• Replaces discontinued 4C-5564 Reamer Head • Helps ensure positive seal of sleeve to injector bore
• For reaming tapered injector seat in copper alloy injector sleeves • Easy to use — use torque wrench to turn in sleeve, up to 11 N·m
• Used with 143-2099 Sleeve Replacement Tool Group • To update 4C-4462 Injector Sleeve Removal and Installation Tool Group
• Made from solid carbide for superior life and performance

Reference
NEHS0675 Tool Operating Manual

ID: C55059T1

Reference
NEHS0675 Tool Operating Manual, “Using the 143-2099 Sleeve Replacement
Tool Group on 3114, 3116 and 3126 Engines”

ID: C79290T1

151-4832 Sleeve Remover Assembly

SMCS Code: 1125-011, 0703 C
Model: 3126B HEUI Engines

• Used to easily remove injector sleeves

• Designed for non-grooved injector sleeves B

Application Procedure
1. Insert tool fully into injector sleeve bore. Expand tool by turning part A and part B
in opposite directions. Sharp set screw points should bite into walls of sleeve.
A Item Description
2. Install pulling bridge, thrust bearing, washer, and nut (item C, part of tool group).
A Expanding segment
Tighten nut on puller stud to remove sleeve.
B Threaded rod
ID: C79321T1 C Puller components
NOTE: Set screw points should protrude approximately 2.0 mm (.08 in) from surface
of pulling tool collet.
Thread 3/4-10 Reference
Overall assembled length with puller 254 mm (10.0 in) RENR1369 Special Instruction, Unit Injector Sleeves
Points 141-4635 Set Screw

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173-1530 Injector Seating Tool Group 7

SMCS Code: 1290-0706, 1290-012
Model: 3114, 3116, 3126 MUI and 3116, 3126 2-Valve HEUI Engines
Essential Tool
1

• Used to seat entire injector seating land into sleeve (eliminates combustion gas leakage) 8
• Used with 9U-5019 Torque Wrench 11
11 2 10
• Trues up out of round injector sleeves that cause combustion gas leakage 10
• Eliminates need to ream newly installed sleeves
• Eliminates injector clamp bolt load relaxation 4 6
3
• Provides consistent seating force from cylinder to cylinder using a simple forcing
screw operation
• Works with existing sleeve removal and installation tooling
• Can be used in place of 142-8279 Plate used for sleeve removal for more control of location
• Forcing bridge mounts same as 142-8279 Plate
• Interchangeable legs work on bare head or with intake manifold in place
9
5
Reference
ID: C79633T1
NEHSO738 Using the 173-1530 Injector Seating Tool Group on Item Part No. Description Not shown
3114, 3116, 3126 MUI and 3116 and 3126 2-Valve HEUI Engines 1 173-1529 Forcing Bridge 4C-5591 Thread Lubricant
2 173-1534 Short Spacer Leg 6V-3073 Plastic Case
3 173-1535 Long Spacer Leg 173-1528 Foam Insert
4 3L-2415 Hex Head Bolt (forcing bolt) NEEG2838 Decal, Case
5 7X-0457 Hex Head Bolt (for forcing bridge)
6 9M-1974 Hard Washer
7 173-1531 Injector Forcing Cover (MUI)
8 173-1532 Injector Forcing Cover (HEUI)
9 146-2597 Push Rod Holder
10 175-7801 Wear Button
11 1P-8116 O-Ring

170-9227 Reamer Shims

SMCS Code: 1000-064, 0700, 0703, 0706
Model: 3116 and 3126 MUI, 3126 HEUI Engines

• Used to control depth of injector sleeve reaming operation; helps eliminate Application Procedure
reamer chatter 1. Start with four shims installed between 4C-8713 Reamer Shank (2) and
• Allows only 0.25 mm (.010 in) of material to be removed at a time—can 4C-8714 Bushing (3).
prevent sleeve from being reamed too deep
2. Ream sleeve until reamer shank contacts shim.
• Provides a positive stop at end of reaming operation
• Thickness: 0.25 mm (.010 in) 3. Remove one 0.25 mm (.010 in) shim (1) at a time and repeat until proper
seat depth is obtained.
• Number of shims per packet: 4

Item Part No. Description

1 170-9227 Reamer Shims
2 4C-8713 Reamer Shank
3 4C-8714 Bushing

Reference 2
NEHS0675 Tool Operating Manual
1
3

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131-3921 Puller Group (HEUI)

111-5051 Injector Wrench (3408 and 3412 HEUI)
SMCS Code: 1250-010
Model: 3408 and 3412 HEUI Engines

131-3921 Puller Group 111-5051 Injector Wrench

• Used to easily remove carbon-fouled injectors from cylinder head • Used to remove and install stainless steel injector sleeves
• Puller has large, balled end, handle for easier removal • Used with 3/4 inch socket
• Puller bridge assembly sits on cylinder head top surface and uses a pivoting • Spline on tool engages internal spline in sleeve
leg extension to keep bridge from sliding off of cylinder head

111-5051 Injector Wrench

1 131-8196 Handle
Hex size (3/4 in)
2 131-8197 Puller Bridge Assembly
Knurled washer diameter 50.8 mm (2.00 in)
3 131-8198 Puller Stud Assembly
Spline 48 tooth
4 093-0386 Plated Washer
131-3921 Injector Puller Group
5 0S-1616 Bolt (1/4-20 x 1.0 in)
Stud assembly overall length 118.5 mm (4.67 in)
6 4B-4276 Washer 111-5051
Stud thread 3/8-16
Bolt size 1/4-20 3
Distance between bolt holes 29 mm (1.1 in) 1
Bridge overall length 270 mm (10.7 in)
2 ID: C66948T1
4

6
5

131-3921
ID: C66947T1

164-5924 Injector Bore Gauge

164-5927 Tube Brush 164-5927
SMCS Code: 1125-571, 0701
Model: 3408 and 3412 HEUI Engines
Essential Tool

• Used to clean and check clearance of injector sleeve tip area

• Proper cleaning of injector tip bore is mandatory when changing HEUI engine injectors 164-5924
• Tools are included in 163-1575 HEUI Injector Rework Kit

Reference ID: C79295T1

REHS0116 Special Instruction

4C-8714 Guide Bushing (Large)

4C-8715 Guide Bushing (Small)
9U-5671 Reaction Sleeve
SMCS Code: 1125-010, 0703
Model: 3114 and 3116 Engines

• Used to replace and ream injector sleeves without removing valve springs — saves time
• 9U-5671 is designed to clear the valve springs and provide adequate support for pulling the injector sleeve
• 4C-8714 and 4C-8715 Guide Bushings allow reaming and sleeve installation without valve spring removal ID: C54933T1

Reference
SEHS9120 Special Instruction

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4C-6591 Bottom Swage

SMCS Code: 1125-012; 0703
Model: 3176

• Replaces discontinued 4C-6714 Bottom Swage

• Used to install injector sleeves in 3176 Engine cylinder heads Reference
• Addition of pilot extension and lead-in chamfer ensure proper swaging of bottom of injector sleeve SEHS9246 Special Instruction
ID: C27034T1

9U-6891 Injector Tool Group 2

SMCS Code: 1125-012 4
Model: C-10, C-12, and 3406E Engines 1

5
• 128-7889 Puller Bridge replaces discontinued 9U-7260 Puller Bridge
(new puller bridge can be used on all three engines)
Item Part No. Description
• Injector tool group is used to remove and install injector 3
sleeves 1 9U-6877 Thrust Bearing
2 9U-7258 Driver Cap
Reference 3 221-9778 Puller Stud
SENR6421 3406E Service Manual, Disassembly and Assembly 4 4K-0367 Full Nut
SENR1002 C-10 Disassembly and Assembly 5 5P-8247 Washer 6
SENR1007 C-12 Disassembly and Assembly 6 128-7889 Puller Bridge
ID: C66728T1

Bore Cleaning Brushes

SMCS Code: 1100-070, 0674
Model: 3406E Engines

• Used to clean injector bores

• 9U-7237 extends reach of all brushes—works with any brush up to 6.0 mm (.25 in) diameter shank
• Used with 4C-5552 Large Bore Brush
ID: C66632T1
Reference
SENR5580 Service Manual; SENR6421 Service Manual Module; Special
Instruction: Disassembly and Assembly 3406E Engine

Item Part No. Description Diameter Wire Diameter Overall Length Brush Length Maximum Safe Maximum diameter
Free Speed of brush shank
1 9U-7244 End Brush 19.05 mm (.75 in) 0.264 mm (.0104 in) 70.0 mm (2.75 in) 25 mm (1.0 in) 20,000 rpm —
2 9U-7237 Drill Extension — — 152 mm (6.0 in) — — 6.4 mm (.25 in)
3 9U-6862 Small Tapered Brush 22.20 mm (.875 in) 0.13 mm (.005 in) 250 mm (10.0 in) — — —
4 9U-6863 Small Bore Brush 15.90 mm (.625 in) 0.20 mm (.008 in) 250 mm (10.0 in) — — —
5 4C-5552 Large Bore Brush — — — — — —

9U-6860 Tool Group

Part No. Description Part No. Description
SMCS Code: 1250-012, 1250-070
Model: 3176, 3176B 1B-2886 Bolt (Qty. 2) 4C-9495 Tee Handle
8H-8556 Socket, 1 inch 7X-0613 Hard Washer
213-3530 Socket, 1 1/8 inch 9U-6631 Foam Insert Set
• Replaces discontinued 4C-4054 1U-8826 Thrust Bearing 9U-6851 Lower Pilot
Tool Group 2J-3506 Full Nut 9U-6853 Tap
• Used to install, clean, and ream 2S-0115 Hard Washer 9U-6854 Puller Screw
injector sleeves in cylinder
3S-2713 Full Nut 9U-6855 Reamer Shank
head
4C-5502 Set Screw 9U-6856 Flare Tool
4C-5538 Reamer Head 9U-6857 Driver
4C-5544 Release Block 9U-6858 Bridge Plate
4C-5552 Large Bore Brush 9U-6859 Pick Set
Reference 4C-6591 Bottom Swage 9U-6861 Puller Stud
SEHS8884, Unit Injector Test Specifications
ID: C55052T1
4C-6730 Roller Expander 9U-6862 Small Tapered Brush
SENR5109, 3176 Service Manual
4C-8720 Guide Bushing 9U-6863 Small Bore Brush
SEHS9246 Special Instruction, operation 4C-8721 Guide Bushing

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169-3374 Injector Sleeves Tool Group

SMCS Code: 1125-0700, 0701, 0703, 0706 11
Model: 3176 and 3176B Engines
10

• Used to quickly and easily remove brass injector sleeves

• Eliminates sleeve tapping (threading) operation—no brass chips to fall into engine 1
• Similar to current 3100 Engine brass sleeve removal procedure
Item Part No. Description
8
1 9U-6858 Bridge
2 1B-2886 Bolt 7
Reference 3 142-8280 Sleeve Stud 6
NEHS0734 Tool Operating Manual, 169-3374 Brass 4 151-4833 Sleeve Jaw
4
Injector Sleeve Removal Group for 3176 and 3176B
Engines
5 156-2870 Puller Stud 2 9
6 1U-8826 Thrust Bearing
7 7D-1649 Washer
8 1F-7958 Nut
9 156-2869 Crimping Swage 5
10 6V-3073 Storage Case 3
11 173-5508 Foam Insert ID: C79796T1

150-3152 Sleeve Installer Screw-In Precombustion Chamber Tools

SMCS Code: 1713-010 SMCS Code: 1106-011
Model: 3126B Engines Model: Most Caterpillar Engines
Essential Tool

• 1D-5343 Wrench required to remove set screw and 1F-0479 Tool to loosen
• Used to remove and install cylinder head injector sleeves precombustion chamber on earlier screw-in type precombustion chambers
• Small diameter holds sleeve • 1F-0479 Tool also used to install these earlier precombustion chambers
• Larger diameter guides sleeve driver using bore of cylinder block
• Includes 8T-7878 O-ring Seal, which holds sleeve on driver
• Small diameter (with O-ring): 29.79 mm (1.173 in)
• Guide diameter: 34.89 mm (1.374 in)

ID: C80353T1
Item Part No. Description
1 ID: T80046T1
1D-5343 Wrench
2 1F-0479 Tool

Drive-In Precombustion Chamber Tools

SMCS Code: 1106-011
Model: Most Caterpillar Engines

• Hydraulic puller combined with tools shown provides simple and efficient
method of removing drive-in type precombustion chamber
• Same tools can be used without hydraulic puller
• Driver used to install drive-in type precombustion chambers in
Part No. Description
cylinder heads; lower end of this tool serves as pilot so hammer
blows can be directed squarely on upper end of chamber 7F-1696 Shaft
2B-1941 Nut Assembly
2B-1902 Saddle, Discontinued
6V-3160 Puller
2B-0399 Driver ID: C09480T1

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5F-9217 Precombustion Chamber Tool Group

SMCS Code: 1106-011
Model: Most Caterpillar Engines

Item Part No. Description

• Spacer (2) and bolt (1) used for removing precombustion 1 1A-2208 Bolt
chamber retainer 2 5F-9072 Spacer
• Wrench (3) required to remove and install precombustion chamber 3 5F-8353 Wrench
• Screw (6), nut (5) and washer (4) used for replacing precombustion 4 4B-4285 Washer
chamber retainer
5 0L-1017 Nut
• Engines with 1-piece precombustion chambers require only
6 6F-5515 Screw
5F-8353 Wrench for removal and installation

ID: T88392T1

8S-0225 Precombustion Chamber Wrench

SMCS Code: 1106-010
Model: 1674, D334, 3400

• Used to remove and install precombustion chambers on 1674, D334, and 3400 Series Engines

ID: C78592T1

5P-0125 Precombustion Chamber Wrench

SMCS Code: 1106-010, 1106-015, 1106-016, 1106-017, 1254-010
Model: 3204, D3, 910, 931

• Used to remove and install precombustion chambers on 3204 Engine

in D3 Tractors, 910 Wheel Loaders, and 931 Track Loaders
Item Part No. Description Quantity
1 5P-3009 Dowel two

ID: 77216T1

5P-0961 Fuel Valve Adapter Wrench 5S-0276 Glow Plug Wrench

SMCS Code: 1106-010 SMCS Code: 1412-010
Model: 3400 Model: Multiple Engine Models

• Used for removal and installation of direct injection fuel valve adapters on • Used to remove and install glow plugs with 3/8 inch hex
3400 Series Engines on D4E, D6D, D6H, 637D, 977L

ID: 88528T1

ID: T97001T1

1P-0550 Glow Plug Tool Group

SMCS Code: 1412-012
Model: Caterpillers Engines with Glow Plugs
Item Part No. Description
1 1P-0547 Reamer

• Used to install current 4S-7812, 4S-7824, and 4S-7832 Glow Plugs

in engines equipped with earlier glow plugs

Reference
GMG00253 included with each group

ID: C09479T1

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Glow Plug Tools

SMCS Code: 1412-010
Model: Most Caterpillar Engines Item Part No. Description
1 1H-5656 Wrench
2 8S-2243 Wrench
• Wrenches and guide screws needed for installation and 3 9S-2573 Socket
removal of glow plugs with 5/16 inch hex on earlier engines 5 9F-4571 Guide Screw
6 5H-7446 Guide Screw

ID: C09478T1

5P-0127 Socket
9S-2573 Socket
SMCS Code: 1412-010
Model: Multiple Engine Models

• 5P-0127 Socket — special 5/16 inch glow plug socket to remove and install glow plugs on 3204, 3400 Series,
later 3306, 1693, D343, D346, D348 and D349 Engines
• 9S-2573 Socket can be used in place of 5S-0276 Wrench for removal of glow plugs with 3/8 inch hex
ID: A09464T1

161-3440 Socket 124-0662 Impact Socket

SMCS Code: 0601-0703, 079 SMCS Code: 1100-010
Model: C-10 and C-12 Engines Model: 3406C and 3406E Engines
Essential Tool

• Used to remove and install cylinder head bolts

• Used to tighten cylinder head bolts under water manifold without removing it • Allows mechanic to use socket with air-powered impact wrenches because
• Works on both single and dual thermostat housings of socket’s heavy-duty construction (using impact wrenches can significantly
• Required according to PS4435 Product Support Program reduce assembly and disassembly time)
• Do NOT use with impact driver • Designed to clear rocker arm mechanism
and rocker cover base
• Heat-treated for added durability and long life

Square drive 3/4 inch Socket 3/4 inch

Double hex socket M16 bolts Socket style 12 point
Overall length 190 mm (7.5 in) Square drive 3/4 inch
ID: C79287T1 ID: C66872T1
Overall length 127 mm (5.0 in)

5P-7275 Glow Plug Wire Installer

SMCS Code: 1412-012
Model: Most Caterpillar Engines

• Used to install glow plug wire on glow plug ID: A37154T1

• Makes it much easier to connect wire to plug because of congestion in area of glow plugs

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Cylinder Head, Valves and Cam Followers Search Engine Tools

6V-3049 Glow Plug Wire Remover

SMCS Code: 1412-011
Model: 3400

• Needed to remove glow plug lead assemblies in 3400 Series PC Engines because of force required for removal and limited access to plugs

ID: A81211T1

9U-7511 Spark Plug Seat Cleaner

SMCS Code: 1100-070, 0703
Model: 3500 and 3600 Spark Ignited Engines

• Used to clean gasket seat of rust resulting from a leaking gasket

• Used to clean threads in cylinder head
ID: C66633T1 To build service kit, order:
External hex 7/8 inch
Internal square drive 3/8 inch Part No. Description
Reference Thread M18 x 1.5 mm 9Y-6792 Gasket (standard), 25 each
NEEG2585 Decal (instructions for inside lid of case) 105-7124 Gasket (oversize), 25 each
Overall length 75 mm (3.0 in)
9U-7512 Foam
6V-6045 Case
NEEG2585 Decal (inside lid)
NEEG2586 Decal (outside case)

154-9521 Spark Plug Seat Cleaner

SMCS Code: 1100-070, 0703
Model: G3400 Engines

• Used to simultaneously clean rust and debris from gasket seat and cylinder head threads
• Used with 3/4 inch, 6 point socket (do not use 12 point socket)
• Spring-loaded design only removes dirt and debris, not metal
ID: C66633T1 Thread size M14 x 1.25
External hex 19 mm (.75 in)
Overall length 75 mm (3.0 in)

5P-1762 Support Bracket

SMCS Code: 7106-010
Model: 3304 and 3306

• Used to support fan drive bracket when cylinder head is removed from chassis

ID: 94085-1T1

6V-2033 Brush
6V-2032 Adapter
SMCS Code: 1105-080
Model: All Caterpillar Engines

• Fine grade abrasive brush used to clean and polish all engine valve stems
• Adapters used to mount brush on appropriate bench or pedestal grinder having 1800 to
3200 rpm maximum

Reference ID: A92586-1T1

SEBF8002, Guideline for Reuseable Parts, Valves and Valve Spring Specifications, instructions for use of brush and information on optional cleaning methods

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Inserts 5P-8699 Tool Group

SMCS Code: 1101-023 Discontinued — Service Parts Available
Model: D353 Engine
Warranty:
Service Parts
Part No. Description Size
• Required to modify former D353 cylinder heads for spacer plate blocks
5P-8695 Core Drill 12,7 mm (.500 inch)
• 5P-8703 Insert quantity: 12
5P-8696 Core Drill 14,3 mm (.562 inch)
5P-8704 Insert quantity: 8
5P-8698 Drill 9,53 mm (.375 inch)
5P-5253 Drill Bushing 9,53 mm (.375 inch)
Reference 5P-7328 Drill Bushing 14,3 mm (.562 inch)
SMHS7339 Special Instruction ID: C80361T1 5P-8694 Drill Bushing 12,7 mm (.500 inch)

6V-9050 Stud Removal Tool Group

SMCS Code: 1101-023
Model: 3200, 3300, 3400

• Designed to remove broken exhaust manifold studs and bolts

• Consists of drill fixture, 2 alignment bushings, 2 drill bushings, and 2 drills
• Removal of broken stud begins by using disc grinder to grind broken stud so 6V-7847 Drill
Fixture can be secured to cylinder head; 1/8 inch drill and drill bushing first used to drill
completely through broken stud; then stud is drilled out using 5/16 inch drill and drill bushing
• Since bolts are used to retain exhaust manifolds on 3200 Family Engines, HeliCoil is
acceptable for repair of these heads; however, studs with taperlock threads are used to
ID: B72304T1
retain exhaust manifolds on 3300 and 3400 Family Engines and HeliCoil cannot be satisfactorily Item Part No. Description
used to repair cylinder heads on these engines.
1 6V-3073 Case
2 6V-4094 Liner
Reference 3 6V-9051 Block
SMHS8297 Special Instruction 4 6V-7847 Fixture
5P-7330 Screw
5 6V-9045 Alignment Bushing, 9,53 mm (.375 inch) I.D.
6 0S-1571 Bolt (two)
7 6V-9046 Drill Bushing, 8,17 mm (.322 inch) I.D.
6V-9047 Drill Bushing, 3,18 mm (.125 inch) I.D.
8 5P-6732 Screw
9 6V-9048 Drill, 7,94 mm (5/16 inch) O.D.
6V-9049 Drill, 3,18 mm (1/8 inch) O.D.

188-3922 Exhaust Stud and Bolt Removal Tool Group

SMCS Code: 1000-023, 0701, 0703
Model: 3114, 3116, 3126, 3126B, 3176, 3176B, 3196, C-10, and C-12 Engines 11 9
10
5 6
,
em B
al

R 76
ov

d 31

• Used to remove broken metric exhaust bolts and studs from engines
,
Stu 6
d 17

2
O RA L olt an26B, 3
TO PE UA haust1B26, 31
O AN ken E3x116, in3 es
M 22 Brro3114-1, 2 Eng

3
C : 1100
9 fo C
8-3 p d
G

• Designed for drilling out studs/bolts to minimum thread diameter — remaining pieces
S
18 rou , an

C
S07 00

SM
EH 20

N
87

G -10
N ry
ua

L TI
br
Fe

4
of thread can be removed and threads cleaned up with a tap C-1 UP
2
R

31
0
C-1
14

• Can be used with engine still installed in machine/vehicle

31
16
/B
76
31 31
UP
26

• Includes a drilling plate, alignment bushings, drill bushings, and drill bits

Item Part No. Description Quantity 1

1 188-3914 Drilling Plate
2 188-3915 Bushing Lock Screw 5 7
3 1U-8163 Drill, 8.5 mm 8
4 1U-8133 Drill, 2.5 mm ID: C80338T1
5 188-3923 Bushing, 8.5 mm (ID)
6 188-3918 Bushing, 2.5 mm (ID) Reference
7 188-3916 Bushing, 10 mm (ID) 4 NEHS0787, Tool Operating Manual
8 8T-4186 Bolt, M10 x 1.5, 40 mm long 4
9 6V-3072 Storage Case
10 188-3921 Foam Insert
11 NEHS0787 Tool Operating Manual
Not shown NEEG2895 Decal

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6V-7028 Spring Seat Enlarger

SMCS Code: 1101-023
Model: All Caterpillar Engines

• Used to machine larger spring seat diameter on 9N-1107 Cylinder Heads;

larger spring seat necessary to install large diameter valve springs and spacers
• Must be used with 1/2 inch electric drill (500-700 rpm) ID: B59028-1T1
Reference
SEHS8131 Special Instruction

227-4397 Socket, 1-1/8 inch 4C-6373 Valve Seal Installer

SMCS Code: 1101-010 SMCS Code: 1104-012, 0703
Model: 3406 Model: 3046 Diesel Engine
Warranty: Lifetime

• Allows mechanic to perform proper engine head service safely and efficiently • Used to install valve seal — easily installed using hand force
on 3406 Engines equipped with Jake Brakes • Prevents damage to valve seal during installation — saves time and
• Used to remove, install and torque extended-length head bolts reduces cost
• 1-1/8 inch deep well, thin wall impact • Knurled for ease of handling
• 3/4 inch drive, 6 point
• Industrial finish

Reference ID: C66692T1

SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engine

Cylinder Condition Analysis Tools

SMCS Code: 1100-023
Model: All Models Item Part No. Descriptionn
1 6K-5875 Hose Assembly
2 1P-5564 Adapter (D.I. Engines)
• Used to analyze cylinder condition on any Caterpillar engine 3 1P-5565 Adapter (Gas Engines)
• Pressurized air is introduced into cylinder; amount of pressure drop 4 Norgren Regulator Model #11-002-049
is indicator of piston ring and valve condition 5 3B-7767 Nipple (Modify nipple by filling with braze
and drilling a 1,02 mm (.040 inch) orifice
Reference hole through braze.)
GMG00694 Special Instruction 6 3B-7762 Tee
7 6V-4142 Nipple
8 9S-7341 Fitting (1/4 inch tube-1/8 inch pipe)
9 8S-2268 Tube Assembly
10 6V-4143 Coupling Assembly
7S-8897 Seal (Part of 7S-8895)
11 8T-0846 Gauge
12 1P-5569 Tip
13 1P-5567 Tip
Not shown 5K-5068 Nipple (two)

ID: C09527T1

9U-7995 Head Guide Pin Reference

SMCS Code: 1100-012, 0703 SENR6458 Special Instruction, Disassembly and
Model: 3046 Diesel Engine Assembly of 3046 Engine

• Used to align cylinder head during engine assembly — two required

• Simple to use (threaded guide pin has screwdriver slot for easy installation)
• Thread: M12 x 1.75
• Overall length: 115 mm (4.5 inch)

ID: C66685T1
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Electrical and Ignition Tools

152-1058 Head Bolt Socket

SMCS Code: 1100-010
Model: 3126B Engines
Essential Tool

Designed for bolt torque of 435 ± 20 N·m (322 ± 15 lb ft)

• Used to remove and install cylinder head bolts Socket size 20 mm, 12 point
• Fits into limited clearance around rocker arm shaft support Drive 3/4 inch
• Impact socket

ID: C79161T1

Electrical and Ignition Tools

6V-7913 Expansion Rod

Part No. Description
6V-7914 Collet 6V-7913 Expansion Rod
SMCS Code: 1450-023 6V-7914 Collet
Model: Delco-Ramy

• Used to remove small roller bearings from recessed holes (e.g., removal of 3T-0843 Roller
Bearing from its housing in 3T-6305 Electric Starting Motor)

ID: B63969T1

9U-7226 Installer Group

SMCS Code: 1104-012, 0703
Model: 3406E Engine

• Used to install valve stem seals — easily installed using hand force
• Prevents installation damage to valve stem seals
• Seals can be installed with cylinder head on or off the engine
• Knurled handles for better grip and zinc-coated to prevent corrosion
• Diameter: 22.2 mm (.87 in)
• Overall length: 140 mm (5.5 in)

Reference
ID: C66656T1
SENR5580 Service Manual

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6V-3025 Battery Cable Repair Kit

SMCS Code: 1402-023
Model: All Caterpillar Engines

• Used for fabrication or repair of 8 through 0000 gauge electrical cables

to include installation of splices or terminals
• Battery and lug-type terminals available from Parts Department
• Correctly done, connections meet Caterpillar and SAE specifications
Item Part No. Description
1 6V-3021 Crimping Tool — multiple dies for various cable sizes (AWG No. 8, 6, 4, 2, 1/0, 2/0, 3/0, 4/0)
2 6V-3022 Cable Cutter — can cut up to 500 MCM copper or aluminum cable

ID: B14012-1T1
Butt splices packaged individually Replacement Dies for 6V-3021 Crimping Tools
(each package includes piece of heat shrinkable insulation) • 1U-6659 Lefthand Die and 1U-6660 Righthand Die for replacement of worn or damaged
Part No. Description Quantity 6V-3021 Crimping Tool dies
6V-3020 Splice (0000) 2 • Retainer plate and 4 fasteners included
6V-3019 Splice (000) 3 • Lefthand die identified with letters A, E, H, J, K, M; righthand die identified with A, B, C, H, K
6V-3017 Splice (00) 4
6V-3018 Splice (0) 3
Reference
SMHS7677 Special Instruction

Ferrule Crimp Tools

SMCS Code: 1403-023
Model: SR4B Generators
Warranty: One Year

• Used to crimp insulated and non-insulated ferrules

• 139-2788 Crimp Tool works on 0.25 to 4.0 mm (.01 to .16 in) square ferrules (AWG 24-12)
• 139-2789 Crimp Tool works on 6 to 16 mm (.24 to .63 in) square ferrules (AWG 10-6)
• Both tools provide uniform, compact crimping on all four sides of ferrule resulting in positive conductor retention
• Once conductor crosssection is selected, crimping force is automatically controlled
• Tools have built-in ratchets to ensure complete crimping, and tool releases (opens) automatically when crimping operation is complete
ID: C44106T1

6V-3000 Sure Seal Repair Kit Item Part No. Description

SMCS Code: 1456-011 1 6V-3001 Crimping Tool
Model: 994 Engine 2 9G-3695 Sealing Plug (fifty)
3 6V-3008 Insertion Tool (Not included with early kits)
• Used to repair any wiring harness which has Sure Seal connectors 4 7N-7779 Socket (100)
• Used to make new wiring harnesses for attachments or modifications to vehicles 5 7N-7780 Pin (100)
6 Oil sample bottle used as container for alcohol lubricant
7 7N-7777 Receptacle, 1 pin (three)
7N-9738 Receptable, 2 pin (three)
7N-7781 Receptacle, 3 pin (three)
7N-8204 Receptacle, 4 pin (three)
9G-3678 Receptacle, 5 pin
9G-3677 Receptacle, 6 pin
9G-3676 Receptacle, 7 pin
9G-3675 Receptacle, 8 pin
9G-3674 Receptacle, 9 pin|
9G-3673 Receptacle, 10 pin
8 7N-7778 Plug, 1 pin (three)
7N-9737 Plug, 2 pin (three)
7N-7782 Plug, 3 pin (three)
7N-8205 Plug, 4 pin (three)
9G-3672 Plug, 5 pin
9G-3671 Plug, 6 pin
9G-3670 Plug, 7 pin
9G-3669 Plug, 8 pin
9G-3668 Plug, 9 pin
9G-3667 Plug, 10 pin
9 6V-3007 Box Assembly
10 NEEG2032 Insert

Reference
SMHS7531-01 Special Instruction

ID: B38426T1
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4C-3406 Deutsch Connector Repair Kit

SMCS Code: 1264-025, 1408-023
Model: 4C-3406: 3406B
4C-3501: 3406B PEEC, 3176
4C-3406 Deutsch Connector Repair Kit
Part No. Description Quantity
• Used to maintain and repair Deutsch connectors on electronic engine controls 1U-5804 Crimp Tool 1
• 4C-3406 replaces discontinued 1U-5803 Deutsch Connector Repair Kit 1U-5805 Removal Tool #14 5
• 4C-3501 Upgrade Kit for 1U-5803 contains only items in 4C-3406 missing from 7T-9742 Long Pin #16/18 50
1U-5803 7X-6195 Receptacle, 9 Pin 2
• Holes must be cut in the existing foam to store these new parts. 8T-5318 Removal Tool #16/18 10
8T-8729 Pin #16/18 50
8T-8730 Socket #16/18 50
8T-8731 Plug, 3 Socket 5
8T-8732 Receptacle, 3 Pin 5
ID: C27204T1
8T-8733 Plug, 5 Socket 5
4C-3501 Connector Upgrade Kit 8T-8734 Receptacle, 5 Pin 5
for 1U-5803 Deutsch Connector Repair Kit 8T-8735 Plug, 9 Socket 5
Part No. Description Quantity 8T-8736 Receptacle, 9 Pin 5
7T-9742 Long Pin #16/18 50 8T-8737 Plug Seal 50
7X-6195 Receptacle 9 Pin 2 8T-9834 Plug, 40 Socket 1
8T-9834 Plug, 40 Socket 1 9W-0844 Socket #14 50
9W-0847 Plug, 9 Socket 2 9W-0847 Plug, 9 Socket 2
NEEG2388 Decal 1 9W-0852 Pin #14 50
ID: C27205T1

1U-9710 Adapter Cable

SMCS Code: 1500-082
Model: Caterpillar Spark-Ingited Engines
Warranty: One Year

• Used with 6V-2100 Multitach to measure RPM on most Caterpillar spark-ignited engines
• Multitach owners have method of measuring RPM of spark-ignited engines
• 6V-2100 Multitach has digital LCD display

Required Tools
Part No. Description
6V-9060 Spark Timing Adapter Group (can be used with the 8T-5300 Engine Timing Indicator Group) ID: C27156T1
1U-9710 Adapter Cable
6V-2100 Multitach (or 6V-3121 Multitach Group)

1P-2977 Alternator Pulley Tool Group

SMCS Code: 1405-017, 1405-020
Model: Delco-Remy Alternators

• Used to remove pulley retaining nut on shaft of Delco-Remy 20-SI and 25-SI Series Alternators

Item Part No. Description Quantity

1 1P-7363 Seal 2

ID: C80221T1

8S-7227 Spark Plug Adapter Wrench

SMCS Code: 1555-011
Model: Multiple Engine Models

• Used for removing nodular iron spark plug adapters on G342, G353, G379, G398
• Inside diameter of nodular iron spark plug adapters is larger than inside diameter
of former brass or steel adapters; O.D. of 8S-7227 Wrench fits I.D. of nodular iron
adapters and prevents damage during adapter removal or installation
ID: C09520T1

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1P-5559 Spark Plug Adapter Wrench

2P-5481 Spark Plug Wrench
SMCS Code: 1555-011
Model: 5.4 inch Bore Natural Gas Engines
Warranty:

• Used to remove spark plugs and adapters on 5.4 inch Bore Natural Gas Engines (G342, G353, G379, G398)
• Especially useful because plugs and adapters are deeply recessed in top of engine
ID: C09346T1
• 1P-5559 Wrench:
Large end: 1.25 in
Small end: .75 in

176-7129 Terminal Removal and Installation Tool Assembly

SMCS Code: 1550-011
Model: All G3500 Non-CSA Electronic Ignition Engines

• Used to remove and install 169-4290 Terminal without removing 169-4295 Extension
• Saves time and money
• Threads easily into terminal
• Design permits quick replacement if shaft (127 mm long) breaks during service
• For removal: 1) insert shaft through spring and thread three revolutions into terminal;
2) pull terminal out
• For installation: 1) screw terminal onto shaft; 2) insert through extension;
3) snap onto transformer head; 4) loosen shaft from terminal ID: C79802T1

132-8263 Terminal Spanner Wrench

SMCS Code: 1409
Model: All G3500 and G3600 EIS Engines

• Used to install and remove 127-8893 Terminal Assembly

• Required to allow proper torquing of terminal assembly (2.70 ± 0.25 N·m, 24.0 ± 2.2 in · lb)
• Accurate torque is essential to avoid damage to terminal components; necked-down diameter
minimizes chance of over-torque

ID: C79272T1

4C-4601 Spark Plug Socket

SMCS Code: 1555-010
Model: G3500 and G3600 Engines
216-1685 Spark Plug Socket
SMCS Code: 1555-010
• Standard spark plug sockets and most deep well sockets cannot be used Model: G3516B (50 Hz), G3516B (60 Hz), G3520B (50 Hz), and G3500C
(these engines use spark plugs that have 18 mm threads, a 7/8 inch hex,
and long porcelain insulator)
• Contains internal grommet to retain plug in socket during installation and removal • Thin wall design eliminates possible socket interference
• Thin wall design eliminates possible socket interference • 1/2 inch drive, 103 mm overall length, 13/16 inch, 6 point hex
• Internal grommet for plug retention

Drive 1/2 inch

Overall length 103 mm
Hex 7/8 inch
Socket style 6 point

ID: C80594T1
ID: C79435T1

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235-9751 Spark Plug Driver Adapter Assembly

SMCS Code: 1555-010
Model: G3500C Engines
Essential Tool

• Used to remove and install 225-0902 Adapter (spark plug)

• Used with 3/4 inch ratchet
• Built-in pilot for easy engagement

ID: D00507T1

9U-7516 Spark Plug Gauge

SMCS Code: 1555-082, 0712
Model: 3300, 3400, 3500, and 3600 Spark Ignited Engines Engine Application Spark Plug Gap
3600 (.011 in)
3600 Ionization probe (.025 in)
• Used to check spark plug gap on spark ignited engines 3500 (.011 in)
• Compact size — easy to carry from job to job 3400 (.015 in)
• Gap wires are retractable — prevents damage when not in use 3400 J-gap (.012 in)
• Gauge has two of each size wires (four sizes in all) 3300 (.025 in)

ID: C66624T1

192-7039 Driver Assembly

SMCS Code: 4450-012, 0734
Model: DV096 Generator Set

• Used to install shaft seal for auxiliary water pump

• Used with hammer and suitable driver with 6.4 mm (.25 in) pilot
• Drive installer onto shaft until O.D. of tool contacts housing
• Saves time during pump overhaul by installing seal at exact location every time
(eliminates guess work)
Reference
Generator Service Manual

ID: C79926T1

6V-4960 AC Current Probe Current range 10A to 1000A rms

SMCS Code: 1400-038 Temperature range -10°C to +55°C (+14°F to +131°F)
Model: Caterpillar Generator Sets
Maximum conductor size 54 mm (2.125 in)
Warranty: One Year
Dimensions 39mm x 104 mm x 205 mm (1.54 in x 4.09 in x 8.07 in)
Cable length 0,9 m (3 ft)
• Used with Caterpillar’s Digital Multimeter for measuring AC current on Caterpillar
Generator Sets and any other application within its capability (see specifications) Frequency range 30 Hz to 1000 Hz
• Clamp-on probe replacing standard test leads of multimeter allowing current Temperature coefficient less than 0.010% per °C (0.006% per °F)
measurements to be made without breaking circuit being measured Circuit-to-ground voltage 650V rms maximum
• Extends AC current measuring ability of multimeter up to 1000 Amperes rms Accuracy at 23°C ± 5°C (73°F ± 9°F), 60 Hz ± 1% of input, 30 Hz
by use of 1000:1 current transformer to 1 kHz ± 2% of input
• Conductors up to 54 mm (2.125 in) diameter can be measured
• Convenient carrying case, available separately, holds 6V-4960 Current Probe
and Caterpillar’s Digital Multimeter (6V-3072 Carrying Case, 6V-6040 Foam
Insert and Decal, “SEHS8026 Electrical Test Kit”)
Item Part No. Description
1 6V-6014 Cable
Reference
SEHS8011 Special Instruction

Home
ID: B47264T1
Dealer Service Tools 2004 3-81
Electrical and Ignition Tools / Lube System Search Engine Tools

225-8266 Clamp On Ammeter

SMCS Code: 1400-038, 1400-081, 1450-038
Model: All
Warranty: Manufacturer’s

Compliant
• Used to measure AC or DC current • Designed with a built-in display, push button zero control for DC operation,
• Compact size and low cost make this unit indispensible “display hold” to freeze display, “max/min recording” to display highest
and lowest readings, auto power-off (unit turns off automatically after
• Clamp-on probe replaces standard test leads (allows current measurements
30 minutes), and low battery indicator
without breaking circuit)
• Shipped with batteries, carrying case, and user’s guide
• Measures current in cables up to 23 mm (0.9 in) diameter
• User selectable 400 Ampere and 1200 Ampere scales for both AC and DC
• Powered by two 1U-9533 AA Alkaline Batteries Weight 190 g (6.7 oz.)
Overall size 183 x 61 x 36 mm (7.2 x 2.5 x 1.4 in)
Resolution 1 Ampere

AC/DC CLAMP METER

Repair Information
OUTPUT

mA A AC 400 ZERO
Service Parts
V Hz 1200
OFF
COM

OFF
MAX/MIN CATE 30W Part No. Description Extech Instruments
CATE 40W
285 Bear Hill Rd.
1U-9533 AA Size Battery
COM

HOLD
0 10 20 30 40 Waltham, MA 02451-1064
225-8266 6V-6014 Cable
Ph: (781) 890-7440
ID: D00363T1 Fax: (781) 890-7864

Carrying Case and Accessories for Discontinued 8T-0900 Clamp-on Ammeter

Item Part No. Description

1 6V-3072 Carrying Case1
2 6V-6040 Foam Insert
3 Form SEHS8026 “Electrical Test Kit”
4 6V-6014 Cable
5 6V-7070 Digital Multimeter
1 Holds 6V-4960 Current Probe also

ID: B54461-1T1

Lube System

175-7546 Oil Filter Cutter Group

SMCS Code: 1318-040, 0678
Model: All Models

• Used to cut open spin-on filters to inspect filter media for contaminants,
a common practice when diagnosing potential machine problems and
internal contaminants.
• Aluminum frame construction
• Designed to cut all types of filters, including aircraft-style filters, without repositioning ID: Item
C80005T1 Part No. Description Required
cutting wheels 1 177-0364 Roller 2
• Heavy-duty double roller and cutting wheel design eliminates binding of filters 2 177-0365 Cutting Wheel 2
• All wear parts are heat-treated steel for added durability 3 177-0367 Pin 4
• Cutting wheels are ground with a double-taper edge for easier cutting Not shown 177-0366 Spacer 2

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4C-5084 Spin-on Oil Filter Cutter

Discontinued — Service Parts Available
Item Part No. Description
Reference
SEHS9160 Special Instruction 1 5P-4811 Cutting Wheel
133-5633 Spacer Insert
9U-5354 Shoulder Screw
2 9U-5356 Saddle
3 9U-5353 Roller
4 9U-5355 Roller Bracket
5 NEEG2002 Decal (Not Shown)
ID: C44398T1

4C-6780 Bushing Removal Tool Group

SMCS Code: 1166-028, 1304-028 and 0704
Model: 3208 Engines

• Removes oil pump bushing fast without damaging timing gear cover
• Works on both naturally aspirated and turbo charged engines Service Parts

• Marked for each engine for easy use Item Part No. Description
1 4C-6781 Bushing Removal Guide
2 4C-6782 Bushing Removal Punch

ID: C26959T1

9S-9273 Coupler
9S-9274 Plug
SMCS Code: 1325-044
Model: D8H, 583H, D9G, DD9G, 594 Length 70.6mm (2.78 in)
Diameter 50.8mm (2.00 in)

• Coupler is quick disconnect adapter for equipment that services high speed oil change attachment
groups; high speed oil change groups provide convenient method for both fill and evacuation of
engine crankcase oil, and a compatible quick disconnect coupler is essential for service equipment
that supplies and evacuates oil
• Minimal chance for airborne contaminates to enter engine during oil changes with high speed oil
change arrangement
• Three different nipples are used in various attachment groups; 9S-9273 Coupler accommodates
all three; steel cable lanyard provided for disconnecting coupler from nipple
• 9S-9274 Plug Assembly used to protect coupler from dirt and other contaminants when not in use
• Easier for customer to meet local regulations concerning oil spillage; leakproof seal created
when coupler connected to nipple; also, no leakage occurs when coupler engages nipple or ID: C27255T1
when connection is broken
• Has 41.3mm (1.62 in) hex for installing 3/4 inch-14 NPTF threaded end into service hose fitting
Item Part No. Description
1 9S-9273 Coupler
Not shown 9S-9274 Plug Assembly
2 1P-7919 Nipple, Bulkhead 37° Male, 1-1/16—12 Thd.
Not shown 8T-5373 Nipple, Face Seal Male, 1-3/16—12 Thd
Not shown 9S-9271 Nipple, 3/4—14 NPTF Thd. Male
Not shown 9S-9272 Cap Assembly (For the 3 Nipples)

Home Dealer Service Tools 2004 3-83

Lube System Search Engine Tools

246-4268 Coupler Rework Fixture Group

SMCS Code: 3279-010 246-4270
Model: 3524B Engine
246-4268

• Used to disassemble and assemble 3524B Engine coupling group

• Used with two 246-4269 Positioning Pin Assembly and two 246-4270 Positioning Pin
Assembly (part of group)
• Allows replacement of individual parts rather than entire group
• Mounts easily on 1P-2420 Transmission Repair Stand using four FT0996 Positioning Legs

Reference 246-4269
RENR2276-02 3524B Engine Service Manual, Disassembly and Assembly

ID: D00723T1

201-2592 Bit
SMCS Code: 1000-010, 0700, 0707
Model: MY2000, C-15, and C-16 Engines
Warranty: Manufacturer's
Male hex 7/16
Male square 5/16
• Special 5/16 inch bit used to remove the square socket oil gallery pipe plugs
Overall length 32 mm (1.25 in)
• Used with standard 7/16 inch socket and ratchet
ID: C80346T1

126-7538 Transmission Oil Nozzle Assembly

126-7539 Crankcase Oil Nozzle Assembly
SMCS Code: 5056, 5060, and 1325-044
Model: Multiple Engine Models

• Used to attach hose of high speed oil change equipment onto component being serviced on
D8R Track-Type Tractor (provides leakproof connection when installed)
• Nozzles help customers to more effectively meet local regulations concerning oil spillage
• Using high speed oil change equipment provides fast and convenient way to fill and
drain oil from components
ID: C66742T1
Part No. Description Length Diameter Thread Size Hex Size Installed to: Use with:
126-7538 Nozzle Assembly 78.7 mm (3.10 in) 48.5 mm (1.91 in) 3/4-14 NPTF 33.3 mm (1.31 in) transmission case oil drain 110-8319 Receiver Assembly
126-7539 Nozzle Assembly 83.8 mm (3.30 in) 54.6 mm (2.15 in) 3/4-14 NPTF 38.1 mm (1.50 in) engine crankcase oil drain 110-8827 Receiver Assembly

Engine Test Tools

Dynamometer Testing Facilities

Miscellaneous drawings available from Division Service Manager:

Engine Base Assembly for Dynamometer Room, Single Base Dynamometer Room, Miscellaneous
Miscellaneous Drawing 2002 Drawing 2014
• Provides details for constructing a very versatile base on which any engine Double Base Dynamometer Room, Miscellaneous
and stand can be secured for dyno testing
• Accomplished by movable tee hooks in permanent floor slots
Drawing 2001
• Provide construction details for single and tandem engine dyno test
arrangements
• Facilities include a roof-mounted exhaust stack which can be pulled up to
ceiling level by means of a winch and cable
• Plans include soundproof doors and acoustical walls and ceiling

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4C-3502 Engine Repair Indicator Kit

SMCS Code: 0781
Model: All Earthmoving Machines
Warranty:

• Designed for dealer Product Support Salesmen Part No. Description

• Consolidates many non-technical engine evaluation service tools into 8T-2844 Temperature Recorder Group
convenient, easy-to-carry-and-use kit; includes simple service tools which 8T-5296 Coolant Conditioner Test Kit
measure crankcase pressure, check coolant conditioner and allow for filter
1U-7264 Screwdriver (flat blade)
inspection
185-3630 Strap Wrench Assembly
• Allows more accurate check of general engine condition than possible with
casual walk-around inspection 214-7338 Ratchet (1/2 inch Drive)
• With Engine Overhaul Estimator (ordered separately), allows qualified 9S-1732 Extension — 127 mm (5.0 inch) (1/2 inch Drive)
personnel to predict possible repair options and to recommend improved 4C-4732 Filter Minder and Filter Service Indicator
customer maintenance practices 4C-4733 Crankcase Pressure Gauge
Consists of three parts: 4C-4730 Carrying Case
• Non-technical engine evaluation service tools (see consist below) and order 1U-7262 Magnet
form for Engine Overhaul Estimator 8H-8580 Putty Knife
• Engine evaluation worksheet which includes guidelines for walk- around 1S-0178 Fitting
inspection of machine’s engine and cooling system 5H-8936 Adapter
• Literature discussing proper engine maintenance practices 8T-9190 Water Bottle
4C-4731 Block Foam Lower
4C-4729 Block Foam Upper
4C-4730 Case
SEHS9037 Use of the 4C-3502 Engine Repair Indicator Kit
PEEP7234 Oil Change Labels (English)
PEEP8211 Engine Evaluation Worksheet
SEBD0717 Diesel Fuel and Your Engine
SEBD0518 Know Your Cooling System
PEDP6101 Repair Before Failure Testimonial
PEDP7101 Managing Preventive Maintenance Before Failure
SEBU5596 Identification Number Location Guide
SEBU6250 Caterpillar’s Machine Lubricant Recommendations
PEHP9013 Air Filter Indicator Facts Sheet
NEHG3012 Tool Announcement — Coolant Conditioner Test Kit
PEDP7105 Scheduling Oil Sampling
ID: C27082T1 SEBD0640 Oil and Your Engine

Reference
SEHS9037 Special Instruction

1U-8835 Scale
SMCS Code: 0781
Model: All Engine Models
Warranty:

• Optional inch scale used with 8T-0452 Gauge Assembly (slack tube manometer) to check gas pressures such as intake manifold or exhaust back pressure
• Easier to read when inch readings are referenced than standard centimeter scale

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Engine Test Tools Search Engine Tools

196-3165 Tool Kit, C-9 Engine

173-5533 Repair Stand Bracket 1 7, 8 9 2 3 4
SMCS Code: 1000-017, 0701
Model: C-9 Engine
5
• 196-3165 Tool Kit used to overhaul C-9 Engines (contains all tools unique to this engine) 11
• 173-5533 Bracket securely attaches C-9 engine to repair stand — bolts to engine
using breather assembly mounting holes 10
• Used with 173-5533 Repair Stand Bracket and 1U-5750 Engine Repair Stand
• Available as a kit or individual parts can be ordered separately

Engine Repair Stand with Adapter Bracket

Part No. Description
173-5526 Engine Stand Bracket
1U-5750 Engine Repair Stand
6 12
ID: C79991T1

Reference 196-3165 C-9 Engine Tool Kit

Service Manual for C-9 Engines Item Part No. Description
1 176-5487 Valve Spring Compressor
2 173-5523 Valve Seat Installer
3 173-5525 Valve Seat Puller
4 173-5524 Driver Valve Guide
5 191-6077 Injector Installer Bracket
6 173-5527 Cylinder Liner Puller
7 136-4632 Spring Loaded Timing Pin
8 139-7064 Spring Loaded Timing Pin Adapter
9 173-5528 Piston Ring Compressor
10 143-9731 Turbocharger Wrench (122 mm reach)
11 143-9730 Turbocharger Wrench (30 mm reach)
12 1U-7430 Front Crank Seal Installer
13 196-5469 Foam Insert
14 196-5472 Storage Case
Not shown NEEG2925 Decal
ID: C79992T1

9U-7530 Tool Kit, 3406E Engine

SMCS Code: 1000-017, 1000-036, 0701
Model: 3406E, C-15, C-16

• Contains tools to remove and install camshaft and cam Service Parts Service Parts
bearing, compress valve springs, install valve seals, valve
Part No. Description Part No. Description
seats, and valve guides, remove and install pendulum
damper, adjust injector prestroke, remove and install injector 9U-7256 Guide Assembly 9U-7227 Injector Height Gauge Assembly
sleeve, test and adjust adjustable idler gear, clean injector 9U-7240 Camshaft Lifting Hook (2 required) 9U-6891 Sleeve Tool Group
bores 9U-7257 Cradle Assembly 9U-7255 Adjustable Idler Assembly
• Also services cable connectors, and provides necessary 9U-7225 Camshaft Pilot (2 required) 9U-7324 Indicator Bracket
electronic cables to test, adjust, and troubleshoot 3406E 9U-7243 Alignment Sleeve 9U-6862 Small Tapered Brush
Engines
9U-7210 Puller Plate 9U-6863 Small Bore Brush
• Packaged in two plastic containers with foam inserts for
ease of handling and storage (Plastic cases and foam inserts 9U-7213 Backup Plate 9U-7244 End Brush,
are not serviced under Cat part number; if these items are 9U-7214 Spacer Plate 9U-7237 Drill Extension
needed, contact Caterpillar Service Technology Group) 9U-7222 Cam Bearing Pilot 4C-5552 Large Bore Brush
• Chart, packaged in each kit, identifies tool requirements by 9U-7223 Alignment Bushing 7X-1715 Adapter Cable Assembly
job and lists reference publication form numbers 9U-7241 Valve Spring Compressor Group 7X-1403 Adapter Cable Assembly
• Total weight: 48 kg (105 lbs.) 9U-7226 Valve Seal Installer Group 7X-1686 Adapter Cable Assembly
9U-6898 Valve Seat Driver 7X-1695 Timing Probe Cable
NOTE: Refer to part number in Tool Guide for individual 9U-6897 Valve Seat Driver 175-3700 DT Service Kit
features/benefits and picture of each tool listed. 9U-6895 Valve Seat Driver NEEG2581 3406E Tooling Reference Chart
9U-6894 Guide Collar
Reference 9U-6896 Guide Bolt
SENR5580 Service Manual

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195-0875 Marine Tool Kit

SMCS Code: 1000-023, 0699, 0701 Recommended Tool List
Model: 3116, 3126, 3126B, 3176, 3196 Marine Engines with Metric Fasteners Part No. Description
1S-0257 Ball Peen Hammer, 12 oz.
1U-5445 Wrench Group, Metric
• Used for basic engine repairs and maintenance
(provides a ride-along tool kit with specific engine tools) 1U-9579 WypAll Paper Wipers (bundle)
• 195-0875 Tool Kit is not serviced as a group (allows for 1U-9784 Combination Padlock
option of adding or deleting tools to fit the customers 5F-4764 Rolling Head Pry Bar, 16 inch
needs) 6V-6193 Diagonal Cutting Pliers, 17 1/2 inch
• 202-8643 Tool Box is a plastic, water-tight container 8H-8575 Extension Assembly
(will not rust or scratch like metal boxes) 8H-8576 Adapter
• Inch sockets and wrenches may be substituted or 9U-5028 Orange Hand Cleaner, 225 ml (7.5 oz.)
added to the kit
230-9519 Reversible Ratchet, 3/8 inch drive
• Tool box capacity: 9 kg (20 lbs)
9U-7290 Screwdriver Set
• Tool box decal: NEEG2916
141-1655 Inspection Light
146-2728 Flexible Pickup Tool
185-3630 Strap Wrench Assembly
ID: C80378T1
194-3574 3/8 Drive, 12 Point Metric Socket Set, 12 piece
202-8643 Tool Box (plastic)

Fuel System Test Tools

Hartridge AVM 20-12C Fuel Injection Test Benches —

132-9753 Fuel Injection Test Bench (480 Volt, 60 Hz)
Discontinued
139-1437 Fuel Injection Test Bench (480 Volt, 50 Hz)
Discontinued
SMCS Code: 1250-036
Model: Caterpillar Engines
Warranty: One Year

Maintenance Parts for Hartridge AVM 20-12C

Test Bench
• 147-1758 Filter Element used for filter block and metering unit (Hartridge
cross reference number 8850073)
• 134-5901 Spares Kit contains:
5 printer ribbons
10 rolls of printer paper
3 main fuses (63 amp), 3 fuses (10 amp)
one 135-6547 Filter for suction port of pump
• 135-6547 Filter used for suction port
• 1R-0749 Fuel Filter which traps particles down to 2 microns in size,
providing protection for test bench fluid

Repair Information
If test stand needs more than general maintenance or adjusting, contact
ID: C78467T1
original equipment manufacturer at the following locations.
Installation Requirements Hartridge
These items are necessary for installation and must be ordered separately. Assembly Technology and Test (ATT)
Hartridge Test Products
• 6V-6067 Calibration Fluid, 208.5 liter (55 gal), or 6V-6088 Calibration Fluid, Tingewick Road
19 liter (5 gal) Buckingham,
• 10W Engine lube oil Buchinghamshire
MK18 1EF
England
Reference
NEHP5618 Sales Brochure Switchboard: (0) 1280-828420
NEVN3781 Video, Introduction to the New AVM 20-12C Fuel Injection Test Bench (VHS) Fax: (0) 1280-828421
NEVP3781 Video, Introduction to the New AVM 20-12C Fuel Injection Test Bench (Pal) Web site: http://www.hartridge.com
NEVS3781 Video, Introduction to the New AVM 20-12C Fuel Injection Test Bench (Secam)
NEHS0663, Hartridge AVM 20-12C Test Stand

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Fuel System Test Tools Search Engine Tools

158-2262 AVM 2-PC Fuel Injection Equipment Test Stand

SMCS Code: 1250-036
Model: Caterpillar Engines
Warranty: One Year
Machine Basics

Compliant • Advanced Video Metering (AVM)
• Designed to Caterpillar specifications to test most injection pumps in the Cat product line. This
includes all Caterpillar-built pumps, Stanadyne DB2 and DB4 pumps used on 3054 and 3056 pre-
emission certified engines, and Zexel and Nippondenso pumps used on 3046, 3064, and 3066.
• Stanadyne, Lucas, and Bosch emission certified pumps may not be serviced by Caterpillar dealers.
• Complies with European CE marking directive and conforms with ECM standards
• Basic machine and metering unit complies with ISO4008, EEC, and UL/CSA standards (pump
mounting system, cooled nozzle block, and master nozzles are unique to Caterpillar)
• “DCdrive” and standard PC architecture allow modem or network connections
• Uses industry standard PC allowing future expansion
• Uses a direct drive, high-torque, 20 horsepower (15 kW) DC motor for low rpm performance
• An on-board air supply with electronic readout is available for setting FARC controls
• Electronic dynamic phasing
• Auto Step test plan editor and execution
• Pressure phasing to 80 bars
• Other features are two variable DC supplies, cooled metering unit, back leakage temperature
ID: C79444T1 measurement at pump outlet, analog speed trim for fine control of governors, digital pressure
displays, drive “nudge” control
• Used to test fuel injection system components for pump • This unit has many common parts currently used with standard Hartridge benches, resulting in
and line fuel systems on Caterpillar engines product support from Delphi Diesel Systems Worldwide

Machine Displays • All functions are menu controlled

• Control panel pivots to permit operation from either side of test stand • On-screen “analog” pressure gauges, a first in the test bench market, allows
• Display modes include; speed, pump output, phasing angle, pressure and test viewing trends and relative measurements while displaying numerical value
stand self diagnostic information for accurate setting
• With exception of oil pressure control valves and emergency stop buttons, a • Dynamic phasing display shows all pump phasing angles (±0.1°)
built-in computer and keyboard control test stand with user friendly simultaneously for rapid adjustment
Windows® • Self-diagnostic function will indicate motor over/temperature, air supply
• Pump output and test stand operating data are displayed on a 38 cm (15 in) failure, dirty filter, stalled motor, and low tank levels
color monitor • Built-in PC allows test data to be stored on standard database software or
print to color printer (not included). Operating data such as test plans can be
Nozzle Block entered, stored, removed and executed
• Cooled nozzle block dissipates heat, at its source, from high-energy
Caterpillar fuel pumps Service
• Articulated support arm pivots beneath front of table, allowing master nozzle • Built-in, self-diagnostic routines are used to detect internal machine
mount to be repositioned without disturbing pump mounting brackets problems, with faults and test results displayed on LCD screen
• Underslung multi-position master nozzle mount has vertical adjustment • All electronic circuits use solid state technology and feature simple plug-in
replacement boards
Injection Pump Mounting Information • All test oil supply and lube system components are located on left-hand side
• Standard Caterpillar pump mounting rail uses existing mounting accessories of bench
and hardware (not included) • All electrical and electronic services are on right side of bench

Testing Worldwide Compatibility

• “Intelligent Firing Order Learning” allows pump to be connected to test • Machines have multiple language capability. Current language choices are
injectors in most convenient way Dutch, English, French, German, Greek, Italian, Portuguese, Spanish, and
• Drive system automatically compensates for load variations (provides a Turkish.
constant, pre-selectable test speed within a range of 30 to 4000 rpm • The machines include the Manual on CD ROM in the following languages,
• All connections and associated valves are grouped together on the bulkhead, Dutch, English, French, German, Greek, Italian, Portuguese, Spanish, and
leaving a large unobstructed, self-draining work area at front of table for Turkish.
tools and fittings • Bench is CSA-approved.
• Powerful Hewlett-Packard computer controlled platform is flexible, and • Bench meets applicable CE directives when on-site commissioning is
upgradeable to meet future requirements and provides accurate metering and completed.
information management/documentation capabilities provide compliance
with current emissions and ISO standards Ordering Information
• High-speed, 12 cylinder advanced metering system reduces test time • 158-2262 AVM 2-PC, 380V to 480V, 50/60 Hz, 3 phase
Test benches are capable of operating in the 380-480 Volt range but actual
Operation voltage will be checked and or changed during the on-site commissioning by the
• Control console pivots to permit operation from either side of test stand authorized Hartridge agent.
• Keyboard height and angle are set to minimize strain On-site startup is provided by the manufacturer.
• Floppy and CDROM can be accessed from front of machine For 220-240 Volt applications a transformer is required.
• Computer and keyboard allow operator to enter data (speed) and observe
results (pump output) on display

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Installation Requirements On-Site Startup and Commissioning

A one-time on-site commissioning and basic bench training is included in the
price of the bench. This service is provided by Hartridge.
• Fuel injection pump mounting and drive hardware must be ordered
separately. Contact your Caterpillar Service Technology Group representative
2142.5 for ordering assistance.
mm
1860 514 Case size 191 x 114 x 209 cm (75 x 45 x 81 in)
mm mm
Gross weight 1170 kg (2580 lbs)
Net weight 970 kg (2140 lbs)
DC motor 14.9 kW (20 hp) high torque
Flywheel 1.8 kgm2 (43 lbft2)
380 mm 1845 mm Motor rpm 30 to 4000 rpm load compensating
850 320
mm mm Electrical supply for 20 hp: 380 to 480 Volt, 3 phase (80 amp max.)

ID: C79452T1 Current requirement 63 Amps, but 100 Amp service is recommended
These items are necessary for installation and must be ordered separately. Transformer requirements 208 to 240 Volt (38 kva) units require a 1U-5560
Transformer
• 6V-6067 Calibration Fluid [208.5 Liter (55 gal)] or 6V-6068 Calibration Fluid
Compressed air supply 6 bar (90 PSI)
[19 Liter (5 gal)]
Water supply 3.0 lpm (.06 gpm)
• 10W Engine lube oil preferred; 10w30 is acceptable
• 380V to 480V, 50/60 Hz, 3 phase (45 amp maximum)
• 3 lpm (.6 gpm) at 20°C maximum temperature at 1.5 bar pressure Computer
PC Routeco
Drive System
Processor Pentium P633
Motor DC Thyristor controlled, 15 kW (20 hp)
Hard disk drive 10 gigabyte
Speed range 30 to 4000 rpm
RAM 64 Mbyte
Speed/torque (rpm/N·m) 0/165, 590/165, 1500/95, 2500/51
Operating system NT Workstation
Floppy disk drive 3.5 inch 1.44 Mb
Continuous Operation Torque Ratings
CDROM drive —
Speed Control
Mouse (PS/2 connection)
Closed loop speed control system zero steady state droop
Serial ports two
Digital speed selection from computer application
Parallel port one
Analogue trim adjustment ±10%
Expansion standard ISA or PCI card interface
Acceleration rate 400 rpm per second
Industrial grade monitor 38 cm (15 in) (diagonal) color 800 x 600 SVGA
“Nudge” function orientates drive to aid pump mounting
Keyboard 102 key with protection membrane cover
Flywheel inertia 1.8 kgm2 (43 lbft2)
Flywheel brake air operated friction brake for emergency stop

Calibration System
Video display metering 12 line
Color display screen 38 cm (15 in)
Capacity 5 to 500 mm3, stroke with 3 measuring modes, calibrate, overcheck, and average
Selectable units (mm3/st, cc/50, cc/100, cc/125, cc/250, cc/300, cc/500) and adjustable scale via upper/lower limits entry
Back leakage flowmeter display 50 to 1500 cc/min or 3 to 90 l/hr
Units cc/min, l/hr, and cc/1000st

Instrumentation
On-screen display Resolution Stability Range Display Units
Tachometer numerical 1 rpm ±1 rpm — — —
Fuel Supply — — — 1 to 4 bars on-screen as numerical value bar, Mpa, PSI, mmHg, mbar, hPa, kPa
and analogue representation
Auxiliary A — — — 0 to 4 bars on-screen as numerical value bar, Mpa, PSI, mmHg, mbar, hPa, kPa
and analogue representation
Auxiliary B — — — 0 to 16 bars on-screen as numerical value bar, Mpa, PSI, mmHg, mbar, hPa, kPa
and analogue representation
Boost Pressure — — — 0 to 4 bars on-screen as numerical value bar, Mpa, PSI, mmHg, mbar, hPa, kPa
and analogue representation
Pressure Phasing 80 bar displayed — — — — bar, Mpa, PSI, mmHg, mbar,hPa, kPa
as numerical value
Lube Oil 7 bar displayed — — — — bar, Mpa, PSI, mmHg, mbar, hPa, kPa
as numerical value
Advance (optional) — 0.1 mm — ±10 mm — mm, DPA°, DPC°, Stanadyne°, Bosch°
Fuel Supply Temperature — — — 0 to 80°C numerical value on-screen °C (°F)
Back Leakage both temperature and — — 0 to 80°C — Flow units: cc/min, l/hr, and cc/1000str
flow numerical values (0 to 175°F)

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Phasing Repair Information

Pressure phasing standard, dynamic phasing optional, and angle of If test stand needs more than general maintenance or adjusting, contact original
rotation shown equipment manufacturer at the following locations.
Resolution display 0.1°
Hartridge
Range Resolution Assembly Technology and Test (ATT)
Static Phasing 0 to 360° 0.1° Hartridge Test Products
12-line Dynamic Phasing 0 to 360° 0.1° Tingewick Road
Buckingham,
Buchinghamshire
Hydraulic System MK18 1EF
Test Oil Supply and Controls England
Electric motor direct pump drive Switchboard: (0) 1280-828420
Pressure rating 550 l/hr and 0 to 4 bar (0 to 60 PSI) Fax: (0) 1280-828421
Pressure phase supply 0 to 80 bar Web site: http://www.hartridge.com
Tank 45 l (10 gal) capacity
Temperature Control
Temperature controlling ±2°C. Reference
Lube Oil Supply NEHS0724 Tool Operating Manual included with bench (may be ordered separately)
Pressure 250 l/hr and 0 to 4 bar
Tank 14 l (3 gal) capacity
Separate hours counters for
Fuel pump
Fuel filter with “change filter” message every 500 hours
Drive
Machine
Auxiliaries
Two DC supply outlets 0 to 25V at 3 amps, which can be parallel
connected to give 6 amps
Multipin 110V connector for external single cylinder calibrator and point of
injection transducers
Clock display real time
Socket for advance kit transducer

Hartridge Fuel Injection Equipment Test Stands—

6V-7900 Test Stand, 208/240 V
Discontinued
1U-8212 Test Stand, 440/480 V
Discontinued
1U-8213 Test Stand, 380/420 V
Discontinued
Repair Information
If test stand needs more than general maintenance
or adjusting, contact original equipment
manufacturer at the following locations.
Hartridge
Assembly Technology and Test (ATT)
Hartridge Test Products
Tingewick Road
Buckingham,
Buchinghamshire
MK18 1EF
England
Switchboard: (0) 1280-828420
Fax: (0) 1280-828421
Web site: http://www.hartridge.com

ID: B83895T1

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FIETS Nozzle Block and Lines

SMCS Code: 1251-036, 0706 9U-7693 FIETS Lines Group
Model: Fuel Injection Equipment Test Stand • Contains the following groups:
9U-7694 Nozzle Group Lines
9U-7697 Discharge Conduit Group
Nozzle block and replacement lines are applicable to all Fuel Injection Equipment 9U-7700 Discharge Lines Group
Test Stands (6V-7900, 6V-7901, 6V-7902, 6V-7903, 6V-9440, 1U-8212, 1U-8213) 9Y-6595 Oil Drain Lines Group
• 9U-7700 Discharge Lines Group — provides all new tubing from nozzle block to
graduates; includes new pulse dampers
Cooled Nozzle Block • 9U-7697 Discharge Conduit Group — bypasses constricting joints in swing arm
• Nozzle holding block uses test oil from phasing pressure circuit to carry
nozzle-generated heat back to sump where it is removed by heat exchanger • 9Y-6595 Oil Drain Lines Group — adds a third lube oil drain line to lube oil sump
(increases drain capacity required for large 3400 Engine pumps)
• Improves work environment by eliminating hot test oil vapors at graduates
• 9U-7694 Nozzle Lines Group — provides nozzle bleed return to test oil sump
• Reduces heat-related deterioration of test stand’s non-metallic lines
• Increases test stand accuracy by minimizing leaks
• Contains replaceable nozzle tip shields to prevent erosion of nozzle block
• Former nylon tubing replaced with teflon tubing for better abrasion resistance of
• Required when using latest test specifications (in TMI) tubes inside swing arm and longer life
• Required when testing pumps from higher horsepower 3400 Servies Engines • Flexible tubing is fuel, heat, and ozone resistant (used for pulse dampers and
lines to graduates)
• Internal routing of teflon lines redirected through front bearing support arm —
reduces kinking and makes line replacement faster and easier
• Corrects possible contamination of test oil from table drain tray on certain
vintage benches

Cooled Nozzle Block Parts

Item Part No. Description Quantity
1 128-5093 Block Nozzle 1
2 128-5094 Tip Shield Fitting 12
3 3J-1907 O-ring Seal 14
4 6L-5551 Socket Head Bolt 2
5 2H-3764 Bolt 2
6 5P-4400 Air Block Connector 12
7 7G-7105 Hose Assembly 2
ID: C66660T1
8 030-7947 Elbow 2

ID: C66661T1

ID: C66659T1 9U-7700 Discharge Lines Group

Item Part No. Description
9U7697 Discharge Conduit Group 1 1U-7648 Tube Cutter
Item Part No. Description 2 7K-8332 Tube SPT Insert
1 9U-7457 Conduit Bracket 3 9U-7702 Tube
2 9U-7458 Conduit Fitting 4 9U-7704 Sleeve
3 9U-7459 Flexible Conduit 5 9U-7705 Flexible Tubing
4 9U-7701 Arm Lining Tube 6 068-9941 Wire Tie
Not shown 8D-7712 Head Screw 7 9U-7699 Flexible Tubing
8 9U-7703 Flexible Tubing
9 9U-7706 Hose Clamp
10 NEHS0593 Tool Operating Manual

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9Y-6595 Oil Drain Lines Group

ID: C66663T1
Item Part No. Description
1 5D-1026 Clamp Hose
2 5G-4545 Tube ID: C66662T1
3 7M-7410 Pipe Plug
9U7694 Nozzle Lines Group
4 9U-7708 Fitting
Item Part No. Description
5 9U-7709 Flexible Tubing
1 5R-7136 Sealing Washer
6 9U-7710 Elbow Fitting
2 9U-7698 Tee Fitting
7 9Y-6595 Cap
3 9U-7699 Flexible Tubing
8 068-9941 Wire Tie
4 9U-7707 Flexible Tubing
5 9U-7706 Hose Clamp
Reference 6 068-9941 Wire Tie
NEHS0594-01, “Using the TMI System to Retrieve Off Engine Injection Pump Test Not shown 1S-9593 Cable Strap
Specifications for the FIETS”
SEHS8200 Special Instruction, “Caterpillar Fuel Injection Equipment Test Stand”
NEHS0593 Tool Operating Manual, “Installing the Replacement Lines on the FIETS”

6V-7904 Diagnostic Unit

SMCS Code: 1250-036
Model: Caterpillar Fuel Injection Equipment Test Stand

• Testing and troubleshooting tool for Caterpillar fuel injection equipment test stand • 28-position selector switch enables 27 monitor points to be read in turn
• Used to test drive system electronics of 6V-7900 Fuel Injection Equipment Test • Reading displayed on 3-digit display and also as positive or negative voltage
Stands (FIETS) level on row of 21 LEDs
• A must for troubleshooting speed control related problems • Only needed for FIETS that require 208/240 VAC power source; all other
• Checks total of 54 functions of FIETS drive system controls; saves time by rapidly FIETS requiring higher voltage sources have built-in diagnostic units
isolating problem area to quickly return FIETS to operation
• Plugs into either 545 controller or 5401 field unit Reference
SEHS8200 and SEHS8202 Special Instructions

Fuel Injection Tube Assemblies

SMCS Code: 1250-030, 0706
Model: Caterpillar Fuel Injection Test Bench (FITB) and Fuel Injection Equipment Test Stand (FIETS)

• Bend-to-fit lines that reduce need for special fuel injection lines
• Data available in TMI uses 9U-6705 Master Nozzles and 9U-5298 and 9U-5299 lines
(see SEHS0594)

Reference
NEHS0594 Tool Operating Manual “Using TMI to Find Pump Specifications”
SEHS8200 Special Instruction (FIETS) ID: C66642T1
Part No. Description Overall Length Use
LEBQ0724 Technical Marketing Information (TMI)
9U-5298 Fuel Injection Tube Assembly 76 cm (30.0 in) Used for testing all in-line pumps and 3208
9U-5299 Fuel Injection Tube Assembly 127 cm (50.0 in) Used for testing all 3400 Vee pumps

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9U-6705 Master Nozzle Group

SMCS Code: 1251-030, 0706
Model: Caterpillar Fuel Injection Test Bench (FITB) and Fuel Injection Equipment Test Stand (FIETS), AVM

• Replaces discontinued 1U-5500 Master Valve Assembly, 9U-5024 Master Valve Assembly,
and 6V-9470 Master Valve Assembly
• Used to test fuel pump delivery rates on FITB and FIETS
• Has improved accuracy of ±1% with four-orifice tip (greatly improved over former valve
assemblies with ±5% accuracy)
• Required when using new pump performance test specifications available in TMI Service Parts

• Use with 9U-5298 and 9U-5299 Tube Assemblies (high pressure fuel lines) Part No.
ID: C66649T1
Description
9U-5037 Bleed Fitting
8T-0659 Bleed Fitting Washer
Reference 7W-4486 Sealing Washer
SEHS8200 Special Instruction (FIETS)
NEHS0594 Tool Operating Manual “Using TMI to Find Off-Engine Test Specs”
LEBQ0724 Technical Marketing Information (TMI)

1P-1795 Valve Group

SMCS Code: 1250-030, 0706
Model: Caterpillar Fuel Injection Test Bench and Caterpillar Fuel Injection Equipment Test Stand

• Used on fuel injection equipment test stands ordered before January 1, 1985
• Only used on Kent Moore 8 cylinder bench

Reference
ID: C55047T1
SEHS8200 Special Instruction, use of master valves

Storage Bags
SMCS Code: 1250-036
Warranty: Manufacturer’s

• Keep fuel lines sealed and protected from dust and dirt
• Ziplock closure prevents oil and other greases from leakage
• Printed with 2-color Caterpillar logo, black part number, and a white area that can be
written on to identify the parts inside the bag
• Transparent so the parts can be visibly identified
• May be used for a variety of purposes
• 3 sealed hang holes on top of bag spaced to fit standard one inch pegboard hooks

Item Part No. Description Outside Dimensions Ziplock closure Clear vinyl back and front
1 152-0789 Storage Bag 22 in x 30 in top (22 in) of bag 10 mil. ID: C66968T1
2 152-0788 Storage Bag 18 in x 24 in top (18 in) of bag 10 mil.

NEHS0594 Using TMI for Finding Injection Calibration Fluid

Pump Off Engine Test Specifications SMCS Code: 1254-025, 1250-036, 1254-038, 1254-081
Model: Caterpillar Fuel Injection Test Bench and Caterpillar Fuel Injection
SMCS Code: 1251-036, 1251-082, 0730 Equipment Test Stand
Model: Fuel Injection Equipment Test Stand
Warranty: None
• SAE J967 (ISO 4113) Calibration Fluid recommended by Caterpillar for use
• Contains complete instructions to obtain test specifications through TMI on in fuel injection test benches, 5P-4150 Nozzle Tester Group and 6V-4022
Cat Network Injector Tester
• New data format gives larger selection of data for each pump (does not require
resetting pump)
Part No. Description Size
• Data can be obtained using injection pump and governor group part number,
or engine arrangement number 6V-6067 Calibration Fluid 208 l (55 U.S. gal.)
• Most current data is always available on line 6V-6068 Calibration Fluid 19 l (5 U.S. gal.)

Reference
LEBQ0724 TMI Technical Marketing Information

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4C-8192 Heavy Duty Drive Group

SMCS Code: 1250-036
Model: 3406, 3408, 3412 PEEC

1
• Used to adapt fuel injection pump drives to drive spindle on fuel injection
equipment test stand 3b
• Used with 6V-7900 Test Stand, Series Fuel, 1U-8212 Test Stand, 440/480 V, 3b
and 1U-8213 Test Stand, 380/420 V 2
• Coupling provides increased service life and is compatible with all past
Caterpillar mounting and drive hardware
• Drive group is required for testing 3408-3412 PEEC pumps

Item Part No. Description

1 4C-8186 Flex Coupling Hub 3a 3
2 1N-7284 Flex Coupling Bolts
3 4C-8187 Flex Coupling (includes 12 bolts, nuts and washers)
3a 4C-8188 Disc Pack (includes 12 disc pack, 6 bolts, washers
and nuts) (service repair) 4
3b 4C-5720 Bolt Group (includes 6 bolts, washers and nuts) 7
(service repair)
7a
4 4C-8190 Hub 7b
5 4C-8189 Drive 5
6 1T-0720 Bolt
7 4C-8723 Jaw Assembly
7a 1R-5396 Bolt
7b 6V-5683 Bolt
6
8 4C-8191 Drive Coupling Guard Assembly
9 6V-3940 Bolt 8
10 126-1827 Drive Rotation Rod
Not shown 4C-8193 Drive Adapter
10
Not shown 4C-8194 Drive Adapter
Not shown FT2469 Rail Rework Drawing
9
ID: C66917T1

Reference
SEHS8200 Special Instruction, and NEHS0624 Tool Operating Manual

Pressure Gauges
SMCS Code: 1251-030, 0782
Model: All Models with Pump and Line Fuel Systems

• Used to replace original gauges on 6V-7900, 1U-8212, and 1U-8213 Fuel Injection
Test Benches, and 132-9753 and 139-1437 (AVM)
• Replaces without modifying test stand
• Displays both kPa and PSI
• Diameter: 102 mm (4.0 in)
• 1/4 inch NPT lower back connection
• Liquid-filled, chrome-plated cast brass case
• Clamp and profile ring included for panel mounting
ID: C54502T1

Reference Part No. Description Replaces Hartridge Gauge

SEHS8201 Special Instruction 9U-6099 Pressure Gauge -100 to +4000 kPa (-14 to 580 PSI)
9U-6100 Pressure Gauge 0 to 700 kPa (0 to 101 PSI)
8T-7637 Pressure Gauge 0 to 7000 kPa (0 to 1015 PSI)
8T-7638 Pressure Gauge 0 to 1400 kPa (0 to 203 PSI)

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9U-7840 Calibration Fluid and Diesel Fuel Test Kit

SMCS Code: 1250-036, 0782
Model: FIETS, FITB, AVM, All Caterpillar Engines

• Used to measure viscosity and specific gravity of SAE J967D (ISO4113) calibration fluid
• Used with fuel injection equipment test stand (FIETS) and fuel injection test bench
(FITB) — helps to maintain accuracy of test equipment
• Performs test to make sure calibration fluid in test equipment is within specifications
• Saves money — fluid is not changed prematurely
• Beakers made from durable Nalgene — will not shatter
• Viscosity cup is individually calibrated for each test group — cup and calibration chart
marked with individual serial number (matched set)
• Used to correct measured horsepower for density of fuel when testing engines on
dynamometers ID: C66641T1
Case (W x L x D) 33 x 40.5 x 15.3 cm (13.0 x 16.00 x 6.00 in)
Item Part No. Description
Weight 2 kg (5.0 lbs.)
1 9U-7839 Stopwatch
Viscosity cup indivdually serialized (includes calibration sheets)
2 1P-7438 Beaker
Beaker material Nalgene
3 5P-2712 Hydrometer, 39°-51°, API
Reference 4 1P-7408 Hydrometer, 29°-41°, API
SEHS8200 and SEHS7466 Special Instructions 5 9U-7842 Beaker
NEHS0607 Tool Operating Manual 6 4C-3975 Plastic Case
NEHS0631 Tool Operating Manual, “General Maintenance for FIETS” 7 9U-7841 Viscosity Cup
Not shown 9U-7917 Button Battery (one required)
NEHS0640 Tool Operation Manual, “Installing Fuel Suction Port on the FIETS”
Not shown NEEG2600 Decal

136-8330 Basic Mounting/Setup Group

SMCS Code: 1250-036
Model: All Fuel Injection Equipment Test Stands (FITB, FIETS, and AVM)

• Replaces discontinued 1U-7426 Pump Adapter Group

• Used to adapt injection pump mounting and drive groups to test stand
1
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Group has been updated to eliminate non-current tooling and add new required tooling
• Tooling is required for off-engine testing of injection pumps and governors
• Parts are serviced separately to reduce dealer cost (no need to purchase tools
already in inventory) 2

3
4
Mounting Hardware
Item Part No. Description Quantity
1 6V-9133 Fixture Assembly 1
2 6V-6103 Screw Assembly 2
3 6V-9134 Screw Assembly 2
4 6V-9138 Clamp Assembly 2
5 6V-9132 Fixture Assembly 1
5

ID: C54987T1

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1 Additional Hardware (Dependent on Pump Model)

Part No. Description Quantity
6V-7793 Coupling Group 1
4L-5937 Injection Pump Fuel Line Assembly 6
A B

3P-1539 Injection Pump Fuel Line Assembly 8

1P-1795 Valve Group 8
2 1U-5223 Valve Fitting 6

Part No. Where Used

3
6V-9132 adapter to bench rails (front)
6
7G-7105 #6 (37 degree) [9/16-18 thread x 965 mm (38.0 in) long]
4L-5937 1.60 mm (.063 in) ID x 431.8 mm (17.00 in) long
7
8N-5132 for master nozzle
1P-1795 original nozzle for injection pump test benches
4 1P-3520 governor shaft, rack adjustment
3P-1539 1.60 mm (.063 in ID x 533.4 mm (21.00 in) long
5
5P-6515 injection pump flushing lines
1T-0416 for master nozzle
1U-5223 bleed return for 1P-1795
9U-5298 1.83 mm (.072 inches) ID x 762 mm (30.0 in) long
9U-5299 1.83 mm (.072 inches) ID x 1270 mm (50.0 in) long
8 9U-6705 for master nozzle
3V-2744 #4 (37 degree) [7/16-20 thread x 610 mm (24.0 in) long]
6V-6103 fixture assembly to bench rails (long)
6V-7793 drive adapt Hartridge 20.00 mm (.787 in) jaw
Lines and Testing Hardware 6V-9133 adapter to bench rails (rear)
Item ID: C79291T1
Part No. Description Quantity 6V-9134 fixture assembly to bench rails (short)
1 1P-3520 Control Group 1 6V-9138 fixture assembly to bench rails
2 126-1827 Rod 1 031-2125 #4 (37 degree) [7/16-20 thread x 1016 mm (40.0 in) long]
3 7G-7105 Hose Assembly 3 126-1827 drive coupling rotation (CAT heavy duty)
4 3V-2744 Hose Assembly 1
5 031-2125 Hose Assembly 1
Service Parts for 1P-3520 Control Group
6 9U-5299 Fuel Line Assembly 12
Item Part No. Description Quantity
7 9U-5298 Fuel Line Assembly 8
1 1P-3493 Bracket 1
8 5P-6515 Lines Group 2
2 2J-6356 Ring 1
3 1P-3487 Lug 1
4 1P-2335 Sleeve 1
5 1A-8285 Nut 1
6 1P-2333 Knob 2
7 1P-3492 Stud 1
8 1P-2333 Knob 2
9 1P-3486 Pin 1
10 1P-3494 Yoke 1
11 1P-3491 Pin 1
12 3B-4609 Pin 1
13 1P-3488 Stud 1
14 6D-4396 Lever 1
15 1A-2029 Bolt 2

Reference
NEHS0593, 9U-7693 Lines Group (Hartridge Bench Upgrade)
NEHS0594, TMI Specification
NEHS0607, 9U-7840 Calibration Fluid Test Kit
NEHS0624, 4C-8192 Heavy Duty Coupling Group (Hartridge Bench UpGrade)
NEHS0625, Tool Operating Manual (3408/12, PEEC NSFS)
NEHS0631, FIETS General Maintenance and Trouble Shooting
NEHS0639, Tool Operating Manual (3406B and 3406C, PEEC NSFS)
NEHS0640, Tool Operating Manual (Calibration Fluid Suction Port)
SEHS7466, FITB Manual (Kent Moore Bench)
SEHS8024, 6V-6070 Governor Adjustment Tool Group
SEHS8200, FIETS Manual (Hartridge Bench)
SEHS9318, 3161 Woodward Test and Adjustment
SMHS7013, 5P-4203 SMFS Tool Group
ID: C66950T1

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6V-3116 Sleeve Metering Adapter Group

SMCS Code: 1250-036
Model: 3208 and 3300 (SMFS) Engines

• Used to mount and test SMFS injection pumps and governors 1 2

• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Group has been updated to eliminate non-current tooling and add new required tooling
3
• Tooling is required for off-engine testing of injection pumps and governors
• Parts are serviced separately to reduce dealer cost (no need to purchase tools already
in inventory)

Item Part No. Description Where Used Qty.

1 2P-8315 Bracket Assembly injection pump housing to fixture assembly 1
2 0S-1588 Bolt bracket assembly to fixture assembly 3
3 1P-7395 Screw hold injection pump housing in bracket 4
5
4 6V-2107 Adapter Assembly injection pump camshaft drive (part two) 1
4
5 6V-2110 Adapter Assembly injection pump camshaft drive (part one) 1
ID: C66951T1

Additional Required Hardware

The following list of hardware is required, but not included as part of the 6V-3116 Adapter Group Sleeve Metering System.
This tooling can be purchased as needed.

Required Hardware for 6V-3116 Adapter Group

Part No. Description Where Used Quantity
6V-9132 Fixture Assembly bracket assembly to rail system (front) 1
6V-9134 Screw Assembly fixture assembly to clamp 1
6V-9138 Clamp Assembly fixture assembly to rail system 1
7G-7105 Hose Assembly fuel supply #6 (37 degree) 1
3V-2744 Hose Assembly fuel return #4 (37 degree), 610 mm (24.0 in) long 1
5P-5008 Reduce #6 (37 degree) to #4 (37 degree) for fuel return 1

Additional Hardware (dependent on pump model)

Part No. Description Where Used Quantity
5P-4203 Tool Group used with sleeve metering fuel system 1
031-2125 Hose fuel return #4 (37 degree), 1016 mm (40.0 inches) long 1
8K-0968 Elbow Fitting V8 fuel supply 1/2-20 thread to #6 (37 degree) 1
5P-2618 Straight Fitting V8 fuel supply 1/2-20 thread to #6 (37 degree) 1
1J-9671 O-ring Seal #5 fitting, fuel supply 1
8L-6557 Fitting #4 (37 degree) to 1/8-27 NPT external 1
3J-7352 Fitting #4 (37 degree) to 7/16-20 thread O-ring 1
3J-7354 O-ring Seal #4 fitting, fuel return 1
5P-3501 Adapter 9/16-18 thread O-ring to 1/4-18 NPT internal 1
3J-1907 O-ring Seal #6 fitting 1
5P-4675 Adapter 1/2-20 thread O-ring to 1/4-18 NPT internal 1
1J-9671 O-ring Seal #5 fitting 1
4H-0553 Fitting 1/8-27 NPT external to 1/4-18 NPT internal 1
3N-6938 Sight Gauge fuel system sight gauge 1
1P-3520 Control Group governor shaft 1
6N-3646 Lever V8 governor control shaft 1
2A-0762 Bolt lever to V8 governor control shaft 1
5P-0537 Washer lever to V8 governor control shaft 1
9M-3858 Spring governor control shaft preload 1
6K-5741 Valve shut-off cock for fuel system 1

Reference Lines and Master Nozzles (dependent on pump model)

NEHS0594 TMI Data Part No. Description Where Used Quantity
SEHS8200 FIETS Manual 3P-1539 Injection Tube Assembly 1.6 mm (.063 in) x 533 mm (21.0 in) long injection lines (IV-M data) 4, 6, or 8
SMHS7013 Tool Group SMFS 9U-5298 Injection Tube Assembly 1.8 mm (.072 in) x 762 mm (30.0 in) long injection lines (TMI data) 8
1P-1795 Master Nozzle Assembly FIETS IV-M data 4, 6, or 8
9U-6705 Master Nozzle Assembly FIETS IV-M data or TMI data 4, 6, or 8

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6V-2009 Adapter Group

SMCS Code: 1250-036
Model: 3204 and 3300 Engines (NSFS)

• Used to mount and test fuel injection pump and governor groups
(tooling is required for off-engine testing) 2
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Group has been updated to eliminate non-current tooling and add new required tooling 3
1
• Parts are serviced separately to reduce dealer cost (no need to purchase tools already
in inventory)
4
5 6
Item Part No. Description Where Used Quantity 7
1 8M-2530 Bolt used with 6V-2101 4
2 6V-2101 Drive Adapter adapts injection pump cam 1 8
12
3 6V-7846 Drive Adapter adapts injection pump cam 1
9 11 13
4 0L-1351 Bolt 3/8-16 x 22.4 mm (.88 in) long, 1
lube adapter to injection pump
5 1A-2029 Bolt 3/8-16 x 28.5 mm (1.12 in) long, 1 14 10
lube adapter to injection pump
6 8S-2331 Bolt used with 6V-7846 1
7 5P-5008 Reducer #6 (37 degree) to #4 (37 degree) 1
for fuel return hose
8 3J-7354 O-ring Seal fuel return fitting 1
9 030-7946 Elbow fuel return #4 (37 degree) port 1 15
10 032-1268 Elbow lube oil supply adapter 1 16
11 5F-7054 O-ring Seal lube oil drain adapter 1
12 2H-3932 O-ring Seal lube oil supply adapter 1
13 6V-0194 Lube Adapter injection pump oil supply and drain 1
14 9U-5297 Cover cover fuel transfer pump opening 1
15 2A-0762 Bolt for 9U-5297 2
16 6V-0120 Mounting Plate mounts to 6V-9132 1
17 3M-0496 Stud 3/8-16 x 65.0 mm (2.56 in) long, 3
mounting plate
18 6V-8801 Nut 3/8-16 mounting plate 3
17
19 1A-2209 Bolt 3/8-24 mounting plate to 6V-9132 4
22
20 9U-7705 Tube lube oil drain 1 21
21 2R-6806 Connector fuel supply #6 (37 degree) port 1
18 19
22 3J-1907 O-ring Seal fuel supply fitting 1

Additional Required Hardware

The following list of hardware is required, but not included as part of the 4C-8200 Mounting
and Drive Group. This tooling can be purchased as needed.

Part No. Description Where Used Quantity

6V-9132 Fixture Assembly front adapter support 1
6V-9138 Clamp Assembly fixture assembly to rails 1 20
6V-9134 Screw Assembly fixture assembly to clamp 1
7G-7105 Hose fuel supply and oil supply #6 (37 degree) 2
ID: C66953T1
031-2125 Hose fuel return #4 (37 degree) 1
Gasket (make from gasket material) for 9U-5297 1 Additional Hardware (dependent on pump model)
Part No. Description Where Used Quantity
6V-6070 Tool Group adjust governor 1
Reference FT2532 Oil Shield for 6V-2014 1
SEHS8200 FIETS Manual and NEHS0594 TMI Data

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135-2916 Mounting Drive Group

SMCS Code: 1250-036
Model: 3406B, 3406C, and 3406 PEEC Engines

• Replaces discontinued 6V-4990 Adapter Group

• Used to mount and test fuel injection pumps
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Tooling is required for off-engine testing of injection pumps
• Parts are serviced separately to reduce dealer cost (no need to purchase
tools already in inventory)

Item Part No. Description Quantity Item Part No. Description Quantity
1 6V-6101 Plate Assembly 1 14 2A-0762 Bolt 2
2 6V-8801 Nut 5 15 9U-5297 Cover 2
3 1J-8668 Stud 5 16 8T-2848 Plug 1
4 0L-1143 Bolt 3 4W-0435 Quad Ring Seal 1
8T-2849 Plug 1
5 9U-7709 Drain Tube 1 4W-4616 Quad Ring Seal 1
6 5D-1026 Hose Clamp 1 7H-2069 Bolt 1
7 7G-7105 Hose Assembly 3 17 030-7947 Fitting 1
8 5P-6661 Fitting 1 18 3J-1907 O-ring Seal 2
9 6V-6102 Support Assembly 1 19 1W-3151 Orifice Fitting 1
10 1S-0004 O-ring Seal 1 20 6N-3646 Lever 1
11 0S-1591 Bolt 1 21 5P-0537 Washer 1
12 8S-5953 O-ring Seal 1 22 2A-0762 Bolt 1
13 3B-1915 Bolt 1 23 9M-3858 Spring 1
24 6V-8918 Bolt 1

ID: C55110T1
Additional Required Hardware
The following list of hardware is required, but not included as part of the 135-2916 Mounting Drive Group.
This tooling can be purchased as needed.

Drive Adapters for 4C-8723 Jaw Assembly

ID: C66945T1
Item Part No. Description Where Used Quantity
1 6V-6097 Camshaft Drive Adapter Assembly camshaft drive (10 degree helix with 50 teeth)
2 1U-8700 Camshaft Drive Adapter Assembly camshaft drive (15 degree helix with 50 teeth)
3 4C-8249 Camshaft Drive Adapter Assembly camshaft drive (15.615 degree helix with 52 teeth)
4 6V-6099 Camshaft Drive Shield Assembly
5 4L-7124 Bolt 4
6 0L-1143 Drive Adapter to Injection Pump Cam Bolt bolt, drive adapter to injection pump cam 3

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Drive Adapters for 4C-8192 Heavy-Duty Coupling Item Part No. Description Quantity
1 4C-8193 Camshaft Drive Adapter Assembly
2 4C-8194 Camshaft Drive Adapter Assembly
5 3 126-1826 Camshaft Drive Shield Assembly
4 Pusher Bolt
5 0L-1143 Drive Adapter to Injection Pump Cam Bolt 3
6 8H-0707 Bolt 4

1 Adapter Part Numbers and Usage

4 4C-8192
4C-8723 Heavy-Duty
Jaw Coupling
6 Usage Assembly Group
3406 Truck Engine — 7FB and 6V-6097 6V-6097 1
4MG3600-DOWN
10 degree Helix with 50 teeth
3406B PEEC Engine — 8TC 1U-8700 4C-8193 2, 3
3406B Truck Engine — 4MG3600-UP
15 degree Helix with 50 teeth
2 3406B PEEC Engine — 3ZJ 4C-8249 4C-8194 2, 3
3406B Truck Engine — 4MG3600-UP
3 15.615 degree Helix with 52 teeth
1 Attach the 4C-8723 Jaw Assembly onto the 4C-8192 Heavy-Duty Coupling Group.
ID: C66943T1 2 Requires 126-1826 Oil Shield Assembly on 6V-6101 Plate Assembly.
3 Requires 4C-8189 Drive Tube.

Test Hardware (PEEC and Non-PEEC Engines)

Item Part No. Description Quantity
8 9 1 8T-1002 Electronic Position Indicator Probe 1
(Part of 8T-1000 Electronic Positioning Group)
7 2 5P-4160 Contact Point 1
10 11 3 5P-4814 Collet 1
6 4 7B-2742 Bolt 1
5 8T-9198 Bracket Assembly 1
6 0S-1615 Bolt 1
5 7 9U-6705 Nozzle Master 6
8 9U-5298 Injection Line Assembly 6
4 9 6V-4186 Pin Rack Zero and Timing 1
Rack Positioning Hardware (3406 Non-PEEC)
3 2
10 9U-5296 Positioning Assembly (Non-PEEC)
1 (3406B and 3406C Rack Adjustment)
ID: C54985T1 11 4F-7957 Bolt

Rack Positioning Hardware (3406 PEEC Engines)

3
Item Part No. Description
1 9U-5292 Rack Pre-load Assembly
2
2 9U-5295 Rack Positioning Assembly
3 9U-5120 Wrench

ID: C54984T1
Reference
NEHS0594 TMI Specification; NEHS0624 Tool Operating Manual; NEHS0639
Tool Operating Manual; SEHS8200 FIETS Manual

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6V-6046 Adapter Group

SMCS Code: 1250-036
Model: 3408 and 3412 Engines (Non-PEEC CSFS)

• Used to mount and test scroll fuel injection pumps and governors 9U-7501 Drive Assembly and 9U-7503 Flange
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM) • Replaces discontinued 1U-5076 Drive Adapter and 1U-5066 Drive Stud
• Group has been updated to eliminate non-current tooling and add new • New tooling provides drive system with more torque transmitting capacity
required tooling
• Tooling is required for off-engine testing of injection pumps and governors 6V-6053 Spill Manifold
• Parts are serviced separately to reduce dealer cost (no need to purchase tools • Required for testing some 12 cylinder injection pumps
already in inventory) • Used with test benches having 10 horsepower or less

Updated Parts
136-3850 Fixture Assembly Reference
SEHS8200 FIETS Manual and NEHS0594 TMI Data
• Replaces discontinued 6V-6054 Fixture Assembly
• Provides a larger rear pump support
• Attaches to rail using two bolts
2
• Uses larger bolts to attach pump housing to rear support 3

1
Item Part No. Description Where Used Quantity 4
1 1T-0720 Bolt drive assembly to flange 2 5 7
2 9U-7503 Drive Flange pump cam drive 1
3 030-7947 Fitting fuel and lube oil supply 2
4 4N-1828 Fitting Orifice fuel return system #4 (37 degree) 1
8 6
5 3J-1907 O-ring Seal fuel and lube oil supply fitting 2 10
6 9M-6590 Bolt pump cam drive 4 11
7 9U-7501 Drive Assembly flange to bench coupling 1
8 9B-7237 Bolt pump housing to 136-3850 2
9 2J-5245 Bolt rear pump support to fixture 2 9
10 136-3850 Fixture Assembly rear pump support to fixture 1
11 1S-0004 O-ring Seal pump housing to 136-3850 2
12
12 1U-6774 Mounting Plate mounts injection pump to 6V-9132 1
13 1A-2209 Bolt plate to 6V-9132 4
14 9U-7705 Tube lube oil drain 1

13
Additional Required Hardware
The following list of hardware is required, but not included as part of the 6V-6046
Adapter Group. This tooling can be purchased as needed.

14
Part No. Description Where Used Quantity
Required Hardware for 6V-6046 Adapter Group ID: C66954T1
6V-9132 Fixture Assembly front adapter support for V8 and V12 1
6V-9133 Fixture Assembly rear support for V12 pumps 1
6V-9138 Clamp Assembly fixture assembly to rails 2
6V-9134 Screw Assembly fixture assembly to clamp 2
7G-7105 Hose fuel supply and oil supply #6 (37 degree) 2
031-2125 Hose fuel return #4 (37 degree) 1
5P-5008 Reducer, 37 degrees Flared #6 (37 degree) to #4 (37 degree) 1
Additional Hardware (dependent on pump model)
1P-3520 Control Group governor shaft 1
7G-7105 Hose fuel transfer pump outlet and inlet 2
030-7942 Fitting fuel transfer pump, inlet 1
030-7947 Fitting fuel transfer pump, outlet 1
3J-1907 O-ring Seal fuel transfer pump fitting 2
6V-6053 Manifold used to run 6 cylinder of 12 cylinder pump 1
5P-6661 Manifold Fitting fuel return #6 (37 degree) 1
8T-9173 Tool governor adjustment 1

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4C-8200 Mounting and Drive Group

SMCS Code: 1250-036, 0706
Model: 3408 and 3412 PEEC (NSFS) Engines

• Used to mount and test fuel injection pumps

• Used with fuel injection equipment test stands (FIETS and AVM)
• Tooling is required for off-engine testing of injection pumps 2
• Parts are serviced separately to reduce dealer cost (no need to purchase tools
already in inventory)
• Requires 4C-8192 Heady-Duty Coupling Group and 9U-7693 Lines Group
(Cooled Nozzle Block) to be installed on test stand
1
Drive Adapter Parts (Part of 4C-8200 Mounting and Drive Group)
Item Part No. Description Use Quantity
1 8T-9527 O-ring Seal centers and seals pump in 4C-8213 1
2 4C-8199 Hub Drive Adapter connects injection pump cam to test stand drive 1
3 8S-2332 Drive Adapter Bolt connects 4C-8199 to injection pump cam 4
3
4 010-2902 Puller Screw removes 4C-8199 from injection pump cam 3
4

ID: C66944T1
5

6
9
10 7
11
13

8a

8a
14
15

8b 8a
12
ID: C78437T1

Pump Mounting Hardware (Part of 4C-8200 Mounting and Drive Group)

Item Part No. Description Use Quantity
5 4C-8213 Front Guard used with 4C-8211 to position pump and retain lube oil 1
6 053-2294 Bolt mount injection pump housing to 4C-8211 and 4C-8212 5
7 1T-0448 Bolt mount 4C-8213 to 4C-8211 4
8a 6V-6103 Clamp Screw Assembly secures 4C-8211 and 4C-8212 to rail 3
8b 6V-9138 Clamp Assembly used with 6V-6103 3
9 4C-8211 Block, Front mounts front of injection pump to rail 1
10 4C-8212 Block, Rear mounts rear of injection pump to rail 1
11 4S-9002 Bolt mount injection pump housing to 4C8212 1
12 1S-0004 O-ring Seal lube oil seal between injection pump housing and 4C-8212 2
13 030-7947 Fitting JIC#6 fitting for 4C-8212 1
3J-1907 O-ring Seal used with 030-7947 1
14 5D-1026 Hose Clamp used with 9U-7709 2
15 9U-7709 Oil Drain Tubing used on 4C-8212 1

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17 13 Testing Parts (Not part of 4C-8200 Mounting and Drive Group)

18 Item Part No. Description Use Quantity
20 13 030-7947 Fitting JIC#6 fitting for 4C-8212 2
19 3J-1907 O-ring Seal used with 030-7947 2
16 7G-7105 Hose Assembly 2
17 4S-3652 Tee Fitting 1
18 9N-3370 Hose Assembly 2

18 19 4C-8220 Fuel Return Manifold (12 Cylinder)1 1

20 4C-8221 Fuel Return Manifold (8 Cylinder)1 1
21 061-9258 Female Swivel1 Tee 1
1 Not required for AVM test stands.

16 21
23

ID: C78438T1

24

22
Fuel Transfer Pump Hardware (Not part of 4C-8200 Mounting and Drive Group)
Item Part No. Description Use Quantity
22 9U-5292 Rack Preload Assembly takes place of fuel rack servo valve 1
23 9U-5120 Spanner Wrench wrench for rack positioning assembly 1
24 9U-5295 Rack Positioning Assembly takes place of shut off solenoid 1

ID: C78440T1

Fuel Transfer Pump Hardware (Not part of 4C-8200 Mounting and Drive Group)
Item Part No. Description Use Quantity
25 4C-9415 Collet Adapter1 adapts injection pump housing to 5P-4814
26 5P-4814 Collet 1
27 Contact Point3 1
28 8T-1002 Electronic Position Indicator Probe2 1
29 8T-1001 Electronic Position Indicator2 1
25
30 3P-1544 Rack Zero Pin 1
31 6V-4186 Timing Pin 1 26
1 Part of 4C-8200 Mounting and Drive Group.
2 Part of 8T-1000 Electronic Positioning Group. 27
3 Part of 6V-6042 Contact Point Group.
28

Reference
NEHS0593 Installing 9U-7693 Lines Group on FIETS
NEHS0594 TMI Data 31
NEHS0624 Installing 4C-8192 Heavy Duty Coupling on FIETS 30
NEHS0625 3408 and 3412 PEEC Testing on FIETS
SEHS8200 FIETS Manual 29
ID: C78439T1

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Zexel and Nippondenso Fuel Pump and Governor Disassemble and Assemble Tools
SMCS Code: 1286-017, 0706
Model: 3046, 3064 and 3066 Engines

• Used to disassemble and assemble fuel injection pump and governor

• Makes overhaul of pump and governor simpler and faster
• Using this specialized tooling reduces the risk of part and component damage

Part No. Description Use

4C-6608 Holding Tray keep parts organized (reduces chance of lost or damaged parts)

ID: C66711T1

Item Part No. Description Use

1 4C-5602 Fixture Group hold pump in any position for ease of repair
(can greatly increase mechanic’s efficiency
during overhaul)
2 4C-5603 Mounting Plate bolts to fuel injection pump and attaches to
4C-5602 Fixture Group; allows attachment of
Nippondenso, Zexel, and Stanadyne pump,
all to the same plate

ID: C66712T1

Item Part No. Description Use

1 4C-5567 Torque Adjusting Socket remove and adjust torque control spring
2 4C-5085 Wrench (3064 and 3066 only) remove and adjust torque control spring
126-2370 Wrench (3046 only) remove and adjust torque control spring
3 5P-1720 Seal Pick remove shims under plunger springs
4 4C-6605 Tweezers remove and install delivery valve (care must be taken
not to damage this part)
5 4C-5574 Seal Protector protects seal face during front cover installation
(seals can be damaged by camshaft keyway slot,
if not protected)
6 4C-4025 Bearing Installer install bearing on camshaft (reduces bearing damage
and part replacement cost) ID: C66713T1
7 4C-4098 Seal Installer install seals in front pump cover

Item Part No. Description Use

1 4C-5601 Plunger Compressor compresses plunger spring and roller so plunger holders can
be installed and removed
2 4C-6381 Lower Plier designed to reach through pump case and remove/install
plungers
3 4C-6380 Plunger Holder hold plungers off camshaft so it can be removed or installed
4 4C-5580 Pulling Adapter remove 4C-4024 Camshaft Holder from camshaft
5 4C-4024 Camshaft Holder hold camshaft while removing and installing retaining nut that
holds flyweights to camshaft
6 4C-6597 Plunger Holder makes removal and installation of roller much easier
7 4C-4956 Nut Socket removes and installs flyweight retaining nut (specially
designed)
ID: C66714T1

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195-0768 Thread Adapter

This adapter is used to adapt the 4C-5601 Plunger Compressor to Zexel pumps with M28 threaded plugs.
To remove existing M26 thread adapter:
1. Remove block with spring fingers (heat may be required to loosen thread lock compound).
2. Remove washer and current M26 thread adapter (silver).
3. Install new M28 thread adapter (black oxide).
4. Install washer and block with spring fingers (use 4C-4030 Thread Lock to secure block with spring fingers).

Item Part No. Description

Reference 1 4C-5601 Plunger Compressor
SENR6572 Supplement for Fuel Injection Pumps for 3064 and 3066 Engines 2 195-0768
ID: C80123T1 Thread Adapter
SENR6573 Supplement for Fuel Injection Pumps for 3046 Engines

Zexel and Nippondenso Fuel Pump and Governor Test and Adjust Tools
SMCS Code: 1286-036, 0706
Model: 3046, 3064 and 3066 Engines

• Used to test and adjust fuel pump and governor after an overhaul
• Used with 8T-1001 Electronic Position Indicator, 8T-1002 Indicator Probe,
6V-3075 Indicator, and 5P-4163 Indicator Tip

ID: C66708T1

Mounting Tools
Item Part No. Description Use
1 8S-2264 Puller Assembly helps remove drive adapter from pump
2 9U-7493 Drive Adapter attaches pump to test stand drive spindle
3 0T-0722 Bolt attaches pump to test stand base plate
4 4S-9191 Flat Washer attaches pump to test stand base plate
5 9U-7494 Pump Mounting Plate attaches pump to test stand base plate
6 6V-9138 Mounting Assembly (T-Bar) pump mounting base (part of Fuel Injection Test Stand)
7 0T-0924 Bolt attaches pump to test stand base plate
8 3B-4506 Lock Washer attaches pump to test stand base plate
9 6V-9134 Lock Screw (used with T-Bar) pump mounting base (part of Fuel Injection Test Stand)
10 6V-9132 Base Plate pump mounting base (part of Fuel Injection Test Stand)
11 118-1713 Washer Attaches pump to test stand drive spindle
12 118-1711 Nut Attaches pump to test stand drive spindle
13 2A-4639 Bolt (2) Attaches pump to test stand drive spindle
3B-4506 Lock Washer (2) Attaches pump to test stand drive spindle
14 9U-7501 Drive Adapter Attaches pump to test stand drive spindle
Not shown 146-7767 Guard Assembly (1)
Not shown 2H-0191 Hex Socket Bolt (4)
Not shown FT2560 Plate Modification for Guard

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Adjustment Tools
Item Part No. Description Use
1 8T-1001 Electronic Position Indicator obtain measurement specifications
2 8T-1002 Indicator Probe obtain measurement specifications
3 6V-3075 Indicator obtain measurement specifications
4 5P-4163 Indicator Tip obtain measurement specifications
5 4C-2982 Indicator Collet as an assembly to measure plunger lift
6 4C-5713 Nozzle Overflow Assembly allows mechanic to see when fuel stops
flowing and then check timing angle
7 4C-5085 Wrench adjusts the setting of torque idling screw
8 4C-5567 Torque Adjusting Socket adjusts the setting of torque idling screw
9 4C-6509 Plunger Spring Retainer replace adjustment shims (holds plunger
spring off top of roller)
10 5P-1720 Seal Pick replace adjustment shims (holds plunger
spring off top of roller)
11 4C-6605 Tweezer helps to remove and install delivery valve
12 9Y-6051 Locknut as an assembly to measure plunger lift
13 4C-5604 Copper Washer (2) as an assembly to measure plunger lift
14 4C-4658 J-tube Fitting as an assembly to measure plunger lift
15 4C-4766 Plunger Adapter as an assembly to measure plunger lift

Calibration Fluid and Lube Line Tooling

Item Part No. Description Use
1 127-4365 Fuel Line (6)
2 4C-4909 Transfer Pump Cover covers transfer pump opening during
testing
3 4C-5708 Copper Washer (2) returns test oil from pump back to
test stand
4 4C-5707 Copper Washer (2) supplies test oil to fuel pump
5 4C-5706 Copper Washer (2) supplies lube oil to pump
6 4C-6609 Lube Oil Supply Fitting supplies lube oil to pump
ID: C66710T1
7 4C-5711 Calibration Fluid Supply Fitting supplies test oil to fuel pump
8 4C-5710 Calibration Fluid Return Fitting returns test oil from pump back to
test stand

Indicator Tools
Item Part No. Description Use
1 8T-1001 Electronic Position Indicator obtain rack measurement specifications
2 8T-1002 Indicator Probe obtain rack measurement specifications
3 5P-4160 Indicator Tip obtain rack measurement specifications
(part of 6V-6042 Indicator
Contact Point Group)
4 3P-1567 Indicator obtain rack measurement specifications
5 4C-5569 Measurement Adapter1 attaches indicator to pump for rack measurement
6 4C-2982 Indicator Collet attaches indicator to pump for rack measurement
ID: C66709T1 7 146-7774 Nylon Screw attaches indicator to pump for rack measurement

146-7780 Rack Position Bracket Group (not serviced)

Serviced by
Item Part No. Description Quantity
1 146-7777 Arm Assembly2 1
2 6V-2057 Point2, 3 1
3 5B-9324 Set Screw2 3
4 3P-1565 Collet2 1
5 146-7771 Rack Measurement Adapter2 1
6 146-7774 Nylon Screw2 1
Not shown 6V-2030 Extension2, 3 1
1 Used for FIETS with original coupling
2 Used for FIETS and AVM with heavy duty coupling
3 Part of 6V-6042 Indicator Contact Point Group
ID: C78497T1

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4C-8145 Throttle Control Indicator Group —

Sets rack and throttle control angle
Item Part No. Description
1 Base Assembly
4C-8135 Lower Plate
4C-8136 Upper Plate
9X-8873 Bolt
2 Indicator Assembly
4C-8142 Adjusting Block
4C-8143 Pointer
6V-0672 Knob (thumb screw)
3 Column Assembly
8T-8889 Bolt
8R-0739 Washer
4C-8137 Upright Bar
ID: C66707T1
6V-8183 Nut
4K-4726 Rod End
4 Throttle Control Linkage
6V-6961 Knob
Reference 4C-8139 Sleeve
4C-8138 Threaded Rod
NEHS0622 Tool Operating Manual, Testing and Adjusting Fuel Injection Pump 4C-8146 Rod End Yoke
and Governor on 3064 and 3066 Engines 4C-8147 Pin
SEHS8200 Special Instruction, Fuel Injection Equipment Test Stand 5 Adjusting Block
6V-8189 Nut
SEHS7466 Special Instruction, Fuel Injection Test Bench 4C-8141 Guide
SENR6573 Supplement, Nippondenso Fuel System 3W-6756 Knob
6 4C-8140 Handle
7 Dial Assembly
4C-8144 Degree Wheel
4M-5281 Bolt
7S-1114 Spring Washer

Injection Pump Off-Engine Disassembly, Assembly, and Bench Test

SMCS Code: 1286-017, 1286-036, 0706
Model: Early 3054 and 3056 Pre-Emission Engines

• Used to disassemble and assemble Stanadyne DB2 and DB4 fuel injection pump
and governor used on pre-emission 3054 and 3056 engines
• Makes adjustments to fuel pump and governor simpler and faster
• Specialized tooling reduces the risk of parts and/or component damage
• Not for use on 3054-3056 Engines with Stanadyne, Lucas, or Bosch emission pumps

NOTE: No tooling is available to disassemble and assemble or bench test Bosch, Lucas,
or Stanadyne injection pumps used on emissions engines.

ID: C66711T1
Part No. Description Use
4C-6608 Parts Tray organize parts during disassembly

Disassembly and Assembly Tools

Item Part No. Description Use
1 4C-5602 Fixture Group disassembly and assembly
2 4C-5603 Plate hold pump during disassembly and assembly

ID: C66712T1

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Disassembly and Assembly Tools

Item Part No. Description Use
4 4C-6839 Wrench adjust governor linkage
5 4C-8124 Linkage Kit set clearance between rear of throttle shaft and
vertical tab on linkage hook
6 4C-6842 Screwdriver set timing trimmer screw
7 4C-6827 Screwdriver with 4C-8128 to remove delivery valve and stop screw
8 4C-8129 Wrench remove spring side advance piston hole plug
9 4C-6845 Fixture with shop air to measure roller-to-roller dimension
10 4C-6623 Bit with 4C-6621
11 4C-6621 Bushing with 4C-6623 to remove advance cam screw
12 4C-6624 Pin
13 4C-8053 Remover
ID: C78492T1
14 4C-8128 Extractor with 4C-6827
15 4C-6829 Installer install pump shaft
16 4C-6989 Socket remove pump end cap
17 4C-6841 Mandrel remove pump bearing

Bench Mounting Tools and Testing Tools

Item Part No. Description Use
1 8S-2264 Puller Assembly remove 9U-7493 Drive Adapter from pump
2 1U-5366 Pump Mounting Plate mount pump on 6V-9132 Base Plate Rail
Adapter
3 0T-0772 Bolt (3) connect fuel injection pump to mounting plate
4 4S-9191 Flat Washer (3) connect fuel injection pump to mounting plate
5 118-1713 Washer connect 9U-7493 to pump
6 118-1711 Nut connect 9U-7493 to pump
7 9U-7493 Drive Adapter connect 9U-7501 Drive Adapter to bench drive
8 8T-6864 Valve Shut-off
9 9U-7501 Drive Adapter
10 2A-4639 Bolt (2) bolt 9U-7501 to 9U-7493
11 5M-2894 Flat Washer (2) bolt 9U-7501 to 9U-7493
12 6V-9134 Lock Screw (used with “T” bar) secure base plate to rails
13 6V-9132 Base Plate
14 6V-9138 Mounting Assembly (tee-bar) secure base plate to rails
15 5M-2894 Flat Washer (4) mount 1U-5366 Plate to base
16 0T-0924 Bolt (4) mount 1U-5366 Plate to base
17 146-7767 Guard1
18 2H-0191 Bolt1 (4)
ID: C78493T1
1 See FT2559 for plate modification.

Calibration Fluid and Lube Line Tooling

Item Part No. Description Use
1 127-4365 Fuel Injector Test Tube Assembly connect injection pump to master nozzle
2 4C-6827 Screwdriver
3 4C-8126 Indicator Assembly measure advance
4 4C-6842 Screwdriver
5 4C-8054 Tap Fitting check transfer pump pressure

ID: C78494T1
Reference
SENR6574 Stanadyne Fuel System (Supplement)
ENG95-1 IRM for 3054 and 3056 Engine Fuel Systems

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6V-6090 Adapter Group

SMCS Code: 1250-036
Model: 3500 Family Engine, D379, D398, D399

• Replaces discontinued 5P-9733 Adapter Group

• Adaptable to former fuel injection test benches and fuel injector equipment test stands
• Designed with interchangeable splines so can be used to test all hydramechanical safety shutoffs
• Has improved test stand mounting and transparent plastic cover

Reference
SEHS8200
SEHS7465
ID: A90397-3T1

2P-5510 Adapter Group

SMCS Code: 1250-036
Model: Fuel Injection Equipment Test Stand

• Used with fuel injection equipment test stand for D342, 1674, D334

ID: 62114T1

5P-5237 Pump Adapter

SMCS Code: 1250-036
Model: 1100 and 3100 Engines 1 2

3
• Used to run off-engine tests on scroll injection pump and governor groups
• Used with fuel injection equipment test stands (FITB, FIETS, AVM)
• Group has been updated to eliminate non-current tooling and add new required tooling
• Parts are serviced separately to reduce dealer cost (no need to purchase tools already in inventory)
4
7
Reference 5 6
SEHS6995 Using Rack Position Tool Groups 8
SEHS8200 FIETS Manual (Hartridge Bench)
10
9

Item Part No. Description Where Used Quantity

1 1U-5102 Adapter Plate injection pump mounting fixture (front) 1 13
2 1A-2209 Bolt front plate to 6V-9132 4 14 15
11 12
3 1U-5118 Support Assembly injection pump mounting fixture (rear) 1
ID: C55112T1
4 4D-3120 Bolt rear support to 6V-9133 1
5 0S-1617 Bolt injection housing to support assembly (rear) 2
6 8M-8157 O-ring Seal lube oil supply 1
7 8M-5260 O-ring Seal lube oil return 1
8 9U-7705 Tube lube oil drain 1
9 1U-6744 Cover covers transfer pump opening 1
10 0T-0102 Bolt used with 1U-6744 2
11 1U-5067 Drive Adapter injection pump cam drive (later series) 1
12 2D-4534 Bolt injection pump cam drive adapter 3
13 1U-5068 Drive Adapter injection pump cam drive (mid series) 1
14 1U-6742 Swivel Arm Assembly rack indicator fixture 1
15 FT2538 Bolt-Hex Soc. Head 2

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Additional Required Hardware

The following list of hardware is required, but not included as part of the 5P-5237 Pump Adapter Group. This tooling can be purchased as needed.

Part No. Description Where Used Quantity

Required Hardware
6V-9132 Fixture Assembly plate to bench rails (front) 1
6V-9133 Fixture Assembly support to bench rails (rear) 1
6V-9134 Screw Assembly fixture assembly to clamp 2
6V-9138 Clamp Assembly fixture assembly to rail system 2
Additional Hardware (dependent on pump model)
7G-7105 Hose Assembly #6 (37 degree) x 965 mm (38.0 in) long 1
3V-2744 Hose Assembly #4 (37 degree) x 610 mm (24.0 in) long 1
031-2125 Hose Assembly #4 (37 degree) x 1016 mm (40.0 in) long 1
5P-5008 Reducer #6 (37 degree) to #4 (37 degree) 1
3P-1823 Pipe Adapter 1/4-18 NPT (external) to 1/4-18 NPT (internal) 1
5P-6661 Connector #6 (37 degree) to 1/4-18 NPTF (external) 1
032-1267 Connector #6 (37 degree) to 1/4-18 NPTF (external) 1
061-7921 Connector #4 (37 degree) to 1/4-18 NPTF (internal) 1
030-3978 Connector #4 (37 degree) to 7/16-20 (O-ring) 1
5P-2645 Elbow, 90 degree #6 (37 degree) to 7/16-20 (O-ring) 1
3J-7355 Union, 37 degree #4 (37 degree) to #4 (37 degree) (flared) 1
3J-1907 O-ring Seal #6 JIC fitting 9/16-18 thread 1
3J-7354 O-ring Seal #4 JIC fitting 7/16-20 thread 1
1P-3520 Control Group control governor shaft 1
6V-2112 Timing Pin fuel pump timing pin 1
8T-9261 Rack Spacer 1
FT2540 Timing Injection Line spill timing injection line 1
4L-5937 Injection Tube Assembly 1.60 mm (.063 in) x 432 mm (17.0 in) injection lines (IV-A data) 8
1P-1795 Master Valve for master nozzle assembly (FIETS IV-A data) 8
9U-6705 Master Nozzle Assembly master nozzle assembly (FIETS IV-A data) 8

5P-9737 Adapter Group

SMCS Code: 1250-036
Model: Mechanical Overspeed Shutoff

• Used for testing all engine mechanical overspeed shutoff groups on fuel injection test bench
• Contains all parts from former 5P-7387 Adapter Group and two additional drive adapters

Cat
Item Part No Description Engine Model
1 1U-5170 Drive Adapter D379, D398, D353
2 1U-5077 Drive Adapter D342C, D397D
3 1U-5081 Drive Adapter D375D, D379, D398, D399
4 1U-5080 Drive Adapter D346, D348,D349 ID: A73544-1T1
5 4H-0553 Lube Adapter
(1/8 inch ext. pipe
to 1/4 inch int. pipe)
6 1U-5099 Adapter Plate

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5P-5240 Adapter Group

SMCS Code: 1250-036
Model: See below

• Used to test small bore scroll injection pump and governor groups — required for off-engine testing
• Used with fuel injection equipment test stands (FITB, FIETS, and AVM)
• Used on two valve engines—four and six cylinder engines with 120.65 mm (4.750 in) bore
diameter; four and six cylinder engines with 114.3 mm (4.50 in) bore diameter; four
cylinder engines with 101.6 mm (4.00 in) bore diameter; and 3204 Engines Item Part No. Description Where Used Qty.
• Group has been updated to eliminate non-current tooling and add new required tooling 1 0L-1351 Bolt 3/8-16 x 38.1 mm (1.50 in) long 2
• Parts are serviced separately to reduce dealer cost (no need to purchase 2 0S-1617 Bolt 5/16-18 x 19.05 mm (.750 in) long 3
tools already in inventory) 3 0T-0102 Bolt 3/8-16 x 15.875 mm (.6250 in) long 2
4 1A-2209 Bolt front plate to 6V-9132 4
5 1A-9579 Bolt 5/16-18 x 38.1 mm (1.50 in) long 1
6 1U-5095 Adapter Plate injection pump mounting fixture (front) 1
7 7F-8607 O-Ring Seal for fuel supply 1
8 1U-6753 Fuel Adapter for fuel supply 1
9 1U-6754 Lube Adapter lube oil 1
10 1U-6755 Lube Adapter lube oil 1
11 1U-6756 Lube Adapter lube oil 1
12 2M-4453 O-ring Seal lube oil supply 1
13 5F-1678 O-ring Seal pump lube oil 1
14 5P-0956 Drive Adapter adapts injection pump camshaft 1
15 1U-5069 Drive Adapter adapts injection pump camshaft 1
16 9U-7705 Tube lube oil drain 1

Additional Required Hardware

The following list of hardware is required, but not included as part of the 5P-5240
Adapter Group. This tooling can be purchased as needed.

Part No. Description Where Used Qty.

Required Hardware (not included in group)
6V-9132 Fixture Assembly plate to bench rails (front) 1
6V-9134 Screw Assembly fixture assembly to clamp 1
6V-9138 Clamp Assembly fixture assembly to rail system 1
Additional Hardware (dependent on pump model)
7G-7105 Hose Assembly #6 (37 degree) x 965.2 mm (38.00 in) long 1
3V-2744 Hose Assembly #4 (37 degree) x 609.6 mm (24.00 in) long 1
031-2125 Hose Assembly #4 (37 degree) x 1016 mm (40.0 in) long 1
5P-5008 Reducer #6 (37 degree) to #4 (37 degree) 1
4H-0553 Special Fitting 1/8-27 NPT (external) to 1/4-18 NPT (internal) 1
3P-1823 Pipe Adapter 1/4-18 NPT (external) to 1/4-18 NPT (internal) 1
5P-6661 Connector #6 (37 degree) to 1/4-18 NPTF (external) 1
032-1267 Connector #6 (37 degree) to 1/4-18 NPTF (external) 1
061-7921 Connector #4 (37 degree) to 1/4-18 NPTF (internal) 1
030-3978 Connector #4 (37 degree) to 7/16-20 (O-ring) 1
2N-1287 Elbow, 90 degree #4 (37 degree) to 1/8-27 NPTF (external) 1
030-7946 Elbow, 90 degree #4 (37 degree) to 7/16-20 (O-ring) 1
001-6498 Elbow, 45 degree #6 (37 degree) to 1/4-18 NPTF (external) 1
5P-2645 Elbow, 90 degree #6 (37 degree) to 7/16-20 (O-ring) 1
3J-7355 Union #4 (37 degree) to #4 (37 degree) flared 1
3J-1907 O-ring Seal #6 JIC fitting 9/16-18 thread 1
3J-7354 O-ring Seal #4 JIC fitting 7/16-20 thread 1 ID: C55113T1
1P-3520 Control Group governor shaft 1
1U-6746 Key drive adapter with bolt on key 1

Reference
SEHS8200 FIETS Manual (Hartridge Bench)
SEHS6995 Using Rack Position Tool Groups

Home Dealer Service Tools 2004 3-111

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5P-5241 Adapter Group 6V-9441 Fuel Pump Adapter Group

SMCS Code: 1250-036 SMCS Code: 1250-036
Model: Fuel Injection Equipment Test Stand Model: 3406A

• Used with fuel injection equipment test stand for D343, 1693 • Used for mounting 3406A fuel systems equipped with Woodward Governor
on fuel injection test bench and fuel injection equipment test stand
• 5P-2404 Adapter Group for testing 3406A fuel systems will not physically
accept systems equipped with Woodward Governors (Woodward Governor
drive housing interferes with bench mounting rails)—adapter group rotates
pump housing 17° to eliminate interference

ID: C09325T1
Service Parts
Item Part No. Description
1 1U-6758 Lube Adapter Assembly
2 1U-5070 Adapter Assembly ID: B89236T1
3 5F-4899
5B-9603
Bolt, 3/8 in x 139
Bolt, 3/8 in x 127
Reference
SEHS8200
4 1U-5096 Adapter Assembly
5 6V-2008 Hose
6 1U-5061 Locating Pin
7 0S-1618 Bolt
Not shown 5F-7054 O-Ring Seal

4C-6907 Governor Drive Group

4C-8980 Test and Adjust Group
4C-8740 Air Supply and Test Group
SMCS Code: 1264-036, 1264-035, 0706-036, 0706-035
Model: 3500 and 3600 Family Engines with Woodward 3161 Governors
Warranty: One Year

• Used for off-engine bench testing and adjusting Woodward 3161 Governors on Fuel Injection Pump Test Stand
• Used with either Fuel Injection Equipment Test Stand (6V-7900, 1U-8212 or 1U-8213 made by Hartridge) or non-current fuel
injection test bench (made by Kent-Moore) and 4C-6100 Torque Control Tool Group
• Eliminates need for specialized governor test bench
• 4C-8980 Test and Adjust Group used to monitor governor terminal (output) shaft position during test; monitoring accomplished
with precision lever (4C-8991) and digital dial indicator (4C-8976)
• 4C-6907 Governor Drive Group used to mount and drive 3161 Governor with fuel injection equipment test stand; parts from
1W-2135 Drive Group (used on 3500 Series Engines) were modified and used in drive gear box; modified parts are called out and
identified; parts of gear box that were not modified are shown in 3500 Series Engine parts books
• 4C-8740 Air Supply and Test Group contains pressure gauges and regulators to perform pneumatic tests and adjustments

Reference
NEHS0545 3161 Governor Test
SEHS9318 Test and Adjust of 3161 Governors On Fuel Injection Test Stand
SEHS9351 Schedules for On Fuel Injection Test Stand

Repair and Service

Repair service for 4C-8740 Air Supply and Test Group: Carrier-Oehler
Repair service for 4C-8976 Dial Indicator: Chicago Dial Indicator Co. Inc.

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4C-6907 Governor Drive Group — Serviced

Item Part No. Description Quantity
1 9F-2247 Pipe Plug 4
2 3P-0647 Seal 4
3 0S-1621 Bolt 2
4 0L-2070 Bolt 4
5 5M-2894 Washer 4
6 1D-4588 Bolt 2
7 1L-0509 Bolt 4
8 6V-6101 Plate Assembly1
9 1A-7669 Bolt 2
10 6V-6103 Screw Assembly
(Not Included in 4C-6907 Governor Drive Group)
Required but not included
6V-6099 Shield Assembly1 1
4L-7124 Bolt1 4
1 Some later 6V-6101 Plate Assemblies do not include shield.
ID: C26955T1

Item Part No. Description

11 4C-6906 Adapter
12 4C-6905 Drive Shaft Assembly
13 4C-6904 Pinion
14 4C-6903 Housing Assembly

Item Part No. Description Quantity

15 9S-4182 Plug 2
16 6V-5048 Seal 2
ID: C26957T1
17 9F-2247 Pipe Plug 2
18 9F-2247 Pipe Plug 2
ID: C26956T1

4C-8980 Test and Adjust Group

Item Part No. Description
1 6V-3072 Plastic Case
2 4C-8986 Foam Block Group
3 Plate Gasket (Make from 1W-9780 Gasket)
4 4C-8977 Cover Plate
5 0S-1615 Bolt (two)
6 2F-7112 Thermometer
7 4C-8979 Test Lead Group
8 140-1016 Digital Indicator (replaces discontinued 4C-8976 Digital Indicator Group)
(contains four E60 0009 Varta batteries)
9 6V-2057 Contact Point (Part of Indicator Group)
10 4C-8978 Dial Indicator Bracket
11 4C-8981 Termin Lever Assembly
12 3H-1392 Bolt
13 4S-5565 Bolt (two)
14 4C-8984 Parallel Gauge
ID: C26954T1 15 4C-9054 Charger1 (110 Volts 60 Hz) (not included in the 4C-8980 Test and Adjust Group) or
4C-9055 Charger1 (230 Volts 50 Hz) (not included in the 4C-8980 Test and Adjust Group)
Not shown (service parts for 140-1016)
140-0027 AC Adapter, 110V-60 Hz
140-0029 AC Adapter, 220V-50 Hz
Not shown
NEEG2470 Decal
1 Used for 4C-8976 Indicator

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4C-8740 Air Supply and Test Group

Item Part No. Description Not shown
1 8T-0841 Plastic Case 8T-0821 Tubing, 16 M (52.5 ft.)
2 8T-0839 Diff Pressure Gauge 5D-9231 Fitting (two)
3 9U-6100 Gauge 3J-7354 O-Ring Seal (two)
4 4C-3974 Union Fitting (four) 4C-3973 Fitting (1/8 in X 1/8 in) (four)
5 1U-5469 Pressure Gauge Male Connector (1/4 in X 1/8 in) (two)
6 3/8 inch Tubing, 0.46 M (1.5 ft.) Bulkhead Union (1/8 in) (two)
7 Air Bulb
(W. A. Baum Co. Inc. Catalog No. 1890)

ID: C26958T1

4C-6100 Tool Group, 3161 Governor Torque Control

SMCS Code: 0782
Model: Multiple Engine Models

• Used to perform variety of “in-vehicle” engine governor and fuel system settings
for D11 Track-Type Tractor and the 777, 785 and 789 Off-Highway Trucks Vehicle Application with Tooling Combinations

• Easily installed on governor without removing surrounding components such as Part No Description
alternator or water hoses D11 Track-Type Tractor
• With correct combination of lever arms and weights, a specific torque is Terminal shaft tools 4C-6101 Torque Arm
applied to 3161 Woodward Governor speeder and terminal shafts; allows 4C-6102 Weight
for setup of governor, setting fuel injection timing, derating of governor for Speeder shaft tools 4C-6098 Torque Arm
high altitude applications, and evaluation of governor schedule 4C-6103 Weight
777, 785 and 789 Off-Highway Trucks
Terminal shaft tools 4C-6099 Torque Arm
Item Part No. Description 4C-6102 Weight
1 4C-6102 Weight, 5 lb. Speeder shaft tools 4C-6098 Torque Arm
2 4C-6099 Torque Arm 4C-6103 Weight
3 4C-6103 Weight, 9 lb.
4 4C-6101 Torque Arm
5 4C-6098 Torque Arm
6 4C-6105 Insert
7 4C-3975 Case
Not shown NEEG2435 Decal

ID: C26944T1

1U-9361 Governor Torque Arm

SMCS Code: 1264-036; 0766
Model: 3500 Marine and Industrial Generator Sets

• Used to test and adjust 3161 governor

• Applies consistent torque to governor and fuel system linkage for more accurate
fuel system adjustments
• Can be installed on terminal shaft of 3161 governor
• Arm applies 10.3 N·m of torque to governor linkage when torque arm is installed
with center line of cylinder-shaped weight in horizontal position. Item Part No. Description
1 3F-7147 Bolt
Reference ID: C27019T1
SEHS9240-01 Special Instruction

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1U-6661 Tester
Discontinued
1U-6662 Block Group
1U-6663 Holding Block Group
4C-6566 Holding Block Group
1U-6665 Power Supply Part No.
1U-6662
Description
Block Group
Discontinued ID: C23555T1

9U-6143 Power Supply Adapter

Discontinued
SMCS Code: 1254-036
Model: 3114, 3116, 3176, 3500 MUI

NOTE: Individual injector testing is replaced by on-engine method using RENR1391 EUI
Engine Software and RENR1390 HEUI Engine Software
• 1U-6662 Block Group used with 1U-6661 Tester (Discontinued) to test 3114
and 3116 injectors; 6V-4022 Injection Tester may be used in place of 1U-6661 Tester
(Discontinued) if 6V-4022 Injection Tester has been modified with 1U-6667 Conversion
Group (See SEHS8922 and SEHS8858 for details.)
• 1U-6663 Holding Block Group used with 1U-6661 Tester (Discontinued) to test 3176
Engine electronic unit injectors; must be used with 1U-6665 Power Supply and 9U-6143
ID: C27122T1
Adapter; may be used with 6V-4022 Pop Tester with 1U-6667 Conversion Group
• 4C-6566 Holding Block Group used with 1U-6661 (Discontinued) or 6V-4022 Pop
Tester to test 3500 MUI unit injectors; 6V-4022 Tester must be modified using
1U-6667 Conversion Group

ID: C23555T1
4C-6566 Holding Block Group
Part No Description
4C-6207 Height Cap
4C-6210 Test Plug Assembly
4C-6563 Holding Block Assembly
4C-6564 Plate Assembly
4C-6565 2 Piece Insert Group
ID: C27121T1 6V-7145 Case

Reference
SEHS8867, Using the 1U-6661 Pop Tester
SEHS8858, Using the 6V-4022 Injector Tester to Test 1.1 L Fuel Injectors
SEHS8922, Installation of 1U-6667 Conversion Group
SEHS8884, Unit Injector Test Specifications for 1.1 L Engines, 1.7 L Engines and
3500 Family Engines
NEEG2565 Decals for Pop Tester
Service Magazine, June 6, 1994, pages 8-9

Current Caterpillar Tests

Engine Spray External Leakdown
VOP Model Test Leakage Rate
ID: C54536T1 GO/NO GO 1.1 Liter Yes Yes No
Item Part No Description GO/NO GO 3176 “A” Yes Yes Yes
1 9U-6143 Power Supply Adapter (discontinued) GO/NO GO 3176B No No No
2 9U-6186 Fuse, 4 Amp GO/NO GO 3500 MUI Yes Yes Yes

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6V-4172 Injector Sleeve

SMCS Code: 1254-038, 1254-081
Model: D11N, 3508, 3512, 3516, 777B, 785, 789, 3500

• Used to cover fuel ports when cleaning injectors on D11N. 777B, 785, 789, and 3500 Series Engines

ID: B19612T1

4C-9279 Plate
SMCS Code: 1290-016; 0706
Model: 3500 Family Engines

• Used to assemble unit injectors

• Provides means to position injector rack in injector body so plunger gear can
be properly meshed with rack during injector assembly
• Allows injector spring replacement with minimal injector disassembly
• Designed for use with 6V-4830 Fixture Group but may be clamped in bench vise
ID: C44391T1

Reference
SEHS9287 Special Instruction

5P-4150 Nozzle Tester Group

SMCS Code: 1250-012, 1254-010, 1254-017, 1254-025, 1250-036, 1254-038, 1254-081
Model: 1100, 3100, 3208, 3400
Warranty: Manufacturer’s

• Used to test all fuel nozzles, including pencil-type nozzles on 1100 and 3100 Series and 3208 Engines,
direct injection capsule-type fuel nozzles on 3400 Series Engines, and capsule-type nozzles used on all other engines

Reference
SEHS7292 Special Instruction

Item Part No Description

1 5P-8744 Adapter Assembly (If desired, quick disconnect fittings may be installed for faster changing
of nozzle adapters. Refer to Engine News of October 3, 1979, for installation instructions.)
2 8T-0859 Gauge 25000 kPa (3600 PSI)
3 8T-0856 Gauge 6000 kPa (870 PSI)
SEHS7605 Caution Label (for 5P-4146)
4 5P-4721 Tube (End fittings not included; included with 5P-4719 and 5P-4720)
5 5P-4244 Adapter
6 5P-4719 Fitting (Includes connecting fitting for 5P-4721)
8T-5313 Fitting
7 5P-4243 Fitting
8 8T-5313 Filter ID: A77831T1
9 4J-7533 Seal (one on each hand valve, qty. 5)
10 6V-0183 Gasket (between reservoir and pump)
Available separately (not shown)
1U-9578 Repair Kit

Service Parts for 5P-8744 Adapter Assembly

Item Part No Description
1 5P-4720 Fitting (Includes connecting fitting for 5P-4721)
2 5P-8741 Adapter
3 5P-8740 Retainer
4 5P-8742 Piston Assembly
5 2S-4663 Seal

ID: A77446T1
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1U-9578 Repair Kit 5P-7448 Adapter

SMCS Code: 1254-025, 1254-036, 1254-038, 1254-081 SMCS Code: 1250-036, 1254-038, 1254-081
Model: Caterpillar Engines Model: Flat Seat Fuel Injection Valves

• Used to disassemble and assemble 5P-4150 Nozzle Tester Group • Used to test and adjust flat seat fuel injection valves
• Contains gaskets, seals, O-rings, steel balls and filter, along with printed on 5P-4150 Tester and also 1P-1795 Master Valve
parts breakdown if parts not included in the kit are needed from fuel injection test bench
• Allows worn or broken 5P-4150 Nozzle Tester Group to be repaired and put
back into operation when used along with other service parts listed in Tool Reference
Guide SEHS8200

ID: A69883T1

8S-2270 Fuel Collector

1U-8857 Extension Tube
SMCS Code: 1250-036
Model: All Fuel Systems
Warranty: None

1U-8857 Extension Tube

• Used with 8S-2270 Fuel Collector to collect spray from 5P-4150 Nozzle Tester
or 8S-2242 Nozzle Tester
• Increases height of 8S-2270 Fuel Collector to prevent splashing of test fluid;
made of plastic and can be cut shorter to meet varying heights required by
different mounting arrangements of Nozzle Tester Group

ID: D00846T1

Tube Assemblies
SMCS Code: 1254-036, 1254-038, 1254-081
Model: D6D, 528, 3300, 3046, 3054, 3056, 3064, 3066

• Used with 5P-4150 Nozzle Tester and 5P-7448 Adapter to test fuel nozzles in 3300 Series DI Engines
• 6V-2170 and 5P-7448 are used on 3054, 3056, 3064 and 3066 Engines (14 mm x 1.5 thd).
• 5P-4718 Adapter is used for early Perkins, 3034 and 3046 Engines (12 mm x 1.5 thd).

Item Part No Description Used to Test

1 6V-2170 Tube Assembly 8N-7001 Fuel Nozzle
2 6V-2171 Tube Assembly 7N-0449 Fuel Nozzle
3 3J-1906 Nut (Part of 6V-2170 and 6V-2171)
4 3J-1905 Sleeve (Part of 6V-2170 and 6V-2171)
5 5P-7448 Adapter (not included with tube assemblies; must be ordered separately)
Not shown 5P-4718 Adapter (not included with tube assembly. must be ordered separately)

ID: A90391T1

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1U-7326 Governor Calibration Bench

1U-9087 Governor Adjust Tool Group
1U-9088 Governor Disassembly and Assembly Tool Group
SMCS Code: 1250-010, 1264-017, 023, 025, 036
Model: 3114, 3116, and 3126 MUI Engines

• Used to disassemble, assemble, test, and calibrate governor groups 1U-7326 Governor Calibration Bench
• All tools in 1U-7326, 1U-9087, and 1U-9088 are serviced separately (groups • Used to adjust governor on 1.1 Liter Engines
can be assembled ordering only tools not currently in a dealer’s inventory) • Used with 1U-9087 and 1U-9088 Tool Groups
• Tools are required to service various governor groups, including Type V (1994 • Used with 9U-7401 Multitach II, 9U-5104 LED Photo Pickup, and 4C-3024
truck versions) and type VI (dual horsepower) governors Charger (not included) to read speed

Service Parts
Part No. Description
4C-4167 Motor Pump Unit, 230 VAC
4C-4168 Motor Pump Unit, 115 VAC 1
4C-4169 Pump Inlet Strainer/Filter
9U-6629 Oil Gearbox
8F-0212 O-ring for Collector Cup
1 230VAC single-phase power is not always available to operate 1U-7326 Governor
Calibration Bench; 4C-4168 is the only special part needed to convert 1U-7326 to
115V AC operation so it can be plugged into any 20 Amp, 115 V outlet.

FT2804 Bracket and FT2805 Plate

ID: C26893T1
• Used to hold 9U-7401 Multitach II onto 1U-7326 Governor Bench
• Used with 1U-7326 Governor Bench
4 • Allows Multitach II to read governor speed
1 2
5 • Both FT tools are made from SAE1018 steel

3 1U-9088 Governor Disassembly and Assembly Tool Group

• Used to disassemble and assemble governor groups (many tools in this group
were part of discontinued 1U-7315 Governor Repair Group)
• Used with 1U-7326 Governor Calibration Bench
• 1U-7606 Servo Disassembly and Assembly Block — properly positions
6 governor assembly to disassemble and assemble output clevis from servo
8 piston, and press backup spring pin in or out (can also be used on older style
servos to safely hold assembly while driving spring pin in or out)
9 • 1U-7635 Servo Disassembly Driver — used to push servo valve shoulder to
avoid damaging valve when removing output clevis from servo piston (use
7
with 1U-7606)
• 1U-7636 Servo Assembly Driver — used to press output clevis into servo
piston (use with 1U-7606)
11 • 6V-9072 Piston Seal Guide — guides new fuel ratio control piston and seal
into housing
10 12
Service Parts
ID: C78470T1
Item Part No. Description
1 1U-7606 Servo Block
Not shown
2 1U-7635 Clevis Driver
8S-3675 Contact Point
3 1U-7636 Servo Driver
1U-7307 Governor Repair Fixture
4 1U-7313 Gauge Block
1U-7312 Calibration Plate
5 1U-7309 Shim Adjustment Tool (Governor Riser)
1U-7637 Foam Insert Set
6 4C-4354 Applicator (retaining ring)
6V-6106 Dial Indicator
7 1U-7314 Shim Weight
6V-7145 Case
8 9S-0229 Contact Point
NEEG2650 Decal
9 1U-7311 Torque Wrench (1.5 mm hex-torque cam adjust)
10 1U-7308 Shim Adjustment Tool (governor spring)
Reference 11 1U-7310 Torque Adjustment Tool
SENR6454 Service Manual, Governor; SEHS8868 Special Instruction,
Using the 1U-7326 Governor Calibration Bench 12 9U-5120 Spanner Wrench

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1U-9087 Calibration Tool Group

• Used to calibrate governors (some tools in this group were part of discontinued 1U-7315 Governor Repair Group or 9U-6880 Throttle Lever Tool Group)
• Used with 1U-7326 Governor Calibration Bench
• 1U-7299 Adjusting Wrench — adjusts governor output (load stop) position and fuel ratio control setting on Type V and later model governors (used with 1U-7300)
• 1U-7431 Adjusting Tool — adjusts low power load stop setting on Type VI governors (used with 1U-7300)
• 1U-7316 Calibration Pin Group — used to calibrate Type V and later model governors and is designed to avoid interference with fuel ration control (cannot be used for
on-engine fuel setting adjustment)

9U-6880 Throttle Lever Tool Group — Serviced

Repair Parts
11 9U-6877 Thrust Bearing
12 9U-6876 Puller Stud
13 9U-6874 Puller Bracket
14 9U-6875 Shoulder Screw
15 9U-6883 Pusher Block Assembly
16 9U-6881 Adjustable Arm Assembly
17 9U-6879 Draw Stud
18 9M-1974 Hard Washer
19 6V-0299 Full Nut
Shown, but not part of group
20 1U-8869 Digital Indicator
ID: C66812T1 Item Part No. Description Not shown
1 4C-9594 Wrench, 1/2 inch (low idle adjustment) 1U-7444 Foam Insert Set
2 1U-5548 Wrench, 8 mm (high idle adjustment) 5P-8245 Hard Washer
3 5P-4205 Tee Wrench (low idle adjustment) 6V-3072 Plastic Case
4 1U-6673 Fuel Ratio Control Adjusting Wrench1 6V-6106 Dial Indicator
5 1U-6672 Rack Adjusting Wrench 9U-5120 Spanner Wrench
6 1U-7299 Adjusting Wrench NEEG2649 Decal
1 159-1783 Fuel Ratio Control Adjusting Wrench is
7 1U-7300 Hex Wrench (3 mm)
51 mm (2 in) shorter than 1U-6673; required for
8 1U-8815 Indicator Point (flat end)
3116-3126 Engines in Challenger 35, 45, and 55
9 1U-7316 Calibration Pin Group
10 1U-7431 Adjusting Tool (dual horsepower screw)

159-1783 Fuel Ratio Control Adjusting and Synchronizing Wrench

SMCS Code: 1250-010, 1264-017, 023, 025, 036
Model: 3114, 3116, 3126 MUI Engines Used in Challenger 35, 45, and 55 Tractors
Essential tool

• Used to adjust fuel ratio control (similar to 1U-6673)

• Shorter length provides necessary clearance for Challengers
• May be used in place of 1U-6673 for most applications
• Overall length: 145.9 mm (5.74 in)
• Hex wrench size: 2 mm

Reference
SENR6454 Service Manual, Governor ID: C79235T1

SEHS8868 Special Instructions, Using the 1U-7326 Governor Calibration Bench

148-3605 Wrench
SMCS Code: 1264-017, 0602-017, 0706
Model: 3116 Engines
Warranty: One Year

• Replaces discontinued 131-5009 Wrench

• Used to remove and install tamper resistant plugs on 3116 governors installed after 01/01/96
• Used with standard socket and ratchet or flat wrench
• Short hex design works well in confined spaces
• 3/8 square drive (required for dual HP governors)
• Tamper resistant plugs protect load stop and fuel air ratio control settings on some Reference
Type IV governors and fuel air ratio control setting only on some Type V governors SENR6454 Service Manual Module, 3114/3116 and
ID: C66935T1
• Hex head diameter: 7/8 in 3116 Engine Governors (MUI)

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Fuel System Test Tools / Fuel System Repair and Adjust Search Engine Tools

4C-8996 Hex Ball Driver, 4 mm Standard 4C-9309 Adapter

SMCS Code: 0706-017, 1264-017, 0601-017 SMCS Code: 1264-036; 0782
Model: 1.1 Liter Family Engines Model: 3114, 3116
Warranty: Lifetime

• Installs any deeply recessed 4 mm hex socket head fastener, such as in • Used to test 2.3 gain governor (available in 1991) for 1.1 L Engines on
1.1 Liter engine governor 1U-7326 Governor Calibration Bench (adapters for earlier pumps included
• Removes and installs the governor riser lever of 1.1 Liter governor (213-4437 with 1U-7326)
Adapter and 6V-4980 Torque Screwdriver also needed) • Used on governor transfer pump outlet fitting
• Use 3K-0360 or 8M-5260 O-Ring Seal with adapter

ID: C27023T1

Driver 4 mm hex ball

Drive 3/8 inch drive, chrome plated
Length 127 mm bit

ID: C44394T1

Reference
SEHS8868 Special Instruction

Fuel System Repair and Adjust

6V-2023 Flow Checking Adapter Group

SMCS Code: 1250-025, 1250-036, 1251-082
Model: Caterpillar Engines

• Used when flow checking all engines that have reverse flow check valves in fuel
injection pump bonnets
• Has variable length pin for opening check valve; replaces 5P-3564, 5P-3565 and
5P-3566 Flow Check Assemblies which had fixed pins
• Pin can be removed entirely from 6V-2023 Group, allowing it to be used instead of
7M-1999 Tube Assembly, to flow time engines which do not have reverse flow
check valves Item Part No. Description
1 6V-2018 Pin
ID: A90378T1
2 6V-2019 Nut
Reference 3 6V-2020 Adapter
SMHS7083 Special Instruction 4 6L-3921 Sealing Washer (three)
5 6F-0612 Jam Nut
6 6V-2021 Fitting
7 5P-2948 Connector
8 4K-9822 Nut
9 4K-9821 Sleeve
10 5P-5630 Tube, 20 cm (8 inch)

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4C-8180 Timing Tool Group Item Part No. Description Quantity

SMCS Code: 0701, 0706, 1251
1 6V-3073 Plastic Case 1
Model: 3408C and 3412C High Performance Marine Engines
2 4C-8185 Foam Block Group 1
3 4C-8182 Gauge Collar 1
• Required tooling used to set engine timing — improves fuel injection 4 6V-7918 Collet Wrench 2
pump-to-engine timing accuracy 5 4C-8184 Gauge, 66.512 mm (2.6186 in 1
• Group includes tooling to accurately set timing gauge to zero 6 5P-4814 Clamp Collet 1
• Tools within this group are serviced separately to help lower dealer cost 7 4C-2982 Collet Assembly (with nylon screw) 1
(some tools may already be on hand at dealership or can be made from 8 4C-8183 Gauge Plate 1
used engine parts)
9 8J-3819 Spring 1
• Works on engines with serial numbers of 8RG, 3JK, and 7BL
10 1N-3257 Retainer Ring 1
• Can also be used to verify fuel pump cam profile
11 4C-8181 Timing Tool Assembly 1
12 4C-8178 Indicator Mount Bonnet 1
13 9U-5120 Spanner Wrench 1
14 4C-8179 Bonnet Nut 1
15 NEEG2651 Decal 1
Not shown 6V-6106 Dial Indicator 1
Not shown 8T-1000 Electronic Position Indicator Group 1
Not shown 5P-7262 Contact Point 1

Reference
NEHS0638 Tool Operating Manual

ID: C55111T1

1P-0540 Flow Checking Tool Group Service Parts

Discontinued — Service Parts Available Item Part No. Description
1 8S-4600 Nipple
2 8S-4599 Coupling Assembly
3 5K-2408 Fitting
4 3B-6488 Pipe Coupling
5 5J-4634 Hose Assembly
6 4M-5317 Bushing
7 7M-1999 Tube Assembly
8 5P-2413 Regulator Assembly

Reference
ID: C09469T1 SMHS7083 Special Instruction

3P-2239 Timing Plate

5P-0294 Crowfoot Wrench
SMCS Code: 1250-025
Model: D8H, D8K

• 3P-2239 Timing Plate used to time accessory drive shaft when fuel pump housing is removed
and reinstalled on later D8H Tractor engines with compact fuel systems and 16.5 degree timing
• 5P-0294 Crowfoot Wrench used to tighten accessory drive gear retaining nut when timing
ID: 92949T1
later engines by fuel flow method

Timing Fixture Plates

SMCS Code: 1000-025
Part No. Engine
Model: Caterpillar Engines
8S-5417 4.75 inch Bore, 4 and 6 Cylinder
two valve engines (Scroll pumps)
8S-4625 951B Traxcavator with 4.5 inch
• Used to time accessory drive shaft to engine
Bore engine and hydraulic governor
with fuel pump housing and governor removed
5P-0143 3204 Engine
5P-4240 D8K Engine (14° 17 inch timing)

ID: 77209T1
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8T-5246 Engine Timing Indicator Group

SMCS Code: 1250-025, 1250-036, 1251-081, 1251-082
Model: Multiple Engine Models

• Used to determine piston true top dead center (TDC) and fuel injection pump timing of most Caterpillar engines
• Replaces discontinued 3S-2954 Indicator Group
• Components for timing each engine in accordance with procedure described in Special Instruction SMHS7083
listed in application chart below
• 6V-2056 Rod and 6V-2057 Contact Point available separately for 3300 Series DI Engines

Item Part No. Description

1 5P-7276 Container (contact points not included)
8S-3675 Contact Point, 3,0 (0.12 in)
6V-2057 Contact Point, 3,17 (0.125 in) ID: C80209T1
3S-3268 Contact Point, 6,35 (0.25 in)
9S-8883 Contact Point, 12,7 (.50 in) Dial
3S-3269 Contact Point, 25,4 (1.0 in) Contact Indicator
5P-7261 Contact Point, 31,5 (1.25 in) Model Adapter Rod Point and Collet
5P-2393 Contact Point, 38,1 (1.50 in) D336 8T-5340 3S-3264 9S-8883 6V-3075
5P-4809 Contact Point, 50,8 (2.00 in) 1676 5P-4814
3S-3270 Contact Point, 44,45 (1.75 in)
5P-6531 Contact Point, 57,2 (2.25 in) 1100 and 3100 8T-3206 8S-2296 9S-8883 6V-3075
Series 3208, 3204 5P-4814
2 6V-3075 Indicator and 3406 DI1
3 5P-4814 Collet 3204 PC 2 8T-5339 3S-3264 9S-8883 6V-3075
4 6V-6105 Block 5P-4814
5 6V-3072 Case 3300 Series DI1 8T-3206 6V-2056 6V-2057 6V-3075
5P-4814
6 8T-5247 Block
3400 Series DI 8T-5340 3S-3264 5P-7261 6V-3075
7 8T-5339 Adapter
5P-4814
8 8T-5340 Adapter
3400 Series PC2 8T-5340 3S-3264 5P-2393 6V-3075
9 8T-5338 Adapter 5P-4814
10 3S-3264 Rod, 180,9 (7.12 in) D353, D379 8T-5338 3S-3264 5P-6531 6V-3075
11 8S-2296 Rod, 133,4 (5.25 in) D398, D399 5P-4814
12 8T-3206 Adapter Engines Not 8T-5338 3S-3264 5P-7261 6V-3075
Listed Above2 5P-4814
13 9S-0239 Adapter Assembly
3406A 8T-3205 3S-3264 6V-3075
14 5S-8090 Rod Assembly 5P-4814
15 6V-2056 Rod Assembly 3406B, 3408B, 8T-3206 5S-8090 6V-2057 6V-3075
16 1T-0416 Bolt 3412B 5P-4814
17 8N-5132 Clamp 1 DI — Direct Injection
18 8T-3205 Adapter 2 PC — Precombustion Chamber

6V-6175 Torque Adapter 2P-8256 Timing Decal

SMCS Code: 1000-025
4C-9874 Torque Adapter Model: 1100, 3100
SMCS Code: 1162-010, 1206-010, 1251-010, 1264-017, 1250-025, 1272-010,
1250-025
Model: D25C, 3304B, 3306B • Attach to crankshaft pulley or damper pulley on 1100 and 3100 Series
Engines as alternate method for flow checking static timing without removing
rocker arm shaft and injection nozzle
• 4C-9874 replaces discontinued 6V-6176 Torque Adapter
• Bolted to fuel pump drive gear on 3300 Series Engines so that specific torque
can be applied to gear by tightening center bolt to specified torque value
• 6V-6175 Adapter used on standard engines; 4C-9874 Adapter used on
engines with automatic timing advance
• Both adapters have 1/2 inch square drive

ID: 57327T1

3-122 Dealer Service Tools ID: B38448T1

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Engine Tools Search Fuel System Repair and Adjust

7F-8748 Timing Fixture 5P-0950 Timing Plate

SMCS Code: 1000-025 SMCS Code: 1000-025
Model: D397, D386, D375, D364 Model: 1100, 3100, 3208

• Used with 1F-8743 Adapter Assembly or 1P-7415 Pointer Assembly to time • Used to time fuel injection pump and governor with front cover removed
fuel injection pump camshaft to engine

ID: 79085T1

ID: T97397T1

6V-9145 Adapter Group

SMCS Code: 1000-025
Model: Caterpillar Engines

• Used to add top dead center (TDC) hole in flywheel; 6V-3100 Engine Timing Indicator Group can
then be used for timing and 6V-3100 Multitach can be used to determine RPM on these engines
• 6V-9143 Transducer Adapter is first placed in timing pin hole to align center punch and drill for
6.35 mm (1/4 in) hole, 3.1 mm (1/8 in) deep at No. 1 TDC mark on flywheel; after this operation,
6V-2197 Transducer is used in adapter for connecting to 6V-3100 Group
ID: B76503T1
Item Part No. Description
1 6V-9142 Drill, 1/4 in
Reference 2 6V-9143 Transducer Adapter
SEHS7742 Special Instruction 2D-6392 Seal (Part of 6V-9145)
6M-5062 Seal (Part of 6V-9145)
5B-3254 Nut (Part of 6V-9145)
3 6V-9141 Center Punch

4C-9287 Timing Advance Holding Tool

SMCS Code: 1272-025
Model: 3406B

• Used when pin timing 1988 and newer 3406B Engines, serial numbers 4MG3600
and up, that have large cone-type retainer on fuel timing advance
• Mounted on timing advance
• Required to hold timing advance at bottom of its travel (retarded position) while
pin timing engine; if not used, position can slip and proper timing is not achieved

Reference
SEBR0544-02 Truck Engine Manual

ID: B83722T1

127-1069 Timing Pin

SMCS Code: 1250-025
Model: 3054 and 3056 Engines

• Used to set engine piston at 100° before top dead center (BTDC) when timing Lucas fuel
pump (at this location, the piston can be more accurately set to a specific position)
• Whistle on top of timing pin confirms that piston is on compression stroke
• Installs into nozzle bore and is held in place with nozzle clamp
Reference
SENR6525 Supplement, Lucas Fuel System
ID: C66730T1
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Timing Setting Tools

SMCS Code: 1250-025
Model: 3054E and 3056E Engines
Essential Tool

• Used to set timing of engine

Item Part No. Description Engine Used On

2
1 230-6283 Locking Pin 3054E
3
2 231-8848 Balancer Fitting Pin 3054E
3 231-8849 Locking Pin 3054E
4
4 230-6284 Locating Pin 3054E
5 226-2270 Timing Piston 3056E 5
6 226-2268 Plug Installer 3056E

6
ID: D00729T1

136-4632 Timing Pin

220-2793 Timing Pin
SMCS Code: 1000-531
Model: 1.1L, 1.2L, 3300, 3176 and 3400 Engines

• Used to determine when crankshaft is positioned at top dead center

• Spring loaded pin presses against flywheel; as engine is rotated pin will drop into hole
as number one cylinder reaches TDC
• Adapters furnished to fit models listed with sufficient clearance behind timing hole ID: D00179T1
• Easier to use than a bolt—allows one man operation
• Hardened pin to resist bending Part No. Description Size Use
• No adapter needed for 3300 and 3400 139-7064 Timing Pin Adapter 1/2 inch-20 3176 C10/12 Engines
139-7063 Timing Pin Adapter 7/16 inch-20 1.1 and 1.2 l Engines

208-9387 Timing Pin

208-9388 Adapter
SMCS Code: 1000-531
Model: 3176C Engine, D7R Track-Type Tractor and C-9 Engine, D6R Track-Type Tractor
Essential Tool

• Pin and adapter allows use of 136-4632 Timing Pin with D6R and D7R 2 5
flywheel housings
• Used with 208-0888 Crankshaft Turning Tool
• Easily determines when crankshaft is positioned at top dead center 1
4
• Spring loaded pin presses against flywheel. As engine is rotated pin drops
into hole when number one cylinder reaches TDC Item Part No. Description
• Easy to use — allows one-man operation 3 1 208-9388 Adapter
• Hardened pin resists bending 2 136-4632 Timing Pin
ID: C80526T1
3 208-9387 Pin
4 Spring (part of timing pin)
5 Spring (part of timing pin)

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9U-6188 Timing Fixture Group

SMCS Code: 1251-036, 0766
Model: 3054 and 3056 Engines
Warranty: One Year

• Four separate tools used in combination to check accuracy of timing mark location
on fuel injection pump or engine
• Needed to determine location of timing mark on engine if front cover is replaced

Item Part No. Description

Reference 1 9U-6189 Drive Adapter
SENR5547 Service Module in SENR5555 Service Manual
2 9U-6190 Gear Adapter
3 9U-6192 Timing Fixture
4 9U-6191 Pointer

ID: C55195T1

157-3719 Fuel Spanner 192-3331 Timing Gauge

SMCS Code: 1251-010 SMCS Code: 1251-531
Model: 3054 and 3056 Engines with Bosch Fuel Pumps Model: 3056 Engines with Bosch Pumps

• Used to remove and install Bosch fuel injection pumps • Replaces discontinued 136-3113 Timing Gauge
• Built-in ratchet mechanism reduces removal/installation time • Used to hold dial indicator while checking injection
• Square drive: 3/8 pump timing on engines with Bosch EPVE fuel pump
• Socket size: 13 mm (12-point)

ID: C79246T1

ID: C78528T1

238-9586 Engine Turning Pinion Assembly

SMCS Code: 1202-018
Model: C/15, C/16, 3400, and 3500 Engines

• Used to rotate engines crankshaft

• Used with 3/4 inch ratchet
• Built with internal needle bearings for smoother and more precise rotation of crankshaft
• Bolts to service tool access hole in flywheel housing

ID: D00651T1

5.4 inch Bore, 6 Cylinder Vehicle Engine Lifter Setting Tools

SMCS Code: 1209-025
Model: 5.4 inch Bore Engine, 3412, 3500 and G3500

Item Part No. Description Use

1 9S-9114 Spacer Position 1P-7410 Timing Plate on 8S-2346 Shaft Assembly
when setting lifters off engine
2 9S-9082 Turning Tool, 1/2 inch drive Rotate crankshaft when setting fuel pump lifters

ID: 92947T1
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Tools for Rotating Crankshaft

SMCS Code: 1202-018, 0701
Model: 3114, 3116 and 3126 Engines

• Used to rotate crankshaft (makes setting valves and engine timing procedures easier)
• Used with 5P-7305 Engine Turning Gear and 1/2 inch square drive ratchet
• Fastens to starter mounting hole using starter mounting bolts
• Rotate gear shaft housing assembly until 5P-7305 Engine Turning Gear engages
flywheel gear before tightening starter mounting bolts

Measure dimension “X” on starter housing to determine which part to use.

Part No. Description Size
9U-6943 Shaft Housing Assembly 146 mm (5.75 in)
9U-7336 Shaft Housing Assembly 127 mm (5.00 in)
5P-7305 Engine Turning Gear 6/8 and 8/10 pitch

ID: C66628T1 ID: C80362T1

9U-6198 Crankshaft Turning Tool 208-0888 Engine Turning Tool

SMCS Code: 1202-024, 0714 SMCS Code: 1202-024, 0714
Model: 3054 and 3056 Engines Model: 3176C and C-9 Engines
Essential Tool

• Used to rotate crankshafts (connects directly to front of crankshafts)

• Has 1/2 inch drive in center to connect ratchet or breaker bar • Used to turn crankshaft in engines with rear PTO flywheel housing
(engages forward spline of upper PTO gear)
• Dimensions: 50 x 140 mm (2.0 x 5.5 inch)
• Used in applications where no flywheel turning tool access is provided
• Heat-treated for added durability
Reference
SENR5555 Service Manual • To install: remove cover plate or hydraulic
pump as needed

Square drive 3/4 inch

ID: C80115T1 Spline 14 tooth

ID: C54937T1

178-8615 Socket
SMCS Code: 1000-018, 0700, 0701
Model: 3114, 3116, 3126 MUI, HEUI, and 3126B Engines

• Used to turn engine crankshaft by hand

• Socket crossbars engage all four bolt heads in front pulley hub
• Prevents over-tightening or loosening of a single bolt when it used
to turn crankshaft clockwise or counterclockwise
• Square drive: 3/4 inch
• Overall length: 90 mm (3.5 in)

ID: C79845T1

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5P-7306 Gear Shaft Housing Assembly

5P-7305 Engine Turning Gear
SMCS Code: 1000-025
Model: Caterpillar Engines

• Makes engine rotation much easier for valve setting and timing procedures, especially on
engines with no compression release
• Any engine that will accept standard short and long nose electric starters can be rotated
• Pinion gear has 6/8 pitch gear on one end and 8/10 pitch on other
• Both ends of pinion have 1/2 inch square drive hole to accommodate standard ratchet
ID: A42403T1

5F-2807 Cap 9S-1743 Ferrule Nut Wrench

SMCS Code: 1252-010
2F-2990 Plug Model: Caterpillar Engines
SMCS Code: 1107-010, 1252-010
Model: D5B, D6D, D9N, IT28, 943, 953, 963, 973
• Used to remove and install fuel injection lines
• 3/4 inch x 1 inch
• Used to protect fuel pumps (cap)
and lines (plug) when removing
them from engine

ID: C05383T1

ID: 76011-1T1

5P-0166 Crowfoot Wrench, 3/8 inch 5P-5195 Fuel Line Wrench

Square Drive SMCS Code: 1100-010, 1202-010, 1252-010, 1254-011, 1254-012
Model: 3406
SMCS Code: 1254-010, 1254-012
Model: D3B, 215, 910, 931B
• Special wrench to tighten inside fuel line nuts at through-head connectors
on 3406 Engines
• Used to torque fuel line nut at precombustion chamber on 3204 Engine in D3
Tractors, 910 Wheel Loaders and 931 Track Loaders • Nuts are tightened to 41 N·m (30 lb.ft.)
• Use Torque Computer, SEHS7150, to apply correct torque • Because of its small size, wrench can be damaged if used in any application
where applied torque exceeds 41 N·m (30 lb.ft.)

.
ID: 77215T1

ID: A30728T1

5P-7260 Socket 5P-0144 Socket

SMCS Code: 1254-010 SMCS Code: 1252-010
Model: D346, D348 and D349 Model: D3, 910, 931, 1100, 3100

• Used with 9S-7353 Torque Wrench to remove and • Used for removal and installation of fuel lines
install fuel nozzle retaining nuts on D346, D348 and on 1100 and 3100 Series, 3208, 3406 and
D349 Engines with Fuel Leak Detection System 3204 Engines in D3 Tractors, 910 Wheel
Loaders, and 931 Track Loaders

ID: 80139T1
ID: , A37348-1T1
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6V-4089 Reamer Assembly

SMCS Code: 1106-010, 1250-012, 1254-010, 1254-012
Model: 1100, 3100, 3200 and 330 Series Direct Injection Engines

• Removes carbon deposits from bores of pencil-type fuel nozzles

ID: B32114T1

5B-1401 Fuel Injection Valve Orifice Cleaning Tool Group

SMCS Code: 1254-070
Model: Caterpillar Engines

• Used to remove carbon from orifice in nozzle end of flat seat-type fuel injection valves
1
• Chuck has hollow handle to store drills
• Do not use these tools to clean capsule-type valves.
Item Part No. Description
1 5B-1254 Chuck
2 5B-2177 Drill 0.5 mm (.0197 in)
5B-2178 Drill 0.610 mm (.024 in)
7B-5724 Drill 0.445 mm (.0175 in)
7F-1522 Drill 0.711 mm (.028 in) 2
6H-8639 Drill 0.813 mm (.032 in)
8M-4813 Drill 0.965 mm (.038 in)
ID: C79315T1

8S-2245 Cleaning Tool Group

SMCS Code: 1254-010, 1254-012, 1254-025, 1254-036, 1254-038, 1254-081
Model: 1100, 3100, 3208

• Used to properly service pencil-type injection nozzles used

in 1100 and 3100 Series and 3208 Engines

Reference Item Part No. Description

SEHS7292 1 8S-2262 Case Assembly
2 8S-2256 Vise Assembly
3 5P-0958 Retractor Assembly
4 8S-2249 Pad
5 8S-2246 Wire Assembly 0,20 (.008 in) Item Part No. Description
ID: B16378-1T1
6 8S-2247 Wire Assembly 0,28 (.011 in) 12 8S-2250 Holding Tool
7 5P-4813 Socket 13 6V-9124 Screwdriver
8 8S-2259 Lapping Compound 14 8S-2254 Retractor Assembly
9 8S-2257 Loupe 15 8S-2255 Scraper
10 6V-4979 Seal Tool 16 8S-2251 Drill
11 2P-5487 Adapter 17 8S-2258 Brass Wire Brush
18 8S-2260 Honing Stone

5P-6229 Extractor
SMCS Code: 1106-010, 1254-010
Model: 3400 Series Direct Injection Engine

• Used to remove fuel nozzle adapter body on 3400 Series Direct Injection Engines
and most other engines with precombustion chambers

ID: A30058T1

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Fuel Injection Valve Nut Removal Tools

SMCS Code: 1254-011
Model: Caterpillar Engines 1

• Used for fuel injection valve nut removal on early engines

Item Part No. Description Size 2 3

1 9B-2029 Wrench 1-3/4 inch hex
2 7B-4973 Wrench 1-7/8 inch hex
3 4B-9918 Handle

ID: 13474T1

6V-4061 Nozzle Puller Group

6V-4054 Nozzle Puller Group
SMCS Code: 1254-010
Model: D5B, D6D, 225B, 225B-3208, 229-3208, 3208, 518

• 6V-4061 Nozzle Puller Group used to remove direct injection fuel nozzles from 1100,
Item Part No. Description
3100, 3200 and 3300 Series DI Engines
1 1B-4206 Nut
• 6V-4054 Puller Group used with 6V-4061 Group to remove 7N-0449 Nozzles in
3300 Series DI Engines (all parts of 6V-4061 Puller Group, except 6V-4153 Plate, 2 2S-5658 Washer
needed) 3 6V-4153 Plate
4 6V-4152 Screw
5 6V-4150 Leg
6 6V-4149 Jaw
7 6V-4151 Leg
Item Part No. Description
1 0S-1618 ID: B31919-1T1
Bolt

ID: B31906T1

6V-6026 Pump Group, 230V, 50Hz

6V-6027 Pump Group, 110V, 60Hz
SMCS Code: 1254-070
Model: Caterpillar Engines

• Used with 6V-4022 Injector Tester to remove air from injector at faster rate during
injector test procedure
• After injector installed on tester, electric priming pumps can be turned on and run
during engine test procedure; pump protected from high pressures by check valve
• Includes fittings and hardware needed for installation on tester; 6V-6026 Pump Group
also includes 230V lamp for replacement of original 110V lamp in 6V-4022 Tester

Reference ID: B60374-1T1

SEHS8065 Special Instruction

8T-2854 Nozzle Retainer Handle

SMCS Code: 1252-012
Model: 3408, 3412

• When used with 5P-0328 Crowfoot Wrench, provides means to hold fuel nozzle
in place while installing fuel lines
• Can be used as handle (10 inch long) for any 3/8 inch drive socket

ID: B96379T1
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6V-6980 Nozzle Puller Group

SMCS Code: 1254-011
Model: 3300

• Replaces discontinued 6V-3129 Puller

• Used for removing 8N-7003 and 8N-7005 Nozzles used in 3300 Series Engines;
can also be used for removal of former 8N-7001 and 8N-7002 Nozzles
• Required because carbon build-up around nozzle stems prevent nozzles from
being removed by hand
Item Part No. Description
1 6V-6197 Screw
NOTE: The 6V-6980 Puller Group should only be used when less than 150 pound-inches 2 6V-6198 Clip
ID: B59013T1
torque is required to pull the nozzle. The nozzle stem will bend or break if more than
3 6V-6199 Button
150 pound-inches torque is applied with the 6V-6980 Puller. For nozzles that are extremely
difficult to remove, the FT1533 Adapter and 1P-0074 Slide Hammer are still recommended. 4 6V-6130 Puller, not serviced
When using these tools, it is often necessary to remove various engine components.

6V-6976 Puller Group

SMCS Code: 1254-011
Model: 3204 Item Part No. Description
1 1B-4206 Nut (also part of 6V-4061 Puller Group)
2 2S-5657 Washer (also part of 6V-4061 Puller Group)
• Used to remove 1W-3996 Direct Injection Fuel Nozzles on 3204 Engines;
3 6V-4153 Place (also part of 6V-4061 Puller Group)
nozzles tend to stick in their bores due to carbon deposits, etc.
4 6V-4152 Screw (also part of 6V-4061 Puller Group)
5 6V-6979 Leg
NOTE: As indicated in the parts list, several parts of the 6V-6976 Puller Group
6 6V-6978 Head
are also used in the existing 6V-4061 Nozzle Puller Group. If the dealer already
has the 6V-4061 Group, only the last four parts (items 5, 6, 7 and 8) are needed 7 6V-6977 Leg
to assemble the 6V-6976 Group. 8 1D-4716 Nut

ID: B51767T1

6V-7020 Nozzle Puller Group

SMCS Code: 1254-010
Model: Caterpillar Engines
Warranty:

• Combines all components of 5 nozzle puller groups listed below without Part No Description Quantity
duplicating commonly-used components 6V-3072 Case 1
• Also included are various maintenance items, such as 6V-4979 Carbon 6V-6982 Tube Assembly 1
Stop Seal Too, 25 extra carbon stop seals and 6V-4089 Reamer for carbon 6V-7031 Block 1
removal; socket, extension and handle included for removal of 5/16 inch-
6V-6980 Nozzle Puller Group 1
12 point hold down screws used on some nozzle clamps
6V-6983 Adapter 1

Reference 5P-7276 Container 1

SEHS8094 Special Instruction 6V-4979 Carbon Stop Seal Tool 1
9L-9098 Carbon Stop Seal 25
6V-4089 Reamer 1
6V-6976 Nozzle Puller Group 1
Nozzle Engine Nozzle
6V-4151 Leg 1
Puller Group Used On Part No. ID: B51775T1
6V-4150 Leg 1
6V-6981 3406 8N-7006
6V-4054 Nozzle Puller Group 1
6V-6980 3300 Series 8N-7001, 8N-7005, 8N-7003
6V-4149 Jaw 1
6V-6976 3204 1W-3996
5P-4199 Handle 1
6V-4061 1100, 3100 9L-8965, 9N-2366, 9N-3299,
and 3200 Series 1W-5829, 9L-6969, 9L-7883 9S-1715 Socket 1
9N-3299 9S-1721 Extension 1
6V-4054 3300 Series 7N-0449

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6V-6981 Nozzle Puller Group 9U-6278 Injector Puller Connector

SMCS Code: 1254-010, 1254-011 SMCS Code: 1254-0706, 0707
Model: 3406 Model: 3054, 3056, 3064, and 3066 Engines

• Used for removal of 8N-7006 Direct Injection Fuel Nozzles • Used to remove stuck injector nozzles due to carbon deposit build-up in bore
from 3406 Engines • Used with 1U-7600 Puller Group
• Uses several parts from earlier 6V-4061 Nozzle Puller Group • 1/2-20 thread (female) on one end and M12 x 1.5 thread (female) on other end

Item Part No. Description

1 1B-4206 Nut
2 2S-5658 Washer
3 6V-4152 Screw
4 6V-6982 Tube Assembly1
5 6V-6983 Adapter1
1 These parts are needed to make the
6V-6981 Nozzle Puller Group from the
earlier 6V-4061 Nozzle Puller Group.

ID: B51772-1T1
ID: C54926T1

Tools for 3406B Engine Fuel Nozzle and 4C-8175 Nozzle Puller Assembly
Fuel Nozzle Adapter SMCS Code: 1254-010, 0706
Model: 3306 Engine
SMCS Code: 1101-010
Model: 3406B
Warranty:
• Used to remove 104-9450 Direct Injection Fuel Nozzle Assembly
• Required for nozzle removal (carbon build-up around nozzle stems prevents
• Smaller tools required to remove and install cylinder heads on 3406B
removal by hand)
Engines, which were redesigned with smaller diameter fuel injection
nozzle adapters • Using specialized puller makes nozzle removal faster, easier, and helps
prevent damage
• As of 6/1/94 the 104-9450 Fuel Injection Nozzle is used only in the
European market

Item Part No. Description

1 1B-4206 Nut
2 8T-3199 Screw
3 6V-6983 Adapter
4 8T-3198 Tube
ID: C54976T1

ID: B96376T1

134-2570 Nozzle Retainer Spanner Wrench

SMCS Code: 1254-010
Model: 3406B, 3406C, 3408, 3408B, and 3412 Engines with P and L Fuel Systems

• Replaces discontinued 8T-3139 Spanner Wrench and 9U-5840 Spanner Wrench

• Used to remove and install 7W-2315 Fuel Injection Nozzle Retainer
• Provides additional clearance for 3406B and 3406C Engines equipped with
Jacobs Engine Brake Hex size 9/16 inch
• Made from SAE4140 steel and heat-treated for long tool life Overall height 20.5 mm (.81 in)
Overall diameter 41.0 mm (1.61 in)
Distance between pins 28.5 mm (1.12 in)

ID: C54981T1

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1U-9725 Wrench
SMCS Code: 1106-010, 1254-010
Model: See below Engine Serial No.
3406B All
3408 S/N 78Z-1277-up
• Used on following engines to remove and replace nozzle adapters S/N 67U-11092-up (D.I.Only)
• Larger and stronger to eliminate breakage when removing tight adapters 3412 S/N 81Z-4579-up
• Works on both 7W-1645 (old style) and 7W-5435 (new style) Nozzle Adapters S/N 38S-13223-up
• Has 1/2 inch square drive for normal usage, and 1-1/8 inch hex so larger drive socket S/N 60M-2477-up
can be used when removing tight adapters

ID: B83741T1

6V-4980 Torque Screwdriver Tool Group

SMCS Code: 1254-036, 1254-081, 3280-016, 4131-016, 4130-017
Model: Caterpillar Engines

• Uses standard 1/4 inch hex drive bits to tighten small fasteners up to 4 N·m (3 lb.ft.).
• Very useful in many applications for applying correct torque to small fasteners; especially
needed to tighten bleed screw on some Caterpillar direct injection fuel nozzles used in
3304 and 3306 Engines
• Makes it is easier to tighten sleeve levers on engines with sleeve metering fuel systems;
tool holder block for torque screwdriver group provides space for 6V-4141 Sleeve Metering
Lever Calibration Tool Group
• Adapter provided for using 1/4 inch drive sockets in other applications within range of this tool

NOTE: Chuck must be loosened prior to removing bits or O-ring seal will be damaged;
ID: B46662T1
O-ring seal, located inside chuck of torque screwdriver, makes gripping the bits possible;
to replace damaged O-ring seal, remove chuck from screwdriver and remove seal from chuck; Part No. Description
install 1P-7363 Seal or 2D-6392 O-ring Seal in chuck and install chuck to screwdriver 6V-6096 Block
148-5675 Case
4C-9785 Block
4C-9785 Foam Block
6V-6082 Bit, 5/64 inch Hex
6V-6074 Bit, 7/64 inch Hex
6V-6076 Bit, 5/32 inch Hex
6V-6073 Adapter, 1/4 inch Hex to 1/4 inch Square
6V-6072 Bit, 9/64 inch Ball End Hex
247-5377 Screwdriver
6V-6075 Bit, 3/16 inch Flat
1U-5895 Line Head
148-5677 (Not shown) Block

9U-7227 Injector Height Setting Gauge

187-0482 Spacer Sleeve
4
SMCS Code: 1290-036, 0706
Model: 3406E Engines 1

9U-7227 Injector Height Setting Gauge Item Part No. Description

• Used to adjust injector Prestroke 1 9U-7227 Injector Height Setting Gauge
• Leaves both hands free to make adjustments 2 187-0482 Spacer Sleeve
2 3 4L-5966 Setscrew
187-0482 Spacer Sleeve 3 4 1U-9084 Flag
• Used to help prevent improper injector height settings
• Used with 9U-7227 Injector Height Gauge with a straight indicator pin
(spacer sleeve can be ordered separately) ID: C80001T1
• Sleeve rests against injector spring to keep gauge square on spring retainer Reference
• Earlier gauges with a support flare machined onto the indicator pin do not need this spacer SENR5580 Service Manual
• All new gauges include a spacer sleeve SENR6421 Service Manual Module, Disassembly
and Assembly 3406E Engines

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9U-7227 Injector Height Gauge 1U-5895 Bit Linehead

SMCS Code: 1290-036, 0706 SMCS Code: 1254-036, 1254-081, 3280-016, 4131-016, 4130-017
Model: 3406E Engines Model: Caterpillar Engines

• Used to adjust injector Prestroke • Required to remove and install bleed screw on Caterpillar 7000 Series
• Leaves both hands free to make adjustments Nozzles, date code H7 and newer, and to tighten bleed screw to exact
torque without stripping threads — prevents leakage
• Included in 6V-4980 Torque Screwdriver Tool Groups; also available
Reference ID: C55191T1
separately to upgrade earlier 6V-4980 Torque Screwdriver Tool Group
SENR5580 Service Manual
SENR6421 Service Manual Module, Disassembly and Assembly 3406E Engines Reference
SEHS7292 Special Instruction

1U-8780 Nozzle Puller Group

SMCS Code: 1000-010, 1100-017, 1254-010, 1254-011
Model: 3200, 3300

• Works to pull all 7000 Series Fuel Nozzles on 3200 and 3300 Series Engines;
short enough to use on rear cylinders on 3208 Engines in highway trucks
• Strong enough to pull stuck nozzles on 3300 Series Engines
• Replaces two nozzle pullers: 6V-6980 Nozzle Puller Group for 3300 Series Engines and
6V-6976 Nozzle Puller Group for 3204 Engines
• Has two adapters, one with full clamp for 3300 Series Engines and one with half clamp for 3200 Series Engines
ID: C27145T1

6V-7025 Guide
SMCS Code: 1250-012
Model: 3406

• Replaces discontinued 5P-4755 Guide

• Used to properly install 5P-2060 Seal onto 4N-3761 Direct Injection Capsule Valve Adapter
on 3406 Engines

ID: A16934T1

9U-5127 Tool Group, 3408 PEEC, and 3412 PEEC

SMCS Code: 1251-036, 1251-025; 0766
Model: 3408 and 3412 PEEC Engine

• Replaces discontinued 4C-9579 Tool Group

• Used to test and adjust fuel pump timing on 3408 and 3412 PEEC Engines
• Increased accuracy
• On-engine field adjustments expand capability of field service mechanics
• Increases service revenue opportunities
• Durable, high quality design — convenient case protects tool investment
• 90 mm long timing pin
• Two 89 mm long rack zero pins
• Modified 3/4 inch crowsfoot with 3/8 inch drive
ID: C55053T1
• Slotted 1 5/16 inch socket with 1/2 inch drive
Item Part No. Description
• Solenoid spanner wrench with 3/8 inch square drive
1 9U-5120 Solenoid Spanner Wrench
• 6V-2112 Pin for Haliburton Engines
2 136-3124 Socket-Sensor (rack)
3 6V-2112 Fuel Pump Timing Pin
6V-4186 Fuel Pump Timing Pin
4 4C-9581 Rack Zero Pin (2)
5 4C-9582 Crowfoot Wrench, 3/4 inch
6 6V-4186 Fuel Pump Timing Pin
Not shown 6V-3073 Case
Not shown 9U-5128 Foam

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9U-5219 Tool Group 3406 PEEC Engines

SMCS Code: 1250-036, 0766
Model: 3406B PEEC Engine

• Replaces discontinued 1U-5540 Tool Group (to update former 1U-5540,

order 9U-5103 Slotted Socket, 9U-5225 Foam Block, and NEEG2516 Decal
• Used to set clearance dimension between engine speed sensor and
4W-2485 Slotted Retainer (pulse wheel)
• Establish zero rack position, necessary before 8T-8697 ECAP can be used
to calibrate rack position sensor without breaking governor seals
• Remove and install 6T-9675 Solenoid (fuel shutoff)
• Set timing position sensor, necessary before 8T-5282 DDT and/or 8T-8697
ECAP can be used to calibrate timing position sensor
• Remove and install water temperature sensor

Reference ID: C44381T1

SEHS8746 Special Instruction
Item Part No. Description Item Part No. Description
1 8T-9198 Rack Indicator Bracket Assembly 6 9U-5103 Slotted Socket
2 5P-4814 Clamp Collet 7 5P-0326 Crowfoot Wrench, 3/4 inch
3 9U-5120 Spanner Wrench 8 1U-5536 Crowfoot Wrench, 1-5/16 inch
4 6V-4186 Fuel Pump Timing Pin, 90 mm 9 1U-5425 Timing Gauge Assembly
5 1U-5426 Zero Rack Compressor Assembly Not shown 6V-3072 Plastic Case
6D-3982 Nut Not shown 9U-5225 Foam Block
7F-2359 Spring
9S-8903 Contact Point Not shown NEEG2516 Decal

9U-5292 Rack Preload Assembly (3400 PEEC)

9U-5295 Rack Position Group (3400 PEEC)
SMCS Code: 1250-036
Model: 3406, 3408, and 3412 Series NSFS (PEEC) Engines with Fuel Injection Pump and Governor Group

• Used to set the PEEC injection pump rack position without an electronic control system

9U-5292 Rack Preload Assembly 9U-5295 Rack Positioning Group

• Used to hold pressure against (preload) rack in plus direction • Used to limit travel of rack and make precision rack adjustments
• Fits in place of pumps’s electronic control unit (BTM) • Fits in place of the rack shut-off solenoid
• Fluted knob provides easy adjustment • Knurled surfaces provide better grip while adjusting rack position
• Outside diameter: 82.6 mm (3.25 in) • Parts are serviced individually
• Knob: 1V-5044

9U-5292 9U-5295
ID: C66931T1

9U-5295 Rack Positioning Group

Part No. Description
9U-5294 Threaded Bushing
Reference ID: C66930T1 9U-5293 Rack Adjusting Screw, 1 3/16-12
NEHS0625 and NEHS0639 Tool Operating Manuals 3S-2713 Full Hardened Nut

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8T-5160 Gas Regulator Setting Tool Group

SMCS Code: 1550-025
Model: All gas engines with Fisher Gas Regulators
(Use FT2613 for gas engines with the 7E-3407 Sprague Gas Regulator)

Item Part No. Description Quantity

• Used to adjust gas line pressure regulator on entire 1 6V-3072 Case
current and noncurrent lines of spark ignition engines
2 8T-5149 Fitting 3
• Can service engines equipped with both smaller regulator
used on 3304 and 3306, and two of the larger regulators 3 8T-5164 Tool
used on larger engines 4 8T-5163 Tool 2
• Allows adjustment of gas regulator spring with no leakage 5 8T-5165 Tool 2
at air side of regulator; air leakage during adjustment 6 8T-5159 Foam Block
causes incorrect settings 7 8T-5162 Adapter 2
6L-7141 Gasket 2
ID: B96714T1
8 8T-5161 Adapter
3H-8012 Gasket
9 6V-6105 Block

3304, 3306 Positive Pressure Regulator 1 each 8T-5161 Adapter

8T-5163 Tool
8T-5149 Fitting
3H-8012 Gasket
3304, 3306 Vacuum Regulator 1 each 8T-5161 Adapter
8T-5165 Tool
ID: B96715T1 8T-5149 Fitting
3H-8012 Gasket
Application Procedure 3400, 3500 Positive Pressure Regulator 1 each 8T-5162 Adapter
1. Select appropriate tool, adapter and gasket for regulator being set and assemble 8T-5163 Tool
8T-5149 Fitting
using 8T-5149 Fitting 7L-7141 Gasket
2. To install, remove gas regulator cap and thread adapter into regulator in place of 3400, 3500 Vacuum Regulator 1 each 8T-5162 Adapter
cap; push tool shaft down until it engages adjustment screw or nut and tighten 8T-5165 Tool
fitting just enough to seal off any air leaks around shaft 8T-5149 Fitting
7L-7141 Gasket
379, 398, 399 Positive Pressure Regulator 2 each 8T-5162 Adapters
8T-5163 Tools
Reference 8T-5149 Fittings
Appropriate Engine Service Manual 7L-7141 Gaskets
379, 398, 399 Vacuum Regulator 2 each 8T-5162 Adapters
8T-5165 Tools
8T-5149 Fittings
7L-7141 Gaskets

Fuel Injection Pump Extractors

SMCS Code: 1251-010
Model: 1100, 3100, 3200

• Use the extractor and wrenches to remove and install fuel injection pumps and retaining bushings

Item Part No. Description Use

1 8S-2244 Extractor
2 8S-2243 Wrench with 8S-2244 Extractor to remove and install fuel injection
pumps on 1100 and 3100 Series Engines and engines with
Sleeve Metering Fuel Systems
3 8T-5287 Wrench with 8S-2244 Extractor to remove and install fuel injection
pumps on engines with compact fuel systems; replaces
discontinued 8S-4613 Wrench
4 5P-1668 Wrench, 3/8 inch drive remove and install fuel pump retaining bushings where
space does not permit use of 8S-2243 Wrench on 1100,
3100 and 3200 Series Engines
ID: A69884T1

Buttress Taps Threads Part Pitch

• Bottoming Size Per Inch No. Diameter
• For cleaning threads on 3300 NSFS and 3400 NSFS fuel system pumps 1.375 in 12 1U-6725 33.746 ± 0.090 mm
1.750 in 12 1U-6726 43.276 ± 0.090 mm

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5P-2682 Bleeder Valve Socket 8T-0833 Fuel Pump Wrench

SMCS Code: 3224-025 SMCS Code: 3205-025
Model: 963, 973 Model: 943, 953, 963, 973
Warranty: Lifetime

• Replaces 9F-0022 Bleeder Wrench • Used for removal and installation of fuel pump on 3408 and 3412 Engines
• Used to loosen air bleeder valve on early forged body fuel pumps (replaces 6V-0094 Universal Joint in this application)
• Fits various drive combinations when
accessibility is a problem
• 1/4 inch square female and 1/2 inch
hex male drive

ID: B96351T1
ID: 92237T1

6V-7050 Compressor Group

SMCS Code: 1251-023
Model: 3406
Item Part No. Description

• Used for servicing fuel pump plunger and barrel assemblies 1 2N-3476 Screw
on 3406 Engines with New Scroll Fuel System 2 6V-7015 Clamp Assembly
• Needed to compress heavier pump lifter springs on these engines 3 5M-7418 Nut
when plunger and barrel assemblies are removed and installed 4 4B-1228 Screw
5 4B-2046 Nut
Reference Not shown 148-5675 Case
SMHS8278 Special Instruction Not shown 6V-7026 Block
Not shown 148-5677 Block

ID: B58583T1

6V-4180 Off-Engine Lifter Setting Tool Group

SMCS Code: 1253-017, 1250-025, 1251-036
Model: All Engines with Forged Body or Compact Fuel Systems

• Replaces 5P-6600 Tool Group

• Includes lifter setting tools for all current engines, including 3400 Series Engines
• Also included are shaft assemblies which clamp positively to camshafts,
eliminating movement between camshaft and degree wheel
• Tools required for individual engines are listed in the application chart below.
• Additional tools needed, but not included, with 6V-4180 Group are also illustrated.

ID: B39254T1
Additional Tools Needed But Not
Included in 6V-4180 Group 6V-4180 Off-Engine Lifter
Item Part No. Description Setting Tool Group
32 5P-6570 Shaft Assembly Item Part No. Description
33 8S-2272 Shaft Assembly 1 9S-6332 Box Assembly
34 1B-3680 Bolt 6V-4181 Tool Holder Block
9S-8105 Liner
35 3F-1417 Washer
36 6V-2012 Gauge Group
37 6V-7926 Indicator Group
38 9M-4567 Wrench
39 9M-4568 Wrench

ID: C80294T1

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Application Charts for 6V-4180 Tool Group

Forged Body Fuel System
Item Components D311 D3400 D326 D346 D353 D379 641
of 6V-4180 D312 D4400 D337 D348 D398 650
Tool Group D315 D4600 D343 D349 D399 651
(Fig. 1) D318 D6100 619C 657
D339 D6600 824A 660
D342 D7700 1693 666
D364 D8800
D375 D11000
D386 D13000
D397 D17000
D468
2 5P-6574 Shaft 1
3 5P-6564 Shaft 1
4 5P-6566 Shaft 12 1
5 5P-6568 Shaft 1
6 7F-8751 Shaft 1
9 2S-6160 Washer 1 1 1 1 1 1
11 0S-1594 Bolt 1 1 1 1 1 1
12 0S-0509 Bolt 1 1 1 1 1 1
13 0S-1617 Bolt 1
18 1P-7415 Pointer 1 1 1 1 1
19 5P-6572 Shaft
20 9M-4567 Wrench 1 1 1 1 1 1
21 9M-4568 Wrench 1 1 1 1 1
31 1P-7410 Plate 1 1 1 1 1 1

Additional Tools Needed But Not Included in 6V-4180 Tool Group

32 5P-6570 Shaft 1
36 6V-2012 Gauge Group 11 11 11 11 11 11
37 6V-7926 Indicator 1 1 1 1 1 1
38 9M-4567 Wrench 11 11 11

Compact Fuel System Additional Tools Needed But Not Included in 6V-4180 Tool Group
Item Components D311H D334 D336 1140 3406 3408 33 8S-2272 Shaft 13
of 6V-4180 D320 D343 1676 1145 3412 34 1B-3680 Bolt 13
Tool Group D330D 1674 1150
(Fig. 1) D333 6193 1160 35 3F-1417 Washer 13
1670 3145 36 6V-2012 Gauge Group 11 11 11 11 11 11
1673 3150
37 6V-7926 Indicator 1 1 1 1 1 1
D8 3160
583 6V-2112 Pin 1 1
3204 2A-0762 Bolt 1
3304
1 Optional
3306
2 619C and 824A only
7 5P-4158 1 1 1 1 1 1
3 “Max-Min” govenor only
8 1F-1375 Bolt 2
4 3204 (45V S/N)
9 2S-6160 Washer 1 1 1 1 1
5 Earlypointer groups have a 5P-6219 Dowel, 15,8 mm (.622 in) diameter
10 2S-0932 Washer 1
installed for 3408 and 3412 engines. Also the 7,14 mm (.281 in) diameter hole
11 0S-1594 Bolt 1 1 1
must be increased to 8,5 mm (.328 in) diameter for use on later 3408 and 3412
12 0S-0509 Bolt 1 1 1 1 fuel pump housings.
13 0S-1517 Bolt 1 1 6A decal, Form SEHS7306, must be applied to early 1P-7410 Timing Plates to
14 8S-2280 Pointer 1 accurately time 3406 Direct Injection Truck Engines (1978 Truck Model Year)
7 3304 (9Z) and 3306 (10Z)
15 6V-6019 Pin 1
8 3204 (10X S/N)
16 1J-6298 Bolt 1
17 2M-5218 Shaft 1
18 1P-7415 Pointer 1
19 5P-6572 Shaft 1
22 7S-5803 Shaft 1
23 6V-3035 Shaft 18
24 5P-1768 Pointer 1 15
25 9S-4446 Shaft 1
26 5P-3601 Adapter 1
27 1P-7420 Pointer 1 1
28 5P-1761 Shaft 1
29 6V-3066 Shaft 17
30 5P-0129 Sleeve 14
31 1P-7410 Plate 1 1 1 1 15 1
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6V-7870 Fixture Group Item Part No. Description

SMCS Code: 1251-010, 1251-017
1 4B-6060 Setscrew (two)
Model: Caterpillar Engines
2 4B-2046 Nut
3 6V-7015 Clamp Assembly
• Designed with adjustable clamp and 5-position turret 4 2N-3476 Screw (four)
• One position used for 3406B Engines with New Scroll Fuel Systems
and remaining 4 positions for other engines with fuel pumps having
reverse flow check valves
• 6V-7871 Repair Kit, consisting of turret and detent, also available

Reference
SMHS8378 Special Instruction ID: B79245T1

Tools for Accessory Drive Gear

SMCS Code: 1250-010
Model: 3204 Vehicular Engines Item Part No. Description
Warranty: None 1 FT1539 Puller
2 FT1540 Puller
• 4 fabricated tools needed to loosen accessory drive gear from 3 8H-8561 Adapter
shaft without removing radiator on 3204 Vehicular Engines
4 FT1538 Puller
• FT1537 Socket and FT1539 Puller used on 45V Vehicular Engines
5 5P-8676 Extension
• FT1537 Socket, FT1538 Puller and FT1540 Puller used on
6 FT1823 Socket
10X Vehicular Engines
• 8H-8561 Adapter and 5P-8676 Extension also required

ID: B19374-1T1

8S-2271 Timing Fixture Group

SMCS Code: 1250-025
Model: 1100, 3100

• Used to time fuel pump housings off-engine on later 1100 and 3100 Series
Engines equipped with hydra-mechanical governors
• 1P-8747 Timing Plate or 1P-7410 Timing Plate can be used

Item Part No. Description

1 8S-2280 Pointer Assembly
2 9S-5446 Shaft
3 0S-1594 Bolt
4 2S-0932 Washer ID: C05384T1
5 1J-6298 Bolt

1P-5550 Fuel Cam Locking Group

SMCS Code: 1250-025
Model: 623B, 824C, 825C, 826C

• Used to lock fuel camshaft in place when resetting pump timing on 1100, 3100 and 3406 Engines

ID: C05389T1

9S-8520 Puller Group

Discontinued — Service Parts Available

Item Part No. Description

1 9S-8527 Bolt
2 5P-3031 Thrust Washer
3 9S-8528 Bolt Assembly

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ID: A13535T1
Engine Tools Search Fuel System Repair and Adjust

8S-4618 Timing Gauge

Item Part No. Description
8S-4620 Timing Gauge 1 3D-7943 Ring
SMCS Code: 1250-025
Model: 920, 930, 977L

• Used to check timing dimension on 4.75 inch bore 2-valve engines

• 8S-4618 used on 6-cylinder engines; 8S-4620 used on 4-cylinder engines
• Provide rapid method of checking timing
ID: C05393T1

Sockets for Special Applications

SMCS Code: 1250-011
Model: 3208, 1100, D379, D398, D399

ID: 92943T1
Item Part No. Description Size Uae
1 9S-5031 Deep Well Socket 5/8 inch, 3/8 inch drive Required for tachometer drive adapter shaft removal on 1100 and 3100 Series Engines equipped with
hydraulic governors; also used for removal and tightening cap on 9L-6969 Nozzle for 3208 Engines
2 8S-2357 Deep Well Socket 9/16 inch, 3/8 inch drive Required to loosen bolt which retains automatic timing advance unit to fuel injection pump camshaft
on 1100 Series Engines equipped with max-min governor
3 9S-6054 Socket Assembly 3/4 inch drive Turning injection pump camshaft when setting lifters on D379, D398 and D399 Engines

Timing Pins
SMCS Code: 1250-025
Model: 1100, 3100, 3406, 3408, 3412, 3306, 3304 D.I.

Item Part No. Description Model

1 6V-2112 Pin (former 8S-2291) 1100 and 3100 Series and 3406 Engines
2 6V-6019 Pin (part of 6V-4180) 3408 and 3412 Engines
3 6V-4186 Pin (part of 6V-4096 and 6V-4096; former 7N-1048) 3306 and 3304 D.I. Engines
Not shown 3P-1544 Pin 328 SMFS ID: B14959T1
Not shown 4C-9581 Pin 3408/12 PEEC

Decal for 1P-7410 Degree Wheel

SMCS Code: 1250-025
Model: 3406B
Timing Pins
SMCS Code: 1251-010, 1251-025, 1000-025
Model: 3054 and 3056 Engines • Used to time 3406 Direct Injection Truck Engines (1978 Truck Model Year) with
static fuel injection timing
• Decal, SEHS7306, must be applied to early 1P-7410 Degree Wheels for accurate
• Used to install injection pumps on 3000 Series engines timing
• Decal provides timing
Part No. Description Use marks in increments
less than one
150-3992 Timing Pin Required to install Bosch injection pumps
degree
150-399 Timing Pin Required to install Lucas and Stanadyne
injection pumps

ID: A71279T1
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9U-5692 Spring Compressor

SMCS Code: 1251-010, 0712
Model: 3406, 3408 and 3412 Engines

• Works on all three engines—3406, 3408 and 3412

• Used to compress heavier lifter springs in pump when fuel pump plunger
and barrel assemblies are removed and installed
• Clamps on side of pump housing and eliminates need to attach to adjoining pump

Reference ID: C47940T1

SENR5148 and SENR4658 Service Manuals

9S-6326 Rack Bearing Installation Tool Group

SMCS Code: 1253-010, 1253-017
Model: D5B, D6D, D8K, 943, 953

• Used for installation of 9S-4160 Rack Bearing on 1674 and D334 Engines and
1W-3285 Rack Bearing on 3304 and 3306 Direct Injection Engines

Item Part No. Description

1 9S-6327 Plate Assembly
8H-9208 Dowel, set of three( part of 9S-6327)
2 1B-2790 Bolt (two)
3 6V-4818 Driver ID: C80206T1

5P-1665 Alignment Plate 6V-0094 Universal Joint

SMCS Code: 1253-010, 1253-017 SMCS Code: 1251-010
Model: D3B, D4E, D5B, D6D, 215, 623B, 910, 931B, 943, 953 Model: 3408, 3412

• Used with 6V-4818 Driver from 9S-6326 Rack Bearing Installation Tool Group • Used for removal and installation of fuel pump on 3408 and 3412 Engines as
• Used to install 9S-4160 Sleeve Bearings in well as other applications where accessibility to fasteners is limited
fuel pump housing of 3304 and 3306 Engine • 3/8 inch drive tool is 40 mm (1.56 in) long, which is shorter than standard
3/8 inch universal joints

ID: D00893T1
ID: A82269T1

Special Taps
SMCS Code: 1250-023
Model: Caterpillar Engines

• Special bottoming hand taps to recondition damaged fuel pump

retainer threads in any compact or sleeve metering pump housing
Part No. Description Size
5P-3013 Tap 1 3/8 inch-12 NF
5P-3012 Tap 1 1/8 inch-12 NF
5P-3011 Tap 1 inch-14 NS

ID: A10162T1

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5P-6217 Fixture 6V-4824 Driver

5P-6218 Bearing Driver 6V-4825 Plate
SMCS Code: 1253-017 SMCS Code: 1253-016, 1253-017
Model: 3408, 3412 Model: 3406B

• Used to install tanged fuel rack • Used to install D-shaped rack bearing in fuel injection pump housing on 3406B
bearings on 3408 and 3412 Engines Engines
• 6V-4825 Plate, bolted to pump housing, pilots bearing as it is driven into
position with 6V-4824 Driver
• Assure bearing installation to correct depth and angle

Reference
3406B Service Manual

ID: A30055T1

ID: B79251T1

7S-7113 Rack Setting Gauge 3H-1690 Fuel Rack Setting Gauge

SMCS Code: 1251-010, 1253-017 SMCS Code: 1251-025
Model: D333, D330, D320, D311H Model: Caterpillar Engines

• Replaces 8M-0530 Gauge • Measures fuel rack setting on all Caterpillar diesel engines using forged
• Measures rack travel in both “fuel on” and “fuel off” directions body fuel injection pumps
• Readings made directly
on vernier scale

ID: T97425T1

ID: T97016T1

1F-7944 Rack Setting Fixture

SMCS Code: 1251-025
Model: 5.4 inch, 5.75 inch Bore Engines

• Used with 3H-1690 Gauge to set fuel rack on some early engines
(5 1/4 inch and 5 3/4 inch bore) with flange type pumps

ID: C09465T1

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1H-6471 Rack Setting Gauge

Discontinued — Service Parts Available

Item Part No. Description

1 6V-2012 Micrometer Depth Gauge Assembly
2 1H-6471 Rack Setting Gauge

ID: C80303T1

5P-0130 Gauge, “O” Set 6V-7941 Overfueling Spring Compressor

SMCS Code: 1251-010, 1250-025 SMCS Code: 1250-025, 1250-036, 1257-025
Model: 3204 Model: Caterpillar Engines

• Used to center fuel rack when adjusting racksetting on 3204 Engine in D3 • Used to make fuel rack and fuel ratio control settings on engines with New
Tractors, 215 and 910 Wheel Loaders, and 931 Track Loaders Scroll Fuel Systems
• Replaces discontinued 6V-2128 Overfueling Spring Compressor
• Plunger travel in former 6V-2128 Compressor was limited by mechanical
stops and would not permit checking full range of rack settings on above
engines; 6V-7941 Compressor does not have internal stops, and thus will
accommodate full range of rack settings

Item Part No. Description

1 7B-1401 Pin
ID: 77210T1
2 3H-1156 Pin ID: B58577T1

6V-7942 Hook
SMCS Code: 1251-025
Model: Caterpillar Engines

• Used to pull rack against rack centering pin on engines with negative rack settings
• Necessary because on some of these engines, overfueling spring may not move rack against centering pin
ID: B58587T1

158-8665 Rack Set Tool 9U-5296 Rack Positioning Assembly

SMCS Code: 0706-025, 0706-082 SMCS Code: 1250-036
Model: 3034 Engines Model: 3204, 3300, and 3406 Series NSFS (Non-PEEC) Engines
Essential Tool

• Used to set injection pump rack while pump is being tested on test bench
• Used to adjust maximum fuel setting if timing case or fuel pump linkage • Used with FITB, FIETS, and AVM test benches
are removed or repaired

Overall length 171.4 mm (6.75 in)

Thread size 1/4-28
Bolt hole diameter 7.5 mm (.30 in)
Distance between holes 63.6 mm (2.50 in)
Service part 6V-8187 Nut

ID: C66933T1
ReferenceID: C79283T1 Reference
SENR5013 Disassembly and Assembly of 3034 Engine NEHS0639 Tool Operating Manual

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6V-9128 Rack Position Tool Group

SMCS Code: 1250-010, 1253-017, 1250-025, 1251-036
Model: Caterpillar Engines

• Provides convenient and accurate way to set or check rack position on Caterpillar Engines
• Used to measure fuel rack position during normal operation of engine, or measure fuel rack position and make any necessary adjustments while
engine is shut down
• Rack setting can be made or checked without removing injection pump
• Replaces discontinued 9S-0240 Rack Position Tool Group; both groups are identical, except new group contains metric dial indicators and low cost plastic case

Item Part No. Description

1 6V-9127 Liner
2 6V-9125 Case
3 9S-0239 Adapter
0S-1616 Bolt, 25,4 mm (1/4 inch-20 x 1.00 inch)
4 5S-8090 Rod
5S-8086 Contact Point
5 9S-8521 Rod
6 8S-4627 Circuit Tester or
8T-0500 Circuit Tester
7 6V-3075 Dial Indicator
8 6V-6106 Dial Indicator
9 5S-8157 Extension
10 5S-8088 Rod Assembly
5S-8086 Contact Point
11 8T-7687 Block
12 9S-2017 Spring
13 9S-7344 Clamp Assembly
0S-1616 Bolt, 25,4 mm (1/4 inch-20 x 1.00 inch)
14 9S-7343 Bracket Assembly
2A-0762 Bolt, 16,0 mm (1/4 inch-20 x 7/8 inch)
15 9S-0227 Bracket Group (see service parts) ID: B79252T1

16 9S-0238 Bracket Group (see service parts)

9S-0227 Bracket Group
17 9S-7350 Bracket Group (see service parts)
18 9S-0225 Bracket Assembly
2H-0191 Bolt, 16,0 mm (10-24 x .625 inch)
19 5P-7276 Container
3S-3269 Contact Point, 25,4 mm (1.0 inch)
9S-8883 Contact Point, 12,7 mm (0.5 inch)
5S-8086 Contact Point, 6,35 mm O.D. (0.25 inch O.D.)
9S-0229 Contact Point, 9,5 mm (0.4 inch)
3S-3268 Contact Point, 6,35 mm (0.25 inch)
9S-8903 Contact Point, 9,50 mm (0.4 inch) ID: C09463T1
8S-3675 Contact Point, 3,1 mm (0.13 inch)
Service Parts
3P-1565 Collet
5P-4814 Collet Item Part No. Description
9S-8518 Plug 1 Bracket Assembly
9S-8519 Plug
2 8S-9456 Rod Assembly
3 Plug
4 Rod
5 9S-0234 Spacer
6 2A-0762 Bolt
9S-0238 Bracket Group Service Parts
7 5S-7348 Screw
9S-7350 Bracket Group Item Part No. Description
1 Bracket Assembly,
Part of 9S-0238 Bracket Group
Bracket Assembly,
Part of 9S-7350 Bracket Group
2 Plug
3 9S-0234 Spacer
4 8S-9456 Rod Assembly
Reference
SEHS8436 Special Instruction
5 2A-0762 Bolt
6 5S-7348 Screw
ID: C09462T1 7 3F-9190 Dowel
8 Hole Attachment
9 9S-0213 Rod
9S-0231 Ring

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9S-0228 Rack Position Tool Group

Discontinued — Service Parts Available
Item Part No. Description
1 9S-0225 Bracket Assembly
2H-0191 Screw
2 9S-8883 Contact Point
3 8S-2283 Indicator

Reference
SEHS6995, rack setting procedure

ID: C09466T1

6V-6070 Tool Group

SMCS Code: 1000-010, 1250-010, 1253-017, 1250-025, 1250-036, 1272-081
Model: Caterpillar Engines

• Used to check and adjust rack and fuel ratio control linkage on all engines with New Scroll
Fuel Systems (NSFS)—new procedure now used to check and adjust rack on these engines
• Replaces discontinued 6V-4095 Group and 6V-4096 Group; all tools in discontinued groups,
except 6V-2128 Compressor which was discontinued, are still available for parts service

Part No. Description Part No. Description

6V-3072 Case (Plastic) 6V-2015 Arm (Part of 6V-2014) (Qty. 2)
6V-6104 Block 217956 Bolt
6V-6105 Block 5B-5689 Gasket
6V-4186 Pin 8H-3128 Bolt (Qty. 3)
6V-2017 Tool 6V-3075 Indicator
0S-1614 Bolt (Qty. 2) 9S-0229 Point
6V-6106 Indicator 6V-2105 Tool Group
6V-2030 Extention 2P-8264 Socket
9S-8903 Point 2P-8265 Socket
5P-4814 Collet (Qty. 2) 6V-6151 Adapter (Overfueling Spring Compressor)
8T-9198 Bracket Assembly (Rack Indication) 6V-7941 Compressor Assembly
6V-6108 Arm (Part of 6V-0109) 6V-7942 Hook
ID: B55879T1
2A-0762 Bolt Form SEHS8024
8H-9178 Bolt (Qty. 2) Form NEEG2119 (Label)
0S-1615 Bolt Form SEES5641 (Layout Chart)
NOTE: An FT2532 Shield is available for the
6V-2014 Bracket Assembly. Refer to the separate 6V-2014 Bracket Assembly (see note below)
article for specifications to make the oil shield.

Reference
SEHS8024 Special Instruction

6V-4069 Body Group

SMCS Code: 1210-010, 1272-010, 1250-025
Model: 3208

• Used to remove fuel pump drive gear from taper on drive shaft before removing
sleeve metering fuel system on 3208 Engines
Item Part No. Description
• Replaces 5P-2371 Puller Plate (provides more pulling force than 5P-2371)
1 5L-4041 Bolt (two)
• Needed because of lack of space in vehicle
2 2H-0191 Bolt
3 6V-4088 Washer

ID: B25987T1

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5P-4203 Sleeve Metering Field Service Tool Group

SMCS Code: 1250-025, 1251-082, 1264-017
Model: Caterpillar Engines

• Used for disassembly, assembly, testing and adjusting Sleeve Metering Fuel System;
used for fuel setting
• Metric tools; values for testing and adjusting given in metric pressures
As a result of changes and improvements in test and adjust procedures, the former
3P-1550 Sleeve Metering Field Service Tool Group was converted to the 5P-4203 S.M.F.S.
Tool Group. Dealers should check the list to determine what tools are required to convert
their 3P-1550 Group to the 5P-4203 Group. Some parts of the former 3P-1550 Group are
no longer needed, but a number of items should be retained in case of the need for
dynamic checking of sleeve shaft movement.

Reference
SMHS7013 Special Instruction

ID: A26668-3T1

Item Part No. Description Item Part No. Description Item Part No. Description
1 2P-8306 Box Assembly 11 5P-0319 Driver 22 4H-0553 Fitting
3P-1548 Block 12 5P-0318 Driver 23 5P-0299 Pin, 19,2831 mm (O.7592 in)
3P-1549 Block
13 1P-0463 Plate 24 5P-0298 Pin, 17,8587 mm (O.7028 in)
2 5P-0301 Driver
14 6L-5551 Bolt 25 5P-4209 Gauge1
3 1P-0529 Handle
15 4L-7124 Bolt 26 3J-6956 Spring
4 4B-4280 Washer
16 4B-4276 Washer (four) 27 8S-7271 Setscrew
5 1D-4538 Bolt
17 5D-9231 Connector (two)2 28 8S-2243 Wrench
6 1D-4533 Bolt 3J-7354 Seal (two) 29 3P-1565 Collet
7 3K-4910 Screw 3B-7734 Nipple
6J-3958 Coupling 30 3P-1567 Indicator includes:
8 0S-1603 Bolt 5P-6531 Contact Point, 57,2 (2.25 in)1
9 FT1632 Bolt3 18 3P-2210 Socket 5P-4228 Spring1
10 8T-0853 Gauge 19 5P-6602 Adapter1 (see note) 31 5P-0302 Bar
8B-8817 Plug (not shown) 20 5P-4205 Wrench1 32 6V-0029 Roll Pin Depth Gauge Tool2
21 3P-1544 Pin 33 6V-3071 Seal Guide2

NOTE: The 5P-4226 Adapter was replaced by the 5P-6602 Adapter, which is required for 3208 Engines with EGR systems.
1 Tools
which must be procured to convert the 3P-1550 Tool Group to the 5P-4203 Tool Group. The 3P-1567 Indicators from former 3P-1550 Tool Groups
must have the 5P-4228 Spring and 5P-6531 Contact Point installed. Some 3P-1567 Indicators had 5P-4809 Points, 50,8 (2.0 in) long.
2 Not included in early 5P-4203 Groups
3 FT1632 Bolt is made from 2H-3740 Bolt. Refer to following article.

The following parts which, were in the 3P-1550 Tool Group, should be retained in
case of the possible need for dynamic checking of sleeve shaft movement:
Part No. Description
3K-6896 Gasket
2P-8333 Cover Assembly
3P-1543 Gasket
3P-1569 Point
3P-2202 Gasket
7B-2742 Bolt
0S-1616 Bolt
4F-9676 Basket

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3P-2200 Sleeve Metering Calibration Tool Group

SMCS Code: 1250-025, 1251-082
Model: Caterpillar Engines

• Used for calibrating (similar to lifter setting) sleeve metering fuel pumps in shop
• Several tools from 5P-4203 Tool Group also needed for this operation
• Metric tools; values for testing and adjusting are given in metric terms, with exception
of torque values and pressures

Reference
SMHS6988 Special Instruction

ID: A35113-1T1
Item Part No. Description Additional tools from 5P-4203 Tool
Group required for pump calibration
1 7W-8120 Bushing
Item Part No. Description
2 1P-7379 Microgauge
1 8S-2243 Wrench
3 3P-1568 Indicator
2 5P-6602 Adapter
4 6V-3186 Collet
6V-3185 Base 3 5P-4205 Wrench
5 5P-6510 Box Assembly 4 5P-4206 Wrench
6 1S-9836 Wrench 5 1D-4533 Bolt
7 3P-1546 Pin 15,9410 6 1D-4538 Bolt
8 3P-1545 Pin 17,3734 7 5P-4209 Gauge
9 3P-1540 Pump assembly 8 8S-7271 Screw
ID: A33381-1T1
10 5P-6557 Spring (Part of 3P-1540) 9 2P-8264 Socket
10 6V-0190 Clamp (two)

5P-3516 Reaming Tool Group 6V-4164 Driver

SMCS Code: 1253-017
Model: 225B, 225B-3208, 229-3208, 3208, 613C 6V-4163 Bit
SMCS Code: 1250-010
Model: Caterpillar Engines
• Used to ream 5P-4810 Camshaft Bearing when front bearing requires
replacement in sleeve metering fuel system pump housings
• Capable of applying torque required to remove and install mounting bolts
for later 8N-2663 Flyweight Carrier in sleeve metering fuel systems

ID: B11831-1T1

Item Part No. Description

1 6V-4164 Driver, 1/4 inch Hex, 3/8 inch square drive
Item Part No. Description
ID: A15401T1 2 6V-4163 Bit, 1/4 inch and 1/8 inch hex
1 5P-3515 Reamer
Reference
SMHS6735 Special Instruction 2 5P-3057 Fixture Assembly

5P-6577 Fuel Setting Tool Group Item Part No. Description

SMCS Code: 1251-010, 1250-025, 1250-036 1 1D-4533 Bolt
Model: Caterpillar Engines 2 1D-4538 Bolt
3 5P-4205 Wrench
4 3P-1544 Pin
• Contains only those tools needed for checking and adjusting
5 3J-6956 Spring
fuel setting on engines with Sleeve Metering Fuel Systems
6 5P-0299 Pin
• All tools in this group also contained in 5P-4203 Field
Service Tool Group 7 5P-0298 Pin
8 5P-6602 Adapter
3P-1565 Collet
3P-1567 Indicator
8S-7271 Setscrew
5P-6531 Point (Part of 3P-1567)
9 5P-7319 Box
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Calibration Tools Reference

SMCS Code: 1250-025, 1251-082 REHS0063 Special Instructions, Sleeve Setting
Model: 3208 Engines with Heavy Sleeve Metering Fuel System SENR3688 Service Manual

• Used to set, test, and adjust heavy sleeve metering fuel pumps — these tools are 5
not available as a group and should be ordered to supplement existing tool groups 1
• Used with 3P-2200 Sleeve Metering Calibration Tool Group, 5P-4203 Sleeve Metering 2
Field Service Tool Group, and 5P-6577 Fuel Setting Tool Group 11

10
90
80
20

0
70 0

1
3

10 90
1
19
60 4

28

0
0
3 6 5
7

9
1 2

20 80
• The 3P-1565 Collet, 8S-7271 Setscrew, and 3J-6956 Spring are required for this

4
0

8
5

37
46
50

30
70
60
40
operation and are part of 5P-4203 Sleeve Metering Field Service Tool Group or 6
5P-6577 Fuel Setting Tool Group 3
• A 6V-6082 Bit, 5/64 Hex, part of 6V-4980 Torque Screwdriver Tool Group, is required 12
4
for 8S-7271 Setscrew to adjust the injection pumps
10 7
• 146-5068 Hex Key required for on engine adjustment for aftercooled engines
• All tools can be stored in a 6V-3073 Case. 6V-4094 foam (convoluted) is used in 8
the lid. Two foam blocks are required in the case bottom, 6V-4873 topped with 9
2P-8289 (convoluted). All foam is cut to fit the case.
ID: C78491T1

3208 HSMFS Service Tools

Item Part No. Description Used with Used to
1 141-6727 Calibration Pump Assembly, 3208 HSMFS 3P-2200 Calibration Tool Group for sleeve lever setting Set sleeve lever position on control shaft during injection
pump assembly
2 141-6737 Adjustable Micro-Gauge 3P-2200 Calibration Tool Group for sleeve lever setting Preset sleeve lever position before final calibration (use a
wicking sealant to lock screw in place the first time this
gauge is used)
3 145-1853 Calibration Fixture 3P-2200 Calibration Tool Group for sleeve lever setting Hold calibrating and zero pins for rack setting and
5P-4203 or 5P-6577 for fuel setting adjustments positioning control shafts for sleeve setting (required for
all 3208 HSMFS and 3208 SMFS injection pumps)
4 3P-1565 Collet
5 Original Load Stop Cover Bolts
6 8S-7271 Setscrew
7 131-3459 Sleeve Holder Position sleeve during pump disassembly and assembly —
simplifies assembly and protects sleeve from damage
8 146-5068 Hex Key-Ball End
9 5P-4809 Point-Indicator
10 3J-6956 Spring
Service parts for 141-6727 Calibration Pump Assembly
11 5P-6557 Spring
12 8T-0116 O-Ring
Recommended but not shown
6V-3073 Case
6V-4094 Foam - Convoluted
6V-4873 Foam - Block
2P-8289 Foam - Convoluted

5P-7253 Socket Assembly

SMCS Code: 1250-025, 1251-082
Model: Caterpillar Engines

• 3/8 inch drive socket assembly used with torque wrench during calibration of Sleeve
Metering Fuel System to apply torque specified for the bolts holding the levers on
sleeve shaft Item Part No. Description
1 5P-7252 Bit, 9/64 inch hex

ID: A50745-1T1

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6V-4068 Cutter Tool Group

SMCS Code: 1253-083
Model: 3208

• Used to machine counterbore and clearance face on camshaft thrust surface of sleeve metering
fuel pump housing on early 3208 Engines; 9N-5822 Thrust Washer can then be installed
• Request drawing of FT1556 Cutter for resharpening dimensions of 6V-4064 Cutter

Reference
SMHS7897 Special Instruction ID: B23865T1
Item Part No. Description Item Part No. Description
1 6V-4067 Drill Bit 7 6V-4064 Cutter
2 6V-4066 Bushing 8 1B-8710 Key
3 2H-2525 Spring Pin 9 6V-4063 Arbor
4 6V-6117 Bushing 10 3B-1142 Retainer (two)
5 1B-4331 Nut 11 9M-5350 Spring
6 4B-5276 Washer 12 2M-0849 Washer

6V-4141 Sleeve Metering Calibration Tool Group

SMCS Code: 1250-082
Model: 3208

• Makes adjustment of sleeve levers easier on Sleeve Metering Fuel Systems

• When used with 6V-4980 Torque Screwdriver Tool Group, adjustment to sleeve
levers on 3208 Engine takes about 5 minutes instead of 15 to 30 minutes Item Part No. Description
• Formerly, tolerances on sleeve lever had to be exact to 0,002 mm (0.00008 in); 1 6V-4137 Fixture Group
it was necessary to use 3P-2220 Calibration Tool Group to make an adjustment 2 3P-1545 Pin, 17,3734 mm
this exact; tolerances were changed to 0,05 mm (0.002 in) with a maximum of
3 8T-0888 Washer
0,05 mm (0.002 in) between each lever, and 6V-4141 Tool Group can make this
adjustment accurately and faster ID: B46661-1T1 4 3P-1546 Pin 15,9410 mm

Reference
SMHS7835 Special Instructions

Tools for Reconditioning 3208 Engine Fuel Systems

SMCS Code: 1250-020
Model: 3208
Warranty:

• Save time and make reconditioning of 3208 Engine fuel systems easier
• Increased efficiency even when rebuilding one fuel system but developed for batch
processing parts when reconditioning as many as 6 fuel systems at same time;
some of fabricated holding fixtures designed to hold 6 parts

Item Part No. Description

1 6V-7039 Driver
2 6V-7045 Hydraulic Puller
Includes:
5P-5247 Puller Assembly ID: B77144T1
4F-0925 Bolt
2K-0337 Locknut Item Part No. Description Item Part No. Description
5K-0405 Wheel
4 6V-7044 Gauge 10 6V-7042 Driver
1K-1465 Pin (four)
Includes: 11 6V-7036 Driver
7M-0320 Screw (two)
2L-4911 Pin
3 6V-7046 Hydraulic Puller 3L-5927 Ring 12 6V-7037 Driver
Includes: 13 6V-7033 Driver
5 6V-7064 Installer
5P-5247 Puller Assembly
6V-7764 Rod 6 6V-7034 Driver 14 6V-7032 Driver
2K-0337 Locknut 7 6V-7035 Driver 15 6V-7065 Installer
5B-4507 Plater (two) Includes:
7D-2347 Pin 8 6V-7038 Driver 6N-8793 Spring
7M-0320 Screw (two) 9 6V-7041 Driver 5H-6005 Seal

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6V-4830 Fixture Group Ultrasonic Cleaner Group

SMCS Code: 1254-010 SMCS Code: 1250-070
Model: Caterpillar Engines Model: Caterpillar Engines

• Used for disassembly and assembly of unit injectors, • Available under either of 2 part numbers for different electrical power supplies
and to check assembled injectors for free rack movement • Components: tank with heater
element and timer switch,
basket, cover (basket and
cover made of stainless steel)
• No parts for this group are
available through Caterpillar
parts system

Item Part No. Description

1 5L-1100 Bearing
2 6V-4092 Socket
3 2N-7229 Spring
4 6V-4874 Screw
5 6V-4875 Stop ID: B60824T1
Part No. Description
ID: B44413T1 6V-6050 Ultrasonic Cleaner Group, 110 V, 60 Hz
6V-6060 Ultrasonic Cleaner Group, 230 V, 50 Hz

6V-6188 Cleaning Tray 6V-4822 Tip Driver

SMCS Code: 1250-020 SMCS Code: 1254-010
Model: Caterpillar Engines Model: Caterpillar Engines

• Holds specific parts of unit injectors in groups while they are cleaned in • Used to separate tip assembly from nut during disassembly of injector
ultrasonic cleaner tank • Can be used as alignment tool during assembly
• Plungers, bushings, tips and needles arranged in sequence so that parts
which fit together and must be kept together can be cleaned but not mixed
• Tray fits in tank of either ultrasonic cleaner group

ID: B60352T1

ID: B63740T1

149-2955 Seal Protector

149-2956 Backup Ring Installer 149-2956
SMCS Code: 1290-012 SA
Model: 3126B Engines

149-2955 Seal Protector

• Used to quickly install stiff O-ring Overall length 121 mm (4.76 in)
and both backup rings in top groove Outside diameter (large end) 40.0 mm (1.58 in)
of HI300 injector Inside diameter (large end) 37.6 mm (1.48 in)
• Prevents steel backup ring from Inside diameter of taper 25.2 mm (.99 in)
deforming or damaging injector
149-2956 Backup Ring Installer
case during ring installation 149-2955
Overall length 105 mm (4.1 in)
Inside diameter 40.75 mm (1.60 in)
ID: C78582T1
Service part 5F-9657 O-ring Seal

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192-5092 Removal Tool 180-0186 Removal Tool

SMCS Code: 1250-011, 0701, 0706 SMCS Code: 1250-011, 0701, 0706
Model: 3126B Engines Model: 3126B HEUI Engine

• Used to easily separate hose from fitting • Used to quickly and easily separate 175-3236 High-Pressure Hose from fitting
• Used on #10 fitting on 192-2963 Oil Supply Hose on HEUI high-pressure pump • Insert beveled edge between fitting collar and hose collar. Hose should
• Separates fitting from hose collar (insert beveled edge between hose collar release from fitting.
and fitting)
• For #6 fitting use 180-0186 Hose Tool

ID: C80067T1 ID: C79847T1

250-6092 Removal Tool

SMCS Code: 1250-011, 0701, 0706
Model: C15 and 3456 Engines
Essential Tool

• Used to quickly and easily separate a hose from a #8 fitting

• Used on C15 Engine turbocharger supply line and 3456 Engine crankgear
• Insert edge of tool between fitting and hose collar to release hose from fitting
• Helps prevent hose damage—angled end of tool allows hose to be pushed off of fitting
8

• Other hose release tools also available: #6 180-0186 and #10 192-5092

ID: D00740T1

185-3213 Seal Positioner

187-5523 Seal Protector
187-5524 Seal Installer Group 187-5523
SMCS Code: 1290-012
Model: 3126B Engines (serial numbers 7AS0001 to 7AS75000)
Essential Tool

• 187-5523 and 187-5524 used to install 185-2161 Seal on 3126B HEUI Injectors
• 185-3213 used to slide seal into final position 187-5524
• 187-5523 Seal Protector has a very thin and delicate edge that could damage a seal 185-3213
if dented. For storage it is recommended that 187-5523 Seal Protector be stored
in the 187-5524 Seal Installer Group.
ID: C80012T1

185-3213 Seal Positioner 187-5523 Seal Protector 187-5524 Seal Installer Group
Overall length 156 mm (6.1 in) Overall length 116 mm (4.6 in) Overall length 127 mm (5.0 in)
Thickness 3.2 mm (.13 in) Outside diameter (large end) 37.7 mm (1.48 in) Outside diameter 44.5 mm (1.75 in)
Width at wide end 63.5 mm (2.50 in) Inside diameter (large end) 32.5 mm (1.28 in) Inside diameter 38.1 mm (1.50 in)
Width at narrow end 25.4 mm (1.00 in) Inside diameter at taper 12.7 mm (.50 in)

Recommended but not included

Part No. Description
Reference
REHS0184 Special Instruction, Removal and Installation
148-5675 Plastic Case
Instructions for the 3126B HEUI Injector
8S-5675 Foam Block (cut to fit)

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152-1057 Injector Installer

SMCS Code: 1250-012, 0700, 0701, 0703, 0706
Model: 3126B Engines, C-9
Essential Tool 1
2

• Used to push injector into bore (attaches to rocker shaft bolt)

• Used with 1/2 inch drive ratchet
• Lever action provides fast and easy installation
3
• Eliminates injector damage which can occur when using other installation methods
• Injector installers built after 9/00 will have a moveable leg allowing it to be used
on the C-9 injector.
• A 191-6077 Attachment Bracket for the injector installer is also needed for the C-9.
• Injector installers built before 9/00 can be modified per the FT2726. The 191-6077
ID: C80146T1 Item Part No. Description
Attachment Bracket is still needed for the C-9 injector.
1 152-1057 Injector Installer
• The 152-1057 comes with the attachment bracket used on the 3126B.
2 3126B Bracket
3 191-6077 Attachment Bracket

6V-4808 Tip Tester Adapter Group Item Part No. Description

SMCS Code: 1254-082
1 6V-4807 Nut
Model: Caterpillar Engines
2 6V-4806 Body
3 6V-1250 Seal
• Installed in tester like a complete injector 4 6F-0722 Seal
• Permits tip assembly to be checked for leakage, valve opening pressure,
and spray pattern

ID: B60365T1

6V-4809 Rack Weight Cup

SMCS Code: 1250-084
Model: Caterpillar Engines

• Used during test for free rack movement

• Weight of cup is 22,68 g (.8 oz), maximum permissible weight that can be added
to rack during test

ID: B60334T1

9U-5132 Timing Tool Group

SMCS Code: 1250-036
Model: 3500 EUI and MUI Engines

• Replaces discontinued 6V-7880 Tool Group (to upgrade 6V-7880 to 9U-5132, order 6V-3072 Plastic Case, 9U-5138 Set Gauge, 9U-5233 Timing Fixture, 9U-5136 Foam
Insert, 129-8602 Solenoid Nut Driver, and Decal NEEG2515)
• Used to test and adjust fuel systems, including fuel timing, rack synchronization, and fuel setting
• Tool group can be used for both MUI (Mechanical Unit Injector) and EUI (Electronic Unit Injector) engines
• 136-4587 Collet Extension and 136-4588 Collet Extension can also be used with this tool group (use 136-4587 for 9U-6273 and 136-4588 for 122-0449)

Set gauge step Rod sleeve extension Timing fixture rod assembly
For EUI engines use 64.34 mm (2.533 in) 122-0449 122-0451 [124.0 mm (4.78 in) long]
For MUI engines use 87.00 mm (3.425 in) 9U-6273 9U-5220 [181.0 mm (7.12 in) long]

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16 Item Part No. Description

12 14 1 6V-3075 Metric Dial Indicator
18
1 2 9U-5137 Timing Fixture1
S
B

3 5P-7276 Container
A
.
C
IN
.
V
R
E
90 0
10 10
/O
FF
90
4 5P-7263 Contact Point, 76.2 mm (3.00 in)
ON

m
80
in
/m

/A
BS 20 20

17
/ -
ZE
RO
80

13
+
ET
ES 1 0 1
PR
70
30

60
28
37
6
0
1 0 9
9

4 5 6
1

4
28
37
30
70 5 9S-8883 Contact Point, 12.7 mm (.50 in)
40
5
40
50 60

6 4C-8753 Extended Collet

15 7 8T-2684 Rack Synchronization Gauge, 12.7 mm (.50 in)
2 3 7 8 6V-7918 Wrench, 5/8
9 8S-3675 Contact Point, 3 mm (.12 in)
10 129-8602 Solenoid Driver
5 4
11 9U-5138 Set Gauge
13 9U-6273 Rod Sleeve Extension2
9 6 14 9U-6272 Nylon Screw2
17 122-0449 Rod Sleeve Extension2
11 Optional Tooling
12 1U-8869 Digital Dial Indicator
8 10 15 5P-4814 Clamp Collet
16 136-4588 Collet Extension
18 136-4587 Collet Extension
ID: C78471T1
Not shown
5P-4160 Contact Point, 19.0 mm (.75 in) (for digital indicator)
Reference 9S-9082 Engine Turning Tool
NEHS0666 Tool Operating Manual 122-0451 Extension Rod Assembly
9U-5220 Extension Rod Assembly
9U-5136 Foam Insert
6V-3072 Plastic Case
1 Part of 9U-5233 Magnetic Fixture Group
2 Additional tooling required, but not part of 9U-5132

Collet Extensions
SMCS Code: 1250-036
Model: 3500 and 3500B Engines

• Used to hold a dial indicator in 9U-5233 Fixture Group with 5P-4814 Collet Clamp
and two (2) 6V-7918 Collet Wrenches
• Released to provide an alternative to the nylon screw-type indicator mount
• Use 136-4587 Extension-Collet with 5P-4814 Collet-Clamp, instead of
9U-6273 Rod Sleeve Extension, to check and adjust fuel timing on 3500 MUI Engines
• Use 136-4588 Extension-Collet with 5P-4814 Collet-Clamp, instead of
122-0449 Rod Sleeve Extension, to check and adjust fuel timing on 3500B EUI Engines

ID: C55104T1
Part No. Description Overall length Diameter Extension length External thread Internal thread
136-4587 Collet Extension 56.5 mm (2.22 in) 19 mm (.7 in) 47.0 mm (1.85 in) 7/16-20 3/8-16
136-4588 Collet Extension 23 mm (.9 in) 19 mm (.7 in) 13.5 mm (.53 in) 7/16-20 3/8-16

6V-6999 Lapping Plates

SMCS Code: 1250-070
Model: Caterpillar Engines

• 3 lapping plates assembled in 6V-7011 Lapping Plate Case make a complete lapping set
• Lapping set permits distribution of lapping work between the 3 plates
• Makes it possible to lap plates against each other to make them flat after a period of use
• All parts need to be ordered separately

Item Part No. Description

ID: B60375T1
1 6V-7011 Lapping Plate Case
2 6V-6999 Lapping Plate (pkg. quantity. 1 each)
3 6V-7151 Lapping Compound

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6V-7151 Lapping Compound

SMCS Code: 1250-070
Model: Caterpillar Engines

• Recommended to lap flat surfaces of parts used inside unit injectors

• Soluble (can be mixed with) in either solvent or water, and can be washed off with water
• Easier to use and to remove than 8S-2259 Compound, part of 8S-2245 Tool Group for pencil-type fuel nozzles,
which will give an acceptable surface finish and can be used if desired
• In dispenser-type container (squeeze bottle)
• Contents: 0.454 kg (16.0 oz)

1U-9395 Plate
1U-8701 Socket
SMCS Code: 1254-010
Model: Caterpillar Engines

• Used with 6V-4830 Fixture Group and 6V-4822 Tip Driver to remove and install nozzle
on type 2 3500 Engine unit injector (Type 2 unit injectors are described in Jan. 1987
Engine News as those with two-piece follower.)
ID: C23727T1
• Make it possible to replace nozzle assemblies that plug or fail; with 1U-9395 Plate
installed on 6V-4830 Fixture Group, injector can be held properly to remove and
Reference
install nozzle assembly SEHS8993 Special Instruction
• Early nose cones on type 2 injectors have serrations on cone that are damaged during
removal; 7C-9795 Replacement Cone available with a hex to tighten it; 1U-8701 Socket
required to tighten cone when replacing nozzle

223-2454 Fuel System and Governor Tool Group, 3114-3116

SMCS Code: 1290-036, 1298-036, 0706
Model: 3114, 3116, and 3126 Engines
Warranty: One Year

• Replaces discontinued 1U-6680 Tool Group 9U-7276 Linkage Loading Assembly and 9U-7275 Linkage Tool Support
• Used to simplify the required testing and adjusting operations • Used to hold linkage in synchronizing position for all cylinders
• Allows more precise fuel system adjustments in significantly less time, • Allows both hands to be free when making adjustments
at less cost, than using previous tooling • Provides more consistent results by applying a constant spring load to the linkage
• Improvements to tool group are described below
9U-7264 Linkage Lever
Timing • Used to actuate linkage when zeroing rack position at each injector

9U-7308 Magnetic Base Indicator Group Fuel Setting

• Attaches directly to tappet on top of each unit injector
9U-7271 Governor Pin Assembly
• Saves time — moves from cylinder to cylinder quickly and easily
• Used to properly position injector control linkage relative to governor housing face
• Use with 9U-7274 Contact Point when making static rack power setting
1U-8869 Digital Indicator • Required for 1994 and later governors where calibration pin connection is not
• Has a programmable preset feature accessible from rear of governor (also works for earlier version governors)
• Allows direct reading of published timing dimensions 9U-7265 Governor Output Clamp Assembly
• Used with the 9U-7269 Timing Gauge Block • Used to hold calibration pin against governor housing face when checking or
adjusting static fuel setting
Synchronization • Works on all governors except ‘94 truck (“Type V”) and later
9U-7270 Synchronization Gauge Block • Prevents setting errors that can result from improper use of holding tool
• Used to set #1 injector to 3.5 mm rack (gives more accurate and
136-4149 Governor Connection Sleeve Pliers
consistent results)
• Used to move linkage cover tube between governor and head to gain access to
• Used on 127-8207 Injector governor/rack linkage connection
220-0123 Synchronization Gauge Block • Pliers have more gripping force than former 6V-0006 Pliers (easier to move stubborn
• Used to Set #1 injector to 3.0 mm rack (gives more accurate and cover tubes)
consistent results) • Pliers have self-locking feature of “Vice-Grip” type pliers
• Used on 127-8213 Injector • Coated with vinyl material to prevent damage to sleeve (refer to “Modifications”
section for reworking older pliers)

NOTE: 1U-6681 Holding Tool (not included) is still needed for some model governors.

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1 7 Item Part No. Description

6
5 1 128-9640 Injector Synchronization Fixture Group
128-8706 Spring Plunger (serviceable part)
2 9U-7270 Sync Gauge Block, 3.5 mm
4 8 220-0123 Sync Gauge Block, 3.0 mm
3 9U-5120 Spanner Wrench (solenoid)
4 1U-8869 Position Indicator (Digital)

10 5 128-8823 Locking Long Nose Pliers 238 mm (9.375 in) long [Early 128-8823
3 9 were 150 mm (6.0 in)]
2 6 1U-6675 Spring Compressor
15 16 7 8T-4177 Bolt (spring compressor)
8 9U-7282 Indicator Fixture Group
11 17 9U-6272 Nylon Screw (serviceable part)
14
9 8C-4984 Bolt, (indicator stand)
10 9U-7263 Contact Point [18.5 mm (.73 in) long
13
Fuel Timing Tooling
18
11 9U-7269 Timing Gauge Block
12 12 123-4940 Magnetic Base Group2
13 128-8824 Deep Offset Wrench (16 mm and 18 mm)
21 22
19 14 128-8825 Deep Offset Wrench (17 mm and 19 mm)
15 9U-7274 Contact Point [85 mm (3.35 in) long]
24
Miscellaneous Engine Tools
23 16 5P-0302 Bar (injector removal)3
25 17 123-4941 Valve Setting Gauge (feeler gauge for adjusting valves)3
20
18 194-3542 Hex Socket Bit Driver, 5 mm3
Fuel Setting Tooling
ID: il4, D00332T1
19 130-2711 Fuel Setting Holding Tool
20 136-4149 Governor Connecton Pliers
The following list of tools is broken down into essential tools, recommended
21 128-8827 Fuel Setting Pin Assembly
tools and improved tools. Many tools used in the existing 1U-6680 Tool Group
are used again in 223-2454 Tool Group. See footnotes for status of tool. 22 1U-7523 Pin Insert Pilot (use with 128-8827 Pin Assembly)3
23 1U-7299 Adjustment (FRC) Wrench (“Type V” 1994 and later Trucks)
If desired, an older 1U-6680 Tool Group can be updated to a 223-2454 Tool
Group by ordering those items with footnotes 1 and 2. Unless otherwise 24 1U-7300 T-handle Wrench, 3 mm hex (“Type V” 1994 and later Trucks)
specified, quantity required is one of each item. 25 1U-6673 Injector Sync and FRC Adjust Wrench (all models except “Type V”
1994 and later Trucks)4
Not shown
6V-7145 Case
Modifications 128-8828 Foam Insert Group
128-9640 Injector Synchronization Plate NEEG2688 Decal
Installing 180-7956 Clamp Assembly Kit may interfere with 128-9640 Injector 1 Recommended or improved tools.
Synchronization Fixture Group during synchronization procedures. Modify the 2 Some of the former 9U-7305 Groups used the new 123-4940 Magnetic Base; check your
injector synchronization plate by machining an additional 6.5 mm (.25 in) from specific tool group.
plate. A 128-9641 Injector Synchronization Plate can be purchased. 3 Referto the appropriate engine Service Manual for additional information on use of
these tools.
4 159-1783
Fuel Ratio Control Adjusting Wrench is 51 mm (2 in) shorter than 1U-6673.
Required for 3116-3126 Engines in Challenger 35, 45 and 55.

136-4149 Governor Connection Pliers

The 136-4149 Governor Connection Pliers can be used for inspection procedures
as outlined in Special Instruction REHS0601, if modified. Remove 10 mm (.4 in)
of rubberized coating from tips of pliers to expose metal teeth. This modification
will not affect the original function of pliers, and it will allow pliers to fit onto
m rivet head.
21 min)
(.8
l
ina
Orig mm
. 5
2 .1 in)
7
(1

Remove shaded area, as shown.

ID: C80079T1

136-4149
Reference
NEHS0610 Tool Operating Manual mm
10 in)
SEBR0551 Service Manual, 3116 Diesel Truck Engine ( . 4
SENR3583 Service Manual, Systems Operation, Testing and Adjusting,
Basic Engine Components — 3114 and 3116 Engines
ID: C80080T1

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1U-6680 Governor and Fuel Injection Adjusting Tool Group

Discontinued — Service Parts Available
Part No. Description Part No. Description
1U-8702 Injector Timing Block 6V-0006 Electrical Connector Pliers
1U-6678 Fixture Group 9U-5120 Spanner Wrench
8T-0267 Socket Head Bolt 1U-6675 Injector Spring Compressor,
4C-4716 Injector Timing Fixture 6 each (8T-4177 Bolt)

6V-6106 Dial Indicator 1U-6672 Rack Adjusting Wrench

1U-8815 Dial Point 1U-6673 Fuel Ratio Control Wrench (FRC)

Adjusting
3S-3268 Contact Point
1U-7523 Pilot Insert Pin
1U-6679 Indicator Group (8T-7352 Bolt)
1U-7305 Insertion Tool
1U-9563 Offset Wrench
Not shown
ID: C26895T1 1U-8790 Nut Driver, 6 mm
4C-5851 Insert Group
6V-7918 Wrench, 2 each
5P-0302 Bar
1U-7563 Hex Wrench, 4 mm
5P-4814 Clamp Collet
1U-7564 Hex Wrench, 5 mm
6V-7145 Case
4C-5851 Foam Insert

1U-9563 Offset Wrench 9U-5129 Seal Remover

SMCS Code: 1105-025, 1272-025 SMCS Code: 1290-010; 0706
Model: 3114, 3116 Model: 3176

• Replaces discontinued 1U-8771 Offset Wrench • Used to remove copper combustion gas seal from unit injector tip on 3176
• Special wrench required for adjusting valve lash and injection timing on 3114 Engines
and 3116 Engine • Designed for quick removal without damaging injector; stretches copper seal
• Four necessary socket sizes — 16mm, 17mm, 18mm, and 19mm so it can be removed by hand (pliers or chisels would likely damage injector)
• Offset for clearing intake manifold • Has short chisel points that indent copper seal when tool is struck with small
hammer; chisel points are shorter than seal thickness to prevent damage to
• Has all metric socket sizes required to adjust valve lash on any 1.1 liter
injector
engine; discontinued 1U-8771 Offset Wrench had 2 sizes, 17mm and 19mm;
world standards for metric fasteners changed and affected 1.1 liter engine;
for example, early engines have 17mm and 19mm lock nuts; later engines
have 16mm and 18mm lock nuts; interim period of engines may have
combination of sizes of lock nuts; no special serial number break exists for
different size lock nuts

ID: C27003T1

5P-2413 Air Regulator Assembly

SMCS Code: 4282-010
Model: 16G

• Enables use of shop air pressure to activate air-fuel ratio controls for
checking or setting fuel rack or rack limiter Item Part No. Description
• Applicable to both mechanical and hydraulically operated controls 1 3B-7262 Nipple
2 4H-0553 Adapter

Reference
SMHS7083 Special Instruction
SEHS7465 Special Instruction

ID: A04786T1

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195-0761 Pressure/Vacuum Pump Group

SMCS Code: 4282-010
Model: 3000 Series Engines With Stanadyne Fuel Injection Pumps
Warranty: 5 year (see details)

• Used to check and adjust aneroid capsule

• Includes other accessories for general diagnostic, testing, and adjusting
procedures requiring vacuum or pressure
• Compound pressure gauge
• Hand-operated, no external power required
• Includes compact carrying case

Maximum vacuum at sea level -85 kPa (23 to 25 in Hg)

Single stroke volume 16.4 cu cm (1.0 cu in)
Maximum pressure unassisted 100 kPa (15 PSI)
Maximum pressure assisted 175 kPa (25 PSI)
Compound pressure gauge range 100 kPa (-30 mm Hg) to 200 kPa (30 PSI)
Vacuum gauge accuracy -85 kPa (15 to 30 in Hg) 3% of full range

ID: C80099T1

Warranty Information Repair Information

The pump is warranted to be free of all defects in material and workmanship for FIVE FULL Prism Enterprises, Inc.
YEARS from the date of original purchase. This warranty does not apply to any defects 6952 Fairgrounds Parkway
caused by negligence of the user, use of the product in any manner other than in accordance San Antonio, TX 78238
with the instructions provided with the product, or damage caused by accidents. It also does Phone: (800) MITYVAC (648-9822)
not apply to gauges, which are warranted for a period of 90 days from date of purchase. (210) 520-8051
A 196-2965 Repair Kit is available. Fax: (210) 520-8039
Website: www.mityvac.com

159-0271 Solenoid Spanner Wrench 6V-9052 Piston Seal Guide

SMCS Code: 1278-016
Model: 3208 Engine with Air/Fuel Ratio Control Override Solenoids 6V-9072 Piston Seal Guide
Essential Tool SMCS Code: 1278-016, 1278-017
Model: D40D, D400D, 3406, 3406B

• Used to install solenoid

• Used with 3/8 inch drive torque wrench • Used to help install piston assembly in fuel ratio control body
• For installation only — DO NOT USE
TO REMOVE SOLENOID

ID: B83727T1

1P-0087 Adjusting Wrench

ID: C79261T1 SMCS Code: 1264-010
Square drive 3/8 inch Model: Caterpillar Engines with Woodward PSG Governors
Solenoid torque specification 20 ± 5 N·m (15 ± 4 ft lb)
Torque wrench setting 16 ± 4 N·m (12 ± 3 ft lb)
• Required for removal and installation of speeder spring in Woodward PSG
governors whenever adjusting pilot valve plunger control position

ID: C05408T1
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6V-0022 Governor Spring Guide Tool Group

SMCS Code: 1264-010 Spring
Engine Model Guide
Model: Caterpillar Engines
3400 Series Std., 6.25 in, 5.75 in, 8M-8403
5.4-6 Cyl., 4.5 in, 4.75 inch Bore
with Scroll fuel system)
• Used to replace worn governor spring guides
3400 Series Electric Set 4N-8140
• With replacement guide, governor housing can be
reused with considerable cost savings 3300 Series 4N-4572
• Engines with replaceable guides listed in chart 1100 Series 9L-9870
3400 Series Marine 6N-5373
Item Part No. Description 5.4 inch-6 Cylinder (later models) 3N-1168
1 6V-0017 Pilot
2 6V-0020 Pin ID: D00924T1

3 6V-0019 Adapter
4 6V-0018 Adapter
Reference
SMHS7356 Special Instruction
5 6V-0023 Adapter

5P-7285 Adjusting Bracket

SMCS Code: 1264-025
Model: 3412

• Used with 3P-1565 Collet and 9S-0215 Dial Indicator to adjust speed droop on engines equipped with Woodward PSG governors

ID: A38984T1

8T-3226 Ring Expander

SMCS Code: 1250-012
Model: 3300, 3406

• Used for ring expanding and seal protection on all 3300 New Scroll Fuel Systems and on all 3406 New Scroll Fuel Systems
• Primary function: expander tool used with 6V-2163 Spring Compressor to install 7N-8821 Retaining Ring on weight carrier shaft; upon compression of spring
assembly, 8T-3226 Ring Expander is inserted over end of weight carrier shaft; 7N-8821 Ring is then slid down over ring expander to its proper place on shaft
• Separate but important function: tool used to protect 4N-0820 Tachometer Drive Seal
when assembling rear governor housing by placing ring expander over weight carrier
shaft prior to assembling governor housing; rear governor housing that includes
tachometer drive seal is then installed by placing it over ring expander; pre-assembled
seal is protected from damage due to its position on housing; rounded top of ring
expander guides seal into its proper position on carrier shaft

ID: C27197T1

ID: C27198T1

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8T-5223 Reamer
8T-5107 Fixture Assembly Part No. Description
8T-5223 Reamer
SMCS Code: 1287-012
Model: 3406B 8T-5107 Fixture Assembly

• Used to bore 8N-9679 Governor Housing on 3406B Engine to install 8N-3945 Bushing and to salvage terminal shaft (throttle) bearing bores

8T-3222 Governor Adjusting Tool Group

SMCS Code: 1264-082
Model: 3406B

• Socket handle assembly along with the 5P-4205 Wrench used to adjust high idle
on 3406B Engine while in the vehicle
• Remove high idle adjusting screw cover, install 8T-3222 Governor Adjusting Tool
Group over locknut, loosen locknut, adjust high idle screw using 5P-4205 Wrench
and retighten lock nut; remove tool group and replace cover on governor

Item Part No. Description

1 9S-1719 Socket Handle
2 5P-4205 Wrench
ID: C54551T1

4C-4354 Applicator
SMCS Code: 1264-012
Model: 3114, 3116

• Required to install Waldes Truarc ring (9X-2315 Retaining Ring, Series 5139-18) on servo on the 3114 and 3116 Governor
• Truarc ring requires a special applicator for installation; 4C-4354 Applicator grasps ring in a recess on underside of tool and holds it tightly
under spring tension with an arm which extends over center section; tool angled so ring can be flattened to enter groove; when prongs
have cleared shaft and ring is locked in groove, applicator can be withdrawn easily

9S-8100 Fuel Transfer Pump Tool Group

SMCS Code: 1080-017, 1256-010, 1256-016, 1256-017, 1361-017
Model: Caterpillar Engines

• Contains five tools for disassembly and assembly of fuel transfer pumps
• 9S-8096 Seal Installer Sleeve for water pumps is no longer part of this group; available separately

Item Part No. Description

Reference
GMGO0578 Special Instruction 1 9S-8104 Press Fixture Assembly
2 9S-8109 Screw Clamp Assembly
3 9S-8102 Seal Tamping Tool Guide
4 9S-8099 Bushing Driver
ID: A92587-1T1
5 9S-8103 Seal Tamping Tool

Fuel Transfer Pump Assembly Tools

SMCS Code: 1256-016
Model: 3406, 3408, 3412

• Used for assembly of fuel transfer pump on

3406, 3408 and 3412 Engines Item Part No. Description
1 5P-2391 Seal Driver
2 5P-2392 Seal Driver
3 5P-2394 Seal Tamping Tool Guide, Discontinued

ID: 88526T1

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6V-6169 Check ValveInstaller

SMCS Code: 1256-012
Model: 3204, 3304B, 3306B, 3406B Series Engines with New Scroll Fuel Systems (NSFS)

• Used to install check valves in fuel transfer pumps

ID: B83735T1

5P-7345 Gauge 1P-2385 Protractor Assembly

SMCS Code: 1259-017 SMCS Code: 1264-025, 5070-016
Model: 963, 963LGP Model: D10, D6H, D7G, D8H, 224, 977L

• Required to calibrate butterfly valve to solenoid on 3208 Engines equipped • Precision tool for measuring all governor linkage angles
with EGR (Exhaust Gas Recirculation) system • Used on any linkage assemblies that are adjusted by
• 5P-6602 Adapter, which replaces 5P-4226 Adapter in 5P-4203 Tool Group and “angle” method
5P-6577 Tool Group, also required for fuel setting on EGR equipped engines

Item Part No. Description Quantity

1 8H-3127 Bolt 2

ID: C09476T1
Reference
SMHS7188 Special Instruction illustrates Woodward Governor linkages
ID: A46365T1 including correct linkage dimensions and angles

2P-8278 Fuel Flow Tube

SMCS Code: 1000-082
Model: Caterpillar Engines
Warranty: One Year

• Install this tube in engine fuel inlet line to determine amount of air entrained in fuel

Reference ID: C05409T1

GMGO0825

9U-6872 In-line Flow Sight 185-3630 Filter Strap Wrench

SMCS Code: 1250-044, 1258-044 SMCS Code: 0602
Model: 777C, 785B, 789B, 793B, D11N, and 994 Model: Caterpillar Engines

• Used to view fuel passing through fuel line during priming • Provides quick, efficient service when removing or installing all spin-on type
on 3500 EUI Engines fuel and oil filters
• Also used to inspect • Capable of applying higher torques
fluid clarity for other required on larger filters without
applications denting filter can

ID: C55192T1
Length 75 mm (3.0 in)
Width across flats 35.05 mm (1.380 in)
Port size 1/2-14 NPTF Item Part No. Description ID: C05388T1
Construction brass with Buna N seals 1 6H-7378 Retaining Ring
Maximum working temperature 93° C (200° F) 2 1P-0551 Spring Pin
Maximum working pressure 345 kPa @ 21° C (50 PSI @ 70° F)

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Special Sockets for Fast Fill Fuel System Adapters

SMCS Code: 0706
Model: Caterpillar Engines
Warranty:

Fast-fill fuel system adapters require special sockets

for their removal and installation
• 3P-2230 Socket used for Wiggins Adapter
• To remove and install Buckeye Adapter, order HG-190 Socket from Apex
Machine and Tool Co, 7659 S. Western Avenue, Chicago, IL 60620

Item Part No. Description

1 3P-2230 Socket
2. HG-190 Socket ID: C09475T1

ID: 66397T1

5P-7339 Lifting Plug Assembly

SMCS Code: 1273-010
Model: 631D, 631E, 633D, 637D

• Used with 6V-2157 Bracket for lifting 9D-1750 Fuel Tanks on 631D, 633D and 637D
Tractors (Make certain threads of lifting plug are fully engaged in fuel tank boss
and that tank is empty before lifting)

ID: A49300T1

1U-8869 Digital Dial Indicator

SMCS Code: 1250-025, 1264-036
Model: 3116, 994

• Intended primarily for engine fuel system and governor adjustments but can • Additional features, such as use with remote printer and computers,
be used in virtually any location or application that requires AGD-2 Indicator described in instructions packaged with indicator
• Can be used for any rack setting that is not greater than 12 mm (.470 in.); only • 1U-8869 Indicator is similar in several ways to 8T-1000 Digital Position
a few engines, such as some 5.4 bore vee engines, have rack settings that Indicator but should not be considered interchangeable; 8T-1000 Indicator
are greater than 12 mm has full one-inch (25 mm) travel, remote readout and dampened transducer
• Especially useful for timing adjustments on engines with unit injectors which allows it to be used for running rack reading; U8869 is less tolerant of
vibration than 8T-1000 and is intended primarily as a versatile replacement
• Has 3/8 inch stem and can be used with standard 3/8 inch collets and
for mechanical indicators
brackets
• Service Part: 3S-3268 Point
• Can directly replace both inch and metric mechanical indicators if measuring
task does not require more travel than 1U-8869 is capable of; replaces
6V-3075, 6V-6106, 9M-9268, 8S-2283, and 9S215 Indicators in most
applications
• Digital (LED) display which reads in either inches or millimeters—readings
displayed to nearest .0005 in. or .01 mm
• Total travel of 12.7 mm (.50 inches) and can be zeroed at any plunger position
which allows 1U-8869 to read either positive or negative in either direction of
plunger travel
• Can be pre-set to read a specific number at a particular plunger position
• Pre-set feature especially useful for measuring or setting timing dimension on
engines with unit injectors (1.1 liter, 3500, 3600); pre-set feature allows
indicator to be set (off engine) to set gauge dimension; when indicator and
timing fixture placed on injector, actual timing dimension is displayed
• Entire head, with display, can be rotated 270° for ease of readability ID: C26881T1
• Power is supplied by two SR 44 batteries contained in indicator

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Toolmaker’s Ink and Ink Remover

SMCS Code: 1290-012, 0645
Model: 3176
Warranty: Manufacturer’s

• Used to check fit of injector nose cone to injector sleeve (poor fit can be corrected
by reaming before final installation)
• Also used in general layout work RE
MOVER
• Sometimes referred to as “layout blue” INK
Part No. Description Size INK
9U-6075 Toolmaker’s ink, aerosol spray 340 g (12 oz.)
9U-6076 Toolmaker’s ink, brush-top can 222 ml (7.5 fl. oz.)
9U-6077 Toolmaker’s ink remover, aerosol spray 397 g (14 oz.) ID: C66621T1

171-1085 Bolt Remover Kit

171-1088 Torque Screw Locknut Wrench
171-1089 Idle Adjustment Locknut Wrench
SMCS Code: 1264-017, 0602-017, 0706
Model: 3054 and 3056 Engines with Stanadyne Pumps
Essential Tool

NOTE: Use of these tamper resistant fastener tools is subject to Environmental

171-1085 Bolt Remover Kit Protection Agency (EPA) regulations. Read warning sheet included with each kit
before using these tools.
• Replaces discontinued 154-7151 Bolt Remover Kit
• Used to remove and install tamper resistant bolts on Stanadyne fuel injection
pump and aneroid shield
• Used with 1/4 and 3/8 inch square drive ratchets
• Used on 5YS, 7MS, 2PW, 3GW serial number engines
• Includes longer 15IPR Torx bit for adjusting torque and idle screw 171-1085

171-1088 Torque Screw Locknut Wrench

• Used to loosen and tighten the torque screw locknut
• Used with 1/2 inch open end wrench and 1-1/2 inch long 15IPR Torx bit

171-1089 Idle Adjustment Locknut Wrench 171-1088

• Used to loosen and tighten the idle adjustment locknut
• Used with open end wrench and screw driver 171-1089
ID: C79387T1

173-9774 Bolt Remover

SMCS Code: 1264-017, 0602-017, 0706
Model: 3054 Engine, serial number 5HK Used in 914G and 1T14G
Essential Tool

• Used to remove and install tamper resistant fasteners used on fuel injection pump access cover
• Hex shank bit fits standard 3/8 inch hex socket
• Use of this tool is subject to EPA regulations. The sale of this tool is intended for internal
Caterpillar Dealer use by qualified mechanics.
• Fastener torque: 22 N·m (16 lb ft)

ID: C79742T1

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Pistons, Rings and Connecting Rods

5P-3519 Piston Ring Groove Gauge

SMCS Code: 1214-020, 1214-082
Model: Caterpillar Engines

• Used to check top and intermediate ring grooves (rectanglar) to determine

piston reuseability
• Includes 6 plug-type gauges that cover all widths of top and intermediate
grooves (gauges numbered 1 through 6)
• Attached tag identifies gauges and their use

Item Part No. Description

1 5P-4227 Tag Holder
Form SEES5544 Instruction Card
2 6V-3190 (#1) Gauge ID: A10746T2
6V-3191 (#2) Gauge
6V-3192 (#3) Gauge
6V-3193 (#4) Gauge Reference
6V-3194 (#5) Gauge
6V-3195 (#6) Gauge
SEBF8049 Guideline for Reusable Parts
Also available for 3500 Engines
4C-4519 Gauge Assembly (not part of 5P-3519)

1U-6431 Gauge Group

SMCS Code: 1214-020, 1214-082
Model: 3406B

• Used for checking ring groove wear on 7C-0473, 7C-3496 and 7W-3668 Pistons found
in some 3406B Truck Engines beginning with 1985 production
• Replaces discontinued 8T-3150 Gauge Group; consists of 6 gauges from 8T-3150 plus
1U-6432 Gauge and revised SEES5678-02 Instruction Card; 1U-6432 and SEES5678-02
Instruction Card can be used to upgrade existing 8T-3150 Gauge Group

ID: B96702T1

Item Part No. Description

ID: C66817T1 1 8T-3144 Gauge Assembly
2 8T-3145 Gauge Assembly
Description
3 8T-3146 Gauge Assembly
SEES5678-02 Instruction Card
4 8T-3147 Gauge Assembly
5 8T-3148 Gauge Assembly
Reference 6 8T-3149 Gauge Assembly
Service Magazine, June 1, 1987, page 15; Truck Engine News, May 1987, Page 7 1U-6432 Gauge Assembly
8, “Use Correct Pistons and Rings for 3406B Truck Engines” 8 5P-4227 Holder SEES5678-02 Instruction Card
9 6V-3196 Chain

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9U-5931 Piston Ring Groove Gauge

SMCS Code: 1214-082; 0763
Model: 3114 and 3116 Engines

• Used to measure piston ring groove

• Checks top and intermediate ring grooves to determine piston reuseability
• Used on one-piece aluminum pistons: 7C-5668, 9Y-7452, 9Y-5536, 7E-1298, 7E-3428, 7E-3578
• Dimensions: 12,7 mm x 9,52 mm x 47,62 mm (.5 in x .37 in x 1.87 in)
ID: C27044T1

Piston Ring Groove Gauge Groups

SMCS Code: 1000-040, 0701, 0767
Model: See below
Essential Tool
Warranty: Manufacturer's

• Used to quickly and accurately check top ring groove pistons for wear
(checks top ring groove only)
• Uses a simple Go/No-Go design (if piston passes through gauge
it cannot be reused)
• Improves reliability of inspection and reduces inspection time
• Gauge repair and recalibration done only by manufacturer (damaged blades
can be replaced and adjustable design allows gauge to be easily recalibrated)

Piston Ring Groove Gauges (Horseshoe Type)

Manufacturer
Part No. Engine Model Recalibration
4C-8164 3114 and 3116 No
186-0190 3126 Yes
ID: C80552T1
4C-8165 3176 No
208-7632 C12 and 3196 Yes
208-7636 C16 Yes Reference
4C-8168 3300 No NEHS0775 Tool Operating Manual
4C-8169 3400 No NEHS0834 Tool Operating Manual
132-4389 3406E No NEHS0909 Tool Operating Manual
132-4390 3500 with Keystone Rings No SEBF8059 Procedure to Clean and Inspect One-Piece Pistons
204-8041 3500HD and 3524B Yes
246-1176 3500A and B with Monotherm Pistons Yes

1U-7616 Compressor Group

SMCS Code: 1214-010, 1225-012
Model: 3500

• Band-type piston ring compressor used for servicing 3500 Series Engines
• Similar to former band-type 6V-4021 Ring Compressor Group—improvements allow
1U-7616 to provide better seating of band assembly on cylinder liner to minimize
possibility of ring breakage
• Has lock to secure compressed piston rings in place on piston
• Two handles for easier handling of piston, rings and rod assembly

Item Part No. Description

1 1U-7615 Band Assembly ID: B83923T1
2 6V-4027 Handle Assembly

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6V-4020 Expander Group

SMCS Code: 1214-010, 1225-011, 1225-012
Model: 3500

• Used to remove and install piston rings on 3500 Series Engines Item Part No. Description
1 6V-4024 Guide Ring
2 6V-4023 Handle Assembly

ID: B14946T1

Piston Ring Expanders

SMCS Code: 1214-010
Model: Caterpillar Engines
Warranty:

• Used to easily and safely remove and install piston rings

• When removing or installing piston rings without suitable tool, rings apt to be broken
or overstressed so they no longer fit cylinder wall properly

Engine Bore mm (inch) Expander Part No. Engine Bore mm (inch) Expander Part No.
5,40 (2.125) 2H-7099 130,2 (5.125) 9F-4917
9,53 (3.75) 7B-7977 133,4 (5.25) 7B-7975
101,6 (4.00) 5F-9058 137,2 (5.4) 7M-3978
108,0 (4.25) 7B-7976 139.7 (5.5 149-7179 ID: T96703T1
114,3 (4.50) 5F-9059 146,1 (5.75) 7B-7974
120,7 (4.75) 7S-9470 158,8 (6.25) 5H-9621

Piston Ring Compressors

SMCS Code: 1214-010
Model: Caterpillar Engines Engine Bore Compressor Part No.
mm (inch)
108,0 (4.25) 1U-6684
• Simple, but practical, one-piece piston ring compressors save time and 133,4 (5.25) 1B-7822
prevent damage to rings when installing pistons in older engines
146,1 (5.75 2B-8184 1
• Taper on inside is ground to a smooth surface so rings slide through easily
158,8 (6.25) 6H-4140 1
• Scissors-type piston ring compressors used on more current Caterpillar 1 Discontinued
engines; much easier and faster to use; ring breakage and injury to fingers
practially eliminated

Typical One-Piece Ring Compressor

Scissors Type Ring Compressor
ID: C79316T1
Engine Bore mm (inch) Compressor Part No.
105.0 (4.13) 187-1462
114.3 (4.50) 5P-3524
120.7 (4.75) 5P-3525
125.0 (4.92) 161-4163
130.1 (5.12) 161-4164
137.2 (5.40) 5P-3526
139.7 (5.5) 149-7180
145 (5.7) 200-3914
146.1 (5.75) 5P-3527
158.8 (6.25) 5P-3528
Scissors Type Ring Compressor
(3126 and 3126B Engines) Typical Scissor-Type
110.0 (4.33) 173-5529 Ring Compressor
ID: C79340T1

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1U-6683 Expander
4C-3601 Ring Expander
1U-6684 Compressor
SMCS Code: 1215-012
Model: 3114, 3116, 3176

• 1U-6683 Expander used to expand piston rings to install them on piston on 3114 and 3116 Engines
• 4C-3601 Ring Expander used to remove and install piston rings on 3176 Engine
• 1U-6684 Compressor used to compress piston rings to install piston into cylinder on 3114, 3116 and 3176
• 1U-6684 Compressor capacity: 76.2 mm (3 in) to 127.0 mm (5 in)

ID: C26884T1

Reference
SENR3582, Specification Module
SENR3583, System Operation Testing and Adjusting
SENR3611, Disassembly and Assembly Manual
SEHS8868 Special Instruction, operation

ID: C27127T1

ID: C26885T1

7F-9303 Connecting Rod Wrench

SMCS Code: 1218-011
Model: D398, D379

• Used to remove connecting rod caps

ID: T97398T1

5P-3550 Connecting Rod Boring Machine

Discontinued — Service Parts Available

Service Parts Service Parts

Item Part No. Description Item Part No. Description
1 5P-2705 Plunger Extension, 12,7 mm (.50 in) 6 5P-3555 Spring
5P-2013 Plunger Extension, 19,1 mm (.75 in) 7 5P-3553 Bushing
5P-2014 Plunger Extension, 28,5 mm (1.12 in)
5P-2015 Plunger Extension, 38,1 mm (1.50 in) 8 5P-2055 Flexible Drive
5P-2016 Plunger Extension, 47,8 mm (1.88 in) 9 5P-2021 Clamping Shaft (two)
5P-2017 Plunger Extension, 57,2 mm (2.25 in)
10 5P-3552 Bushing
5P-2018 Plunger Extension, 66,6 mm (2.62 in)
5P-2019 Plunger Extension, 76,2 mm (3.00 in) 11 5P-4376 Rod
5P-2020 Plunger Extension, 85,9 mm (3.38 in) 12 5H-4051 Tool Bit, 35,0 mm (1.375 in) Carbide Tip
2 5P-2012 Plunger Assembly 5H-4052 Tool Bit, 50,8 mm (2.00 in) Carbide Tip
3 5P-2022 Spindle Assembly 13 5P-2023 Tool Bit Setting Gauge Assembly
ID: D00954T1 5P-2056 Contact Point (Part of 5P-2023)
4 5P-2010 Mandrel Body, 66,6-101,6 mm
5P-2058 Dial Indicator (Part of 5P-2023)
(2.62 in-4.00 in)
5P-2011 Mandrel Body, 101,6-139,7 mm ( 14 Use the following locating bushing to
4.00 in-5.50 in) center the connecting rod in the boring
machine.
5 6H-9691 Seal

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Locating Bushing
Part No. Connecting Rod Assembly
New (Former) Part No.
5P-3543 (2H-8234) 5B-2058, 6F-4323, 6F-4325, FH5348
5P-3542 (2H-8235) 5B-1447, 5B-1456, 6F-1952, 6F-3276, 6F-4318,
6F-4319, 6F-4321, 9F-2326, 9F-2330, 4H-9733,
8H-5322, 7M-4835, 4S-6867
5P-3539 (2H-8236) 5B-1919, 6F-4324, 6F-4326
5P-3541 1 (7M-6030) 8H-9354, 3K-6142, 9L-6016, 9L-8369, 9L-9326,
1M-1079, 4N-2218, 9N-8002, 5S-6360
5P-3544 1 (1S-7999) 8F-9411, 3H-3109, 4L-3841, 4M-7573, 4M-9218,
7M-4923, 4N-0371, 4N-0390, 4N-4339, 1P-0009,
1S-4618, 3S-8285, 9S-8492, 8N-1728, 7N-3229
5P-3538 1 (5S-9943) 9M-3980, 5S-2793
ID: D00960T1 5P-3545 (7S-3102) 4N-4261, 4N-6018, 4N-9001, 4N-9002, 2P-2671,
1S-1862, 2S-1601, 9S-5455
1 Later
bushings have the tapered portion machined so that connecting
Reference rods with tapered pin bearings can be properly located.
SMHS6870 Special Instruction

5P-4777 Torsion Bracket

5P-4778 Feed Cylinder
SMCS Code: 1218-023
Model: Caterpillar Engines
Warranty: 5P-4777 Torsion Bar: G
5P-4778 Feed Cylinder: M

• Make up hydraulic feed mechanism needed for use with 5P-3550 Connecting Rod Boring Machine
• Can also be used on former 2H-6782 Boring Machines with or without 5P-2009 Rework Group

NOTE: Later bushings have tapered portion machined so connecting rods with tapered pin bearings
can be properly located. ID: A26474T1

9U-5945 Rod Locating Group

9U-5948 Expanding Segment Group (1.1)
SMCS Code: 1219-024, 0672
Model: 3114 and 3116 Engines

• Aligns 3114 and 3116 connecting rods in 5P-3550 Connecting Rod Boring Machine
prior to boring rod eye bushings
ID: C27038T1
• 5P-3550 Connecting Rod Boring Machine is discontinued and not available from
Caterpillar Item Part No. Description
1 9U-5948 Expanding Segment Group (consists of 3 segments
9U-5948 Expanding Segment Group (1.1): and one 7T-0507 O-Ring)
• Consists of three 50.8 mm (2 in) long segments of split collet and an O-ring 9U-5945 Rod Locating Group includes:
(segments sold only as a group) 2 9U-5944 Expander Nut (2)
• Sold separately — not part of 9U-5945 Rod Locating Group 3 9U-5943 Bushing Locating Rod
4 9U-5946 Bushing
Not shown 9U-5947 Expander Cone

9U-5949 Expander Segments Group

SMCS Code: 1218-028, 0677
Model: 3500 Family Engines

• Used when replacing bushing/bearing in connecting rod

• Insures proper alignment of rod before boring of rod eye bushing
• Used with 9U-5945 Rod Locating Group and discontinued 5P-3550 Connecting Rod Boring Machine
ID: C27045T1
• Three 50.8 mm (2.0 in) long segments of a split collet and two O-rings
• Service Part: 0S-0768 O-Ring

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5P-2050 Connecting Rod Checking Fixture

SMCS Code: 1218-082
Model: Caterpillar Engines except 3600 Engines

• Provides accurate method for measuring pin bore misalignment and rod distortion on Caterpillar connecting rods
(except those on 3600 Engines)
• Connecting rods can be checked before and after rebuild
• Checking fixture and related tools serviced individually to allow dealers to purchase only tools needed for specific engines
• Required: 5P-2050 Checking Fixture, 5P-2051 Position Arm, 5P-2052 or 5P-2053 Crank Mandrel; and appropriate pin
mandrel and plunger assembly (listed in application chart)

Item Part No. Description Quantity

1 Checking Fixture
2 5P-2057 Contact Point (part of 5P-2050) 2
3 5P-2051 Position Arm
4 5P-2012 Plunger Assembly (part of 5P-2052 and 5P-2053)
5 Plunger Extension Assemblies (Refer to Application Chart) 9
6 Pin Mandrels (Refer to Application Chart) 25

Reference
SMHS7366 Special Instruction

Application for 5P-2050 Checking Fixture

Plunger
Connecting Rod Crank Extension Pin Mandrel Pin Mandrel
Engine Series Assembly Mandrel mm (inch) Bushing In Bushing Out ID: 82256T1
1140, 1145, 1150, 1160 9L-8369, 9L-9326, 9N-0407, — 5P-2013 5P-2030 —
3145, 3150, 3160, 3108 9L-6016, 9N-8002, 9L-6272 19.1 (.72)
D3, 910, 931, 3204 4N-2218, 6N-8012 — 5P-2013 5P-2030 —
19,1 (.75)
D311H, D320A 8H-9354 — 5P-2705 5P-2029 —
12,7 (.50)
944 (58A) 3K-6142 — 5P-2705 5P-2029 —
12,7 (.50)
1673, D330, D330A, 1M-1079 — 5P-2014 5P-2031 —
D333, D333A 28,5 (1.12)
1670, 1673, D330B, D333B 9M-3980 — 5P-2014 5P-2033 —
28,5 (1.12)
D330C, D333C, 1673C, D334 5P-2793 — 5P-2014 5P-2033 —
1674, 3304, 3306 28,5 (1.12)
D330C, D333C, 3304, 3306 5S-6360 — 5P-2014 5P-2031 —
28,5 (1.12)
D336, 1676 1S-2862 & 4N-6018 — 5P-2015 5P-2033 —
38,1 (1.50)
D4400, D4600 5B-1919 & 6F-4325 — 5P-2013 5P-2034 5P-2049
19,1 (.75)
D3400 5B-1919 & 6F-4326 — 5P-2013 5P-2032 5P-2045
19,1 (.75)
D315, D318 6F-4323 — 5P-2014 5P-2024 5P-2046
28,5 (1.12)
D311 6F-4324 — 5P-2013 5P-2041 5P-2048
19,1 (.75)
D337F, D326F 4H-5348 — 5P-2015 5P-2034 5P-2047
38,1 (1.50)
D326, D337 8F-9411 & 3H-3109 — 5P-2015 5P-2027 5P-2037
38,1 (1.50)
D343, 1693 4M-9218 & 3S-8285 — 5P-2015 5P-2027 5P-2036
38,1 (1.50)
3406, 3408, 3412 4N-0371, 6N-1828, 6N-3911, — 5P-2017 5P-2027 5P-2036
4N-0390, 7N-3231, 7N-3229 57,2 (2.25)
641, 650, 651, 4M-7573, 4N-4339 — 5P-2016 5P-2027 5P-2036
657, 660, 666 66,6 (2.62)
D346, D348, D349 4N-4261, 2P-2671, 4N-9001 — 5P-2016 5P-2027 5P-2036
9S-5455, 2S-1601, 4N-9002 66,6 (2.62)
D8800, D13000 6F-1952, 6F-4319, 9F-2326 — 5P-2016 5P-2028 5P-2039
47,8 (1.88)

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Application for 5P-2050 Checking Fixture

Plunger
Connecting Rod Crank Extension Pin Mandrel Pin Mandrel
Engine Series Assembly Mandrel mm (inch) Bushing In Bushing Out
D6100, D6600 5B-1447, 6F-4321 — 5P-2015 5P-2028 5P-2038
D7700, D11000 38,1 (1.50)
D353 4H-9733 — 5P-2017 5P-2026 5P-2039
57,2 (2.25)
D353E 7M-4923, 9S-8492 — 5P-2017 5P-2025 5P-2035
57,2 (2.25)
D339, D32 8H-5322, 7M-4835 — 5P-2016 5P-2026 5P-2039
47,8 (1.88)
D342 (31B-3985, 32B-2269) 4S-6867 — 5P-2016 5P-2026 5P-2039
47,8 (1.88)
D17000 5B-1456, 6F-4318, 9F-2330 — 5P-2017 5P-2026 5P-2039
57,2 (2.25)
D364, D375, D386, D397 6F-3276 — 5P-2019 5P-2026 5P-2039
76,2 (3.00)
D379, D398, D399 4L-3841, 1P-0009, 1S-4618 — 5P-2020 5P-2025 5P-2035
85,9 (3.38)
3500 8N-6020, 1W-4800, 7C-8608 — 5P-2018 8T-2842 8T-2841
66,6 (2.62)

9U-5917 Pin Mandrel, Bushing Out

9U-5918 Pin Mandrel, Bushing In
SMCS Code: 1218-082, 0767
Model: 3114 and 3116 Engines

• Used to check connecting rods

• Provides accurate method for measuring bore misalignment and rod distortion
• Rod can be checked before and after rebuild with rod eye bushing in or out
• Used with 5P-2050 Connecting Rod Checking Fixture, 5P-2053 Crank Mandrel, and 5P-2013 Plunger
Extension Assembly
• Length: 140 mm (5.5 inches)
• Composition: steel
ID: C27043T1

Tools for Connecting Rod Pin Bearing Removal and Installation

SMCS Code: 1218-010
Model: Caterpillar Engines

Hydraulic Service Tools for use with 5P-8639 Press Group

• Used to remove and install both tapered and standard connecting rod pin bearings
Part No. Description Quantity
• Basic 5P-8639 Press Group required for all engines in addition to other tools for each family
of engines; refer to table for hydraulic service tools for use with 5P-8639 Press Group 8F-0024 Hose 1
• 5P-8655 Tool Group required for current engines with standard rods 1P-2375 Coupler Assembly 1
1P-2376 Coupler Assembly 1
Hydraulic Pump (Electric or Hand) 1
Reference
SMHS7295 Special Instruction
Refer to table below to select appropriate hydraulic pump and for
comparison of hydraulic pump press time.
Loading and
Hydraulic Pump Press Time1 Unloading Total Time
Part No. Seconds Time Seconds Seconds
2P-5500/2P-5550 10-15 45 55-60
(Electric)
3S-6224/8S-8033 3-5 45 48-50
(Electric)
1 Press time will vary slightly with rod and tool size

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Service Parts for 5P-8639 Connecting Rod Bearing Press Group (Basic)
Item Part No. Description
1 5P-8640 Clamp Bar
2 5P-8641 Clamp Bar
3 5P-8643 Post Assembly
4 5P-8642 Clamp Pin
5 5P-9725 Cylinder Group (5P-9724 Repair Kit is available)
6 5P-0159 Cap (part of 5P-9725)
7 1P-2375 Coupler Assembly (part of 5P-9725)
1P-7437 Cap (part of 5P-9725)

ID: A64865T1

Service Parts for 5P-8655 Connecting Rod Tool Group (Standard)

Item Part No. Description
1 5P-8663 Adapter
2 5P-8661 Spacer
5P-8662 Spacer
5P-8654 Spacer (also in 5P-8652)
5P-8647 Spacer (also in 5P-8644)
3 5P-8656 Adapter, D320 or 3204, 3208, D330 and 3300
5P-8657 Adapter, D330 and D330
5P-8658 Adapter, 1693, 3400
5P-8659 Adapter, D342, D353
5P-8660 Adapter, D353, D398
ID: A64864T1

Tools for Removing and Installing Tapered Connecting Rod Bearings

SMCS Code: 1219-010
Model: Caterpillar Engines

• Following is a complete list of tools required for bearing removal and installation.
Use the application chart to select the tools for each engine connecting rod assembly.

Reference Item Part No. Description Item Part No. Description

SMHS7295 Special Instruction 1 5P-8653 Adapter 8 6V-3042 Adapter
2 6V-2049 Adapter 8T-5261 Adapter

3 6V-4819 Spacer 9 6V-3043 Spacer

4 5P-8650 Adapter 10 6V-3297 Spacer

5 5P-8645 Adapter 11 5P-8647 Spacer

6 5P-8646 Adapter 12 5P-8651 Spacer

7 5P-8649 Adapter 13 6V-3029 Spacer ID: B51372T1

Rod
Engine Rod Push R and L Bar Part No.
Model Assembly Adapter Spacer Adapter Clamp Position
D346 4N-9001 5P-8645 5P-8647 5P-8646 5P-8641 UP
D348 4N-9002 5P-8645 5P-8647 5P-8646 5P-8641 DOWN
D349 4N-4261 5P-8645 5P-8647 5P-8646 5P-8641 UP
2P-2671 5P-8645 5P-8647 5P-8646 5P-8641 UP
9S-5455 5P-8645 5P-8647 5P-8646 5P-8641 UP
3204 6N-8012 5P-8645 6V-4819 5P-8653 5P-8641 DOWN
3208 9N-3504 5P-8645 6V-4819 5P-8653 5P-8641 UP
3300 8N-1721 5P-8645 6V-3029 6V-2049 5P-8641
3400 7N-3229-6 5P-8649 5P-8651 5P-8650 5P-8640 UP
7N-3231-6 5P-8649 5P-8651 5P-8650 5P-8640 UP
8N-1726-9 5P-8645 6V-3197 5P-8646 5P-8640
8N-2486-9 5P-8645 6V-3197 5P-8646 5P-8640 UP
3500 1W-4800 5P-8649 6V-3043 6V-3042 5P-8640 DOWN
6° 8N-9647 5P-8649 6V-3043 6V-3042 5P-8640 DOWN
3500 8N-6020 4C-8725 4C-8726 4C-8727 5P-8640 DOWN
10° 7C-8608 DOWN
1.1 l 2W-9128 4C-9749 4C-9751 4C-9750 5P-8641
12.5°

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1U-6242 Pin Bushing Adapter

1U-6244 Spacer
1U-6243 Push Adapter
SMCS Code: 1219-010, 0714
Model: 3176 Engine

• Used to remove and install piston pin bearing on 9Y-1170 and 4P-2232 Connecting
Rod Assemblies
• Used with 5P-8639 Press Group
• The base plate of the 5P-8639 Press Group must be modified in order to remove
and install the piston pin bearing. Drill and tap a 5/8-11 hole, 225.00 mm (8.858 in),
from the center of the largest bore. Refer to diagram.
ID: C66704T1
Reference
SMHS7295 Special Instruction

ID: C66695T1

1U-9032 Pin Bushing Adapter Reconditioning Connecting Rod Tools

SMCS Code: 1218-020
1U-9033 Spacer Model: Caterpillar Engines
Warranty:
1U-9034 Push Adapter
SMCS Code: 1219-010, 0714 • Used to produce smoother surface finish (10 MU or less required) in piston
Model: 3406E Engine pin bearing
when new piston pin bearing is installed in connecting rod and 4W-7402
Piston is used
• Used to remove and install connecting rod pin bearing (9Y-6054 Connecting • Smoother surface finish required only for new piston pin bearings
Rod Assembly) • 8T-2841 and 8T-2842 Pin Mandrel used with 5P-2050 Rod Checking Fixture
• Used with 5P-8639 Press Group to check bend, twist, and center distance
• Specifically designed for connecting rods with 12° taper
Reference
SMHS7366 Special Instruction
SEBF8075 Guideline for Reusable Parts

ID: B99645T1
Item Part No. Description
Reference
ID: C66705T1 1 8T-3103
8T-3105
Buffing Tool Group
Buffing Wheel (service part)
SMHS7295 Special Instruction
2 8T-3104 Polishing Compound
3 8T-2840 Bushing Compound
4 8T-3171 Tool Bit
5 8T-3170 Set Screw
Not shown 8T-2841 Pin-Mandrel (Bushing Out)
Not shown 8T-2842 Pin-Mandrel (Bushing In)

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139-9039 Snap Ring Pliers

SMCS Code: 1225-010
Model: 3400 Engines

• Used to remove specially designed piston pin retaining rings without holes such as 7E-5665 and 7E-1177
• Holds ring in tight clearance against piston pin
• Overall length: 213 mm (8.4 in)

ID: C66570T1

4C-8725 Pin Bushing Adapter 4C-9749 Pushing Adapter

4C-8726 Spacer 4C-9750 Bushing Adapter
4C-8727 Push Adapter 4C-9751 Spacer
SMCS Code: 1219-010, 0705 SMCS Code: 1219-010, 0705
Model: 3500 Family Engines with 7C-8608 (10°) Connecting Rod Assemblies Model: All 1.1 Liter Engines

• Allow 5P-8639 Press Group to be used to remove and install piston pin • Used to remove and install connecting rod bearings
bearings in 3500 Family Engines with 7C-8608 Connecting Rod Assemblies • Provides economical means to rebuild connecting rods
(10° taper on piston pin end)
• Fits rods with 10° taper

Reference
ID: C27027T1 SMHS7295 Special Instructions
Reference ID: C54931T1
SMHS7295 Special Instruction

8T-7748 Polishing Wheel

SMCS Code: 0674
Model: Caterpillar Engines

• Replaces discontinued 6V-6147 Polishing Wheel

• Scotch-Brite polishing wheel used to easily clean and remove discoloration from Caterpillar piston pins
• Cleaning will not damage surface finish and makes it easier to determine if pins are reuseable

Reference
SEBF8051 Guideline for Reusable Parts

ID: B60205T1

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Pistons, Rings and Connecting Rods Search Engine Tools

Parts Baskets for Handling Pistons and Piston Pins

SMCS Code: 0661
Model: Caterpillar Engines

• Durable parts baskets for handling pistons and piston pins during reconditioning of
these components
• As dealers begin to process more piston and rod assemblies for exchange programs,
efficient material handling systems need to be used to reduce repair times and prevent
handling damage.
• Baskets especially useful because handling damage is one of major reasons that pistons
and pins cannot be reused
• Baskets formed from heavy-gauge wire and dipped in plastisol coating
• Each piston and pin held in place and prevented from contact with each other
• Baskets can be used to hold pistons and pins during cleaning operation because coating
is resistant to heat and mild chemical cleaning agents often used in agitating-type ID: B60772T1
cleaners or hot spray wash cabinets

ID: B60778T1

ID: B60771T1

Tool
Tool No Name Capacity Engine Models
6V-7004 Piston 8 3200, 3300 Series
Basket
6V-7003 Piston Pin 24 3204, 3208, D330C, D333C,
Basket 1673C, 3304, 3306, 1674, D334
6V-7099 Piston Pin 12 D342, D343, 1693, D346, D348,
Basket D349, 3400 Series

Induction Bearing Heaters and Ring Heater

SMCS Code: 1215-012
Model: All Models

• 150-7723 Ring Heater replaces discontinued 1U-5454 Heater Ring • Handles parts from 20 to 280 mm (.8 to 5.1 in) inside diameter and material
• Used to heat bearings, gears, rings and bushings where a press fit is up to 60 mm (2.4 in) thickness [A 150-7723 Ring Heater attachment increases
required; also used to heat tapered connecting rods before a replacement capacity from 70 to 330 mm (2.8 to 13.0 in) inside diameter with a maximum
bushing is installed thickness of 65 mm (2.5 in)]
• Parts are heated by inducing low voltage and high current into the part • Additional temperature detectors are available in the 10°C increments
between 60°C (140°F) and 170°C (338°F)
• Heating time normally takes 30 to 60 seconds (depending on size) and
temperature detector will automatically shut off heater when part reaches • Temperature detectors and timers are available from:
correct temperature [up to 110°C (230°F) standard detector] Jergens, Inc. TODA, Inc.
• If higher temperatures are required, the temperature detector should not be 19520 Nottingham Road 12-23, 4-CHROME, GINZA, CHUO-KU
attached to part (use a 164-3310 Infrared Thermometer, 9U-7043 Cleveland, OH 44110, U.S.A. Tokyo, 104, Japan
Temperature Recorder Group, or similar temperature measuring device to Phone: (216) 486-2100 Phone: (03) 541-3961-5
obtain desired temperature of part) or Cable: TOBAYOOKOO, Tokyo
• Heater will demagnetize a part after heating cycle Telex: J27796, TOBAINC

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Camshaft and Timing Gear Tools

ID: B06770-1T1

Part No. Description

ID: B81099T1
6V-6996 Induction Bearing Heater (110V, 60 Hz) E
6V-7118 Induction Bearing Heater (220V, 50 Hz)

150-7723 Ring Heater

Item Size
C A 60 mm
F B 95 mm
A C 35 mm
D D 35 mm
E 55 mm
F 180 mm

B
ID: C78593T1

B A
6V-6996 and 6V-7118 Heaters 6V-6996 and 6V-7118 Heaters
with 150-7723 Ring Heater without 150-7723 Ring Heater
C Minimum inside diameter (A) 20.3 mm (0.8 in) 20.3 mm (.8 in)
Maximum outside diameter (B) 157 mm (6.2 in) 112 mm (4.4 in)
Maximum thickness (C) 81.3 mm (3.2 in) 81.3 mm (3.2 in)

150-7723
ID: C78594T1

Camshaft and Timing Gear Tools

131-1525 Camshaft Alignment Pilot Assembly

SMCS Code: 1210-010
Model: C-10 and C-12 Engines

• Used to remove and install camshafts (threads directly onto end of camshaft)
• Made from aluminum to prevent damage to cam bearings
• Two cross-drilled holes provide means of removing pilot assemblies after Length 98 mm (3.9 in)
camshaft is installed Outside diameter 74.74 mm (2.943 in)
• Two required—thread one into the other to make installation Stud M10 x 1.5 thread
between engine and firewall easier

Reference
SENR1002 and SENR1007 Service Manual Modules

ID: C66925T1

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Camshaft Installation Tools

SMCS Code: 1202-012
Model: 3500

• Direct replacement for discontinued 6V-4019 Pilot Group; new tooling can be used
on all earlier engines
• When installing camshaft into camshaft bearings in cylinder block, it is necessary
to provide pilot/guide for camshaft to prevent damage to bearings; because of changes
in camshafts of 3500 engines, there are new installation tools that pilot camshaft
from both ends until camshaft is in place
• Designed so camshaft can be installed from either end of engine

Item Part No. Description Quantity

1 8T-3167 Guide Assembly 1
2 8T-3168 Pilot Assembly 2
3 8T-3169 Crank Assembly 1
4 8S-3887 Bolt, 1/2 inch 13 x 11 inch 4
5 4J-7945 Bolt, 3/4 inch 10 x 1-1/2 inch 2 ID: C07357T1
6 0S-1617 Bolt, 5/16 inch 18 x 3/4 inch 2
7 0S-1594 Bolt, 3/8 inch 16 x 1 inch 3

Application Procedure
1. Use three 0S-1594 Bolts, finger tight, to install 8T-3167 Guide Assembly
on flywheel housing or front cover as shown

ID: C07359T1
3. Put engine oil on all bearings and camshaft journals. Install pilot and
camshaft through guide assembly until pilot is located in first bearing.
Tighten bolts on guide assembly while turning camshaft.
4. On 3508 Engines, complete the installation of the camshaft while rotating
camshaft. Remove tooling and complete engine assembly.
On 3512 and 3516 Engines, one end of separated camshaft is rotated and
installed as far as camshaft joint. Attach other end of camshaft and
complete installation while rotating camshaft. Remove tooling and
complete assembly of engine.
ID: C07358T1
2. Install 8T-3168 Pilot Assemblies and 8T-3169 Handle Assembly on
camshaft as shown. Two-piece camshafts should be separated for
installation.

125-0200 Camshaft Pilot

SMCS Code: 1202-012
Model: 3500B Engine with Large Diameter Camshaft

• Used to remove and install 106-4584 Camshaft—simply threads onto end of camshafts
and functions as a guide during installation or removal
• Used with 8T-3169 Crank Assembly to help rotate camshaft during engine assembly
and disassembly (use two 0S-1617 Bolts to attach crank assembly to camshaft)
• Length of pilot is designed to be supported by two camshaft journals at the same time
(prevents camshaft from dropping as it is installed through each bearing journal)
• Groove in end of pilot provides clearance for dowel pin in camshaft (eliminates ID: C66726T1
removal of dowel) Item Part No. Description
• Made from aluminum to prevent scratching or other damage to journal surfaces 1 2P-1303 Taperlock Stud (part of 125-0200)
• Diameter: 91.9 mm (3.62 in) 2 0S-1617 Bolt (two required)
• Length: 305 mm (12.0 in) 3 8T-3169 Crank Assembly

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125-0201 Camshaft Guide Assembly

SMCS Code: 1202-012
Model: 3500B Engines

• Used to install camshaft from either end of engine

• Reduces installation time and helps prevent camshaft bearing damage
• Used with front or rear housing in place (does not bolt to bare block face)
• Overall length: 303 mm (11.9 in)
• Tube inside diameter: 91.98 mm (3.621 in)
ID: C78578T1

Camshaft Removal and Installation Tools

SMCS Code: 1110-010, 0705
Model: 3406E Engines

• Used to remove and install camshaft in chassis

• Prevents damage to camshaft and bearings
• Provides way to lift camshaft without pinching fingers
ID: C55188T1

9U-7256 Guide Assembly (Item 1) 9U-7225 Camshaft Pilot (Item 3)

Tube (outside diameter x length) 102 x 195 mm (4.0 x 7.7 in) Material Aluminum
Plate (w x l x t) 205 x 296 x 9.5 mm (8.0 x 11.6 x .38 in) Rod (diameter x length) 84 x 85 mm (3.3 x 3.3 in)
Plate offset from end of tube 65 mm (2.5 in) Threaded stud (serviced by 3D-0490 Stud) 1/2 inch-13 x 1.0 inch
9U-7243 Alignment Sleeve (Item 2) 9U-7240 Camshaft Lifting Hook (Item 4)
Material Steel tube Handle (diameter x length) 25 x 120 mm (1.0 x 4.8 in)
Tube (diameter x length) 85 x 430 mm (3.3 x 17.0 in) Hook (diameter x length) 6.4 x 180 mm (.25 x 7.0 in)
9U-7257 Cradle Assembly (Item 5)
Reference Rod (diameter x length) 40 x 140 mm (1.5 x 5.4 in)
SENR5580 Service Manual, 3406E Engines Plate (w x l x t) 91 x 130 x 7.9 mm (3.5 x 5.0 x .31 in)
SENR6421 Disassembly and Assembly Manual

177-8003 Cam Tool Group

SMCS Code: 1000-010, 0700, 0701, 0703, 1210-010
Model: 3406E, 3456, C-15, C-16, C27/C32

1
• Used to remove camshaft through front or rear of cylinder head
• Used with three 6L-4697 Bolts to connect adapter to camshaft (not included)
• Used on many machines, cab over trucks, or when cylinder head is off for repair 3 4
• Saves time by allowing cam removal without removing other components 5
• Pilot sleeve simultaneously engages two cam bearings to guide cam without 2
damaging bearings — loosely assemble components to prevent tool
alignment problems
• To remove camshaft through front of cylinder head, screw only pilot sleeve into
opposite end of camshaft
• To remove cam through rear of head: 1) remove cam gear; 2) bolt adapter onto
camshaft; 3) screw pilot sleeve onto adapter
• Minimum pilot sleeve clearance between head and other components: 368 mm (14.5 in)
ID: C79803T1
Item Part No. Description
1 177-8001 Pilot Sleeve
2 177-8002 Adapter (3406, C-15, C-16, C27/C32 rear install)
249-2963 Adapter (C27/C32 front install)
3 1F-7958 Full Nut
4 5P-8245 Hard Washer
5 3D-0472 Taperlock Stud

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8S-2241 Camshaft Bearing Installation and Removal Group

SMCS Code: 1211-010
Model: Caterpillar Engines

• Used to remove and install camshaft bearings in most Caterpillar Engines

• Each collet designed to handle bearing diameter range listed in chart;
replacement O-ring seals used to retain collets also listed

Item Part No. Description

1 8S-8287 Thrust Bearing Assembly
2 8S-8288 Cone
Inner Diameter
3 8S-8282 Collet Assembly Size Range Replacement
4 8S-8284 Collet Assembly Collet No. mm (inch) 0-Ring Seal
5 8S-8285 Collet Assembly 1P-0552 28,58 — 38,10 4J-0520
(1.125 — 1.500)
6 8S-8289 Tube
8S-8282 43,66 — 50,80 4J-0521
7 8S-8293 Long Extension (1.718 — 2.000)
8 8S-8281 Tool Box 8S-8283 48,42 — 57,15 4J-0522
9 8S-8291 Threaded Shaft (1.906 — 2.250)
10 8S-8290 Nut 8S-8285 60,33 — 69,85 4J-0524
11 8S-8884 Backup Nut (2.375 — 2.750)

12 8S-8286 Screw Expander

13 8S-8883 Backup Nut
ID: D00918T1
14 8S-8882 Backup Nut
15 8S-8292 Short Extension (two)

5P-1666 Puller Plate

5P-1667 Spacer Tube
SMCS Code: 1211-010, 1253-017, 1230-010, 3258-017
Model: D379B, D398B, D399, 657E

• Used with 8S-2241 Group for camshaft bearing removal and installation on 6.25 inch
bore V Engines (two 8S-8292 Short Extensions and one 8S-8293 Long Extension
required from 8S-2241 Group)
ID: 77662T1
Item Part No. Description
1 5P-1666 Puller Plate
2 5P-1667 Spacer Tube
3 8S-8292 Short Extension (two required) (part of 8S-2241 Tool Group)
4 8S-8293 Long Extension (part of 8S-2241 Tool Group)

1P-5545 Adapter Group 6V-4869 Adapter

SMCS Code: 1211-010, 1211-012
Model: 1100, 3100, 3208 6V-6174 Plug
SMCS Code: 1211-010
Model: 3400
• Used with 8S-2241 Tool Group to install camshaft bearings on 1100 and 3100
Series and 3208 Engines
• Used with 8S-2241 Tool Group to remove and install camshaft bearings in
3400 Series Engines
• 6V-4869 Adapter used for collet assembly
• 6V-6174 Plug used for cone

ID: C05376T1
Item Part No. Description
1 0S-0509 Bolt

ID: B62643T1

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Camshaft Bearing Remove/Install Tools

SMCS Code: 1211-010
Model: 3500B Engines

• Used to remove and install two sizes of camshaft bearings — makes overhaul
much simpler and reduces chance of bearing damage during installation
• Used with 6V-4077 Camshaft Bearing Tool Group and 8S-2241 Camshaft Bearing
Installation and Removal Group
• Designed to trap camshaft bearing between camshaft bearing pilot and
backup plate — can be pushed (removed) or pulled (installed) using 6V-4077
and 8S-2241 Tool Groups
• Install thin-walled bearings by placing 125-2741 Camshaft Bearing Sleeve over Part No. Description
the camshaft bearing pilot 125-2739 Cam Bearing Pilot
• Parts are plated and hardened for durability and long life 125-2740 Backup Plate
ID: C66892T1
125-2741 Cam Bearing Sleeve

Larger diameter of pilot 97.9 mm (3.85 in)

Small diameter of pilot 85.9 mm (3.38 in)
Outside diameter of sleeve 92.1 mm (3.63 in)

ID: C66893T1

6V-4077 Camshaft Bearing Tool Group

SMCS Code: 1211-010 Item Part No. Description
Model: D11N, 3512, 3516, 777B, 785, 789, 994 1 6V-4011 Spacer
2 6V-4015 Pulling Bar
3 6V-4013 Screw
• Used with components of 8S-2241 Tool Group for manual removal
4 2J-3506 Nut
and installation of camshaft bearings in 3500 Series Engines
5 5P-8248 Washer
• Otherwise 5P-5247 Hydraulic Puller can be used
6 0S-1621 Bolt
7 6V-3177 Pilot Group
8 6V-4012 Plate
9 6V-4010 Pulling Plate
ID: B14941-1T1 10 6V-4005 Spacer (two)

Camshaft Bearing Remove/Install Tools

SMCS Code: 1211-010
Model: C-10 and C-12 Engines

• Used to remove and install camshaft bearings

• Used with 8S-2241 Camshaft Installation and Removal Group, 0S-1629 Bolt, and
8M-8778 Taperlock Stud
• Tools can be used to remove or install camshaft bearings (for installation, assemble parts
as shown in illustration)
• Large diameter of bearing pilot guides bearing into bearing bore on engine for ID: C66740T1
easier installation
Camshaft Bearing Tooling
• Reaction sleeve is designed with clearance for bolts on engine front housing
Item Part No. Description
1 129-6672 Puller Plate
129-6673 Bearing Pilot 2 129-6671 Reaction Sleeve
Overall outside diameter 80.92 (3.186 in) 3 8M-8778 Taperlock Stud
Outside diameter of bearing pilot 74.850 (2.9469 in) 4 129-6673 Bearing Pilot
5 Camshaft Bearing
Reference 6 129-6674 Backup Plate
SENR1002 Special Instruction C-10 Disassembly and Assembly 7 0S-1629 Bolt

SENR1007 Special Instruction C-12 Disassembly and Assembly Not shown 8S-2241 Camshaft Bearing Installation and Removal Group

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Camshaft Plates, Pilots, and Sleeves

SMCS Code: 121-010
Model: C-11 and C-13 Engines 201-4213 201-4214

• Used to remove and install camshaft bearings

• Used with 8S-2241 Camshaft Installation and Removal Group
• Large diameter of bearing pilot guides bearing into bearing bore on engine block for
easier installation
201-4209
201-4212
• Receiving sleeve designed with clearance for front housing engine bolts

Service Parts
Part No. Description
201-4208 Backup Plate
201-4211
201-4209 Bearing Pilot
201-4211 Pilot Assembly
201-4212 Pilot Assembly
201-4213 Puller Plate
201-4214 Receiving Sleeve 201-4208
ID: D00386T1

Camshaft Bearing Removal and Installation Tools

SMCS Code: 1111-010, 0703
Model: 3406E Engines

• Used to remove and install camshaft bearing with head removed

ID: C55190T1
• Used with 8M-8778 Stud, 6V-4013 Threaded Screw, 8S-8292 Short Extension,
(2 required), 8S-8293 Long Extension, (2 required), 2J-3506 Nut, 5P-8248 Washer,
Item Part No. Description Overall dimensions (diameter x
5P-5247 Hydraulic Puller Assembly and hydraulic pump thickness)
• Hydraulic force easily removes bearings and prevents damage during installation 1 9U-7210 Puller Plate 95.0 mm (3.75 in) x 19.0 mm (.75 in)
2 9U-7223 Alignment Bushing 85.0 mm (3.30 in) x 32.0 mm (1.25 in)
Reference
3 9U-7222 Cam Bearing Pilot 90.0 mm (3.50 in) x 70.0 mm (2.75 in)
SENR5580 Service Manual, 3406E Engine
4 9U-7213 Backup Plate 108.0 mm (4.25 in) x 57.0 mm (2.25 in)
SENR6421 Disassembly and Assembly Manual
5 9U-7214 Spacer Plate 90.0 mm (3.50 in) x 4.0 mm (.16 in)

132-3904 Camshaft Retainer

SMCS Code: 1100-010
Model: 3406E Engines

• Used to hold camshaft in cylinder head during removal and installation

• Install retainer across camshaft bearing between two camshaft lobes
• Failure to use retainer can result in damaged camshafts (retainer is extremely
cost-effective when compared to price of new camshaft)

ID: C66765T1

ID: C66764T1

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8F-3671 Gear Installation Group

SMCS Code: 1212-012
Model: Caterpillar Engines

• Used with 6V-3160 Hydraulic Puller to install camshaft gears and accessory drive gears
Item Part No. Description
1 8F-3669 Spacer
2 8F-3667 Nut
3 6H-6988 Sleeve (D9 Tractor Only)
4 8F-3668 Nut
5 8F-3670 Stud; Make from 1U-7758, 1-1/8 inch-12-NF x 10.5 inch
ID: T97404-1T1

Gear Installation Tools

SMCS Code: 1207-012 Item Part No. Description
Model: 933, 951, 955, 977 1 1B-4210 Nut
2 4M-3251 Adapter
3 Spacer
• Necessary only when installing accessory drive shaft with engine installed
in 933 Traxcavators and in 951, 955, and 977 Traxcavators with 4-1/2 inch
bore engines equipped with mechanical governors

ID: T97459T1

173-2021 Puller Group

SMCS Code: 1000-011, 0700
Model: 3300 Engine
193-9199 Socket Assembly
SMCS Code: 1150-010, 0700, 0704
• Used to quickly and easily remove or install idler gear stub shaft with a
Model: C-15, C-16, C-17, and C-18 Engines
common slide hammer
Warranty: Manufacturer’s
• Used with 1U-7600 Slide Hammer or similar tool with 1/2-20 threads
• Helps eliminate damage to bore of cylinder block and stub shaft • T27 Torx socket fits special Torx cap screw on cam gear and
• Used by slipping cup over the stub shaft; idler access “peanut” cover and front gear housing
insert puller pin through side of cup and • Square drive: 3/8 inch
oil feed hole in the stub shaft
• Inside bore diameter: 35 mm (1.38 in)
• Service Part: 173-2023 Pin

ID: C80070T1

ID: C79789T1

8F-3672 Gear Removal Plate

SMCS Code: 1206-010, 4054-010, 4262-015, 4262-017
Model: Caterpillar Engines

• Removal of camshaft or accessory drive gear with hydraulic puller (2) is simple
operation combining use of plate (1) and push-puller (3)

Item Part No. Description

1 8F-3672 Plate
2 6V-3160 Hydraulic Puller
3 8B-7548 Push-Puller

ID: C05379T1
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167-3834 Puller Group

SMCS Code: 1000-011, 0700, 0701
Model: 3176, 3176B, 3196, C-10, and C-12

1
• Used to remove press fit camshaft gear without pulling camshaft or disturbing overhead components
• Used with dealer supplied 10,000 Psi 1U-5230 Single Acting Hand Pump, 3S-6224 Electric Hydraulic Pump, 2
or equivalent
• Used with induction gear heater to install cam gear (not included) 5 3
• Saves time on front cover repairs
• For engines built through May 1998 Item Part No. Description
• Only works on cam gears with lightening holes; 1 167-1999 Puller Leg
will not fit solid hub gears 2 167-1998 Puller Plate
4
3 5P-8247 Hard Washer
4 6B-6683 Nut
Reference 5 167-2000 Hydraulic Cylinder ID: C79618T1
NEHSO760 Tool Operating Manual
Required parts, not included
138-7575 Lifting Link Hydraulic ram single action
5P-2566 Bolt 1/2-13 (for lift link) Ram stroke 51 mm (2.0 in)
5P-8245 Washer (for lift link) Ram capacity 25 ton

9U-6896 Guide Bolt

SMCS Code: 1212-010, 0714
Model: 3406E Engines

• Used to easily align camshaft gear during installation by supporting weight of camshaft gear
• Used with 1P-7405 Eye Bolt
• Length: 127 mm (5.0 in)
• Thread: 5/8 in-11

Reference
SENR5580 Service Manual; SENR6421 Service Manual Module, Disassembly
and Assembly 3406E Engines
ID: C66607T1

8S-2264 Puller Group

8S-8375 Sleeve
SMCS Code: 1162-010, 1207-010, 1207-011, 1251-010, 1286-012, 1250-025, 3100-017
Model: D330C, D333C, 3304 and 3306 Engines

Used for various pulling operations such as:

• Removing accessory drive gears on D330C, D333C, 3304 and 3306 Engines
• Removing crankshaft front pulley on 1100 and 3100 Series Engines
ID: C05378T1
• Water pump disassembly and assembly on D342, D353 and 3406 Engines
• Used with an 8S-8375 Sleeve to remove the accessory drive gear on 4.75 inch bore two valve engines
• Also used in other general purpose applications
8S-2264 Puller Group
• Available separately: 6V-7837 Screw, length 2.81 inch, 3/4 inch-16 thread
Item Part No. Description
1 8S-8375 Sleeve (not part of 8S-2264 Group)
2 8S-5133 Plug
3 8S-6470 Screw
4 8S-5132 Puller Plate

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4C-5613 Puller Group

SMCS Code: 1803-011
Model: 3406

• Used to remove air compressor drive gear

• Has wide puller jaws that distribute load across more surface area on gear and prevent
damage to splined teeth; conventional puller jaws will not properly grab under gear hub
due to clearance problems, so they are used to grab in spline tooth area where they
may damage gear teeth
• Can be used for general purpose pulling operations
Item Part No. Description
• 3-leg, 10-ton puller with wide, flat puller jaws
1 4C-5628 Crossarm Body
2 4C-5626 Forcing Screw
ID: C27247T1
3 4C-5625 Puller Jaw
4 4C-5624 Spring Clip
5 4C-5627 Tip

132-5451 Air Compressor Gear Holder

SMCS Code: 1803-017
Model: 3406E, C-10, and C-12 Engines

• Used to keep air compressor shaft from turning while Inside diameter 127 mm (5.0 in)
removing or tightening drive gear retaining nut Height including pins 88.9 mm (3.50 in)
• Holder makes removing and installing nut much simpler Pin diameter 12.7 mm (.50 in)
and faster — also reduces possibility of damage during Retaining nut final torque 462 ± 54 N·m (340 ± 40 lb ft)
overhaul procedure
• Use shop vise to hold air compressor assembly
• Service Part: 6B-6683 Nut

ID: C54978T1

4C-9991 Idler Shaft Retrofit Tool Group

SMCS Code: 1206-010, 1201-019,
0670 (for 9U-5033), 0671 (for 9U-5034)
Model: 3500

• Used to retrofit idler gear shaft on 3500 Vee engines

• Easily and accurately aligns drill and tap for drilling and tapping bolt holes
from 1/2-13 to 5/8-11 thread
• Eliminates replacing cylinder block
• Used with 1P-3048 Wrench Assembly and 1U-9218 1/2 inch Drill

Item Part No. Description Size

1 9U-5033 Core Drill 17/32 inch, 4-fluted
2 9U-5034 Bottoming Tap 5/8 inch-11 Thd
3 1A-5822 Bolt (not part of 4C-9991 Tool Group) 1/2 inch — 13 x 2-3/4 inch
4 9X-8883 Bolt 5/8 inch — 11 x 2-3/4 inch
5 6V-4857 Lockscrew (qty, 2)
6 4C-9993 Guide Plate ID: C26994T1
7 4C-9994 Drill Bushing .500 inch
8 4C-9995 Drill Bushing .531 inch
9 4C-9996 Drill Bushing .625 inch Reference
10 4C-9997 Drill Bushing .635 inch (pilot for .625 inch tap) SEBF8166 Guideline for Reuseable Parts
Not shown 4C-9992 Idler Shaft Retrofit Pilot

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Camshaft and Timing Gear Tools Search Engine Tools

9U-7255 Adjustable Idler Assembly 9U-6148 Idler Shaft Removal Group

SMCS Code: 1206-036, 0766 SMCS Code: 1206-011, 0714
Model: 3406E Engines Model: 3064 and 3066 Engines

• Used to set backlash between camshaft gear and adjustable idler gear • Used to remove idler gear shaft
• Used with 9U-7324 Indicator Bracket, 7H-1942 Dial Indicator, 3S-3268
Contact Point, and 7H-1940 Universal Attachment (assures correct setting
of backlash after tightening mounting bolts
to adjustable idler gear) Item Part No. Description
• Holds adjustable idler gear in correct 1 9U-6147 Removal Stud
position while tightening mounting bolts 2 8T-4244 Nut (M12 x 1.75)
• Distance between centers: 3 9U-6146 Sleeve Assembly
204.03 mm (8.033 in) Not shown 6V-8231 Nut (M10 x 1.25)

Reference
SENR5580 Service Manual
ID: C66631T1 ID: C54947T1
SENR6421 Service Manual Module, Disassembly and Assembly
3406E Engine
Reference
SENR5553 Service Manual, 3066 Diesel Engines

195-7503 Shaft Installer Group

SMCS Code: 1206-012
Model: 3034 Engine
Essential Tool 2

Item Part No. Description

• Used to install front idler gear shaft 1 195-7503 Shaft Installer Group
• Eliminates guesswork and measuring to determine installation depth 1 2 159-9076 Rear Drive Handle
(when installer contacts block, shaft is installed to proper depth)
• Used with 159-9076 Rear Drive Handle (sold separately)
Overall size 50 mm (2.0 in) diameter x 80 mm (3.1 in) long
Reference Weight 2 kg (4.4 lbs)
SENR5013 Service Manual, Disassembly and Assembly O-ring Seal 095-1595
3034 Engines for Caterpillar-Built Machines
ID: C80119T1

6V-0098 Socket, 9/16 inch Extention Hex Drive

SMCS Code: 1210-010
Model: 3204 Engines

• Used for removal and installation of 4N-5201 Tachometer Drive Stud in camshaft of D3B, IT28, 215, 910, 931B, 943
ID: A86937-1T1
• Tightened to 14,9 ± 2,8 N·m (132 ± 24 lb in) torque when installing stud

9U-7324 Indicator Bracket

SMCS Code: 1206-036, 0766
Model: 3406E Engines

• L-shaped bracket used to fasten dial indicator to front housing (allows backlash between camshaft gear
and idler gear to be measured)
• Used with 7H-1942 Dial Indicator, 3S-3268 Contact Point, and 7H-1940 Universal Attachment

Reference
SENR5580 Service Manual: Height 66 mm (2.6 in)
Threaded hole in long leg 1/4 inch-20
SENR6421 Service Manual Module, Disassembly and
Assembly 3406E Engine Clearance hole in short leg 8.20 mm (.312 in)
ID: C66625T1

3-182 Dealer Service Tools 2004 Home

Engine Tools Search Starting Systems / Engine Lifting and Positioning

Starting Systems

2H-8581 Clutch Adjusting Wrench 6V-4058 Universal Extension

SMCS Code: 1528-025 SMCS Code: 1500-010
Model: Caterpillar Engines Model: 3400

• Used for clutch adjustment on 3 5/8 inch bore starting engine • Needed on 3400 Series Truck Engines to remove and install bolts that hold
starter on engine;
on some engines, truck frame rails prevent easy access to starter
• 1/2 inch drive tool consists of 5/8 inch double hex socket on a 6 inch
extension

ID: B31772T1

ID: C79692T1

Engine Lifting and Positioning

6V-0097 Engine Rebuild Stand

SMCS Code: 1003-010, 1000-029, 1157-010, 1302-010, 3010-010, 3101-029, 3258-010, 4002-017
Model: All engine models from 3204 through D348 and 3412

• Designed to provide most efficient means for engine reconditioning NOTE: To mount D348 or 3412 Engine on earlier 6V-0097 Stands, it is
• Design permits dynamometer testing of engine on stand necessary to modify front supports to provide clearance for oil coolers. Also, to
mount 3208 Engines, right rear support must be modified to provide clearance
• Normally used with 9S-9081 Sling Assembly and 9S-9060 Dual Hook Hoist to
for starting motor. If these modifications are required, request the following
rotate engine during disassembly and assembly
drawings from Division Service Manager:
• Superior to former 9S-8500 Stand because of its rigid, one-piece construction
and polyurethane rather than steel wheels FT1513 — Modification for D348 or 3412 Engines
FT1530 — Modification for 3208 Engines
• Portable with use of 1P-0090 Dolly and channel construction allows handling
with lift truck with two sides
Length 1854 (73 in)
Reference Width 1016 (40 in)
SMHS7861 Special Instruction
Height 610 (24 in)
Weight 272 Kg (600 lb.)

ID: B41151T1
Service Parts
Part No. Description Quantity
9S-8503 Screw Assembly 2
6V-2026 Wheel 2
3B-4629 Cotter Pin 4
0S-1587 Bolt 4
5P-8245 Washer 12
1A-1135 Bolt 2
ID: B31801-1T1 5P-8247 Washer 2
1H-1200 Pin 2
4B-4283 Washer 2

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Engine Lifting and Positioning Search Engine Tools

4C-9832 Large Engine Roll-Over Stand

SMCS Code: 1000-017; 0632
Model: 3508, 3512 and 3516 Engines

• Used for disassembly and assembly of 3508, 3512 and 3516 Engines • Engine can be positioned vertically in any of 4 positions by one person
• Self-contained hydraulic system without the need of overhead lifting equipment
• Air-driven hydraulic pump and hoses included • Complete 360° rotation of engine
• Protective valve arrangement for positive rotational control • Each full cylinder stroke provides 90° of engine rotation
• Portable — heaviest component 190 lbs. • Pivot lock pin provides positive anti-rotational locking every 30°
• Does not need permanent mounting • Bolt-on feet allow engine stand members to stand alone during installation
or storage
• Does not need electrical power
• Low enough to be installed on engine resting on its oil pan on floor
• Enhances safety of large engine repair
• Additional brackets for other engines and off-highway front struts planned
• Minimizes engine handling time — improves work efficiency
for the future
• Adaptable for on-site marine engine repair
• Two 12-ton jacks included
• Stand-to-engine mounting bolts and brackets for 3500 Engines included

Capacity 20,000 lb.

Item Part No. Description

1 7X-0341 Bolt, 1/2 inch-13 THD x 177.8 mm (7 in)
2 8C-6857 Bolt, 3/4 inch-10 x 69.8 mm (2 3/4 in)
3 9U-5770 Mounting Bracket, 3500
4 6V-8182 Full Nut, 3/4 inch-10 THD
5 9U-5755 Outboard Tube Weldment
6 8T-9313 Bolt, 3/4 inch-10 THD x 177.8 mm (7 in)
7 9U-5753 Outboard Frame
8 9U-5754 Cylinder End Frame
9 1U-9754 Hydraulic Jack, 12 ton
10 9U-5775 Pin As.
11 9U-5760 Hydraulic Cylinder
12 9U-5772 Foot
13 9U-5779 Hydraulic Hose, 609.8 mm (24 in)
ID: C27042T1
14 5P-2228 Bolt, 1/2 inch-13 THD x 25.4 mm (1 in)
15 9U-5780 Hydraulic Hose, 990.6 mm (39 in)
16 9U-5773 Counterbalance Valve
Additional Service Parts (not shown)
17 9U-5774 Air/Hydraulic Pump
9U-5757 Jack Tube Weldment
18 9U-5778 Hydraulic Hose, 1828.8 mm (72 in)
9U-5758 Cylinder End Shaft Weldment
9U-5759 Outboard Shaft Weldment
9U-5761 Cylinder Mount Pin
9U-5762 Spacer
9U-5763 Spacer
9U-5764 Special Washer Reference
NEHS0566 Tool Operating Manual
9U-5767 Bearing Shield
8T-0238 Bearing Cone
6K-8328 Bearing Cup
9U-5776 Bolt, 5/8 inch-11 THD x 177.8 mm (7 in)
9U-5781 Cotterless HitchPin
9U-5782 Cotter Hitch Pin
9U-5783 Pin
NEEG2004 Decal
1P-2375 Quick Connect Coupler As., male
7X-0265 Bolt, 1/4 inch-20 THD x 69.8 mm (2.75 in)
5S-2201 Hex Socket Head Bolt, 5/8 inch-11 THD x 31.75 mm (1 1/4 in)
3D-8913 Elbow Pipe, 90°-30° NPSM-EXT
1P-2376 Quick Connect Coupler As, female
2K-3549 Roll Pin, 3/8 in x 101.6 mm (4 in)
1J-8136 Roll Pin, 3/8 in x 50.8 mm (2 in)
457012 Spring Pin

3-184 Dealer Service Tools 2004 Home

 Engine Tools Search Engine Lifting and Positioning

171-4660 Engine Stand Adapter Assembly 1U-6238 Mount Bracket Group

SMCS Code: 1000-017, 0700, 0701, 0705 SMCS Code: 1000-017, 0630
Model: 3408 and 3412 Model: D379, D398, D399, G379, G398, G399 Engines (6.25 Inch Bore)

• Used to mount engines to roll-over stand (does not require removal • Used to attach engines to 4C-9832 Large Engine Roll-Over Stand during
of front gear train) disassembly and assembly
• Used with 4C-9832 Large Engine Roll-Over Stand • Makes engine overhaul simpler and faster while providing a more convenient
• Front and rear plates are interchangeable workspace for mechanic
• Camshaft work must be done with front bracket removed • Two 1A-7669 Bolts and ten 1D-5499 Bolts included (attaches mounting
brackets to engine block)
• Flywheel housing and front gear housing must be removed
• Bolts meet or
• Works best as a short block tool
exceed SAE
Grade 8
1
2

ID: C79737T1 ID: C66720T1

Item Part No. Description Part No. Description Size Quantity
1 171-4660 Engine Stand Adapter Assembly 1A-7669 Bolt 1/2-13 thd. x 178 mm (7.0 in) 2
2 4F-0411 Bolt 1D-4599 Bolt 5/8-11 thd. x 178 mm (7.0 in) 10
3 5M-2894 Hard Washer Mounting Brackets

1U-7502 Repair Stand, Heavy-Duty, 2000 lb. 1U-9352 Engine Stand, 1000 lb.
SMCS Code: 0630 SMCS Code: 0630
Model: Engines within 2000 lbs. Model: Engines within 1000 lbs.

• Adjustable universal mounting arms (4) provide way to mount endless variety • Use for lift truck, car, and light truck engine service
of engines, transmissions, torque converters, rear axles, and other components • 4 adjustable attachment arms make engine mounting fast and easy
without using special adapters
• Engine can be rotated full 360° with turn of handle
• Gearbox allows full rotation of mounted unit for service with just a turn of the
• Locking pin secures work in any of 8 positions
crank — locks in position
• Both rear wheels lock tightly to anchor stand; 2 swivel casters
• Can be easily maneuvered from storage to work area
in front provide great mobility
• Locking rear wheels anchor stand at desired work locations
• Disassemble by removing only one bolt for easy transport
Capacity 2000 lbs.
Weight 280 lbs.

Capacity 1000 lbs.

Weight 100 lbs.

ID: C34501T1
ID: C07978T1
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Engine Lifting and Positioning Search Engine Tools

1U-5750 Diesel Engine Repair Stand, 6000 lbs.

SMCS Code: 0630
Model: Engines within 6000 lbs.

• 1U-5750 includes universal engine adapter assembly which permits use of engine mounting adapters
• Integral, 12-ton jack raises work to provide swing radius needed to turn work
• Turning even a 3-ton diesel 360° is easy — a 96 to 1 ratio worm and gear set does the job easily
• Crank handle can be locked in any position
• 2 front wheels and 2 rear casters permit easy mobility; floor locks anchor 1U-5750 in place
• Required floor space: 48 inch W x 55.5 inch L
• Weight: 698 lbs.

Engine Adapter Plates for 1U-5750

• Order only adapters needed for engines being worked on; universal adapter assembly required
for mounting all but John Deere adapters to stand
• Warranty: Manufacturer’s

NOTE: Products are shipped F.O.B. Searcy, Arkansas. Each Engine mounting plate includes
all the necessary hardware and an engine application chart.

ID: C27015T1
Reference
Tool Guide, Lifting, Blocking and Clamping Section

ID: C27014T1

Item Part No. Description

1 1U-7517 1 For International Harvester engines; DT-466 in-line 6 cyl., DV-550, MV-404,
MV-446, V304, V345, V392, 4-152, 4-196, 4-194, 9.0 liter V8 and the 6.9l (Ford).
Wt., 62 lbs.
2 1U-7510 1 For Cummins engines: All NH, NTC and NTE 855 Series in-line 6 cyl; 378 Series
V6; 504, 555 and 903 Series V8; KT 1150 Series in-line 6 cyl., L10. Wt., 41 lbs.
3 1U-7513 1 For Mack engines: V8 1000 and 1980 thru current 672 in-line 6 cyl. and 477
Scania series. Note: No. 206629 supersedes No. 205100. Wt., 32 lbs.
4 1U-5749 1 For Caterpillar engines; Nos. 1673, 1674, 1693, 3304, 3306 and 3406 in-line 6 cyl.;
Nos. 1100 and 3208 V8; No. 3408 V8. Wt., 68 lbs.
5 1U-7511 1 For Mack engines: All 672, 673, 675 and 711 Series in-line 6 cyl. Wt., 49 lbs.
6 1U-7518 1 Allison transmission mounting plate, for use with 1750-A engine stand.
Handles Allison transmission Nos. AT500, MT600, MT 6 speed, VH, VS and
V730. Wt., 25 lbs. ID: C07979T1
7 1U-7508 Universal adapter plate assembly. Included with 1U-5750. (Must be used with
all plates below except John Deere plates.) Wt., 114 lbs.
8 1U-7509 1 For Detroit engines: 53 Series in-line 6 cyl., 6V and 8V; 71 Series in-line 6 cyl.,
6V, 8V and 12V; 92 Series 6V and 8V; 8.2 liter V-8. Wt., 58 lbs.
Not shown 9U-5161 For Caterpillar Engines: 1.1 and 1.7.
1 Must be used with 1U-7508 Universal Adapter Plate Assembly

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206-0030 Foot Plate

SMCS Code: 1000-017, 0701
Model: 1U-5750 Rollover Stand

• Used to provide a place for operator to stand and/or a place for tools or parts
• Used with 1U-5750 Engine Repair Stand
• Enhances usability of rollover stand
• Specially shaped to fill in space between hydraulic jack and end post
• Coated with anti-skid material and painted with high visibility yellow paint
• Steel construction 9.5 mm (.38 in) thick

ID: C80511T1

Installation Instructions
1. Installs without disassembling rollover stand
2. Parking brake pins must be unscrewed and reinstalled when positioning plate

ID: C80506T1

173-5533 Repair Bracket Assembly

SMCS Code: 1000-017, 0630
Model: C-9 Engine
Essential Tool

• Used to mount C-9 Engine on 1U-5750 Diesel Engine Repair Stand

• Using this bracket allows engine to be rotated 360 degrees
• Attaches in place of crankcase breather cover (breather cover must first be removed)

ID: C80537T1

180-2877 Adapter Group

SMCS Code: 1000-017, 0700, 0705
Model: MY2000 C-15 and C-16 Engines and 3406E Engines

• Used to mount MY2000 C-15 and C-16 “Weight-Reduced” engines onto 1U-5750 Engine Repair Stand Engine repair stand capacity 2721.6 kg (6000 lbs)
• Allows 360 degree rotation of engine
• Attachment location minimizes number of components that must be removed
• Also fits 3406E Engines at the same attachment location
1
2
Application Procedure 3
1. Remove filter assembly from inlet manifold side of engine.
2. Install 180-2874 Special Studs into two 3/4 inch threaded holes below 4
head gasket joint.
3. Install 180-2873 Special Studs into two 3/4 inch threaded holes midway
down cylinder block. 6
4. Screw studs in as far as possible (some may bottom-out before stud Item Part No. Description
shoulder contacts cylinder block). 1 180-2876 Plate
5. Install 180-2875 Spacer Assembly, 180-2876 Plate, and 5P-8248 Hard 5 2 2J-3506 Full Nut
Washers. ID: C79866T1 3 5P-8248 Hard Washer
6. Securely tighten 2J-3506 Full Nuts. 4 180-2875 Spacer Assembly

7. Attach 180-2876 Plate to head of 1U-5750 Engine Repair Stand. 5 205-9315 Special Stud (long)
6 205-9314 Special Stud (short)

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Engine Lifting and Positioning Search Engine Tools

179-9561 Mounting Bracket Group

SMCS Code: 3050-017, 0630
Model: 950F Wheel Loader
4
3
• Used to mount transmission on 1U-5750 Engine Repair Stand
• Used with three 8L-3745 Socket Head Cap Screws to mount bracket to engine repair stand
1
• Used with four 1D-4622 Bolts to mount transmission to bracket
• Eyebolt allows bracket to be lifted in place with a hoist
• Provides safe handling of transmission during disassembly, maintenance, and assembly
• Allows 360 degree rotation for easy access and repair 2

Engine repair stand capacity 2721.6 kg (6000 lbs)

ID: C79867T1
Item Part No. Description Thread Length
1 179-9561 Mounting Bracket Group
2 1D-4622 Bolt 3/4-10 203 mm (8.0 in)
3 3L-9168 Eye Bolt
4 8L-3745 Socket Head Cap Screw 1-8 127 mm (5.0 in)

179-9562 Mount Bracket Assembly 1

SMCS Code: 3030-017, 0630
Model: 924 Wheel Loader
2

• Used to mount transmission on 1U-5750 Engine Repair Stand

• Used with three 8L-3745 Socket Head Cap Screws to mount bracket to engine repair stand 3
• Used with four 8C-3413 Socket Head Cap Screws to mount transmission to bracket
• Provides safe handling of transmission during disassembly, maintenance, and assembly
• Allows 360 degree rotation for easy access and repair

Engine repair stand capacity 2721.6 kg (6000 lbs)

ID: C79868T1
Item Part No. Description Thread Length
1 179-9562 Mount Bracket Assembly
2 8L-3745 Socket Head Cap Screw 1-8 127 mm (5.0 in)
3 8C-3413 Socket Head Cap Screw M12 x 1.75 120 mm (4.8 in)

6V-7762 Dual Hook Hoist

SMCS Code: 0633
Model: Engines within weight range of 1800 kg to 3600 kg (4000 lb to 8000 lb)

• Provides necessary capacity to handle larger engines when used with conversion group and correct accessories
• Replaces 9S-9060 Dual Hook Hoist, 9S-9090 Eye Assembly, and 9S-9081 Sling Assembly
• FT1778 Rollover Hoist Cart can be fabricated to transport 6V-7762 Hoist from one shop area to another
• 6V-7778 Bracket Assembly and 6V-7779 Sling Assembly are accessories with 3632 kg (8000 lb) capacities

Reference
SMHS8279 Special Instruction

Item Part No. Description

1 6V-7762 Dual Hook Hoist, 1800 kg (4000 lb) capacity
ID: B60986-1T1
2 FT1778 Rollover Hoist Cart
3 9S-9081 Sling Assembly, 1800 kg (4000 lb) capacity
6V-7779 Sling Assembly, 3600 kg (8000 lb) capacity
4 9S-9077 Spacer, 25,4 (1.00 in) (four)
5 9S-9076 Spacer, 50,8 (2.00 in) (four)
6 6V-7778 Rollover Bracket Assembly (four)

3-188 Dealer Service Tools 2004 Home

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9U-7847 Bolt
SMCS Code: 1000-017, 701
Model: 3046 Diesel Engine

• Used to fasten 3046 Engine to engine stand for disassembly and assembly (four bolts required)
• Used with 1U-9352 Engine Stand ID: C66703T1

• Provides a source for this special hard-to-find bolt (most common fine-threaded bolts are not long enough)
• Size: M10 x 1.25 x 90 mm (3.5 in)
• Metric bolt class (grade): 10.9 Reference
SENR6458 Special Instruction, Disassembly and Assembly of 3046 Engines

1U-8763 Lifting Bracket Assembly

SMCS Code: 1000-710, 0632
Model: 3046, 3054, 3056, 3114 and 3116

• Used to remove and install Caterpillar small engines on all backhoe loaders • Seven to eight times faster than conventional methods — remove/install in
• Adjustable lifting bracket has traversing lifting eye to angle the load for as little as 30 to 40 minutes after severing engine connections
easier removal and installation • Reduces damage — considerable damage to lines and tubing can occur
• Offset traverse beam clears chassis box beam over rear of engine and also unless a carefully controlled angling device is used
clears the cab — not necessary to remove cab to remove or install engines • Will handle weight load of engine with transmissions attached
• Saves considerable time — without bracket, removal time is approximately [approximately 908 kg (2000 lbs.)].
four hours and an additional four hours to install • Can be used in other applications where critical load angulation is required.

Reference Maximum load capacity 1816 kg (4000 lbs.)

Service Magazine Article 5/23/88, page 17 Span adjustment for 3114, 3054 and Perkins Engines 584 mm (23.0 in)
Maximum span adjustment (adapts readily to 3116 Engine) 838 mm (33.0 in)
Item Part No. Description
1 4K-0367 Nut
2 0S-1625 Bolt
3 4D-3704 Washer
4 5P-8245 Washer
5 1A-5822 Bolt
6 1K-6872 Lock Nut
7 1U-8762 Hook
8 5P-0370 Lock Pin
9 8T-4223 Washer
ID: C66657T1

8F-2550 Engine Tilting Group

SMCS Code: 1202-010
Model: D364, D375, D379, G379, D386, D397, D398, G398, D399, G399

• Used to remove and install crankshafts; refer to charts

(many parts are part of 8F-2250 Engine Tilting Group)

Item Part No. Description Quantity

1 8F-4228 Hinge Yoke 4
2 0L-1178 Bolt 4 ID: D00996T1
3 8F-4235 Plate 2 Item Part No. Description Quantity
4 8F-4233 Hinge Block 4 14 8F-4226 Yoke 8
5 1D-4616 Bolt 4 15 8F-4231 Lower Stud 4
6 Spacer 16 Turn Buckle 4
7 Upper Stud 4 17 8F-4230 Upper Stud 4
8 8F-4225 Bolt 4 18 1B-4334 Nut 8
9 8F-4234 Upper Hinge Block 4 19 6F-7058 Pivot Bracket Nut 4
10 8F-4227 Hinge Yoke 4 Not Shown
11 5B-9385 Bolt 12 3B-4618 Cotter Pin 32
12 5F-9892 Pin 16 0S-0107 Washer 12
13 8F-4239 Hinge Block 4 1B-4209 Nut — Used as lock under plate 2

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Engine Lifting and Positioning Search Engine Tools

No.Req’d No.Req’d No.Req’d

D399 D398 D379 Length Thread
Part No G399 G398 G379 Description mm (inch) Ends
FT0733-2 3 2 2 Stud 203,2 (8.00) R.H.
FT0111 3 2 2 Stud 254,0 (10.00) R.H.
FT0111-A 3 2 2 Stud 520,7 (20.5) R.H.
FT0733-10 3 2 2 Stud 596,9 (23.5) R.H.
FT0733-1 3 2 2 Stud 152,4 (6.00) R.H. & L.H.
FT0733-5 3 2 2 Stud 292,1 (11.5) R.H. & L.H.
FT0733-7 3 2 2 Stud 469,9 (18.5) R.H. & L.H.
FT0733-9 3 2 2 Stud 546,1 (21.5) R.H. & L.H.

No.Req’d No.Req’d No.Req’d No.Req’d No.Req’d No.Req’d

D399 D398 D379 D399 D398 D379
Part No G399 G398 G379 Description Part No G399 G398 G379 Description
8F-4239 1 12 8 8 Block 0L-1178 1 6 4 4 Bolt, 3/4-2 inch long
5B-1181 1 6 4 4 Turnbuckle 8F-4233 1 6 4 4 Hinge Block
8F-4230 1 6 4 4 Stud, 368, 4B-4281 2 2 2 Washer
3 mm (1 1/4 in-14.5 in) 9B-5677 2 2 2 Eyebolt, 5/8 inch
long
1
1D-4720 2 2 2 Nut, 5/8 inch
8F-4231 6 4 4 Stud, 228,
6 mm (1 1/4 in-9 in) long FT0731 1 Support Beam, L.H.
1B-4334 1 12 8 8 Nut, 1 1/4 in FT0735 1 Support Beam, R.H.
8F-4226 1 12 8 8 Yoke FT0734 6 4 4 Support Beam
0S-1587 18 12 12 Bolt, 1/2 in-1 3/4 in long FT0736 6 4 4 Support Bracket
5F-9892 1 30 20 20 Pin FT0732 2 2 2 Lifting Channel
3B-4618 1 60 40 40 Cotter Pin FT0113A 1 1 Support Beam
1D-4609 12 8 8 Bolt, 3/4-3 inch long FT0113 1 1 Support Beam
1A-5964 12 8 8 Bolt, 3/8-4.5 inch long 8F-4423 2 2 2 Flywheel Lifting Bracket
1D-4717 12 8 8 Nut, 3/8 inch 2 2 Guide Pin, 254 mm
(7/8-NF) long
6V-6546 6 4 4 Bolt, 1/2-13.5 inch long
2 Guide Pin 254 mm
8F-4225 1 6 4 4 Bolt, 3/4-10 inch long (1 inch-NF, 10 inch) long
8F-4228 6 4 4 Hinge Yoke 2 2 2 Small Hoist
1 Part of the 8F-2550 Engine Tilting Group

Motor Grader Rear Engine Support Groups

SMCS Code: 0632
Model: All G-Series Motor Grader Engines
Warranty: Model Serial Number Tool Group
12G 61M-12027 & Up A
• Used to service all G-Series Motor Grader engines 3WC1067 & Up A

• Allow removal of motor grader transmission without removing engine 14G 96U-7046 & Up D
3L193 & Up D
• Saves about 4 hours of labor
16G 93U-2679 & Up E
• Motor grader model serial number listed in chart coincides with release of load sensing hydraulic systems,
120G 87V-8360 & Up C
threaded gland hydraulic cylinders, and corporate electrical systems 11W-1251 & Up C
• Contain 2 support assemblies which bolt to both sides of flywheel housing to support engine; forcing bolt 61W591 & Up C
and lock nut properly position support assembly, which is attached to rear of engine, against top surface 2AB62 & Up C
of motor grader frame 130B 74V-2321 & Up B
12W-1082 & Up B
Engine Support Group D (Use 3 washers between support 59K82 & Up B
assembly and flywheel housing at each 7K-4370 bolt.) Part No. Description Quantity 140G 72V-10334 & Up A
2P-8913 Support Assembly 2 13W741 & Up A
Engine Support Group A 50H-1261 & Up A
1D-5118 Jam Nut 2 4N-7862 Support Assembly, Right 1 160G 4JD141 & Up A
8H-6508 Forcing Bolt 2 4N-7864 Support Assembly, Left 1
7K-4370 Bolt 4 1D-5118 Jam Nut 2
4B-5275 Washer 12 8H-6508 Forcing Bolt 2
Engine Support Group E (Use shims as required between 0S-1595 Bolt 8
support assembly and flywheel housing at both support
locations.) 4B-4280 Washer 8 Part No. Description Quantity
4N-7358 Support Assembly 2 Engine Support Group B Engine Support Group C
1D-5119 Jam Nut 2 6N-6689 Support Assembly 2 3P-0132 Support Assembly 2
4B-6208 Forcing Bolt 8 1D-5118 Jam Nut 2 1D-5118 Jam Nut 2
8S-9092 Bolt 4 8H-6508 Forcing Bolt 2 8H-6508 Forcing Bolt 2
4N-6063 Shim 12 7B-3235 Bolt 4 0S-1595 Bolt 4

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3600 Engine Tools

8T-9209 Turbocharger Blocking Tool

SMCS Code: 1052-078, 1053-078, 0702-078
Model: 3600 Engines

• Prevents rotation of turbocharger impeller (allows emergency engine operation at reduced power)
• When rotation of turbocharger is prevented, air flow through turbo is maintained and lubricating oil flow
must be stopped. (For procedure to stop lubricating oil, refer to Special Instruction SEHS8704.) The output
power of the engine must then be limited so exhaust gas temperature at cylinders does not exceed
480°C (900°F).
• To stop rotation, disconnect air inlet; install key (3)
Item Part No. Description
into impeller bushing; secure with plate (4)
1 0S-1595 Bolt1, 1/2-13 x 1-1/4 inch (Qty 4)
2 0S-1593 Lock Washer1 (Qty 4)
3 Key
ID: C54484T1
4 Plate
1 Items are not part of 8T-9209

137-7024 Turbocharger Wash Group

SMCS Code: 1052-074
Model: 3600 Engines

• Used to remove deposits which form on the diffuser and turbine blades when an engine
is operated on heavy fuels
• Washer provides cleaner turbines resulting in increased performance of turbocharger
• Use only with fresh, clean water (additives, solvents, salt, and dirt in water tend to form
deposits on diffuser and turbine blades)

3 2 6 7
Item Part No. Description
1 130-3298 Flow Meter
ID: C54979T1
2 130-3299 Screen
3 130-3300 Regulating Valve
4 130-3301 Needle Valve
5 130-3295 Quick Disconnect Nipple
6 130-3296 Quick Disconnect Nipple
4 1 5 7 130-3297 Quick Disconnect Coupler

ID: C78595T1

4C-8769 Valve Seat Driver

SMCS Code: 1103-012, 1100-017, 1103-010
Model: 3600 Engines

• Used to install water-cooled valve seat inserts

• Serves as guide and driver, helping to prevent insert damage during installation
and ensuring insert is uniformly installed in cylinder head
• Overall length: 355 mm (14.0 in )
• Diameter of knurl handle: 65 mm (2.5 in )

ID: C44366T1

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200-5958 Wear Sleeve Installer

Installation
121-7705 Stud Assembly 1. Install wear sleeve in installer.

121-7700 Distorter Block 2. Thread four studs into crankshaft.

SMCS Code: 7558-010, 0701 3. Install sleeve and installer onto studs.
Model: 3600 Engines 4. Install washers and nuts.
Warranty: One Year
5. Tighten nuts to pull wear sleeve onto crankshaft.
• Used to remove and install crankshaft wear sleeve — essential to correctly 6. When inside face of installer bottoms against end of crankshaft, sleeve is
remove and install sleeve without damage to sleeve or crankshaft installed to correct depth.

Removal Reference
• Use the 121-7700 Distorter Block with 5P-7409 Distorter SENR3594 Service Manual Module, Disassembly and Assembly
• Distorter block bolts directly to engine housing using one of the cover
mounting holes and bolt
121-7705 Stud Assembly
• Tools work together to make an indentation in the sleeve (helps to loosen
sleeve from crankshaft) Threads on large end 1 1/8-12

• Distorter tool is rotated between distorter block and wear sleeve to create an Threads on small end 1/2-13
indentation in the metal (similar to using a hammer and chisel to make the
indentation)
• Making four indentations around the crankshaft wear sleeve should allow
sleeve to easily slide off crankshaft
Part No. Description
1 121-7705 Stud Assembly
2 1F-7958 Full Nut
3 5P-8245 Washer
4 200-5958 Wear Sleeve Installer
5 5P-7409 Distorter
6 121-7700 Distorter Block
ID: C66839T1

4C-6593 Valve Lash Tool

SMCS Code: 1105-036, 1100-036, 1000-035, 1105-081
Model: 3600 Engines

• Used to easily check and adjust valve lash clearance of intake and exhaust valve
• Part of 4C-6594 Timing and Fuel Setting Tool Group
• Used with 6V-3075 Dial Indicator and 8S-3675 Contact Point (parts of 4C-6594 Tool Group);
both can be secured in valve lash tool by tightening nylon thumb screw
• 4-3/8 inch fabricated steel bracket with:
- 1/4-24 plastic thumb screw to hold a dial indicator in place
- 3/8-16 bolt with 1-1/2 inch diameter knurled knob for ease of installing to valve
rocker cover base
ID: C27013T1

4C-6585 Cylinder Pressure Measuring Indicator Group, 3000 PSI

SMCS Code: 1223-035, 1223-030, 1223-082, 1223-081, 1000-035, 1000-030, 1000-082, 1000-081
Model: 3600 Engines
Warranty: Manufacturer’s

• Troubleshooting tool used to check cylinder pressure on 3600 Family Diesel Engines
• Easily provides relative average peak cylinder pressure on running engine
• Not recommended for use on other than diesel engines because static pressure
indication would require too much tapping to bring pointer to correct reading
• Used with 7E-1699 Manual Valve Group designed so any movement of valve stem
due to engine vibration tightens valve stem against its seat; prevents valve from
accidentally opening during engine operation
• K-107 cylinder pressure indicator manufactured by Kiene Diesel Accessories, Inc.
Repair and Service
Kiene Diesel Accessories, Inc.
• Equipped with 3-1/2 inch Zytel nylon Bezel and case, threaded Bezel, Bourdon tube 325 So. Fairbanks Street
gauge, dual range 0-3000 PSI and 0-210 Kg/cm2, metal case and service tool Addison, IL 60101
• Kiene AX-13A standard indicator connection (M) by 1-1/16-10 Whitworth (F), ID: C54482T1
Phone: 708-543-5950
wing nut and plug, 45° bend, 6 inch long
Fax: 708-543-5953

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4C-6987 Socket 184-3131 Cylinder Head Stud Socket

SMCS Code: 1100-010; 0703
Model: All 3600 Engines except 3618
Assembly
SMCS Code: 1100-010
Model: 3618 Engines
• Used for removal and installation of cylinder head nuts
• Saves time by installing nuts prior to use of tensioners and removing nuts • Used to quickly remove and install cylinder head nuts
after releasing torque after tensioning is released
• Used with hydraulic stud tensioners of • Also known as a “nut spinner”
4C-5858 Tool Group
• Maximum torque: 340 N·m (250 lb ft)

ID: C79651T1

ID: C80002T1

4C-9839 Safety Retainer Group

SMCS Code: 1100-017; 0703
Model: 3600 Engines

• Used for disassembly and assembly of cylinder head assembly

• Steel strap safety retainer for pulling rod in case pulling rod accidentally breaks
• Fits around 5P-5247 Hydraulic Puller Assembly (fastened to bottom with 2 screws)
• If the pulling rod accidentally breaks and the retainer becomes deformed, the retainer should be replaced.
• Dimensions: 1/8 inch thick x 1-3/4 inch wide x 290 mm (11.4 in) long (Length allows full stroke of
5P-5247 Puller Assembly)
Item Part No. Description Quantity
ID: C27022T1
1 2M-5139 Screw 2

130-6993 Injector Seat Cleaning Brush

SMCS Code: 1100-070
Model: 3600 Engines

• Used to clean injector bore seats (also part of 9U-5106 Diesel Tool Group)
• Used with 1/4 inch drive drill Overall length 318 mm (12.5 in)
• Made of stainless steel — provides best cleaning results without causing damage ID: C66924T1 Brush diameter 47.6 mm (1.88 in)
to injector bore seat (other brushes may not have the stiffness to clean or be too stiff Wire diameter 0.25 mm (.010 in)
and cause damage)

130-2534 Bridge Dowel Gauge

SMCS Code: 1100-082
Model: 3600 Engines

• Used to check straightness and projection of 4W-5441 Bridge Guide Dowel

• Bridge dowels that are not straight will not go through gauge and must be replaced
(fast and easy method of determining reusability)
• Also used to check projection of dowel above cylinder head
• Gauge quickly and accurately measures 105 ± 2 mm (4.1 ± .08 in) height requirement
for bridge guide dowels
• Inside diameter: 19.09 mm (.752 in)

ID: C66798T1

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Valve Guide Gauges

SMCS Code: 1104-082, 0763
Model: 3600 Engines

• Used to check wear and correct installation of valve guide

• 9U-6401 Gauge quickly gives “use again” or “do not use again” status of valve guides ID: C55198T1
• 9U-6399 Gauge used to check newly installed valve guides (passing gauge through valve
guide determines straightness (deformation) of inside diameter and shows if an area is
below minimum diameter)
Part No. Description Diameter (Go) Diameter (No-Go)
9U-6401 Valve Guide Gauge 16.106 mm (.6340 in) x 50.8 mm (2.00 in) long 16.209 mm (.6381 in) x 50.8 mm (2.00 in) long
9U-6399 Valve Guide Gauge 16.003 mm (.6300 in) x 175 mm (6.9 in) long 16.059 mm (.6322 in) x 50.8 mm (2.00 in) long

4C-2980 Valve Projection Group

SMCS Code: 1103-081, 0763
Model: 3600 Engines

• Used to clearly and accurately measure the amount of valve recession on the 3600 Engine (diesel and gas)
• Used with 1U-8869 Dial Indicator
• Allows accurate documentation of valve recession to determine the appropriate time to service the cylinder head

Service parts
Item Part No. Description Quantity
1 1U-8869 Dial Indicator 1
2 9U-6272 Nylon Screw (part of 4C-2982 Collet Assembly) 1
3 4C-2982 Collet Assembly 1
4 4C-2979 Projection Gauge Block (3600) 1
5 5P-4160 Contact Point 1 ID: C66690T1
6 4C-2981 Valve Projection Base (3600) 1
Not shown 6V-3073 Case 1 Reference
Not shown 4C-2983 Foam Block Group 1 NEHS0617 Tool Operating Manual, 3600 Valve Projection Tools
Not shown NEEG2622 Decal 1

4C-6506 Vibration Damper Repair Group 4C-6507 Fill Gun

SMCS Code: 1205-044; 0714 Air pressure requirements 5 to 100 PSI
Model: 3600 Engines
Material All metal
4C-6508 Fill Tube
• Used to rebuild vibration dampers on all 3600 Family Engines Approved material General Electric silicone fluid No. 600000CS
• Correctly salvaged dampers can perform normally until next overhaul Fluid quantity 283 g
• Includes all tools for safe rebuild — saves time and money Diam. 50 mm
• Pneumatic fill gun saves time during silicon fluid injection and leaves operator’s hands free for O.A.L. 226 mm
other tasks; easy twist-lock loading; smooth uniform bead dispensing; no after-dripping Cartridge fitting 1/4-18 NPT
• Lifting brackets ensure damper properly lifted to best angle for filling
• Includes four 4C-6508 Silicone Fill Cartridges (Additional cartridges may be
necessary depending on damper size)
• 4C-6507 Fill Gun inludes 10 ft. air line with standard 1/4 inch fittings

Reference
SEBF8152 “Procedures to Rebuild Vibration Dampers on 3600 Family Engines” Item Part No. Description
1 4C-6507 Fill Gun
Repair and Service 2 4C-6508 Fill Tube
Repair parts for 4C-6507 Fill Gun available from:
3 6V-5049 O-Ring Seal
ELCO Industries, Inc. 4 5P-3238 Fitting
5110 Falcon Rd., P.O. Box 7009
Rockford, IL 61125-7009 5 8C-6866 Fitting
Telephone: 800-435-7213 6 6V-2156 Link Bracket

ID: C27040T1
3-194 Dealer Service Tools 2004
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Engine Tools Search 3600 Engine Tools

1U-9570 Dowel Puller Group

SMCS Code: 1000-015
Model: 3600 Engines
Item Part No. Description
1 1U-9568 Metal Box (not serviced)
• Used for pulling 5/8 inch and 3/4 inch dowels
2 1U-9569 Foam Block (not serviced)
• Makes the job quick and easy
3 8T-9413 Nut
4 1U-9571 Handle
Stand height 88.9 mm 5 1U-9574 Shaft
Shaft length 452.6 mm 6 1U-9575 Slide Hammer
Slide hammer weight 6 lbs. 7 1U-9573 Extractor, 3/4 inch
8 1U-9572 Extractor, 5/8 inch
9 1U-9576 Dowel Retriever Stand
10 1U-9577 Forcing Collar ID: C27060T1

229-3639 Overhaul Protection Kit

SMCS Code: 1000-017, 1225-010, 1100-010, 1216-010, 1214-010, 1213-010, 1239-010
Model: 3600 Engines

Service Parts
• Each kit contains enough plastic protective covers and plugs Part No. Description Quantity
for one cylinder 6P-6605 Plug, intake hole in block 1
• Easily installed and quickly removed 4C-9516 Protective Plug, water manifold in head 1
• Protect fuel lines and openings in cylinder head from dust and 7H-2902 Protective Plug, water jacket in block 4
dirt and serve as moisture seal while engine is overhauled 4C-9517 Protective Plug, injector hole in head 1
• 4 plastic web sleeves in each kit reduce impact damage to threads 4C-9518 Protective Plug, 3/16-16 thd, fuel lines 4
of cylinder head studs
4C-9519 Protective Cap, 3/16-16 thd, fuel line connectors on head and block 4
4C-9521 Protective Cap, 9/16-18 thd, oil line connectors in head and block 2
4C-9524 Protective Web Sleeve, threads on cylinder head studs 4
229-3608 Protective Plug, Cylinder Liner and Bore 2
229-3611 Rod Journal Cover 1

128-5113 Thread Repair Insert

SMCS Code: 1223-023
Model: 3600 Engines

• Replaces discontinued 4C-6409 Thread Repair Insert ID: C66729T1

Outside thread 2-12
• Used to repair stud holes with damaged threads (only one of four holes per head
can be repaired using this insert) Inside thread 1 5/8-12
• Install by drilling damaged hole to 1 59/64 inch and threading hole using a 2-12 tap Overall length 270 mm (10.6 in)
• Threaded repair insert is locked into place with 9S-3265 Retaining Compound Drill 4C-6415 Drill
Tap with pilot 4C-6417 Tap
Extension tap 4C-6416 Tap
Reference
SEBF8151 Guideline for Reuseable Parts

Ring Groove Gauges

SMCS Code: 1214-082, 0763
Model: 3600 Engines

• Used to check piston ring groove wear to determine Part No. Description
reuseability of piston
1U-9029 Ring Groove Gauge (oil ring)
• Simple to use (if gauge slides into groove and touches
1U-9030 Ring Groove Gauge (third ring)
the step, piston is not reusable)
4C-3654 Ring Groove Gauge (top and second ring)
• Three separate gauges (checks all four piston ring grooves)
Not Shown
• Gauges clearly marked with “top and second ring”,
“third ring”, and “oil ring” for easy identification 197-3710 Ring Groove Gauge (top and second ring), 3618 only
• Made from heat treated steel for better wear resistance
• Size (L x W): 75 mm (3.0 in) x 19 mm (.8 in)
ID: C66556T1
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133-1531 Threaded Insert

SMCS Code: 1052-023, 0676
Model: 3600 Engines with Turbochargers
Warranty: Manufacturer’s

• Used to repair stripped or damaged threads in turbocharger housings

• Used with 4C-9730 Tap and 8T-2793 Installation Tool
• Will withstand 540°C (1000°F) temperatures
• Thread specification: M10 x 1.5

ID: C66961T1

4C-6713 Spark Ignited Combination Tool Group

SMCS Code: 1000-017, 1000-036, 0701
Model: 3600 Series Spark Ignited Engines

The 4C-6713 Spark Ignited Combination Tool Group consists of 9U-5105 Basic • Install water pump seals
Tool Group and 9U-5107 Spark Ignited Tool Group. Both tool groups contain • Disassemble centrifugal oil filter
essential tools to test and adjust, remove and install, and disassemble and • Remove and install camshaft segment
assemble components of the 3600 Spark Ignited Engine. The 9U-5105 Basic Tool
Group can be used on either diesel or spark ignited 3600 Engines. • Drain fuel from fuel filter housing to remove filter element
• Drain oil and remove filter element from oil filter housings
The 4C-6713 Spark Ignited Combination Tool Group contains tools to:
• Protect crankshaft rod journal and align connecting rod assembly onto
• Remove and install cylinder liner, piston, and connecting rod as an assembly crankshaft during removal and installation of piston and rod assembly
• Remove and install vibration damper • Remove and install spark plugs
• Remove and install piston pin retainer (snap ring) • Rotate crankshaft
• Remove and install flywheel and rear gear assembly • Align piston pin during assembly of piston and connecting rod
• Remove and install crankshaft main bearings • Check and adjust valves
• Remove and install camshaft bearings 9U-5107 Spark Ignited Tool Group • Provide lifting eye bolts and link brackets necessary to service 3600 Family
• Remove and install cylinder head Part No. Description Spark Ignited Engines
• Remove and install piston rings 1U-8869 Digital Dial Indicator • Support piston and connecting rod assembly while removing and installing
• Remove and install rear idler gears 4C-4601 Spark Plug Socket rod bearing (cylinder head installed)
4C-6593 Adjusting Tool
Reference 4C-8568 Liner Puller Group
SENR4255 Service Manual 4C-8995 Ring Expander Group
SENR5500 Service Manual 4C-9043 Compressor Group
5P-4160 Contact Point
SEHS9599 Special Instructions
9U-5156 Cleaning Tool Group

4C-8568 Liner Puller Group (part of 9U-5107 Group)

Model: 3600 Spark Ignited Engines
SMCS Code: 1216-010, 1000-017, 0701

• Used to easily remove 300 mm (11.8 in) cylinder liners from block using
hydraulic pressure
• Used with 8T-3035 Lines Group, 8T-0820 Pressure Gauge, 3S-6224 Hydraulic Reference
Pump (115V 50/60 cycle), or 8S-8033 Hydraulic Pump (230V 50/60 cycle)
SENR4255 Service Manual
• Twenty-two tons of pulling force with two 5P-5247 Hydraulic Puller ID: C27033T1
Assemblies (included) SENR5500 Service Manual
• For ease of handling, hoist can be fastened to 4C-8568 Liner Puller Group

Item Part No. Description Quantity Item Part No. Description Quantity
1 8T-2835 Lifting Bracket 9 8T-2836 Nut 2
2 4C-8565 Top Ring 10 4B-5278 Washer 2
3 6V-7078 Bridge Support 2 11 6V-7077 Puller Leg 2
4 6V-7069 Rod Spacer 4 12 4D-3120 Bolt 8
5 4C-8566 Bottom Ring 13 4H-6996 Spring Pin 8
6 2J-5245 Hex Socket Head Bolt 6 14 6V-7076 Foot 2
7 5P-5247 Hydraulic Puller Assembly 2 Not shown 4B-5276 Washer 2
8 6V-7079 Bridge Not shown 1B-4331 Nut 2
Not shown 2K-6073 Bolt 4

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4C-8995 Ring Expander Group (part of 9U-5107 Group)

Model: 3600 Spark Ignited Engines
SMCS Code: 1215-010, 1000-017, 0701

• Used to remove and install piston rings without damage to rings or piston
• Designed to fit 300 mm (11.8 in) piston rings

ID: C27036T1

4C-9043 Piston Ring Compressor Group (part of 9U-5107 Group)

Model: 3600 Spark Ignited Engines
SMCS Code: 1215-010, 1000-017, 0701

• Used to install piston and connecting rod assemblies

• Band-type ring compressor for 300 mm (11.8 in) piston
• Over-center adjustable lock
• Proper seating of band assembly on cylinder liner to minimize possibility of ring breakage
• Four tabs for support while securing to piston
• Two handles for easier positioning of piston and rings

Reference Item Part No. Description

SENR4255 Service Manual 1 6V-4027 Handle Assembly
SENR5535 Service Manual ID: C27035T1

9U-5156 Cleaning Tool Group (part of 9U-5107 Group)

Model: 3600 Spark Ignited Engines
SMCS Code: 1106-070, 0680

• Used to clean prechamber seats on cylinder heads Item Part No. Description
• Used with 3/8 inch drive speed handle 1 150-5431 Pad Cut Down Disc
(easily removes rust with 10-20 turns of handle) ID: D00347T1
2 150-5483 EXL Unitized Roloc Disc
• Pilot helps to keep tool aligned Extension length 230 mm (9.0 in)
Major O.D. 78 mm (3.0 in)
Drive end 3/8 inch square (female)
Extension end 1/4-20 thread

9U-5105 Basic Tool Group

SMCS Code: 1000-017, 1000-036, 0701
Model: 3600 Engines

The 9U-5105 Group consists of the following The 9U-5105 Group consists of the following The 9U-5105 Group consists of the following
tools. Each is discussed separately. tools. Each is discussed separately. tools. Each is discussed separately.
Part No. Description Part No. Description Part No. Description
1F-7958 Nut 4C-9819 Universal Joint 9U-6251 Suspension Yoke Assembly
1P-7405 Eyebolt 5D-1972 Bolt (2) 9U-6461 Phoenix Screwdriver
1P-7407 Eyebolt 5P-7409 Sleeve Distorter 121-7700 Distorter Block
1P-7409 Eyebolt 5P-8245 Washer 121-7705 Stud Assembly
1U-8692 Piston Pin Guide 8T-0890 Puller Group 126-6918 Head Lifting Bracket
1U-9392 Damper Guide Pin (2) 8T-0914 Flywheel Guide Pin (2) 126-6919 Head Ligting Bracket
1U-9393 Damper Guide Pin (2) 8T-0960 Handling Tool Group 126-6920 Handle Rod
1U-9824 Oil Drain Tool Group 8T-0970 Camshaft Bearing Tool Group 134-0932 Main Bearing Driver
4C-6173 Fuel Drain Tray Assembly 8T-3022 Rod Guide Group 136-1452 Internal Pliers Assembly
4C-6357 Guide Group 8T-3029 Support Group 138-7573 Link Bracket (2)
235-0632 Cylinder Installation Tool Group 8T-3034 Water Pump Seal Driver 138-7574 Link Bracket (2)
4C-9426 Damper Guide Pin 9U-5932 Camshaft Torque Extension 138-7575 Link Bracket (2)
4C-9451 Idler Rear Wrench 9U-5981 Snap Ring Retainer 145-5190 Piston Support Group
4C-9452 Idler Rear Wrench 9U-6244 Support (2) 191-1135 Cylinder Space Assembly (2)
4C-9818 Hex Shank 9U-6248 Guide Bolt(3) 200-5958 Sleeve Installer

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Miscellaneous Tools
8T-3034 Water Pump Seal Driver (Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1361-016, 0708

• Used to seat ceramic ring and rubber seat into water pump housing (knurled handle for better grip)
• Also installs carbon seal onto pump shaft (pressed onto shaft until light contact with ceramic seal face is made)
• Length: 210 mm (8.3 in)
• Seal diameter: 63 mm (2.5 in)
Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual
ID: C55124T1

1U-9824 Oil Drain Tool Group (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1381-011, 0707

• Used to drain oil from filter housing (keeps engine clean, captures all used oil,
reduces cleanup cost)
• 9U-9822 and 9U-9821 Trays catch oil; 5N-5566 Hose routes it to a container
(trays attach to filter housing with four 9S-8752 Nuts)
• 1U-9823 Scoop provides convenient way to carry used filters to a disposal area
(filter is also too hot to handle without scoop)
• Allows filter replacement while engine is running
• Drain trays and scoop made from heavy-gauge sheet metal
• Scoop diameter: 203 mm (8.0 in)

Reference
ID: C55127T1
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual Item Part No. Description
SENR4259 Service Manual Module of SENR4255 Service Manual 1 1U-9823 Filter Scoop Assembly
2 9S-8752 Nut, Qty. 4 (not part of 1U-9824)
3 1U-9822 Tray Assembly, Upper
4 1U-9821 Tray Assembly, Lower
5 5N-5566 Hose (not part of 1U-9824)

4C-6173 Fuel Drain Tray Assembly (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1261-011, 0706

• Used to drain fuel from filter housing (keeps engine clean, captures all fuel,
reduces cleanup costs)
• 7V-0198 Hose and 4C-6173 Tray catches fuel; 5N-5566 Hose routes it to a container
(tray attaches to filter housing with two 4F-4879 Bolts)
• 1U-9823 Scoop, from 1U-9824 Oil Drain Tool Group, provides convenient way
to carry used filters to a disposal area
• Allows filter replacement while engine is running
• Drain tray made from heavy-gauge sheet metal with 25 mm (1.0 in) spout

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual
ID: C55128T1
SENR4259 Service Manual Module of SENR4255 Service Manual
Item Part No. Description
1 7V-0198 Hose (not part of 4C-6173)
2 4F-4879 Bolt, Qty. 2 (not part of 4C-6173)
3 4C-6173 Tray Assembly
4 5N-5566 Hose (not part of 4C-6173)

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4C-9451 and 4C-9452 Idler Gear Wrench (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1206-010, 0602

• Used to remove and install bolts on rear idler gear of 3612 and 3616 Engines
(accesses hard to reach bolts)
• Has 3/4 inch square-drive to connect torque wrench
• Torque extensions of 4 inch and 10 inch are etched on each wrench so correct
torque can be calculated (Refer to SEHS7150 Special Instruction for correct
torque wrench setting.)
• Two opposite L-shaped wrenches ID: C55129T1
12-point socket: 1 1/8 inch
Square-drive end: 3/4 inch Reference
SENR3594 Service Manual Module of SENR3590 Service Manual

9U-6461 Phoenix Screwdriver (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1408-079, 0604
Warranty: Manufacturer‘s

• Used to tighten Phoenix connectors to correct torque (prevents over-torque

and thus damage to terminals)
• Length: 180 mm (7.0 in)

ID: C54935T1

8T-0890 Puller Group (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1328-015, 0707
Bolt size and length 1/2-13 x 10.5 in
• Used to remove rotor cover from centrifugal oil filter (allows Nuts (3) 1/2-13 thread
replacement of 7C-8390 Rotor Liner) Bridge 35 x 40 x 169 mm (1.4 x 1.6 x 6.7 in)

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual

ID: C55126T1

Cylinder Head
8T-0960 Handling Tool Group (Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1203-010, 0632

• Used to raise and lower crankshaft main bearing cap and 207-5034 Stud Tension Tool Group
• 4C-8357 Tray Support Rail is installed in oil pan baffle holes and supports 8T-0872 Stud
Tensioner Tray (tray used as work table to support main bearing caps or stud tensioner
tooling before they are lifted into place)
• 8T-0947 Tee Handle is used as handhold to aid in alignment of 207-5034
• 8T-0956 Bracket Group is installed into crankcase access cover openings on each side
of engine (adjustment screws allow precise leveling of 207-5034)
ID: C55134T1
• Two 8T-0916 Pins connect this handling group to main bearing caps
(use 4K-0367 Nuts on pins)
• Most parts in the group are assembled with pins and spring clips
(clips prevent tooling from falling into oil pan)

Home Dealer Service Tools 2004 3-199

 3600 Engine Tools Search Engine Tools

Item Part No. Description

1 8T-0916 Pin
2 8T-0959 Hitch Pin
3 8T-0955 Tensioner Lift Tube Group
4 8T-0948 Lift Lever Group
5 8T-0872 Stud TensionerTray
6 8T-0961 Rail Retainer Bushing
7 4C-8357 Tray Support Rail
8 4K-0367 Full Nut
9 8T-0947 Tee Handle
10 1B-4430 Jam Nut
ID: C55135T1 11 8T-0946 Tension Lift Stud
Reference 12 8T-0963 Shaft
SENR3594 Service Manual Module of SENR3590 Service Manual 13 5P-0370 Lock Pin
SENR3600 Service Manual Module of SENR3595 Service Manual 14 8T-0956 Bracket Group
SENR4259 Service Manual Module of SENR4255 Service Manual 15 No longer available

8T-0820 Pressure Gauge (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1100-010, 1203-010, 0616

• Used to provide pressure reading of hydraulic pumps when used with 207-5034 Stud
Tensioner Group or 8T-0970 Cam Bearing Tool Group or 6V-7073 Liner Puller Group
or 4C-8568 Liner Puller Group
• Used with 3S-6224 Hydraulic Pump (115V) or 8S-8033 Hydraulic Pump (230V);
2N-1931 Fitting, 45° Street Ell can be used to make gauge face more visible
• Liquid-filled gauge has face calibrated with both kPa and PSI
Pressure range 0-70 000 kPa (0-10,000 PSI)
Reference Operating temperature -20°C to 65°C (-4°C to 150°F)
SENR3594 Service Manual Module of SENR3590 Service Manual
Male-threaded connection 1/4-18 NPTF
SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual Gauge diameter 102 mm (4.0 in)
ID: C55131T1

8T-3035 Lines Group (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1000-017, 0618

• Used to connect hydraulically operated tool to hydraulic pump—3S-6224 Hydraulic

6D-7726 Hose Assembly
Pump (115V) or 8S-8033 Hydraulic Pump (230V); used in the following applications:
remove and install cylinder head and crankshaft main bearings, camshaft bearings, Length 3480 mm (137.0 in)
and cylinder liners Maximum pressure rating 70 000 kPa (10,000 PSI)
• Used with 207-5034 Stud Tensioner Tool Group, 6V-7073 Liner Puller Group, Threaded connections (both ends) 1/4-18 NPTF
8T-0970 Camshaft Bearing Tool Group, 6V-7073 Liner Puller Group or 4C-8568 Liner Puller Group 1P-2375 Coupler Assembly (male)
Threaded connection 3/8-18 NPTF
Proof pressure 82 000 kPa (12,000 PSI)
Burst pressure 137 000 kPa (20,000 PSI)
1P-2376 Coupler Assembly (female)
Threaded connection 1/4-18 NPTF
Proof pressure 82 000 kPa (12,000 PSI)
Burst pressure 144 000 kPa (21,000 PSI)
8T-5206 Manifold
Number of ports 6
Threaded connection (female) 3/8-16 NPTF
Plug (3/8-18 NPTF) 3J-5390 Plug
Item Part No. Description
1 6D-7726 Hose Assembly
ID: C55132T1 2 3J-5390 Plug
Reference
3 8T-5206 Manifold SENR3594 Service Manual Module of SENR3590 Service Manual
4 1P-2375 Coupler Assembly (male)
SENR3600 Service Manual Module of SENR3595 Service Manual
5 1P-2376 Coupler Assembly (female)
SENR4259 Service Manual Module of SENR4255 Service Manual

3-200 Dealer Service Tools 2004 Home

Engine Tools Search 3600 Engine Tools

126-6918 Head Lifting Bracket (3600 Vee)

126-6919 Head Lifting Bracket (3600 In-line)
126-6920 Handle Rod (Part of 9U-5105 Group)
SMCS Code: 1100-010
Model: 3600 Engines

• Replaces discontinued 8T-2860 Head Lifting Bracket (3600)

• Used to remove and install heads on 3600 Engines — 126-6918 used for Vee engines
126-6919
and 126-6920 used for in-line engines
• Lifting bracket for Vee engines is designed with 25° angle (keeps bottom of head
parallel to 25° block angle)
• Attach lifting bracket bolt to head with two 5D-1972 Bolts (3/4 in-10 11 3/4 in) 126-6918
(Part of 9U-5105 Group) 126-6920
• Handle rod screws into either bracket and helps mechanic position head during assembly
ID: C66731T1
• Not shown: 5D-1972 Bolt (3/4 in-10 11 3/4 in) Working load limit for either lifting bracket 227 kg (500 lbs)

Crankshaft and Camshaft

8T-3029 Camshaft Segment Support Group (Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1210-010, 0635

• Used to support camshaft segments during removal and installation

[weight of camshaft segments 28 kg (62 lb)]
• Swivel assembly is adjustable for easier alignment of segment during installation
• 8T-3050 Bracket bolts directly into the bottom two bolt holes of camshaft cover
on 3606 and 3608 Engines
• 1U-6311 Cam Support Adapter allows the 8T-3050 to be mounted in bottom
two holes of camshaft covers on 3612, 3616 and 3618 Engines
(use two 3/8-16 bolts to attach 1U-6311 to 8T-3050) Item Part No. Description
1 8T-3049 Swivel Assembly
Reference 2 8T-3050 Bracket ID: C55136T1
SENR3594 Service Manual Manual Module of SENR3590 Service Manual
3 3/8-16 Bolt (not part of 8T-3029)
SENR3600 Service Manual Module of SENR3595 Service Manual 4 1U-6311 Camshaft Support Adapter
SENR4259 Service Manual Module of SENR4255 Service Manual 5 8T-3048 Lifting Bar

9U-5932 Camshaft Torque Extension (Part of 9U-5105 and 9U-5106 Groups)

SMCS Code: 1210-010, 0602
Model: 3600 Engines

• Used to remove and install bolts retaining thick-flange camshaft segments

• Designed with minimum clearance to fit onto the bolts (Conventional sockets
cannot reach the bolts.)
• Using the extension requires a calculation to determine the correct torque.
The extension uses a four inch lever arm. Use Form SEHS7150 to calculate
the proper torque wrench setting.

ID: C54907T1

Drive (square) 1/2 in

Socket (12 point) 15/16 in
Length of extension 100 mm (4.0 in)

Home Dealer Service Tools 2004 3-201

3600 Engine Tools Search Engine Tools

8T-0970 Camshaft Bearing Tool Group, 3600 Engines (Part of 9U-5105 Group)
156-7155 Camshaft Bearing Tool Group, 3618 Engines (Not Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1211-010, 0635

• Used to remove and install camshaft bearings (not possible by any other means)
• 8T-0968 Bridge will pilot in bearing bore on one side and when reversed, pilot in
cylinder block bearing bore on other side
• Used with 3S-6224 Hydraulic Pump (115 V) or 8S-8033 Hydraulic Pump (230 V);
other required tooling is 8T-3035 Lines Group and 8T-0820 Pressure Gauge

Cylinder
Capacity 180 kN (20 ton)
Stroke 76 mm (3.0 in)
ID: C55137T1
Maximum operating pressure 69 000 kPa (10,000 PSI)

Item Part No. Description Item Part No. Description

8T-0970 Camshaft Bearing Tool Group, 3600 Engines 156-7155 Camshaft Bearing Tool Group, 3618 Engines
1 6V-7047 Cylinder1 1 6V-7047 Cylinder1
2 8T-0969 Rod1 2 8T-0969 Rod1
3 8T-0968 Bridge 3 156-7157 Bridge
4 8T-0972 Pilot 4 156-7154 Pilot
5 8T-0971 Plate 5 156-7156 Plate
6 0L-1143 Bolt1 6 0L-1143 Bolt1
7 0S-1619 Bolt1 7 0S-1619 Bolt1
8 8T-0973 Insert1 8 8T-0973 Insert1
ID: C55138T1
1 Common to both groups

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual

134-0932 Main Bearing Driver (Part of 9U-5105 Group)

SMCS Code: 1203-010 Blade width 90 mm (3.54 in)
Model: 3600 Engines
Blade thickness 6.35 mm (.250 in)
Pin diameter 19.48 mm (.767 in)
• Used to remove and install crankshaft main bearings (older 6I-4528 Main Bearing Threaded puller hole in pin 8-32
and new 111-3378 Main Bearing) without removing crankshaft
• Bearings are easily removed by inserting tool into crankshaft journal lubrication
hole and rotating crankshaft clockwise to roll bearing out
• Will also roll in new bearings by rotating crankshaft in a counterclockwise direction
• Threaded hole in pin allows easy removal from oil passage if tool shears
(tool is designed to shear to prevent damage to crankshaft) Item Part No. Description
1 134-0932 Main Bearing Driver
2 8F-3469 Seal
Reference
SENR3594 Module of SENR3590
SENR3600 Module of SENR3595
SENR4259 Module of SENR4245
SENR5535 Module of SENR5500

ID: C66909T1

3-202 Dealer Service Tools 2004 Home

Engine Tools Search 3600 Engine Tools

Piston and Connecting Rod Assembly

145-5190 Piston Support Group, (Part of 9U-5105)
SMCS Code: 1219-010; 0635
Model: All 3600 Engines

• Used to safely support piston and connecting rod assembly on all 3600 Engines
when replacing connecting rod bearing
• Mounted in place of oil cooling jet with two 0S-1619 Bolts (after engine rotated
until piston at top dead center position)
• Lightweight aluminum for ease of installation
• Knurled for firm grip ID: C78550T1 Support capacity 102 Kg (225 lbs.)
• Not shown: 0S-1619 Bolts, 3/8-16 x 3 inch (2)

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual

8T-3022 Rod Guide Group (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1225-010, 0635

• Used to protect crankshaft bearing journal from damage

• Guides help align connecting rod onto crankshaft during installation
(held to connecting rod studs with 8T-2859 Nut)
• Both parts constructed from aluminum to help prevent scratching
of finished machined surfaces
• Guide dimensions: 163 x 109 x 32 mm (6.4 x 4.3 x 1.2 in)
• Knurled nut: 3/4-16 thread

Reference
SENR3600 Service Manual Module of SENR3595 Service Manual Item Part No. Description
ID: C55159T1
SENR4259 Service Manual Module of SENR4255 Service Manual 1 Guide (not serviced separately)
2 8T-2859 Nut

4C-6357 Guide Group (Part of 9U-5105 Group)

Model: 3612 and 3616 Engines
SMCS Code: 1225-010, 0714

• Used to protect crankshaft bearing journal from damage

• Guides help align connecting rod onto crankshaft during installation
(held to connecting rod studs with 8T-2859 Nut)
• Both parts constructed from aluminum to help prevent scratching
of finished machined surfaces
• Guide dimensions: 163 x 96.5 x 30.5 mm (6.4 x 3.8 x 1.2 in)
• Knurled nut: 3/4-16 thread

Reference Item Part No. Description

SENR3594 Service Manual Module of SENR3590 Service Manual 1 Guide (not serviced separately)
ID: C55160T1 2 8T-2859 Nut

1U-8692 Guide, Piston Pin (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1255-017, 0714

• Used to easily install piston pin into piston and rod assembly Reference
(pin is put onto guide which helps align piston and rod bores) SENR3594 Service Manual Module of
• Constructed of lightweight aluminum SENR3590 Service Manual
SENR3600 Service Manual Module of
Diameter 228 mm (9.0 in) SENR3595 Service Manual
Length 642 mm (25.3 in)
SENR4259 Service Manual Module of
Weight 7 kg (14.0 lb) SENR4255 Service Manual

Home
ID: C55161T1 Dealer Service Tools 2004 3-203
3600 Engine Tools Search Engine Tools

136-1452 Internal Pliers Assembly (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1225-017, 0603

• Used to remove and install piston pin retainer or snap ring (pliers have locking handles
for easier installation)
• Use with 9U-5981 Snap Ring Retainer to provide added protection if snap ring slips off pliers
• Replaceable tip makes pliers more economical
• Length: 40 cm (16 in)
• Service Part: 1U-6728 Tip Set Reference ID: C55162T1
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual

9U-5981 Snap Ring Retainer (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1225-017, 0714

• Used to contain piston pin retainer (snap ring)

• Used with 136-1452 Internal Pliers Assembly during disassembly and
assembly of piston and connecting rod
Handle 31.8 mm (1.25 in) square tubing
Reference Body diameter 42.9 mm (1.68 in)
SENR3594 Service Manual Module of SENR3590 Service Manual Body length 200 x 200 mm (7.8 x 7.8 in)
SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual

ID: C54503T1
Block
235-0632 Cylinder Installation Tool Group (Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1213-010, 0632

• Replaces discontinued 4C-9041 Cylinder Installation Tool Group

• Used to remove and install cylinder assembly, cylinder liner, and piston and
connecting rod assembly (provides convenient method of attaching a hoist)
• Piston and connecting rod assembly can be removed separately using
235-0612 Bracket, 9S-1366 Bolt, and 5P-1076 Washer
Item Part No. Description Quantity
Reference 1 1F-7958 Nut 2
SENR3594 Service Manual Module of SENR3590 Service Manual 2 9S-1366 Bolt 2
SENR3600 Service Manual Module of SENR3595 Service Manual 3 5P-1076 Washer 6
SENR4259 Service Manual Module of SENR4255 Service Manual 4 1U-7619 ID: C55163T1
Spacer 2
5 0V-0375 Bolt 2
6 4C-9040 Bracket 2
7 235-0612 Bracket Assembly 1

4C-9818 Shank-Hex (Part of 9U-5105 Group)

4C-9818 Hex Shank
4C-9819 Universal Joint (Part of 9U-5105 Group) Shank size 7/16 hex
Model: 3600 Engines
SMCS Code: 1202-018, 0601 Shank length 32 mm (1.3 in)
Drive end 1/2 inch square drive with lock button
Overall length 70 mm (2.8 in)
• Used to easily rotate crankshaft
4C-9819 Universal Joint
• Used with 213-3110 Socket, or similar part, and
1/2 inch drill (reversible variable speed drill works Outside diameter 30 mm (1.9 in)
best, but is not necessary) Overall length 63 mm (2.5 in)
Male drive end 1/2 inch square drive with lock button
Item Part No. Description Female drive end 1/2 inch square drive
1 213-3110 Socket, 1 1/8 in
2 4C-9819 Universal Joint
ID: C27051T1
3 4C-9818 Hex Shank

3-204 Dealer Service Tools 2004 Home

Engine Tools Search 3600 Engine Tools

191-1135 Cylinder Liner Spacer Assembly (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1216-012, 0705

• Used to install cylinder liner into block (using two will easily and evenly seat the liners)
• Steel tube designed to fit over head studs
• Used with two head-stud nuts, 4C-6987 Socket (184-3131 Socket for 3618 Engines)
and 214-7338 Ratchet (1/2 inch Drive)
• Length: 314.32 mm (12.375 in)
• Two required

ID: C54494T1

Vibration Damper and Flywheel

4C-9426 Damper Guide Pin (Part of 9U-5105 Group)
Model: 3600 Engines
SMCS Code: 1205-010, 0714

• Used to align and support vibration damper during assembly and disassembly
of 3606, 3608, and 3612 Engines (two required)
• Square-drive (1/2 in) socket for easy installation and removal
Diameter 25 mm (1.0 in)
Reference Length 152 mm (6.0 in)
SENR3594 Service Manual Module of SENR3590 Service Manual Thread 1-14 thread
SENR3600 Service Manual Module of SENR3595 Service Manual Weight 0.6 kg (1.30 lb)

SENR4259 Service Manual Module of SENR4255 Service Manual

ID: C55164T1

1U-9393 Damper Guide Pin (Part of 9U-5105 Group)

Model: 3600 Engines
SMCS Code: 1205-010, 0635

• Used to align and support single vibration dampers (two required)

• Square-drive (1/2 in) socket for easy installation and removal

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual Diameter 25 mm (1.0 in)

SENR4259 Service Manual Module of SENR4255 Service Manual Length 152 mm (6.0 in)
Thread 1-8 thread
ID:Weight
C55164T1 0.6 kg (1.30 lb)

1U-9392 Damper Guide Pin (Part of 9U-5105 Group) 8T-0914 Flywheel Guide Pin (Part of 9U-5105 Group)
Model: 3600 Engines Model: 3600 Engines
SMCS Code: 1205-010, 0635 SMCS Code: 1156-010, 0635

• Used to align and support outer vibration damper • Used to align and support flywheel and rear gear
of dual vibration dampers (two required) support assembly during installation and removal
• Square-drive (1/2 in) socket for easy (two required)
installation and removal • External square-drive (1/2 in) for
easy installation and removal

Diameter 28.4 mm (1.12 in) Diameter 28.4 mm (1.12 in)

Length 254 mm (10.0 in) Length 610 mm (24.0 in)
Thread 1 1/8-8 thread Thread 1 1/8-12 thread
Weight 1.3 kg (2.90 lb) Weight 3 kg (6.0 lb)
ID: C55165T1
Reference ID: C55166T1
SENR3594 Service Manual Module of SENR3590 Service Manual Reference
SENR3600 Service Manual Module of SENR3595 Service Manual SENR3594 Service Manual Module of SENR3590 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual SENR3600 Service Manual Module of SENR3595 Service Manual
SENR4259 Service Manual Module of SENR4255 Service Manual

Home Dealer Service Tools 2004 3-205

3600 Engine Tools Search Engine Tools

9U-5106 Diesel Tool Group

Model: 3600 Diesel Engines

Consist 6V-7073 Liner Puller Group (Part of 9U-5106 Group)

Part No. Description Model: 3600 Engines
6V-7073 Liner Puller Group
SMCS Code: 1216-011, 0705
8T-3033 Ring Expander Group
4C-6594 Timing Tool Group • Used to remove and install cylinder liner using hydraulic pressure (hoist attaches to puller to easily
1U-8795 Governor TorqueArm
handle tool and cylinder liner)
8T-3268 Bolt (2)
• Hydraulic pump connects to two 5P-5247 Hydraulic Puller Assemblies for a combined pulling force of
195 kN
4C-5719 Piston Ring Compression Group (22 ton)
9U-5932 Torque Extension • Used with 3S-6224 Hydraulic Pump (115 V) or 8S-8033 Hydraulic Pump (230 V); other required tooling is
130-6993 Injector Bore Brush 8T-3035 Lines Group and 8T-0820 Pressure Gauge
5P-0328 Crowfoot Wrench, 7/8 inch (Fuel Line)
5P-0329 Crowfoot Wrench, 15/16 inch (Fuel Line)

Item Part No. Description

1 5P-5247 Hydraulic Puller Assembly (two required)
1U-7618 Hardware Group (includes the following parts)
2 2J-5245 Bolt
3 6V-7074 Top Ring
4 8T-2835 Bracket
5 6V-7069 Spacer
6 6V-7079 Bridge
7 8T-2836 Nut
8 4B-5278 Washer
9 6V-7078 Support
10 6V-7075 Bottom Ring
11 6V-7077 Leg
12 4D-3120 Bolt
Reference 13 4H-6996 Pin
SENR3594 Service Manual Module of SENR3590 Service Manual
14 6V-7076 Foot
ID: C55167T1
SENR3600 Service Manual Module of SENR3595 Service Manual Not shown 1B-4331 Nut
Not shown 4B-5276 Bolt
Not shown 2K-6073 Bolt

8T-3268 Bolt (Part of 9U-5106 Group)

Model: 3600 Engines
SMCS Code: 1290-011, 0706

• Used to remove unit injector by evenly tightening two bolts at the same time

Reference
SENR3594 Service Manual Module of SENR3590 Service Manual
SENR3600 Service Manual Module of SENR3595 Service Manual
Overall length 139 mm (5.5 in)
Pilot diameter 6.0 mm (.24 in)
Pilot length 27 mm (1.1 in)
Thread 5/16-18

ID: C55168T1

3-206 Dealer Service Tools 2004 Home

Engine Tools Search 3600 Engine Tools

8T-3033 Ring Expander Group (Part of 9U-5106 Group)

Model: 3600 Engine
SMCS Code: 1215-010, 0714

• Used to easily remove and install piston rings

• Using incorrect tool can lead to broken or over stressed rings causing improper
fit inside the cylinder
Item Part No. Description
Reference
SENR3594 Service Manual Module of SENR3590 Service Manual 1 8T-3232 Ring
2 8T-3233 Handle Assembly
SENR3600 Service Manual Module of SENR3595 Service Manual

ID: C55169T1

4C-6594 Timing and Fuel Setting Tool Group (Part of 9U-5106 Group)
Model: 3600 Engines
SMCS Code: 1250-036, 0766

• Replaces discontinued 6V-6170 Timing and Fuel SettingTool Group

• Used to accurately test and adjust injector synchronization and fuel timing dimension
• 4C-6593 Valve Lash Tool is used to check and adjust valve lash clearance of intake
and exhaust valves using a dial indicator (used with 6V-3075 Dial Indicator and
8S-3675 Contact Point)
• 6V-3075 Dial Indicator has black numbers and markings for positive travel and red
markings for negative travel (1U-8869 is an optional digital indicator)

Reference
SENR3593 Service Manual Module ID: C55171T1
of SENR3590 Service Manual Item Part No. Description Item Part No. Description
1 6V-9058 Fixture Assembly 9 4C-8753 Extended Collet1
SENR3599 Service Manual Module
of SENR3595 Service Manual 2 6V-3075 Dial Indicator 10 5P-7276 Storage Container
3 1U-8869 Digital Indicator (optional) 11 6V-9057 Rack Synchronizing Gauge
SEHS9599 Special Instruction
4 6V-9056 Set Gauge Not shown 6V-7145 Case1
5 4C-6593 Valve Lash Adjusting Tool1 Not shown 4C-6595 Top Insert1
6 6V-7918 Wrench (2) Not shown 4C-6596 Bottom Insert1
7 8S-3675 Indicator Contact Point 1 Parts
used to upgrade a 6V-6170 to a 4C-6594 (also order
8 5P-7263 Indicator Contact Point an NEEG2491 Decal)

1U-8795 Governor Torque Arm (Part of 9U-5106 Group) 9U-5932 Camshaft Torque Extension
Model: 3600 Engines (Part of 9U-5105 and 9U-5106 Groups)
SMCS Code: 1700-036, 0766 SMCS Code: 1210-010, 0602
Model: 3600 Engines
• Holds governor or actuator terminal shaft to fuel “ON” position while injectors
are being adjusted • Used to remove and install bolts retaining thick-flange camshaft segments
• When torque arm is installed with weight in horizontal position, 18.6 N·m • Designed with minimum clearance to fit onto the bolts (Conventional sockets
(13.65 lb-ft) is applied to governor linkage cannot reach the bolts.)
• Shaft clearance hole • Using the extension requires a calculation to determine the correct torque.
diameter: The extension uses a four inch lever arm. Use Form SEHS7150 to calculate
16.3 mm (.64 in) the proper torque wrench setting.

Drive (square) 1/2 in

Reference ID: C54907T1
Socket (12 point) 15/16 in
SENR3594 ServiceID:Manual Module of SENR3590 Service Manual
C55125T1 Length of extension 100 mm (4.0 in)
SENR3600 Service Manual Module of SENR3595 Service Manual

Home Dealer Service Tools 2004 3-207

3600 Engine Tools Search Engine Tools

146-2727 G3600 Operator Tool Group 191-1135 Cylinder Liner Spacer Assembly
SMCS Code: 1000-036 SMCS Code: 1216-012
Model: G3600 Engines Model: All 3600 and G3600 Engines
Essential Tool

• Used to monitor engine performance and provide daily service on

an engine
• Used with 8T-9190 Bottle Group
• Tool group contains tools to: lubricate pivot joints of waste gate,
fuel mixing valve, and choke linkage; remove spark plugs and chase
threads; clean and gap spark plugs; take oil samples; troubleshoot
and record data from ECM
• Pad of data sheets is included with tool group to record all service • Used to install cylinder liner into cylinder head
information • Used with 4C-6987 Socket and two cylinder head
stud nuts
• Used with 184-3131 Socket for 3618 Engines
ID: C80052T1
• Steel tube fits over cylinder head studs
• Using two spacer assemblies will easily and evenly seat cylinder liners
• Overall length: 314.32 mm (12.375 in)

146-2726 Maintenance Tool Group

SMCS Code: 1000-017, 1000-036, 0701
Model: G3600 Engines

• Used to perform routine maintenance tasks on G3600 Engines

Item Part No. Description Use

3
1 6V-9124 Screwdriver Used for terminal strips 1
2 146-2739 Cylinder Pressure 2
Adapter Connects outside air pressure source to
RS-

cylinders on 3500 and 3600 Engines during HOLD

Tot
23
2 TR

al H UE RM
arm S MULT
onic IMET
cylinder leak down testing REC CMP
Dis ER

4
tort
REL
EDIT ion
%

DC/AC RANGE

3 9U-7330 Multimete Test and adjust electrical circuits 10

A
mV
v ˚C/˚F
HI/LO
TRIG

mA

4 148-2997 Valve Recession Measures valve seat recession by placing A

OFF
Hz

DU
TY

Tool Kit magnetic block on top of valve rotator with rod TE

MP

OFF
10

extending to top of cylinder head (used with

A
FU MA
SE X
D

40 14
A
0m 6-4

6V-3075 Dial Indicator or 1U-8869 Digital Indicator)

FU A MA
REM SE X MA
AC X 08
OVE D
DC 75
0V
0
IN mA 10
00
PU V
TS A
BE MAX
FO 60 TE
RE CO 0V MP
SW M

5 138-7573 Link Bracket Turbo lift bracket 5

IT
CH
IN
G V
RAN H
z
GES

6 146-2742 GAV Lash Tool Set gas admission valve (GAV) lash by installing
7
in valve cover base rear bolt hole and adjusting
5P-2056 Indicator Tip on gas admission rocker
arm flat (use with 147-5536 Indicator Contact
Point and 6V-3075 Indicator on gas admission 6
rocker arms with pin)
7 143-8995 Leak Down Tool Tests check valves in prechamber 11
8 9U-6244 Support Turbo support 8
9 4C-6593 Adjusting Tool Check and adjust valve lash 9 10
10 146-2728 Flex Pickup Tool Remove check valve seal
11 1P-0529 Handle Waste gate tool 12
12 9U-6248 Guide Bolt Install equally spaced bolts in outer ring of 14
holes in back of turbocharger compressor
housing during assembly 15 16
.01 25
.0
2

13 9U-7516 Spark Plug Gauge Check spark plug gap

MA
DE

13
IN
US

17
A

.01 1

14 9U-7511 Seat Cleaner Spark plug seat cleaner

.01
5

15 1P-0462 Drive Plate Waste gate tool

16 6L-5897 Bolt Waste gate tool
17 143-8997 Check Valve Checks leak down fixture (143-8995) before
testing check valves 18
18 4C-4601 Spark Plug Socket Remove and install spark plugs
19 9S-5031 Socket Removes combustion sensor spark plug
20 Carrying Case
Not Shown 1U-8860 Blowby Pickup Group Check blow by volume 19 20
Not Shown 8T-2700 Indicator Group Measures volume of blowby gas coming from ID: C78549T1
crankcase breather and air velocity through
radiator

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143-8995 Leak Down Check Tool 6

5
50
40 60

30 300 70
200 400

143-8997 Check Valve (Dummy)

20 80
100 500

3 4 10

0 kPa
PSI
600

100
90

SMCS Code: 1106-040, 0701 7

Model: G3606, G3608, G3612, and G3616 Engines
2

• Used to test prechamber check valves for leakage

A
• When 827 kPa (120 PSI air pressure is applied, pressure cannot leak down below
689 kPa (100 PSI) within five seconds
• Used with external compressed air supply, air pressure gauge with a maximum 1
1378 kPa (200 PSI capacity, and quick action shut-off valve
• 143-8997 Dummy Check Valve is used to verify that leak down check tool does Item Part No. Description
not have any leaks 1 143-8997 Dummy Check Valve
• A 2M-4453 O-Ring Seal is included with leak down check tool and is a service part ID: C78499T1 2 2M-4453 O-Ring Seal
• When connecting air supply, it must be as close as possible 3 143-8995 Leak Down Check Tool
[within 300 mm (12 in) max] to inlet side of air pressure gauge
4 Tube
• Maximum air pressure (pressure gauge): 1378 kPa (200 PSI)
5 Pressure gauge
• Maximum length between tool and leak down check valve: 304 mm (12.0 in)
6 Ball valve
7 Air supply
Reference A 305 mm (12.0 in) maximum length
NEHS0676 Tool Operating Manual

4C-6583 Governor Calibration Tool 9U-5102 Main Bearing Journal Cover

SMCS Code: 0766; 1264-025, 1264-036
Model: 3600 Locomotive Engine with PGEV Governor
Assembly
SMCS Code: 1202-075, 1202-022, 0663
Model: 3600 Engines
• Holds the governor shaft to the fuel “on” position when synchronizing injectors
• Makes it easier to rotate governor terminal shaft and easier to hold it in • Used to protect crankshaft bearing journals from impact damage during
position when adjusting power setting removal, installation, and transportation
• Has 2 dowels on one side to fit into 2 holes on governor shaft position indicator • Made from oil resistant rubber
• 12.7 mm (1/2 in) square drive connection on other • Spring and hook latching device makes attaching simple and easy
side for attaching socket wrench as lever arm
• Overall size (l x w):
830 x 120 mm (32.0 x 4.7 in)

ID: C54487T1

ID: C27062T1

147-2285 Diesel Valve Seat Group

SMCS Code: 1100-020, 0767
Model: 3600 Diesel Engines

1
• Used to measure valve seat angle after machining of seat
• Pilots in valve guide to ensure that seat is perpendicular to guide
• Features knurled handle for positive grip
• Lightly oiling tool before storage is recommended to prevent corrosion of precision machined surfaces
• Tool group includes case and foam insert 2

Item Part No. Description Seat Angle Overall Length Pilot Diameter
1 147-1642 Valve Seat Angle Gauge 30.5° 344.50 mm (13.56 in) 16.00 mm (.630 in)
2 147-1643 Valve Seat Angle Gauge 31° 344.50 mm (13.56 in) 16.00 mm (.630 in)
ID: C78527T1
Reference
Not shown 6V-3072 Protective Case SEBF8129 Guideline for Reusable Parts
Not shown 147-3660 Custom Foam Insert SEHS0095 Special Instruction

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3600 Engine Tools Search Engine Tools

207-5034 Stud Tensioner Tool Group

Model: 3600 Engines
SMCS Code: 1100-010, 1203-010, 0617
Warranty: Six Months

• Used to tension cylinder head studs and main bearing studs

• Used with one of these pumps: 3S-6224 Hydraulic Pump (115V) or 8S-8033 Hydraulic Pump (230V);
8T-0820 Pressure Gauge and 8T-3035 Lines Group also required
• Used with 8T-0960 Handling Tool Group to remove and install main bearings
• Simultaneously tension four cylinder head studs or two crankshaft main bearing studs
(use 8T-0960 Handling Tool Group when removing crankshaft main bearings)
• 4C-5816 Retainer Collar attaches as protective device to 8T-0895 Cylinder Group before tightening
or loosening crankshaft main bearing studs (helps contain 207-4607 Collar and stud in case of breakage)
• 8T-0493 Cylinder Test Stud, 8T-0495 Test Stud Spacer, and two 207-4607 Thread Collars are used to test 8T-0895 Cylinder Group
• 9U-5141 Nut Turning Handle used to loosen and tighten nuts while studs are extended
(9U-5141 Nut Turning Handle replaces discontinued 4C-6986 Nut Turning Handle)
• 4C-6987 Socket used to pretorque cylinder head nuts

Reference 8T-0895 Cylinder Group

SENR3594 Service Manual Module of SENR3590 Service Manual Applied force of each cylinderat maximum pressure 1540 N @ 69 000 kPa (173 ton @ 10,000 PSI)
SENR3600 Service Manual Module of SENR3595 Service Manual Piston area 223 sq cm (34.6 sq in)
SENR4259 Service Manual Module of SENR4255 Service Manual Weight 20 kg (45.0 lb)

SEHS9342 Special Instruction

Item Part No. Description

1 207-4607 Threaded Collar (bearing stud)
2 8T-0889 Threaded Collar (head stud)
3 8T-0898 Cylinder Head Pedestal
4 8T-0891 Threaded Collar (head stud)
5 8T-0896 Bearing Pedestal
6 8T-0494 Test Stud Spacer
7 8T-0493 Cylinder Test Stud
8 8T-0897 Cylinder Head Pedestal
9 4C-6987 Socket
10 9U-5141 Nut Turning Handle
11 1B-0581 Bolt
12 4C-5816 Collar Retainer
ID: C55130T1
13 0L-1351 Bolt
14 8T-0895 Cylinder Group

156-7159 Camshaft Separation Assembly

SMCS Code: 1211-010
Model: 3618 Engines (serial numbers 2MW1-UP)

• Used to separate camshaft segments

• Replaces separating method which used jacking screws
(these holes are no longer available in current camshafts)
• Used with 9X-8881 Bolt
• Bolt length: 57.2 mm (2.25 in)
• Bolt size: 5/8-11

Reference
RENR1333-01 Service Manual

ID: C80016T1

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156-7160 Piston Support 178-5063 Rod Cap Guide (3618)

SMCS Code: 1219-010 SMCS Code: 1225-010
Model: 3618 Engines Model: 3618 Engines (2MW1-Up)

• Used to easily remove and install connecting rod cap

• Guides (two) thread into lower portion of connecting rod
• Helps prevent damage to connecting rod cap
• Thread: M24 x 3.0

• Used to safely support piston and connecting rod assembly

while replacing connecting rod bearings
• Made of lightweight aluminum for easy installation
• Mounts in place of cooling jet with existing bolts

ID: C79898T1

ID: C79887T1

145-0316 Cleaning Kit Item Description Quantity

SMCS Code: 1350-070
1 Handle 1 1
Model: 3600 Gas Engines with Two-Stage After Coolers
2 Rod 3
3 Brush 12
• Used to clean water tubes in 2-stage after coolers 4 Connector 2
• Soft deposits left by coolant are removed by inserting brushes into after cooler
tubes and working back and forth through the length of coolant tubes
2
• Kit includes 9.5 mm (.38 in) diameter brushes, rods, handle, and connector
• Rotate cleaning rods and brushes in clockwise direction to prevent parts from unscrewing 4

3
ID: C78536T1

187-6273 Prechamber Machining Tool Group (G3600)

SMCS Code: 1101-063
Model: All G3600 Engines

• Used to remove pitting and corrosion in lower sealing surface of prechambers

• Machines lower sealing surface of prechamber
• Maximum material removal: 0.5 mm (.02 in)

NOTICE
Use with caution and as a last resort to salvage cylinder heads.
Excessive material removal could result in loss of core credit of the
cylinder head. Follow step-by-step directions in NEHS0790 Tool
Operating Manual provided with this tool.

Reference
NEHS0790, Using the 187-6273 Prechamber Machining Tool Group (G3600)

ID: C80035T1

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151-8689 Template Seal 156-7162 Wrench Assembly - Isolator

SMCS Code: 1101-036
Model: 3600 and G3600 Engines
Stop Adjusting Tool (3618)
SMCS Code: 7253-025
Model: 3618 Engines
• Just outline I.D. and O.D. of template to reveal sealing surface
• Used to easily and quickly identify area • Used to adjust isolator stops
of cylinder head that needs a smooth
sealing surface • Extra long, to reach recessed isolator stops
• Any nicks, gouges, and/or damage • Overall length: 220 mm (8.7 in)
in this area may result in incorrect • Socket type: 3/4 inch, 12 point
sealing

ID: C78579T1 ID: C80003T1

9U-7522 Head Repair Tool Group 1

SMCS Code: 1100-015, 016 2
Model: All 3600 and G3600 Engines

8
• Used for general disassembly and assembly of cylinder head

7
Reference
3600 and G3600 Engine Service Manuals; Cylinder Head Disassembly 3
and Assembly Module

4 5
10

Item Part No. Description

1 4C-8540 Dowel and Plug Driver
2 4C-8731 Dowel Pulling Rod
6
3 4C-9839 Safety Retainer Group with 2M-5139 Machine Screws
4 8T-2673 Stop Sleeve
5 8T-2674 Valve Seat Driver 9
6 8T-2676 Valve Guide Driver Assembly 11
7 8T-2679 Pulling Rod Assembly
8 8T-2781 Cylinder Support Pedestal ID: C80193T1

9 9U-6399 Valve Guide Gauge

10 9U-6401 Valve Guide Gauge 12
11 130-1449 Valve Seat Puller Group
12 8T-2660 Compressor Group

ID: C80190T1

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148-9704 Seal Installer Group

SMCS Code: 1063-012, 7555-012
Model: 3600 Diesel and Heavy Fuel Oil Engines

• Used to install seals on high pressure aftercoolers (HPAC) 1 2

• Group contains seal compressors and pliers to consecutively install both seals—makes
installation easier and faster, while helping to eliminate seal damage during installation

3 4

ID: C78545T1
Item Part No. Description
Item Part No. Description Qty. 1 1 148-6442 Ring
1 148-9705 Seal Ring Compressor 2 2 2 148-6443 Ring Insert
2 148-9707 Ring Compressor Pliers 2
3 148-6444 Seal Driver
4 148-6445 Seal Installer
ID: C78568T1
Not shown 148-9706 Foam

Exhaust Manifold Wrenches

194-4944 Ratchet, 3/8 inch Drive 194-4935
SMCS Code: 1059-015
Model: 3618 Engines 195-9264

• Used to remove and install hard-to-reach exhaust manifold bolts

• Designed for minimum clearance

Part No. Description 194-4944

194-4935 Exhaust Manifold Wrench, half moon chrome, 12 pt, box end 5/8 & 3/4
195-9264 Exhaust Manifold Wrench, ‘S’ shaped chrome, 12 pt, box end 11/16 & 3/4
194-4944 Ratchet chrome, multi-position, 3/8 in drive ID: C80369T1

9U-6249 Cylinder Tool Group

9U-6250 Pump Tool Group
SMCS Code: 1052-017, 0714
Model: 3600 Engines

• Both tool groups used together to disassemble and assemble 3600 Engine turbochargers
• Used with 6V-7030 Micrometer Depth Gauge Group (metric) or 6V-2012 Micrometer
Depth Gauge Group (inches), and 8T-5096 Dial Indicator Group
• Hoses and fittings working pressure: 10,000 PSI (68,900 kPa)

9U-6249 Cylinder Tool Group (3600 Turbo)

Service Parts
Item Part No. Description Quantity
ID: C66723T1
2 9U-6244 Support2 2 Item Part No. Description Quantity
5 5P-5247 Hydraulic Puller Assembly 1 Not shown
6 9U-6251 Suspension Yoke Assembly2 1 4C-9658 Protective Case 1
11 9U-6255 Removal Housing Assembly 1 9U-6685 Foam Block 1
13 1D-4614 Bolt 1 9U-6686 Foam Block (top) 1
14 1D-5119 Jam Nut 1 Decal NEEG2543
15 9U-6256 End Plug 1 1U-7566 Wrench Hex, 8 mm 1
16 126-8290 Spanner Wrench 1 1U-7564 Wrench Hex, 5 mm 1

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9U-6250 Tool Group, Pump (3600 Turbo) Item Part No. Description Quantity
Service Parts Not shown
Item Part No. Description Quantity 4C-9664 Travel Vault 1
1 8F-0024 Hose Assembly 2 9U-6252 Foam Block 1
3 9U-6246 Adapter Assembly 1 9U-6684 Foam Block (top) 1
4 1U-5230 Hand Pump 1 Decal NEEG2544
7 9U-6253 Removal Shaft Assembly 1 7J-9108 O-Ring Seal 1 4
8 9U-6254 Installation Shaft Assembly 1 1 Partof 9U-6253 Removal Shaft Assembly and part of 9U-6254
9 9U-7262 Plate 1 Installation Shaft Assembly (both assemblies are part of
10 2J-3506 Full Nut 1 9U-6250 Pump Tool Group)
2 Part of 9U-5105 Basic Tool Group, 3600
12 9U-6243 Extension Handle 1
17 9U-6248 Guide Bolt 2 3
Reference
NEHS0615 Tool Operating Manual, 3600 Turbocharger Disassembly and Assembly

195-8104 ABB Turbocharger Tool Kit (TPL61)

SMCS Code: 1052-017, 0714 2
Model: 3612 Marine Engines 1 3

• Used to disassemble and assemble ABB TPL61 turbochargers

Item Description Quantity 4

1 Tool Box
2 Shackle
3 Ring Bolt 2 5 9
4 Guide Tube 7
5 Radial Bearing Pin
6 Press On Bushing 6
7 Bar
8 Forcing Screw 4 8
12
9 Mounting Supports 2
10 Puller Screw 3
10 11
11 Stud 2
ID: C79939T1
12 Press on Tool Assembly 2
Not shown NEEG2923 Decal Reference
REHS0811 Special Instruction, Disassembly and Assembly of TPL61 Turbocharger

187-3703 Tool Group (NA297)

SMCS Code: 1052-017
Model: 3600 Engines 1
Essential Tool

• Used to disassemble and assemble Napier NA297 Turbochargers

4
Reference 3
REHS0285 Special Instruction, Disassembly and Assembly of the Napier NA297 Turbocharger

Item Part No. Description 2

1 177-9811 Turbo Thrust Collar Tool Group
2 177-9781 Turbo Compressor Lifting Bracket Assembly
3 177-9856 Turbo Impeller Removal Tool Group
4 177-9791 Turbine Locking Tool
7
5 178-0193 Torque Adapter (30 mm)
6 178-0196 Torque Adapter (1 1/8 inch) 5 6
7 177-9809 Turbo Bearing Guide Rod 8
8 177-9852 Insert Guide Rod
ID: C79888T1

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179-1904 Stud Tensioner Tool Group

SMCS Code: 1100-010, 1203, 0617, 0632
Model: 3618 Engines
Essential Tool

Compliant
Stud Tensioner Tool Group Main Bearing Cap Handling Group
• Used to simultaneously tension four cylinder head studs or two crankshaft • Part of 179-1904 Stud Tensioner Tool Group
main bearing cap studs • Air cylinder raises and lowers main bearing caps for main bearing inspection
• Comes with seal kits for cylinder groups and pump group or replacement
• Made of lightweight aluminum for easier use
Cylinder Groups • Allows one-person operation
• Smaller, lighter cylinders with convenient carrying handles • Ideal for tight engine compartments
• Pistons return automatically when hydraulic pressure is released
• Gear driven turning sleeve allows stud nut rotation with 1/2 inch square drive 160-0475 Support Tray
ratchet • Used to place 153-8488 Cylinder Group onto 156-7168 Main Bearing Cap
Handling Group
• Used with 160-4901 Tray Support Rail
• Recommended but not included

Tensioning force
Part No. Description at maximum pressure Maximum stroke Overall dimensions Weight
153-8487 Stud Tensioner Cylinder Group 1100 kN at 150 mPa 8 mm (.31 in) 161.5 mm (6.36 in) high x 9.6 kg (21 lbs)
(Cylinder Head) (247,289 lbs at 21,755 PSI) 143.0 mm (5.63 in) diameter
153-8488 Stud Tensioner Cylinder Group 2015 kN at 150 mPa 10.0 mm (.32 in) 182.2 mm (7.17 in) high x 18.2 kg (40 lbs)
(Main Bearing) (452,990 lbs at 21,755 PSI) 188 mm (7.4 in) diameter

Hydraulic Pump (Electric)

Maximum pressure 150 mPa (21,755 PSI)
Voltage 230/400 Volts (50/60 Hz)
Weight 33 kg (73 lbs)

Stud Tensioner Tool Group

2 Item Part No. Description

7 90 100
1 153-8488 Stud Tensioner Cylinder Group, Main Bearing
1
80 0
11
70
0
00 12
60 150
00
100 0
13
50 00
200 0
14
40 0

2 153-8487 Stud Tensioner Cylinder Group, Cylinder Head

00
500 230 0
15
30 psi
a
MP
20 0 ®

10
0

3 156-7166 Hydraulic Pump, Electric

8
4 178-9313 Distribution Coupler
3 5 178-9312 Hose (Qty 4)
5 6 156-7167 Hydraulic Pump, Manual (optional)
7 185-0683 Comparison Gauge
8 185-4436 Pressure Gauge
Not shown
178-9051 Bushing, M45 x 3 thread (Cylinder Head)
178-9053 Sleeve (Cylinder Head)
4 6 178-9058 Seal Kit (Cylinder Head)
175-0184 Bushing, M56 x 4 thread (Main Bearing)
8
175-0185 Sleeve (Main Bearing)
175-0191 Seal Kit (Main Bearing)
178-9314 Pump Seal Kit
Socket Extension (1/2 inch drive, 127 mm (5.0 in) long)
Swivel Head Ratchet (1/2 inch drive)
ID: C79881T1

NOTE: Items 1 through 8 Manufacturer's Warranty

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Main Bearing Cap Handling Group 156-7168 Main Bearing Cap Handling Group
(part of 179-1904 Stud Tensioner Tool Group)
4 Item Part No. Description
1 160-0476 Bearing Cap Lift Base
2 160-0464 Air Cylinder
3 160-0473 Lift Assembly
4 178-9141 Bearing Cap Lift Bracket
5 5P-6011 Air Line
6 160-0465 Air Control Box
3
5 6
2
®
16
0-0

Reference
46
5

NEHS0762 Tool Operating Manual; Operation and Maintenance of the

179-1904 Stud Tensioner Tool Group Used on 3618 Engines
RENR1333 Service Manual; Disassembly and Assembly of 3618 Engines
1
5

ID: C79882T1

191-5320 Stud Tensioner Tool Group

229-9453 Pump Accessory Group
Hydraulic Pumps
SMCS Code: 1000, 1100, 1203, 0617, 0632
Model: All 3600 Engines Except 3618

Compliant
• Used to simultaneously loosen or tighten nuts on four cylinder head studs or two crankshaft main bearing cap studs
• Used with 8T-0960 Handling Tool Group for easier removal and installation of main bearing caps
• Requires one 191-5320 Group, one 229-9453 Group, and one of optional pumps listed
• Compact, lightweight cylinders have convenient carrying handles
• 3612 and 3616 Diesel Engines also require two each 225-5637 Support and 225-5636 Adapter
• Optional gear drive permits faster installation of nut onto stud (uses a 1/2 inch square drive ratchet)
• ISO9001 Certified

Basic Tooling Required

11 1
191-5320 Stud Tensioner Tool Group (required)
Item Part No. Description Qty.
1 191-5322 Cylinder Head Cylinder Group 4
2 191-5333 Cylinder Head Support 4
3 2
3 191-5323 Main Bearing Cylinder Group 2
4 191-5335 Main Bearing Support 2
5 9U-5141 Nut Turning Handle 2
6 — Spanner Wrench 2
7 — Swivel Head Ratchet (1/2 inch square drive) 2
11 191-5324 Bushing (For 191-5322 Group) 4
191-5326 Bushing (For 191-5323 Group) 2
4

5
7
6
ID: D00429T1

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15
120
110
100
90
130

0
150 140

1500
0
2000
0
2300
psi
®

MPa

10
0
8
0
5000 20
80 1000
70 30
60 50 40

Pumps, Hose, and Coupler (requires one 229-9453 Group and one pump option)
Item Part No. Description Qty.
10 227-6724 Hydraulic Pump, Electric, 120 V 1
227-8834 Hydraulic Pump, Electric, 240 V 1
191-5347 Hydraulic Pump, Pneumatic 1
156-7167 Hydraulic Pump, Manual
229-9453 Pump Accessory Group, Includes:
8 178-9312 Hose Assembly 4
9 178-9313 Distribution Coupler 1
15 185-0683 Comparison Gauge 1
10

ID: D00434T1

12
229-9457 Auxiliary Group
Item Part No. Description Qty.
13
12 225-5637 Support (Used with 191-5322 and 191-5324) 2
13 225-5636 Adapter (Used with 191-5322 and 191-5324 ) 2

NOTE: Adapter and support bushing are required for 3612 and 3616 diesel
engines only. Needed for front cylinder heads adjacent to fuel filter housuing
supports. Taller adapter and support provides necessary clearance. ID: D00440T1

Optional Tooling
Optional Gear Drive Group (permits faster rotation of nut onto stud)
Item Part No. Description Qty.
14b
14 191-5341 Gear Drive Group (optional, includes items 14a and 14b) 1
14a 191-5343 Turning Sleeve (for 191-5322 Cylinder Head Cylinder Group) 4
14a 192-4316 Turning Sleeve (for 191-5323 Main Bearing Cylinder Group) 2
14b 191-5342 Gear Drive Assembly 6

14a

ID: D00441T1

17
Service Parts
Item Part No. Description Qty.
8
8 178-9312 Hose Assembly 1
9 178-9313 Distribution Coupler 1
15 185-0683 Comparison Gauge 1
16 185-4436 Pressure Gauge (service part for 227-6724, 227-8834, and 191-5347 Pumps) 1
17 178-9058 Seal Kit (for 191-5322 Cylinder Head Cylinder Group) 1
9 0
0
0

11
10
12
0
13

00
0

150
14

00
0

200
15
00
230
MP
a
psi
®

0 0

90 10
0

15
00 500
80 100 20

175-0191 Seal Kit (for 191-5323 Main Bearing Cylinder Group) 1

70 30
60 50 40

227-6725 Seal Kit (for 227-6724 Pump and 227-8834 Pump) 1

16
194-8202 Seal Kit (for 191-5347 Pump) 1
ID: D00441T1

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191-5322 Cylinder (Cylinder Head Studs)

Maximum tensioning force 1100 kN (247,289 lbs)
Maximum operating pressure 150 mPa (21,755 PSI)
Effective piston surface 73.2 cm2 (11. in2)
Stroke 10 mm (.39 in)
Weight 9.5 kg (21 lbs)
191-5323 Cylinder (Main Bearing Cap Studs)
Maximum tensioning force 2015 kN (452,990 lbs)
Maximum operating pressure 150 mPa (21,755 PSI) Reference
Effective piston surface 134.3 cm2 (20.8 in2) NEHS0866 Operation and Maintenance of Stud Tensioner Tooling Group
Stroke 10 mm (.39 in) used on 3600 Engines (except 3618)
Weight 19.5 kg (43 lbs) SENR4259 Disassembly and Assembly G3606 and G3608 Engines
227-6724 and 227-8834 Electric Hydraulic Pump SENR5535 Disassembly and Assembly G3612 and G3616 Engines
Oil quantity 3.8 Liters (.84 gal) SENR3600 Disassembly and Assembly 3606 and 3608 Engines
Maximum operating pressure 150 mPa (21,755 PSI)
SENR3594 Disassembly and Assembly 3612 and 3616 Engines
Voltage, frequency 120/240 Volts, 60/50 Hz
Weight 33 kg (73 lbs)
191-5347 Pneumatic Hydraulic Pump
Oil quantity 4.0 Liters (.88 gal)
Maximum operating pressure 150 mPa (21,750 PSI)
Air pressure 3.5 to 8 Bar (51 to 116 PSI)
Air consumption 104 to 206 gpm
Weight 22 kg (48.5 lbs)
Oil Specifications
Oil viscosity at 50°C (122°F) 1.75 E-9.1 Centistokes
Oil temperature (maximum) 60°C (140°F)
Oil approval HLP10 nach/acc.to VDMA 24318 bzw./resp. DIN51525

160-0475 Support Tray

160-4901 Support Tray Rail
SMCS Code: 1203-010, 0632
Model: 3618 Engines

• Used to support 153-8488 Tensioning Cylinder being manually placed onto

156-7168 Bearing Cap Handling Group
• Tray support rail easily fits onto engine oil pan baffles

160-0475

160-4901
ID: C79874T1

Reference
RENR1333 Service Manual; Disassembly and Assembly of 3618 Engines
ID: C79875T1

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