Caterpillar. Dealer service tools catalog (2018)

Diagnostic Tools

ELECTRICAL TOOLS

Specifications

• Temperature sensor: Requires type K

Function

Range

Resolution

Accuracy

thermocouple (included)

400 mV

0.1 mV

±(0.3% reading + 2 digits)

4 V

0.001 V

±(0.5% reading + 2 digits)

• IR spectral response: 6 - 16µm

DCVoltage

40 V

0.01 V

±(0.5% reading + 2 digits)

• IR emissivity: 0.95 fixed

400 V

0.1 V

±(0.5% reading + 2 digits)

600 V

1 V

±(0.8% reading + 3 digits)

• IR distance ratio: 8:1

50 - 400 Hz, 400 Hz - 1 kHz

400 mV

0.1 mV

• Input impedance: >7.5M ohm (VDC and VAC)

±(1.5% reading + 15 digits), ± (2.5% reading + 15 digits)

4 V

0.001 V

±(1.5% reading + 6 digits), ± (2.5% reading + 8 digits)

• ACresponse: True RMS

AC Voltage

40 V

0.01 V

±(1.5% reading + 6 digits), ± (2.5% reading + 8 digits)

• ACVbandwidth: 50 Hz to 1 kHz

400 V

0.1 V

±(1.5% reading + 6 digits), ± (2.5% reading + 8 digits)

600 V

1 V

±(1.8% reading + 6digits), ± (3% reading + 8 digits)

• Display: 4000-count backlit liquid crystal

400 µA

0.1 µA

±(1.5% reading + 3 digits)

4000µA

1 µA

±(1.5% reading + 3 digits)

• Overrange indication: ”OL” is displayed

40 mA

0.01 mA

±(1.5% reading + 3 digits)

DC Current

• Auto power off: 15 minutes (approximately)

400 mA

0.1 mA

± (1.5% reading + 3 digits)

4 A

0.001A

±(2.5% reading + 5 digits)

• Operating temperature: 0° to 50°C (32° to

20 A

0.01 A

±(2.5% reading + 5 digits)

122°F)

50 to 400 Hz, 400 Hz to 1 kHz

400 µA

0.1 µA

• Storage temperature: -20° to 60°C (-4° to

±(1.8% reading +8 digits), ±(3.0% reading +7 digits)

140°F)

4000µA

1 µA

±(1.8% reading +8 digits), ±(3.0% reading +7 digits)

AC Current

40 mA

0.01 mA

±(1.8% reading +8 digits), ±(3.0% reading +7 digits)

• Weight: 342 g (0.753 lb) (includes holster)

400 mA

0.1 mA

±(1.8% reading +8 digits), ±(3.0% reading +7 digits)

4 A

0.001A

±(3.0% reading +8 digits), ±(3.5% reading +10 digits)

• Size: 187 x 81 x 50 mm (7.36 x 3.2 x 2.0 in)

20 A

0.01 A

±(3.0% reading +8 digits), ±(3.5% reading +10 digits)

(includes holster)

400Ω

0.1Ω

±(0.8% reading + 4 digits)

4 kΩ

0.001 kΩ

±(0.8% reading + 2 digits)

40 kΩ

0.01 kΩ

±(1.0% reading + 2 digits)

Resistance

400 kΩ

0.1 kΩ

±(1.0% reading + 2 digits)

4 MΩ

0.001 MΩ

±(1.0% reading + 2 digits)

40 MΩ

0.01 MΩ

±(3.0% reading + 5 digits)

40 nF

0.01 nF

±(5.0% reading + 7 digits)

400 nF

0.1 nF

±(3.0% reading + 5 digits)

Capacitance

4 µF

0.001 µF

±(3.5% reading + 5 digits)

40 µF

0.01 µF

±(3.5% reading + 5 digits)

100 µF

0.1 µF

±(5.0% reading + 5 digits)

5.000 Hz

0.001 µF

±(1.5% reading + 5 digits)

50.00 Hz

0.01 Hz

±(1.5% reading + 5 digits)

500.0 Hz

0.1 Hz

±(1.2% reading + 2 digits)

5.000 kHz

0.001 kHz

±(1.2% reading + 2 digits)

Frequency

50.00 kHz

0.01 kHz

±(1.2% reading + 2 digits)

500.0 kHz

0.1 kHz

±(1.2% reading + 2 digits)

5.000 MHz

0.001 MHz

±(1.5% reading + 4 digits)

10.00 MHz

0.01 MHz

±(1.5% reading + 4 digits)

Sensitivity: 0.8 V RMS min. @ 20% to 80% duty cycle and <100 kHz;

5 V RMS min @ 20% to 80% duty cycle and >100 kHz

0.1 to 99.9%

Pulse width:

Duty Cycle

100µs- 100ms

0.1%

±(1.2% reading + 2 digits)

Frequency:

5 Hz to 150 kHz

-20° to 750°C

1°C

±(3.0% reading + 3 digits)

Temp (type-K)

-4°

to 1382°F

1°F

(probe accuracy not included)

-20° to 270°C

1°C

Temp (IR)

±2.0%reading or ±2°C, ± 4°F

-4° to 518°F

1°F

NOTE: Accuracy is stated at 18° to 28°C (65° to 83°F) and less than 75% RH. Accuracy

specifications consist of 2 elements: (% reading) - This is the accuracy of the measurement circuit.

(+ digits) - This is the accuracy of the analog to digital converter.

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Diagnostic Tools

ELECTRICALTOOLS

Electrical Test Group

Model Usage: All

European Union compliant, CE marked

• User-selectable 400 and 1200 ampere scales

for both AC and DC

Warranty: Manufacturer’s One Year

Three versatile electrical diagnostic tools

• Powered by two 1U-9533 AA Alkaline

complete with case, leads, and instructions

Batteries

• 237-5130 Infrared Multimeter

• Refer to 225-8266 Clamp On Ammeter

• Used to measure AC/DC voltage and current,

listed in this Dealer Service Tools Catalog for

resistance, capacitance, frequency, duty cycle,

complete information

and temperature

• CE Compliant

• Infrared thermometer and laser pointer

Current Detector

• Large, backlit LCD display 4000-count digital

multimeter

• Used to detect AC current in a circuit

• Refer to 237-5130 Multimeter with Infrared

• Also used to detect presence of PWM signal

Thermometer listed in this Dealer Service

to electronically controlled fuel injector or

Tools Catalog for complete information

solenoid

REPAIR INFORMATION

• CE Compliant

• Non-contact AC current range from 200

Extech Instrument

9 Townssend West

milliamperes to 1000 amperes

225-8266 Clamp On Ammeter

Nashua, NH 03061

• Locates current flow even where voltage

Phone: (781) 890-7440, ext: 220

• Used to measure AC or DC current

detectors cannot work

Fax: (781) 890-7864

Email: repair@extech.com

• Clamp-on probe replaces standard test leads

• Adjustable sensitivity

and allows current measurements without

breaking circuit

• Audible and visible indication of current

presence

• Measures current in cables up to 23 mm

(0.9 in) diameter

• CE Compliant

Part Number

Description

260-5800

Electrical Test Group

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1-27

Diagnostic Tools

ELECTRICAL TOOLS

Fluke 87V Multimeter

Warranty: Manufacturer’s Limited Lifetime

European Union compliant, CE marked

• Optional magnetic hanger for easy setup and

viewing freeing your hands for other tasks

• Replaces discontinued 9U-7330 Fluke 87-3

Multimeter

• Improved sleep mode for long battery life

• Used to test and adjust electronic circuits

• Inputs are protected to Category III,

1000V, and Category lV 600V to withstand

• Improved measurement functions,

impulses in excess of 8000V and reduce risks

troubleshooting features, resolution, and

related to surges and spikes

accuracy to solve more problems on motor

drives or electro-mechanical equipment

• Includes basic test leads, alligator clips, and

bead-type thermocouple probe

• Built-in thermometer allows temperature

readings without using additional equipment

• Complete with 9V battery, Getting Started

(Type K Thermocouple)

Manual, and CD with detailed instruction

manual

• Selectable filter for accurate voltage and

frequency measurements on motor drives

Specifications

• Large-digit display with bright two-level

• Size: 201 x 98 x 52 mm (7.9 x 3.9 x 2.1 in) with

backlight makes it significantly easier to read

holster

than older models

• Weight: 624 g (22 oz) with holster

• Min/Max and average recording to capture

• Battery life: 400 hours typical using 1U-9534

variations automatically

Alkaline 9V

• Removable holster with built-in test lead and

probe storage

Part Number

Description

257-9140

Fluke 87V Multimeter

Replacement Fuses

European Union compliant, CE marked

Replacement Fuses a

3N-5612

Voltage rating

600 V

Current rating

1 A

Size (diameter)

10.3 x 34.9 mm (13/32 x 1 3/8 in)

110% load indefinitely, opens at 135% load within

Load carrying capacity

1 hour

171-5207 Fuse (11A)

Voltage rating

1000 V

Current rating

11 A

10.3mm diameterx38.1 mm (13/32in diameterx

Size

1 1/2 in)

110% load 4 hours, opens at 135% load within 1

Load carrying capacity

hour

171-5209 Fuse (440 mA)

Voltage rating

1000 V

Current rating

15 A

10.3mm diameterx34.9 mm (13/32in diameterx

Size

1 3/8 in)

110% load 4 hours, opens at 135% load within 1

Load carrying capacity

hour

Short circuit interruption

100,000 A at 600 VAC

a. Also fits discontinued 9U-7330 Fluke 87 Multimeter and others

1-28 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

Fluke 355 True-RMS 2000

Model Usage: EPG Installations

• Auto-ranging and auto-zeroing ohms,

Specifications

continuity and frequency measurements

Warranty: Manufacturer’s Limited Lifetime

• Dimensions: 300x98x52 mm (12 x 3.75 x 2 in)

• Category IV 600V and Category III 1000V

• Frequency Range: DC and10 Hz to 1 kHz

• Current Range: 0 to 2000 A AC or DC

• Voltage Range: 0 to 1000 VDC or 0 to 600 VAC

• Resistance Range: 0 to 400 K ohms

Part Number

Description

329-9303

Fluke 355 True - RMS 2000

Extech Milliohm Meter

Model Usage: Generators

European Union Compliant, CE marked

Specifications

Warranty: Manufacturer’s

• Measure winding resistances on generators

• Dimensions: 250 x 190 x 110 mm (9.8 x 7.5 x

4.3 in)

• Four terminal Kelvin measurements

• Resistance:

• Over-temperature and over-voltage protection

Range

Resolution

Current

Accuracy

• 5 ranges with 100µ Ohm max resolution

± (0.5%rdg

200.0 m

0.1 m

100mA

+2 digits)

• Large 2000 count LCD display

± (0.5%rdg

2000 m

1 m

100mA

• Auto-hold and auto power off

+2 digits)

± (0.5%rdg

• Invalid test indicators prevent inaccurate

20.00

0.01

10mA

+2 digits)

measurements

± (0.5%rdg

200.0

0.1

10mA

+2 digits)

• Built-in water-resistant case, shoulder strap

± (0.5%rdg

2000

1mA

• Complete with 8 AA batteries, and 2 sets of

+2 digits)

test leads (4 wire with 4 alligator clips and 4

• Power: 8 AA batteries

wire with 2 Kelvin alligator clips)

• Weight: 1.5 kg (3.3 lb)

NOTE: Please consult with appropriate EPG

Service Engineering resources for tooling

recommendations for switchgear testing.

Part Number

Description

430-8927

Extech Milliohm Meter

Serviceable Parts

430-8928

Test Leads w/Kelvin Clips

1U-9533

AAAlkaline Batteries (in parts system)

DT Connector Service Kit, Wedge Removal Tool

Model Usage: All Models with Electronic

• Maintain/repair Deutsch style connectors on

Reference

Controls

electronic engine control harnesses

• SEHS9615, Special Instruction - A black

Warranty: Caterpillar ^®One Year

• 175-3700 DT Connector Service Kit -

plug and connector body has been released

connector/contact assortment for owners of

to improve sealing. Refer to SEHS9615 for a

discontinued 4C-3406 Connector Service Kits

more details on interchangeability.

which have 1U-5804 Crimp Tool

NOTE: 1U-5804 Crimp Tool is not included but

• 147-6456 Wedge Removal Tool included in

can be ordered separately.

kits - also available separately

Item

Part Number

Description

175-3700

Connector Service Kit (less crimp tool)

147-6456

Wedge Removal Tool (included in kit)

152-7997

Utility Box

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Diagnostic Tools

ELECTRICAL TOOLS

Relay Tester

Essential Tool

• Used to diagnose faulty 12V and 24V relays

• Checks normally OPEN and normally CLOSED

(checks one at a time)

relays, with and without resister or diode

Model Usage: Any Cat^®equipment with relays

listed

• Designed to test square “ice cube” style

• Powered by two 1U-9534 Batteries, 9 Volt

relays such as 3E-6477, 3E-9362, 265-8025,

Warranty: Manufacturer’s One Year

• Controls include voltage slide switch, relay

146-9439, 248-2841, 140-9378, 158-5089,

energize test button, and position No. 1 and

3E-5239, and 115-1615

No. 2 circuit test lamps

• Test relays with various terminal

• Portable design is great for field use

arrangements using one of four different

connectors

Part Number

Description

317-9760

Relay Tester

Corrosion Cable Group

Model Usage: Marine Engines

• Used to determine if metal parts exposed to

• Determines if zinc levels are low, good, or too

seawater, within an engine, are subject to

high— proper levels of zinc extend service

Warranty: Caterpillar ^®One Year

corrosion

life of all parts exposed to sea water

• Used with 257-9140 Multimeter

Specifications

• Checks low level voltage by clipping black

• Probe (Red): 6 m (20 ft) long

cable to metal part and placing silver probe

• Alligator Probe (Black): 3 m (10 ft) long

into sea water inside the component

Part Number

Description

244-1536

Corrosion Cable Group

Cylinder Position Sensor Test Box

Model Usage: Models using hydraulic cylinder

• Used to troubleshoot cylinder position sensors

References

position sensors

• Usedwith digital multimeter to read duty

• REHS2553, Guideline for Reusable Parts and

Warranty: Caterpillar ^®One Year

cycle, frequency, and voltage

Salvage Operation

• Compact, plastic design for use in the field

• NEHS0993, Tool Operating Manual

• Internal 1U-9534 9V battery powers position

Specifications

sensor

• Size: 76.2 x 50.8 x 38.1 mm (3 x 2 x 1 in)

• Cable length: 1.83 m (6 ft)

Part Number

Description

276-7273

Cylinder Position Sensor Test Box

Induction Meter

Model Usage: D7E Electric Drive

• This meter measures resistance in the stator

Specifications

from phase to phase, searching for internal

Warranty: Manufacturer’s

• Dimensions: 184 x 87 x 41 mm (7.24 x 3.43 x

issues.

1.61 in)

• Used with the optional 212-2158 four-foot

• Weight: 0.34 kg

leads

Part No.

Description

478-9228

InductionMeter

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Diagnostic Tools

ELECTRICALTOOLS

Cylinder Position Sensor Adapter Cable

Model Usage: Tier 4F MWL, MG, TTT, WTS

• Used with 276-7273 Cylinder Position Sensor

• Tier 4F MWL, MG, TTT, WTS and LMT moving

and LMT

Test Box to connect to M12 connector on

to sensor that uses M12 connector

cylinder position sensors

Warranty: Caterpillar ^®One Year

Part Number

Description

433-9168

Cylinder Position Sensor Adapter Cable

Serviceable Parts

102-8804

Receptacle Kit

9X-3401

Gold Pin Connection

8T-8737

Seal Plug

3E-3377

Receptacle Lock Wedge

Voltmeter Leads

Model Usage: All Models

• Push-button generates a load in an electrical

• Not designed for high voltage circuits

circuit so a load test (voltage drop test) can be

Warranty: Six Months

• Do not use positive probe in negative side of

made with component removed

circuit

• Use up 28.5 volts (DC or AC) only

• Use only with a digital voltmeter

• Maximum 5 to 8 seconds per test

• Will not function with ammeter or ohmmeter

• Not for computer (ECM) INPUT circuits

Reference

• NEHS1270 Tool Operating Manaual

Part Number

Description

275-9936

Voltmeter Leads

Multimeter MiniTec

Model Usage: All Models

European Union Compliant, CE marked

• 10A fuse protection

Warranty: Caterpillar ^®One Year

• 4000 counts on large LCD with full function

• Overload protection and indication

indication

• Auto power-off saves battery life.

WARRANTY INFO

• Measures AC/DC voltage and current,

• Includes protective rubber holster

Call 877-439-8324

resistance, capacitance, frequency and

• General purpose bead wire

temperature

• Type K temperature probe (model MN26T)

• Temperature measurements to 1400°F (760°C)

• Two 1.5V AAA batteries and test leads

• Duty cycle, continuity and diode test

• Autoranging with manual range override

Part No.

Description

Dimensions

Weight

505-3152

Multimeter MiniTec Group

122 x 61 x 40 mm (4.8 x 2.4 x 1.6 in)

260 g (9.17 oz)

Part No.

Description

212-2158

Lead Group

212-2159

Fuse 10 Amp

1U-9535

Battery 1.5 Volt AAA

8Q-6668

Fuse 500mAmp

8T-0458

Thermocouple

JULY 2018 Diagnostic Tools

1-31

Diagnostic Tools

ELECTRICAL TOOLS

Fluke 123B Scopemeter, 20 MHz Dual Channel

Model Usage: All Models

European Union Compliant, CE marked

• Optional wifi adapter connected to internal

USB port wirelessly transfers information

Warranty: Manufacturer’s

• This tool replaces 152-7213.

to PC, laptop or Fluke Connect^®mobile app.

• Shielded test leads for oscilloscope,

(WiFi USB radio available from Fluke, WiFi not

resistance and continuity measurements

permitted in all countries)

• Resistance, continuity, diode and capacitance

• Rugged design to withstand 3g vibration,

meter measurements

30g shock, and rated IP51 according to EN/

• Save or recall data and instrument setups

IEC60529

• Li-Ion rechargeable battery with seven-hours

• Highest safety rating in the industry: safety

operation (four-hour charge time)

rated for CAT IV 600 V

Part No.

Description

Dimensions

Weight

Fluke 123B Scopemeter,

259 x 132 x 55 mm

1.4 kg (3.2 lb)

506-8279

20 MHz Dual Channel

(10.2 x 5.2 x 2.15 in)

including battery pack

Item

Included

Fluke Test Tool

Rechargeable Li-ion Battery Pack

yes

Switch Model Power Supply, Adapter/Battery Charger

yes

Shielded Test Leads with Black Ground Leads

yes

Test Lead Black (For Grounding)

yes

Hook Clips (red, blue)

yes

Banana-to-BNC Adapters (black)

yes

Safety Information and CD-ROM with User Manuals

yes

Power Cords Included:

Country / Region

Plug Style

Manufacturer’s Part No.

North America

NEMA 5-15P

YL-1212

Continental Europe

Schuko CEE7

YL-1212

United Kingdom

UKBSI 363

YL-6012

Australia/New Zealand

Australia AS/NZS3112

YL-4612

Switzerland

Switzerland SEV1011

YL-4612

Italy

Italy CEI 23-16

YL-4512

Brazil

Brazil NBR14136

YP-04/YC-12

1-32 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

Fluke 741B Calibrator Battery Replacement

Model Usage: 3600 Generator Sets, Marine

• NiMH7.2 v, 3500 mAh

• 150 x 56 x 22 mm (5.9 x 2.2 x 0.9 in)

Warranty: Manufacturer’s

Part Number

Description

163-0097

Fluke 741B Calibrator Battery Replacement

Fluke 753 Calibrator

Model Usage: 3600 Generator Sets, Marine

European Union Compliant, CE marked

• Calibrates 3600 Protection Systems,

Marine Monitoring Systems, 3600 Engine

Warranty: Manufacturer’s

• Used to source/simulate volts, mA,

Management Systems, 3600 Electronic Unit

thermocouples, RTDs, frequency, ohms, and

Injector Systems, 3600 Custom PLC Systems

pressure calibrate transmitters

• Automatically records and documents

Specifications

calibration results

• Dimensions: 245 x 134 x 63 mm (9.6 x 5.3 x

• Measure and source simultaneously with one

2.5 in)

compact, rugged, reliable tool

• Weight: 1.2 kg (2.7 lb)

• Stores up to 8000 readings

• Batteries : 7.2 V, 4400 mAh, 30 Wh, Internal

• Operates in English, French, German, Italian

battery pack Li-ion

and Spanish

• Operating Temp.: -10 to 50°C (14 to 122°F)

• Comes with three-year warranty

• Storage Temp.: -20 to 60°C (-4 to 140°F)

• Includes Battery Charger & Li-ion Battery Pack

Part Number

Description

396-4789

Fluke 753Calibrator

Service/Repair Parts

396-4790

Battery Charger: 146 x 76 x 64 mm (2.8 x 3 x 2.5in)

396-4791

Li-ion Battery Pack: 152 x 7 x 25 mm (6 x 2.8 x 1 in)

JULY 2018 Diagnostic Tools

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Diagnostic Tools

ELECTRICAL TOOLS

Technical Data

Specifications

• Ramp Functions:

• Step Functions:

- Source functions: Voltage, current,

• Data Log Functions:

resistance, frequency, temperature

- Measure functions: Voltage, current,

- Rate: 4 steps/second

- Manual Step: Selectable step, change with

resistance, frequency, temperature,

- Trip detect: Continuity or voltage (continuity

arrow buttons

pressure

detection not available when sourcing

- Autostep: Fully programmable for function,

- Reading rate: 1, 2, 5, 10, 20, 30, or 60

current)

start delay, step value, time per step,

readings/minute

repeat

- Maximum record length: 8000 readings

• Loop Power Function:

(7980 for 30 or 60 readings/minute)

- Voltage: Selectable, 26 V

• Safety Specifications:

- Accuracy: 10%, 18 V minimum at 22 mA

- Agency Approvals: CAN/CSA C22.2 No

- Maximum current: 25 mA, short circuit

1010.1-92, ASNI/ISA S82.01-1994, UL3111,

protected

and EN610-1:1993

– Maximum input voltage: 50 V DC

Measurement Accuracy

1 Year

2 Years

100.000 mV

0.02% + 0.005 mV

0.03% + 0.005 mV

Voltage DC

3.00000 V

0.02% + 0.00005 V

0.03% + 0.00005 V

30.0000 V

0.02% + 0.0005 V

0.03% + 0.0005 V

300.00 V

0.05% + 0.05 V

0.07% + 0.05 V

Range

40 to 500 Hz

Resolution

1 Year

2 Years

Voltage AC

3.000 V

0.001 V

0.5%+0.002 V

1.0%+0.004 V

30.00 V

0.01 V

0.5% + 0.02 V

1.0% + 0.04 V

300.0 V

0.1 V

0.5% + 0.2 V

1.0% + 0.2 V

1 Year

2 Years

Current DC

30.000 mA

0.01% + 5 uA

0.015% + 7 uA

110.00 mA

0.01% + 20 uA

0.015% + 30 uA

1 Year

2 Years

10.000 Ω

0.05% + 50 mΩ

0.07% + 70 mΩ

Resistance

100.00 Ω

0.05% + 50 mΩ

0.07% + 70 mΩ

1.0000 kΩ

0.05% + 500 mΩ

0.07% + 0.5 Ω

10.000 kΩ

0.1% + 10 Ω

0.15% + 15 Ω

Resolution

(2 Years)

Accuracy

1.00 to 110.00 Hz

0.01 Hz

0.05 Hz

Frequency

110.1 to 1100.0 Hz

0.1 Hz

0.05 Hz

1.101 to 11.000 kHz

0.001 kHz

0.005 kHz

11.01 to 50.00 kHz

0.01 kHz

0.05 kHz

Source Accuracy

1 Year

2 Years

100.000 mV

0.01% + 0.005 mV

0.015% + 0.005 mV

Voltage DC

1.00000 V

0.01% + 0.00005 V

0.015% + 0.0005 V

15.0000 V

0.01% + 0.0005 V

0.015% + 0.0005 V

1 Year

2 Years

Current DC

22.000mA(Source)

0.01% + 0.003 mA

0.02% + 0.003 mA

Current Sink (Simulate)

0.02% + 0.007 mA

0.04% + 0.007 mA

1 Year

2 Years

10.000 Ω

0.01% + 10 mΩ

0.015% + 15 mΩ

Resistance

100.00 Ω

0.01% + 20 mΩ

0.015% + 30 mΩ

1.0000 kΩ

0.02% + 0.2 Ω

0.023 + 0.3 Ω

10.000 kΩ

0.02% + 3Ω

0.03% + 5Ω

2 Years

0.1 to 10.99 Hz

0.01 Hz

0.01 to 10.99 Hz

0.01 Hz

Frequency

11.00 to 109.99 Hz

0.1 Hz

110.00 to 1099.9 Hz

0.1 Hz

1.100 to 21.999 kHz

0.002 kHz

22.000 to 50.000 kHz

0.005 kHz

1-34 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

RTDs and Thermocouples

Device

Measure Accuracy

Source Accuracy

10 Cu (427)

3°C

1°C

100 Pt (3916)

0.3°C

0.1°C

100 Pt (3926)

0.3°C

0.1°C

100 Pt (385)

0.3°C

0.1°C

200 Pt (385)

0.3°C

0.1°C

500 Pt (385)

0.3°C

0.1°C

1000 Pt (385)

0.3°C

0.1°C

120 Ni (672)

0.3°C

0.1°C

0.3°C

0.2°C

0.5°C

0.3°C

0.2°C

0.3°C

0.2°C

0.3°C

0.9°C

0.8°C

1.0°C

0.9°C

0.6°C

Resolution: 0.1°C, except 1°C for 10 Cu. Best case, mid-range accuracies. Sensor inaccuracies not

included. For 2-wire and 3-wire RTD measurements, add 0.4°C. Thermocouple accuracies with

external cold junction. For internal add 0.2°C.

Electrical Specifications

Measure Accuracy

Source Accuracy

Measure Range

Source Range

(% of reading + % of

(full scale)

full scale)

110.000 mV DC

0.025% + 0.015%

110.000 mV

0.01% + 0.005%

1.10000 VDC

0.025% + 0.005%

1.10000 V

0.01% + 0.005%

11.0000 VDC

0.025% + 0.005%

15.0000 V

0.01% + 0.005%

110.000 VDC

0.05% + 0.005%

300.00 VDC

0.05% + 0.005%

VAC, 20 - 40 Hz

2% + 10 Counts

VAC, 40 - 500 Hz

0.5% + 5

VAC, 500 - 1 KHz

2% + 10

VAC, 1 kHz - 5 kHz

10% + 20

30.000 mA DC

0.01% + 0.015%

Source 22.000 mA

0.01% + 0.015%

110.00 mA DC

0.01% +0.15%

Simulate 22.000mA

0.02% + 0.03%

11.000 Ω

0.05% + 50

11.000

0.01%+ 20 m

110.00 Ω

0.05% + 50

110.00

0.01%+ 40 m

1.1000 kΩ

0.05% +0.5

1.1000 k

0.02% + 0.5

11.000 kΩ

0.1% +10

11.000 k

0.03% + 5

1.00 - 109.99 Hz

0.05 Hz

0.00 - 10.99 Hz

0.01 Hz

110.0 - 1099.9 Hz

0.5 Hz

11.00 - 109.99 Hz

0.1 Hz

1.100 - 10.999 kHz

5 Hz

110.0 - 1099.9 Hz

0.1 Hz

1.100 - 21.999 kHz;

11.00 - 50.00 kHz

50 Hz

2 Hz; 5 Hz

22.000 - 50.000 kHz

JULY 2018 Diagnostic Tools

1-35

Diagnostic Tools

ELECTRICAL TOOLS

Insulated Tip Test Lead Set

Model Usage: All Models

• Spring loaded insulators over metal probe

• Optional accessory lead set for multimeters

tips to prevent tips from making accidental

which have 9.5 mm (0.375 in) diameter input

Warranty: Caterpillar ^®One Year

electrical contact with wires and terminals

connectors; older meters have larger diameter

during testing; accidental electrical contact

connectors

can be a problem when reaching into

Specifications

electrical circuitry with normal test leads

which have as much as 19 mm (0.75 in) of

• Lead length: 1378 mm (54 in)

bare probe exposed; on 1U-8115 Test Lead

• Connectors: 9.5 mm (0.375 in) diameter

probes, only very tip of probe normally

shielded banana plug

exposed

Maximum voltage rating: 700 VAC or VDC

•

• However, since insulating sleeves are spring

• Color: 1 red and 1 black lead

loaded, they can be pushed back at any time

to expose more of metal tip; allows metal

• Probe tip diameter: 1.77 mm (0.070 in)

probe tip to enter small diameter holes

• Probe tip length: 15 mm (0.6 in) maximum

when testing connectors; insulators can be

pushed back and locked in position to uncover

approximately 6.3 mm (0.25 in) of bare probe

Part Number

Description

1U-8115

Insulated Tip Test Lead Set

Cable Assembly (GSC Data Cable)

Model Usage: Generator Sets

• Used to flash-program EMCP2+ Generator

• Requires Cat^®ET and communication adapter

Status Control (GSC) module

Warranty: Caterpillar ^®One Year

• Flash-programming only used for field updates

• Used with universal communications adapter

cable (139-4166)

Part Number

Description

152-7143

Cable Assembly (GSC Data Cable)

USB Adapter Cable, Serial (RS232) Adapter Cable

Model Usage: Forestry Products - Feller

• Adapter cables used to service, troubleshoot,

309-9891 Serial Adapter Cable

Bunchers

and reprogram IQAN Parker electronic control

• Used to service electronic control modules

modules from a personal computer (PC)

Warranty: Manufacturer’s One Year

• Used with “IQANdevelop” software program

309-9888 USB Adapter Cable

• PC software available from Media Logistics

• Used to troubleshoot and reprogram

- NETG5037

electronic control modules

• Used with “IQANrun” software programs

• PC software available from Media Logistics

- NETG5038

Part Number

Description

309-9888

USB Adapter Cable

309-9891

Serial (RS232) AdapterCable

1-36 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

Trimmer Adjustment Tool

Model Usage: All Models

• Allows easier adjustment of small screwdriver

• Gain and level controls on VR3 Voltage

adjustments found on VR3 and VR4 Voltage

Regulator are inside regulator case and

Warranty: Caterpillar ^®Six Months

Regulators and 2301 Woodward Regulator

difficult to adjust when generator set is in

Controls

operation; inability to see the control and

vibration of regulator make fine adjustments

• Constructed of glass-filled, nylon body with

very difficult

stainless steel blades; one end has recessed

blade to provide captive screwdriver for

• Prevents broken controls on Woodward 2301

adjustments that are difficult to see; other

Controls caused by improper tool usage and

end has exposed blade to reach adjustments

excessive force required for adjustment when

that are behind panels and have small access

wrong tool is used

holes

Part Number

Description

4C-4029

Trimmer Adjustment Tool

Analog Gauge Tester Group

Model Usage: All Models

• Used to test and troubleshoot analog

used in combination to simulate senders

temperature, pressure, fuel or articulation

output

Warranty: Caterpillar ^®One Year

gauges

• Fuse protected from electrical overload

• Easy-to-use, hand-held unit

• Not for use with the Cat^®Quad Gauge

• Tool Operating Manual includes charts for

Module

specific gauges

• Resistance tolerance: ±10% at full scale

• Decrease troubleshooting time and reduce

• Linearity tolerance: ±5% independent

cost by eliminating replacement of good parts

• Group includes all items in figure

• Diagnose temperature, fuel or pressure gauge

problems to determine if gauge, wiring or

Reference

sender is faulty

• NEHS0786, Tool Operating Manual

• 0 to 50, 500, 1500 and 34,000 ohm dials

Part Number

Description

189-1720

Analog Gauge Tester Group

Electronic Tool Kit

Model Usage: Forestry Products

• Used to repair IQAN receptacles and plugs

• Yellow Crimp Tool: Crimping JPT (Junior

used on Parker electronic control modules

Power Timer), no seal

Warranty: Manufacturer’s One Year

• Tool kit includes crimp tools, extraction tools,

• Blue Crimp Tool: Crimping Microtimer (with

and all terminals necessary for repairing

seal/no seal)

connector assemblies

• Red Extraction Tool: Extracts single-locking

• 309-9895 Terminal Kit (part of 309-9893 Tool

tab Junior Power Timer pins

Kit) is also available as a serviceable part

• Yellow Extraction Tool: Extracts double-

locking tab Junior Power Timer pins

Reference

• NEHS1023, Crimp Tool Operating Manual

• Blue Extraction Tool: Extracts double-locking

tab Microtimer pins

Items

• Terminal Kit: (See other chart for included

• Red Crimp Tool: Crimping JPT (Junior Power

items)

Timer), with seal

Part Number

Description

309-9893

Tool Kit

JULY 2018 Diagnostic Tools

1-37

Diagnostic Tools

ELECTRICAL TOOLS

Tool Group

Model Usage: CT660

Used to properly install replacement terminal

Specifications

ends in electronic engine control, engine

Warranty: Manufacturer’s

• Dimensions: 487.68 x 477.52 x 137.16 (19.2 x

management systems and many of the cab

18.8 x 5.4 in)

wiring harnesses and connectors.

Allows replacement of only damaged connector

without replacing complete harness

Part Number

Description

440-4999

ToolGroup

Terminal Kit

Item

Specification

Qty.

Microtimer (no seal)

18-20 AWG (0.75 mm²)

100

Microtimer (with seal)

18-20 AWG (0.75 mm²)

100

Microtimer Cavity Plug

100

Microtimer Seal

100

JPT (no seal)

18-20 AWG (0.75 mm²)

JPT (no seal)

14-16 AWG (1.5 mm²)

JPT (with seal)

14-16 AWG (1.5 mm²)

JPT (with seal)

18-20 AWG (0.75 mm²)

JPT (with seal)

18-20 AWG (0.75 mm²)

JPTCavity Plug

JPT Seal

18-20 AWG (0.75 mm²)

JPT Seal

14-16 AWG (1.5 mm²)

Part Number

Description

309-9895

Terminal Kit

Ampseal Connector Perimeter Seal Kit

Model Usage: Electronic Engines

Tool Description:

• Replacement perimeter seals are made of

colored silicone rubber

Warranty: Caterpillar ^®One Year

• Replacement seals for all AMPSEAL

connectors

• A damaged perimeter seal can allow moisture

and dirt to affect mated connections

Part Number

Description

Color/Size

Quantity

264-7029

2-pin connector seal

Red

264-7030

3-pin connector seal

Yellow

264-7031

4-pin connector seal

Yellow

264-7032

6-pin connector seal

Red

264-7033

8-pin connector seal

Yellow

264-7034

12-pin connector seal

Yellow

369-4181

AmpsealConnectorSeal Kit

4C-4787

Utility Box (9 compartment, plastic)

7 x 3.75 x 1.24 in (178 x 95 x 31 mm)

1-38 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

Extension Lead Group

Warranty: Manufacturer’s

• Used to extend leads to provide a longer

• Two color-coded female couplers (included)

reach from multimeter.

allow two sets of 360-3122 Extension Leads

to be connected together

• Used with 257-9140 Fluke 87V Multimeter

and 157-7213 Fluke 123 Scopemeter

• 600V CAT IV, 1000 V CAT III, 10A rating

• Includes one pair of color-coded (red/black)

• UL Listed

silicone insulated leads 1.5m (5.0 ft) long

Part Number

Description

360-3122

Extension Lead Group

Electrical Diagnostic Tools

Essential Tool

331-6561 High Voltage Meter

• A 9 Volt battery powered voltmeter proof

(North America Only)

tester with 500V output is included

Model Usage: 795F AC Off-Highway Truck

• Used to measure Voltage

• Unit comes with two 20 cm (8 in) fixed length

Warranty: Manufacturer’s

fiberglass hotsticks

• Digital Voltmeter with removable handles has

10.2 mm (.4 in) LCD backlit display

• Includes 9 Volt Alkaline batteries, carry case

with foam insert, and calibration instruction

• Voltmeter features timed auto shut-off to

manual

extend battery life

• Unit will shut off or not operate if battery is

low

Item

Description

Qty

Carrying Case with Foam Insert

Handles

5000 Volt Voltmeter

Proof Tester

Part Number

Description

331-6561

High Voltage Meter (North America Only)

331-6563

DischargeResistor Tool

359-9241

High VoltageMeter(Europe)

Before using any of these instruments, make sure to test and inspect the equipment to ensure that it is working properly and is in safe working condition.

Failure to do so can cause serious injury or death and may result in erroneous test measurements

JULY 2018 Diagnostic Tools

1-39

Diagnostic Tools

ELECTRICAL TOOLS

Discharge Resistor Tool

• 1m (3 ft) cable between discharge sticks

• Includes carry case with foam insert

• Used to discharge Voltage (up to 3kV) from capacitor

Part Number

Description

331-6563

DischargeResistor Tool

Fluke Connect

Model Usage: All Models

FLK-3000FC Connect

FLK-V 3000FC AC Voltage Module

Warranty: Manufacturer’s

• Work safely near electrical panels while

• One pair TL224

wearing less PPE

• One pair AC285

• Fluke Connect wireless test tools put tools,

• Two AA batteries (installed)

not your body, near live electrical panels

• One magnet strap

• Reduce the risk of arc flash by separating

• Information pack

yourself from hazardous measurement

situations

FLK-A 3001FC AC Current iFlex

• Fluke 3000 FC Series Wireless Multimeter can

• One iFlex 10" coil and module

send measurement data to a smartphone

• Two AA batteries (installed)

• Take measurements up to 20 meters away

One magnet strap

•

• USB adapter collects logged data from remote

• Information pack

modules

• Custom build a group using 467-0979 Foam

FLK-PC 300FC PC Adapter

and 4C-9658 Case

• USB PC Adapter

• Includes one pair TL175, one pair AC175, 3 AA

• SW3000 Windows Utility Software CD

batteries (installed), information pack

Foam Insert for Pelican Case 4C-9658

• Hard case holds up to 8 modules, USB radios,

• Multimeters, sensors and cables

Item

Part Number

Description

467-1968

FLK-3000FC Connect

467-1969

FLK-V 3000FC AC Voltage Module

467-1971

FLK-A 3001FC AC Current iFlex

467-1973

FLK-PC 300FC PC Adapter

467-1974

C3003 Three-Compartment Soft Case

467-0979

Foam Insert for 4C-9658

4C-9658

Pelican Case

1-40 JULY 2018 Diagnostic Tools

Diagnostic Tools

ELECTRICALTOOLS

High Voltage Meter (Europe)

• Used with 257-9140 Fluke 87V Multimeter

• 1000 VDC verifier

(not included)

• Holder for Fluke 87V Multimeter

• Resistive attenuator (0-30kV) mounted on

• 20 cm (8 in) cable connects attenuator to

38 cm (15 in) probe

multimeter

• Ground lead mounted on 38 cm (15 in) handle

• Includes carry case and instruction manual

with 1 m (3 ft) long cable to attenuator

• NIST traceable certification

Item

Description

359-9241

High VoltageMeter(Europe)

Carrying Case

Holder for 257-9140 Fluke Multimeter

0-30 KV Probe with 1m (3 ft) Insulated Cable

Ground Lead Handle

Probe Extensions

Harness Braiding Cutter

Model Usage: All Models

• Allows operator to easily cut braiding when

• Braiding Cutter includes a safety ball and a

repairing harnesses

safety cap

Warranty: Caterpillar ^®One Year

Part Number

Description

Dimensions

377-6198

Harness Braiding Cutter

5 1/8 in Long

Phase Meter Assembly

Model Usage: Generator Sets

European Union compliant, CE marked

Specifications

Warranty: Manufacturer’s Three Year

• Used to test three functions including open

• Battery Life: Approximately 200 hours

phase, phase sequence, and motor rotation

• Battery: Standard 9 V

• One half of unit measures phase sequence

• Size: 153 x 72 x 35 mm (6.02 x 2.83 x 1.37 in)

of a 3-wire system using power from system

• Weight: 218 g (7 oz) including battery

under test (lamp indicators will indicate

3-phase sequence or an open phase situation)

• Operating temperature: 0 - 40°C (32 - 104°F)

• Other half of unit measures 3-phase motor

• Phase Sequence:

rotation on a powered or unpowered motor

- Input Voltage: 3 phase to phase inputs

(indicates whether motor shaft has clockwise

100 V AC to 600 V AC maximum

or counter-clockwise rotation)

- Frequency range: 45 to 70 Hz

- Operating time: 10 minutes ON maximum

• Supplied with three CAT III rated color-coded,

at 600 V AC; 10 minutes OFF minimum at

large alligator clips and test leads

600 V AC

• Ratedfor CAT III 600V on both testing phase

- 3-phase: Approximately 7mA per phase of

sequence and motor rotation

AC power source

• Conforms to EN61010-1:2001; CAT III 600V,

• Motor Rotation:

Pollution Degree 2, Class 2; CSA 22.2-1010.1;

- Operating time: 10 minutes ON maximum;

and EN61557-7

10minutes OFF minimum

• Zippered carrying case for portability

- Tester field: 14 mA of 9 battery

• Includes test leads (red, green, and blue) with

alligator clips, soft vinyl case, Users Manual,

and 9 V battery

Part Number

Description

349-4198

Phase Meter Assembly

JULY 2018 Diagnostic Tools

1-41

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Deutsch HD Style Connector Field Repair Kit

Model Usage: Electronic Engines

• Redesigned from the discontinued 4C-3406

• Quantities adjusted to better reflect most

HD Style Field Repair Kit (1U-5804 Crimp

commonly used connectors

Warranty: Caterpillar ^®Six Months

Tool in discontinued 4C-3406 has been

• Convenient new carrying case allows

removed from 190-8900 to avoid duplicate

connectors to be found easily

tool expenses at reorder)

• Easy-to-use chart for parts reordering

• Each connector in its own sealed plastic bag

NOTE: 1U-5804 Crimp Tool is not included with

for cleanliness

group. Order separately.

Part No.

Description

Qty.

126-1767

Pin #14

126-1768

Socket #14

151-6320

Removal Tool #14

152-7997

Utility Box

190-8900

Deutsch HD Style Connector Field Repair Kit

7X-6195

Receptacle, 9-Pin

8T-8731

Plug, 3-Socket

8T-8732

Receptacle, 3-Pin

8T-8733

Plug, 5-Socket

8T-8734

Receptacle, 5-Pin

8T-8735

Plug - Connector

8T-8736

Receptacle, 9-Pin

8T-8737

Seal Plug

9W-0847

Plug, 9-Socket

9X-3401

Pin #16/18

9X-3402

Socket #16/18

1-42 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Blowby Group

Model Usage: All

European Union compliant, CE marked

• Built-in USB serial interface

Warranty: Caterpillar ^®One Year

• Used to trend volume of blowby gases

• Tool operating manual includes charts to

released through engine crankcase breather

convert readings from inches of water to cubic

(measures inches of water on orifice tube)

feet/minute

• Input uses convenient quick-disconnect fitting

• Uses a 9V battery for power

• Large LCD display with backlighting

• To conserve battery life, an automatic power

off feature turns unit OFF after 20 minutes

• Eleven units of measure (user selectable by

front panel push button)

• Includes large and small orifices, two 1/8 -

27 NPT hose barb fittings, a two foot long

• Max/Min/Avg recording

1/8 ID x 1/4 inch OD clear tubing, 6V-3073

• Zero function for offset correction or

Carrying Case, 6V-4094 Foam Inserts, 368-

measurement

8645 Lid Decal

• Advanced features include DATA HOLD,

MIN-MAX-AVG RECORD mode, ZERO/OFFSET,

AUTO POWER OFF

Unit of Measure Display

Icon

Pounds per square inch

PSI

Inches of mercury

in Hg

Milli-bar

mbar

Millimeters of mercury

mm Hg

Kilo-Pascals

kPa

Kilograms per centimeter squared

Kg cm²

Inches of water

in H2O

Feet of water

ft H2O

Centimeters ofwater

cm H2O

Bars

bar

Ounces per squareinch

ozin²

Part Number

Description

368-8645

Blowby Group

NOTE: Pressure inputs of 0.689 Bar (10 PSI) or higher will damage the instrument. Do not apply

pressure higher than the maximum pressure listed in the specification chart.

Pressure inputs of 0.689 Bar (10 psi) or higher will damage the instrument. Do not apply pressure higher than the maximum pressure listed in the

specification chart.

JULY 2018 Diagnostic Tools

1-43

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Blowby Group (Continued)

REPAIR INFORMATION

Reference

• Data hold: Freezes displayed reading

Extech Instruments Corporation

• NEHS1110, Tool Operating Manual

• Sensor: Built-in piezoelectric sensors

9 Townsend West

Nashua, NH 03061

• User Guide: Heavy-Duty Differential

• Zero / offset function: Pushbutton activation

Pressure Manometer, Model HD700 (OEM

Email: repair@extech.com For repair or calibration, call

• Sample rate: 0.5 sec. (approx.)

781-890-7440, ext: 220 for a Return Authorization Number and

manufacturer supplied)

shipping instructions

• Compatibility: Air or non-corrosive and non-

Specifications

For repair or calibration, call 781-890-7440, ext: 220 for a

ionized gas (not intended for use with liquids)

Return Authorization Number and shipping instructions

• Display: Four-digit LCD with function

• Auto power OFF: Meter turns off after approx.

indicators

20 minutes to conserve energy (can be

• Units of Measure: bar, mbar, PSI, kg/cm², mm

deactivated)

Hg, inches Hg, kPa, feet H2O, inches H2O, cm

• PC interface: Built-in USB serial interface

H2O, and oz in²

• Storage conditions: 0 to 60°C (14 to 140°F);

• Accuracy: ± 0.3% FS [@ 25°C (77°F)]

<80% RH

• Repeatability: ± 0.2% to 0.5% FS

• Operating conditions: 0 to 50°C (32 to 122°F);

• Linearity / hysteresis: ± 0.3% FS

<80% RH

• Combined accuracy: ± 1.1% FS

• Battery power: 9V alkaline battery (BAT low

battery indicator)

• Maximum pressure: 0.689 bar (10 PSI)

• Battery life: 125 hours typical

• Response time: 0.5s typical

• Size: 30 x 23 x 10 cm (12 x 9 x 4 in)

• Input circuit: Differential inputs (P1 and P2)

• Weight: 4.5 kg (9 lb, .9 oz)

• Input ports: Two metal 4.8 mm (.189 in),

barbed for 3.17 mm (.125 in) ID tubing

Specifications

Range

Resolution

kPa / mbar / PSI

13.78 / 137.8 / 2

0.01 / 0.1 / 0.001

mm Hg / in Hg

103.4 / 4.072

0.1 /0.001

ozin²

0.01

cm H2O / in H2O / ft H2O

140 / 55.40 / 4.616

0.1 / 0.01 / 0.001

kg cm²

0.140

0.001

bar

0.137

0.001

Ampseal Style Connector Field Repair Kit

Model Usage: All

• Used to maintain and repair Ampseal style

• Connectors available in quantities most

connectors on electronic engine control

commonly used

Warranty: Six Months

harnesses

NOTE: 1U-5804 crimp tool is not included.

• Connectors individually sealed in plastic bag

Please order separately.

for cleanliness

Part Number

Description

362-3555

Ampseal Style Connector Field Repair Kit

1-44 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Wire Removal Tool

Model Usage: 121-9588 - 3116/3126 Engines

195-7970/151-6320/121-9588

• Used to remove pins and sockets from

with HEUI (Hydraulic Electronic Unit Injection),

Deutsch and AMP style connectors

• Handle size: 12.7 x 25.4 mm (0.5 x 1.0 in)

151-6320 - All Models With Electronic Controls,

• Versatile new design allows removal of 14,

• Material: plastic

195-7970 - All Models with Electronic Engines

16, and 18 gauge pins and sockets from

Warranty: Caterpillar ^®Six Months

121-9588 Removal Tool, 16 gauge TXL

connectors

• Used to remove wires from 40-pin connectors

• Made from a more durable material than

used on ADEM II (Advanced Diesel Engine

former tool (reduces breakage)

Management) controls

195-7970 Deutsch DFN Style Connector

• Tool slips over OD of wire and compresses

Service Tool

wire retaining spring inside connector

• Used to remove the wire/socket assembly

allowing wire to be removed

from Deutsch DFN style connector plugs

• If used improperly tool will break away before

• Tool slips over OD of wire and compresses

causing damage to connectors pin or socket

socket retaining mechanism inside connector

151-6320 Removal Tool, 14, 16, 18 gauge

allowing wire/socket assembly to be removed

SXL/GXL

• Replaces discontinued 121-9587 Removal Tool

(16 gauge GXL)

Part Number

Overall Length

121-9588

56.6mm (2.23in)

151-6320

57.5mm (2.26in)

195-7970

57.0mm (2.24in)

Terminal Extraction Tool

Model Usage: 554, 574 Forwarder; 550, 570, 580

• Used to remove stamped and formed

• Due to various wire sizes, both tools are

Harvester

terminals from AMP electrical connector

required

bodies

Warranty: Caterpillar ^®One Year

Part Number

Description

195-1179

Extraction Tool

Terminal Extraction Tool (JPT)

Model Usage: All models with JPT terminals

• Replaces 195-1178 Extraction Tool

• Improved design allows for easier extraction

of terminals (insert tool prongs to release

Warranty: Caterpillar ^®One Year

• Used to extract Junior Power Timer (JPT)

terminal from connector)

terminals on switch connectors inside vehicle

cab and other locations

• Durable spring steel construction

• Overall length: 82.5 mm (3.25 in)

Part Number

Description

290-9703

Extraction Tool

JULY 2018 Diagnostic Tools

1-45

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Removal Tool

Essential Tool

• Used to remove wire and socket assembly

• Wires are removed by inserting pin completely

from 64-pin 100 watt delphi connector

into hole beside socket (unlatches socket)

Warranty: Caterpillar ^®One Year

Part Number

Description

266-1683

RemovalTool

Removal Tool

Model Usage: All

• Used to remove pins and sockets from

• Material: Plastic

Deutsch and AMP style connectors

Warranty: Caterpillar ^®Six Months

• Wire gauge: 20, 22

• Tool slips over OD of wire and compresses

• Contact Size: 20

wire, retaining spring inside connector to

allow wire to be removed

Part Number

Description

355-2848

RemovalTool

Deutsch Terminal Tool Set (7 Pieces)

Model Usage: All

• Used to remove pins and sockets on Deutsch

• Stainless steel shaft construction and fitted

style electrical connectors.

anodized aluminum handles with knurled

Warranty: Caterpillar ^®Six Months

surface for improved grip and control

• Provides coverage for wire gauges between

4 to 20

Part Number

Description

509-6474

Deutsch Terminal Tool Set (7 Pieces)

1-46 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Crimping Tool, Extraction Tool

Essential Tool

• Crimp tool is used to crimp pins onto

• Extraction tool enters contact cavity from

electronic wires for installation, repair, and

front of connector, releasing the pin or socket

Warranty: Caterpillar ^®One Year

maintenance applications

contact

• Extraction tool removes AMP Mate-N-Lock

• Works with wire sizes ranging from 20 to

and AMP Mate-N-Lock II pins and socket

14 AWG

contacts from connectors

Part Number

Description

Use

Used On

239-5260

Crimping Tool

Used to crimp pins

Electronic wires

Used to remove pins and

246-8636

Extraction Tool

Connectors

socket contacts

Optional Die Set (Sold Separately)

AMP Terminal Die Crimp

Woodard F-series

Used to crimp AMP terminals

329-5658

Set (Use with 239-5260

Actuator on 3500

770854-1 and 770854-3

Crimping Tool)

Gensets

JULY 2018 Diagnostic Tools

1-47

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Crimping and Extraction Tools

Model Usage: Various

• Used to crimp and extract terminals used with

• Provides crimp and extraction tools for JPT

the B5M5 ECM connector

and MQS terminals

Warranty: Caterpillar ^®Six Months

Part No.

Description

Dimensions

Weight

290-9703

JPT Extraction Tool

75 x 25 x 25mm (3 x 1 x 1 in)

0.1 kg (0.22 lb)

509-3830

Crimp Handle without Dies

25x250x100mm(1x10x4in)

1 kg (2.2 lb)

290-9703

509-3831

JPT Die Set (use with 509-3930)

25 x 25 x 25mm (1 x 1 x 1 in)

0.1 kg (0.22 lb)

509-3832

MQS Die Set (use with 509-3930)

25 x 25 x 25mm (1 x 1 x 1 in)

0.1 kg (0.22 lb)

509-3833

MQS Extraction Tool

75 x 25 x 25mm (3 x 1 x 1 in)

0.1 kg (0.22 lb)

509-3831

509-3832

509-3830

509-3833

Hand Crimp Tool

Model Usage: All Machines using GT Series

• Used to crimp pins onto wires for installation,

Specifications

Connectors

repair and maintenance applications

• Dimensions:265 x 95x 40 mm

Warranty: Manufacturer’s

• Used with wire sizes 20 to 14 AWG

(10.4 x 3.7 x 1.6 in)

• Provides production style crimp on Delphi

• Weight: 0.4 kg (0.9 lb)

GT150 and GT280 series terminals

Part Number

Description

449-9627

HandCrimpTool

Extraction Tool, Bosch Extraction Tool

Model Usage: All models that use C3.4B

• Used to extract Tyco and Bosch electrical

• Made of plastic and steel

Powertrain

connections for servicing without damage

Warranty: Caterpillar ^®Six Months

Part No.

Connectors

Dimensions

398-1335

Tyco

107 x 20 mm (4.21 x 0.79 in)

398-1337

Bosch

110 x 20 mm (4.33 x 0.79 in)

1-48 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Connector Pin Extraction Tool

Model Usage: All Models

• Allows the removal of pins or sockets from TE

Specifications

clean body series connectors used on next

Warranty: Manufacturer’s

• Dimensions: 75 x 19 x 1.9 mm

generation info displays.

(2.952 x 0.748 x 0.074 in)

• Weight: 0.227 kg (0.5 lb)

Part No.

Description

490-3634

Connector Pin Extraction Tool

Crimping Tool, Extraction Tool

Model Usage: All

• Used to properly remove and install APEX

• Crimping tools accurately and easily crimps

2.8 mm terminals

terminals to wire with minimal force

Warranty: Manufacturer’s

• Extraction tool removes terminals from

• Use 399-1594 for 14 and 16 gage wires

connector by inserting the tip into the service

• Use 399-1595 for 18 and 20 gage wires

port of the connector and pulling the wire and

terminal from the connector

Part No.

Description

Dimensions

399-1594

Crimping Tool

220 x 75 x 40 mm (8.66 x 2.95 x 1.57 in)

399-1595

Crimping Tool

220 x 75 x 40 mm (8.66 x 2.95 x 1.57 in)

399-5778

Extraction Tool

120 x 13 mm (4.72 x 0.51 in)

NEXG4508 Service Program Module, 3406 B/C Truck Engine

Model Usage: 3406 PEEC Truck Engine

• Software [in EPROM chip]

References

Warranty: Caterpillar ^®One Year

• Installed in 7X-6400 DDT by customer to

• SEHS8743, Special Instruction

provide all service functions for 3406 B/C

• NEEG2501, Diagnostic Code Card

Truck Engine

NEEG2502, Driver’s Card

•

• Version number printed on module and can

be displayed on DDT screen under Mode 00

(present version number compatible with all

versions of 3406 B/C Truck Engine control

personality modules)

NEXG4509 Service Program Module, 3176/3406E Truck Engine

Model Usage: 3176/3406 Truck Engine

• Software [in Erasable Programmable Read

References

Only Memory (EPROM) chip]

Warranty: Caterpillar ^®One Year

• SEHS8808, Special Instruction

• Installed in 7X-6400 or 7X-1055 DDT by

• NEEG2501, Pocket Card

customer to provide all service functions for

• NEEG2502, Pocket Card

3176 and 3406 Truck Engines

• Version number printed on module and can

be displayed on DDT screen under Mode 00

(present version number compatible with all

versions of 3176 and 3406E Truck Engines

control personality modules

JULY 2018 Diagnostic Tools

1-49

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Software Module, Challenger 65/75/85

Model Usage: Challenger 65/75/85

• Software [in Erasable Programmable Read

• Version number printed on module and can be

Only Memory (EPROM) chip]

displayed on DDT screen under Mode 00

Warranty: Caterpillar ^®One Year

• Installed in 7X-6400 or 7X-1690 DDT by

Reference

customer to provide all service functions for

• SEHS9203, Special Instruction

3176 Engine in Challenger 65/75/85

Service Technician Workbench (STW)

Essential Tool

Computer Recommendations

Laptop Computer

Model Usage: All Models

The following configuration is recommended to

Desktop Computer

run STW on a laptop computer.

Service Technician Workbench (STW) is an

The following configuration is recommended to

umbrella application tying Caterpillar^®software

run STW on a desktop computer.

• 1.4 Ghz Pentium-compatible processor

based service tools together with a common

• 2.4 GHz Pentium-compatible processor

• 512 MB RAM minimum (1 GB recommended)

look and feel, installation, support, training,

• 512 MB RAM minimum (1 GB recommended)

• 20 GB hard disk drive with at least 1.5 GB

and delivery. STW is a platform that provides

hard drive space available

a framework to enable the technician to

• 40 GB hard disk drive with at least 1.5 GB

troubleshoot, repair, and report on the repair

hard drive space available

• File transfer device (such as a 3.5 inch disk

process. The applications under the STW

drive or USB port and compatible jump drive)

• File transfer device (such as a 3.5 inch disk

umbrella are: Component Based Troubleshooting

drive or USB port and compatible jump drive)

• Third generation DVD drive

(CBT), Cat^®Electronic Technician (ET), Challenger

Technician, M300 Technician, Flash File Search

• Third generation DVD drive

• 11 inch or larger active matrix color screen

(FFS), Technical Analysis (TA), Dataview and

• Hewlett Packard Laserjet V or compatible

• 17 inch VGA (1024 x 768, 256 colors) adapter

Data Technician, Upload Utility and Standalone

printer

and monitor

Service Report. All tests and reports generated

• 16-bit sound card (for use with Computer

• Pointing device (built in or external)

from these applications can be compiled into one

Based Training and Multimedia)

• Emulation or LAN adapter and software

STW Service Report.

• Hewlett Packard Laserjet V or compatible

suitable for the dealer host computer

STWis available on CD; order NETG5030

printer

• MicrosoftWindows 98,NT 6.0,2000or XP

through Caterpillar Media Logistics.

• Pointing device (built in or external) such as

• Microsoft Internet Explorer version 5.5 or 6.0;

Direct Benefits to Dealer’s Service

Microsoft Ballpoint Mouse

browser must support Java Script and HTML,

Business

• Microsoft Windows 2000 or XP

version 2

• Reduces time to access necessary information

• Microsoft Internet Explorer version 5.5 or 6.0;

• TCP/IP Dialup Adapter (needed only for

relevant to diagnostic and repair process

communicating between SIS and Service

browser must support Java Script and HTML,

• Reduces time to correctly troubleshoot

version 2

Advisor or DBS through Parts Integrator); also

problems and identify best repair process

need TCP/IP Dial-up Adapter to send and

• TCP/IP Dialup Adapter (needed only for

• Reduces purchase of printed service literature

receive feedback in STW

communicating between SIS and Service

• Reduces time to prepare complete and

Advisor or DBS through Parts Integrator). Also

• RS232 port with 16550AF UART or PCMCIA

accurate service reports

need TCP/IP Dial-up Adapter to send and

card to RS232 adapter or USB to RS232

receive feedback in STW

adapter (Cat^®part number 370-8059)

• Reduces processing time for complete and

accurate work order information necessary for

• RS232 port with 16550AF UART or PCMCIA

• Ethernet or USB port (needed only for users

prompt and accurate invoicing

card to RS232 adapter or USB to RS232

with Dataview II)

adapter (Cat^®part number 370-8059)

• Reduces processing time for complete and

accurate warranty claims

• Ethernet or USB port (needed only for users

with Dataview II)

1-50 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Electronic Engine (ET) JERD2129

Model Usage: All models with electronic

Diagnostic Capabilities

Recommended PC Configuration

controls

• ET has separate pull-down menus for

• IBM PC compatible with Pentium IV 2.4 GHz

Cat^®Electronic Technician (ET) is a service tool

selecting different function screens and

processor or higher

designed to run on a personal computer under

includes a HELP Function Screen which is very

• 512 MB of RAM

Microsoft Windows. With ET you can display the

easy to use

• 1 GBavailable on hard disk drive

status of a group of parameters (temperatures,

• Diagnostic software helps technicians make

pressures, etc.) simultaneously, view and clear

• File transfer device

accurate repairs, in a short time frame, on

active and logged diagnostics, or display the

products that are increasingly complex

• 14.1inch XGA screen (800 x600)

current configuration of an Electronic Control

• Views events where irregularities occurred

• Microsoft Windows 2000, ME, XP

Module (ECM).ET can perform theseas well as

and were logged by the ECM

many other tasks, such as:

• RS232 port with 16550AF UART or compatible

• Views and changes configuration of the ECM

• View events where irregularities occurred and

• Built-in pointing device or mouse

were logged by the ECM

• Retrieves engine totals for fuel used, miles

• Microsoft Internet Explorer 5.5 or higher

traveled, andmore

• View and change configuration of the ECM

If your Microsoft Internet Explorer screen size is

• An ECM summary screen allows viewing of

• Perform diagnostic tests

640 x 480, press the maximize button to fill the

the ECM version

screen.

• Perform calibrations

Other screens allow diagnostic tests and

•

• View trip information through Trip Summary,

Ordering Information

calibrations to be performed

Histograms, and Custom reports

Cat^®ET software is included on the STW

Output data can be viewed in either English or

•

• Print reports and diagnostic results

installation CD and can be ordered through the

metric units

Media Logistics System:

ET is designed to communicate with the ECMs

The minimum PC Configurations should not be

through the communication data link.

• NEXG5030 STW software (includes ET

used as a standard when buying new personal

software)

ET allows the technician to obtain data, analyze

computers to run ET.

it, and then diagnose existing and potential

But if you have existing equipment that meets

Licensing Information

problems.

these minimum requirements, it will run ET.

An ET license is required to activate the ET

Software Features and Requirements

program after installation. Licensing the

program at https://on-linelicensing.cat.com

• Each license is a license for 1 computer

automatically generates an order in the Media

• Software subscription includes Caterpillar^®

Logistics System for a Dealer ET subscription to

Flash Memory Software

JERD2129.

Harness, Bypass Messenger

Essential Tool

• Used to flash Messenger when

• Used with ET/Winflash

communicationthrough service connector is

Model Usage: Marine, Industrial, and On-

• Power is provided by service connector

not possible

Highway Truck Engines

Part Number

Description

Warranty: Caterpillar ^®One Year

239-9967

Bypass Messenger Harness

JULY 2018 Diagnostic Tools

1-51

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

NEXG4514 ECAP Executive/Utility Service Program Module

Model Usage: All Electronic Controlled Engines

• Software [in Erasable Programmable Read

• Current SPM may be marked NEXG4514 V1.1,

Tested by ECAP

Only Memory (EPROM) chip]

7X-1350 V1.1, or 8C-5363 V1.1; all 3 are same

current software and will do same job; version

Warranty: Caterpillar ^®One Year

• Included in discontinued 8T-8697 ECAP; does

number printed on SPM; also displayed

not have to be ordered separately except for

on ECAP screen during power up self test

very early ECAP’s with V1.0 installed

and can be displayed on screen under SPM

• NEXG4514 runs the ECAP; selects Metric

Version Number screen

or English display units; handles interface

with SPM’s in ECAP and interface with

Reference

adapters connected to port 3; provides basic

• SEHS8741, Special Instruction

communication abilities with ports 1 and 2

NEXG4522 Truck Service Program Module, All Highway Truck Engines

Model Usage: All Highway Truck Engines

• Software [in Erasable Programmable Read

References

Only Memory (EPROM) chips] and subscription

Warranty: Caterpillar ^®One Year

• SEHS9349, Special Instruction

for updates

NEEG2501, Diagnostic Code Card

•

• Installed in discontinued 8T-8697 ECAP by

• NEEG2502, Driver’s Card

customer to provide all service functions for

all Highway Truck Engines

• Version number printed on module and can

be displayed on ECAP screen under SPM

Version Number screen compatible with all

versions of all Highway Truck Engine control

personality modules

NEXG4516 Service Program Module, Marine/Industrial Engines

Model Usage: 3408, 3412 Marine/Industrial

• All Electronically Controlled Marine and

References

Engines

Industrial Engines

• SEHS9199, Special Instruction, Using the

Warranty: Caterpillar ^®One Year

• Software [in Erasable Programmable Read

ECAP NEXG4516

Only Memory (EPROM) chips] and subscription

• Marine/Industrial SPM (included with SPM)

for updates

NEEG2490, Pocket Card

•

• Installed in discontinued 8T-8697 ECAP by

customer to provide all service functions for

all Highway Truck Engines

• Version number printed on module and can

be displayed on ECAP screen under SPM

Version Number screen compatible with all

versions of all Highway Truck Engine control

personality modules

1-52 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Cable

Model Usage: All Electronic Controlled Engines

• Used to provide power to ECAP through

• T-harness connects between ECAP and

Tested by ECAP

external power source - ECAP retains power

T-cable to ECM

during engine cranking

Warranty: Caterpillar ^®One Year

• 3 connections for external power sources are

• Used with discontinued 8T-8697 ECAP

available - 5P-7366 Cable Assembly (for

connection to battery), 8T-9276 AC Power

• Cable assemblies can be connected to AC

Supply, and Converter

power adapter or battery - T-harness allows

cable leading to electronic control module

(ECM)to remain connected

Item

Part Number

Description

7X-1856

CableAssembly-Adapter

8T-9276

Converter As - 12V DC 1A

5P-7366

Cable Assembly - Power

NEXG4518 Service Program Module, Challenger 75

Model Usage: Challenger 75

• Software [in Erasable Programmable Read

References

Only Memory (EPROM) chip]

Warranty: Caterpillar ^®One Year

• SEHS9202, Special Instruction

• Installed in discontinued 8T-8697 ECAP by

• NEEG2456, Diagnostic Code Card

customer to provide all service functions for

3176 Engine in Challenger 65/75/85 Tractor

• Version number printed on module and can be

displayed on ECAP screen under SPM Version

Number screen

NEXG4512 Configuration Aid Service Program Module

Model Usage: 3406B PEEC, 3176 Engines

• Customer Specified Parameters, including

• When using NEXG4512 program, discontinued

all truck configuration information, can be

8T-8697 ECAP can be powered by a 12-Volt

Warranty: Caterpillar ^®One Year

saved in discontinued 8T-8697 ECAP internal

Converter or from electronic engine control

• Software [in Erasable Programmable Read

memory for later use, even if power removed

using 8T-5275 T-Harness; the converter allows

Only Memory (EPROM) chip], installed in

from ECAP; can be reviewed and changed, if

use of program with discontinued 8T-8697

discontinued 8T-8697 ECAP by customer and

necessary; program steps user through any

ECAP in office or shop area; parameter values

subscription for update

parameters affected by change and provides

defined can then be printed or saved to

• User friendly, menu driven interface to help

samechecking as when values were first

discontinued 8T-8697 ECAP memory; 8T-5275

determine values for Customer Specified

entered

Cable allows program to read and write

Parameters; user defines configuration

Customer Specified Parameters directly to and

• List of configuration and parameter values can

of truck by selecting values from lists of

from electronic engine control

be printed using compatible serial interface

such items as: engine rating, axle ratio,

printer; Split Chart can also be plotted; chart

• Version number printed on module and can be

transmission, tire size and type; custom

shows shift points for each transmission gear,

displayed on ECAP screen under SPM Version

values not in the lists can be entered by user

along with engine RPM and vehicle speed

Number screen (present version number V1.1)

• Once configuration defined, program steps

limits

Reference

user through each Customer Specified

Parameter; does all necessary calculations

• SEHS88342, Special Instruction

and checks values entered for validity and

conflict with other parameters; also displays

and defaults to typical values for each

parameter

JULY 2018 Diagnostic Tools

1-53

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Adapter Cable Assembly

Model Usage: 3406 PEEC, 3176 Engines

• Help service 3406 PEEC and 3176 engines

• ”T” cables with individual tip jacks on pigtail

portion of cables; can be inserted into system

Warranty: Caterpillar ^®One Year

• Provide test points for individual wires in

wiring harness at connector locations;

wiring harness to facilitate troubleshooting of

individual tip jacks on pigtails labeled same as

engine control system

wire to which they are connected in harness;

standard probe tips, like those on multimeter

leads, can be inserted into tip jacks

Part Number

Description

326-4904

Adapter Cable Assembly, 3-Pin DT Breakout

8T-8694

AdapterCableAssembly, 5-PinBreakout

8T-8695

AdapterCableAssembly, 9-PinBreakout

8T-8726

AdapterCableAssembly, 3-PinBreakout

Adapter Cable Assembly, 40-Pin Breakout

Model Usage: 3176 Engines

• Used in servicing 3176 Engine

• ”T” cable with individual tip jacks on pigtail

portion of cable; may be inserted into

Warranty: Caterpillar ^®One Year

• Provide test points for individual wires in

electronic engine control system wiring

wiring harness to facilitate troubleshooting of

harness at connector locations; on 9X-1160

electronic engine control system

Adapter Cable Assembly 2 small probes with

tip jacks can be inserted into appropriate

connector socket to look at signal on any

wire or between any 2 wires; standard probe

tips, like those on multimeter leads, can be

inserted into tip jacks

Part Number

Description

9X-1160

AdapterCableAssembly,40-Pin Breakout

Breakout Harness for 308-5087 Air Fuel Ratio Control

Model Usage: G3408C and G3412C Natural Gas

• PC-USB Connection used to flash the air fuel

Reference

Engines with Air Fuel Ratio Control

ratio control

• REHS7861, Special Instructions

Warranty: Caterpillar ^®One Year

• Software provided

Specifications

• Connects air fuel ratio control to main engine

• Dimensions: 145 x 150 x 90 mm

wiring harness

(5.7 x 5.9 x 3.5 in)

• Breakout harness is required to update

certain G3400C Air Fuel Ratio Control systems

referenced in special instruction noted below

Part Number

Description

423-0691

Breakout Harness

1-54 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Cable Assembly, Small, 40 Pin Breakout

Model Usage: 3406E and 3176B Electronic

• Used to provide test points for individual

• Probe tips on leads of standard multimeter

Engines

wires in wiring harness

can be inserted into tip jacks of pigtail -

allows serviceman to check signal on any wire

Warranty: Caterpillar ^®One Year

• Troubleshooting of electronic engine control

or between any 2 wires

systems faster, easier, and more convenient

• Connectors are A/B keyed

• 2 probes attached to pigtail portion of harness

- 9X-1314 Wire Assembly, Red and 9X-1315

Wire Assembly, Black

Item

Part Number

Description

9X-1314

Red - Wire Assembly

9X-1315

Black - Wire Assembly

All items

7X-1715

Adapter Cable Assembly

Harness Assembly

Model Usage: All models with ADEM III and

• Contains additional ECM protection circuitry

• Improves service tools ability to maintain

A4:E4 ECMs

communicationsduring engine cranking

• Used to provide communication link between

Warranty: Caterpillar ^®One Year

Cat^®ET and ADEM III or A4:E4 ECMs

• Replace blown (open) fuse with 8K-4644 Fuse

(1 Amp)

• Used with 217-0113 Main Harness Assembly

• Donot use this harness on Cat^®Implement

• Attaches to engine harness ECM connection

and Transmission ECMs

• Requires auxiliary battery power (such as

service truck battery)

Part Number

Description

328-2292

EngineECM Bypass Harness

Harness Assembly (ADEM IV E2 ECM)

Model Usage: ADEM IV:E2 ECM

• Used to provide communication link with

• Used with 217-0113 Main Harness Assembly

ADEM IV:E2 ECM

Warranty: Caterpillar ^®One Year

Part Number

Description

277-4734

ECM Application

Harness Assembly (ADEM IV E1 ECM)

Model Usage: A4:E1 ECM

• Used to provide communication link with

• Used with 217-0113 Main Harness Assembly

ADEM IV:E1 ECM

Warranty: Caterpillar ^®One Year

Part Number

Description

224-4899

ECM Application

JULY 2018 Diagnostic Tools

1-55

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Harness Assembly

Essential Tool

• 328-2292 has additional protections to

NOTE: Discontinued 167-9225 change level

eliminate risk of damaging non-engine ECMs

00 and 01 tool kit bypass harness may damage

Model Usage: 217-0113 - ADEM II, ADEM III,

the internal circuitry of non-engine ECMs when

and ADEM IV, 328-2292 - ADEM III and A4:E4

• IMPORTANT! This protection only prevents

the tools are connected to a 12 or 24VDC power

Electronic Control Modules

damage to Cat^®non-engine ECMs and will

supply. This harness should ONLY be used to

not allow 328-2292 to work on these ECMs

Warranty: Caterpillar ^®One Year

service Cat^®engine ECMs. Inappropriate use

(see note below)

of these tools could result in a service claim

• Harness change will be implemented and

rejection. For questions, please contact the

available around the end of the second

Dealer Service Tools Hotline at 1-800-542-8665

quarter of 2008

(US) or 1-309-675-6277 (worldwide).

• This harness replaced discontinued 167-9225

Service Bypass Harness

Item

Part Number

Description

ECM Application

Bypass harnesses available for these other ECM applications

(all are used in conjunction with 217-0113 Harness)

217-0113

Main Harness

328-2292

EngineECM Bypass Harness

444-9738

ECM Application

VIMS Main, VIMS Application

Bypass harnesses available for these other ECM applications

(all are used in conjunction with 217-0113 Harness)

224-4899

ECM Application

ADEM IV E1

—

277-4734

ECM Application

ADEM IV E2

CAT Implement and Transmission ECMs

—

317-2652

ECM Application

(notavailable untilMay 2008)

Harness Assembly

Model Usage: A4:M1 and A4:M5 ECM

• Used to test implement and transmission

• 9-pin plug connects to 217-0113 Main

control modules

Harness Assembly

Warranty: Caterpillar ^®One Year

• Used with 217-0113 Main Harness Assembly

• 70-pin plugs connect to transmission or

implement ECM

• Used to provide communication link between

Cat^®ET and transmission or implement ECMs

Part Number

Description

317-2652

ECM Application

Adapter Cable Assembly, 40-pin T-harness Large Engine

Model Usage: 3500 and 3600 Engines

• Used to adapt 7X-1715 Cable Assembly to

• Adapts a square 40-pin AB-keyed connector

3500 and 3600 Engines

on 7X-1715 Cable Assembly (40-pin Breakout

Warranty: Caterpillar ^®One Year

Small Engine) to a square 40-pin CD-keyed

• Length: 30 cm (12 in)

connector on 3500 and 3600 Engines

Part Number

Description

134-5195

Adapter Cable Assembly, 40-pin T-harness Large Engine

1-56 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Breakout“T”

Essential Tool

• Used to provide test point for all individual

• Connects between ECM and main wiring

wires in engine wiring harness of 70-pin

harness

Model Usage: 3176B, C-10, C-12, 3406E, 3600

connector ECM

Natural Gas Engines and other 70-pin ECM’s

• Allows testing access to all 70 wires

Warranty: Caterpillar ^®One Year

Part Number

Description

208-0059

Breakout “T”

Breakout “T” Harness

Essential Tool

• Used to test engine wiring harness with

• Provides testing access to all 120 individual

120-pin ECM connectors

wires

Model Usage: All engines with ADEM IV ECM

• Connects ECM and main wiring harness

• Approximate length: 61 cm (24 in)

Warranty: Caterpillar ^®One Year

Part Number

Description

257-8718

Breakout “T” Harness

Breakout “T” Harness Assembly

Model Usage: All Engines with B4:M1 ECM and

• Used to test engine wiring harness with

• Providestesting access to all 54 wires during

other 54 pin ECMs

54 pin ECM connectors

operation

Warranty: Caterpillar ^®One Year

• Used with 9X-1314 Red Multimeter Test

• Approximate length: 800 mm (31.5 in)

Probes and 9X-1315 Black Multimeter Test

• Made with 18 AWG wire

Probes

• Connects ECM and main wiring harness

Part Number

Description

316-5376

Breakout “T” Harness Assembly

Model Usage: All Engines with E5 ECMs and

• Used to test engine wiring harness with 128

• Provides testing access to all 128 wires during

other 128 Pin ECMs

Pin ECM connectors

operation

Warranty: Caterpillar ^®One Year

• Used with 9X-1314 Red Multimeter Probes

• Approximate length: 800 mm (31.5 in)

and 9X-1315 Black Multimeter Probes

• Made with 18 AWG wire

• Connects ECM and main wiring harness

Part No.

Description

375-5959

Breakout “T” Harness Assembly

JULY 2018 Diagnostic Tools

1-57

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Breakout Harness (EGRV)

Model Usage: CT660

European Union Compliant, CE marked

Reference

Warranty: Manufacturer’s

• Now also used on the 2015 13L

• NEHGE2015-136

• The EGR valve electrical connector is the

same as the I6.

Part No.

Description

Dimensions

Weight

485-8926

Breakout Harness (EGRV)

76.2 x 381 mm (3 x 15 in)

0.227 kg (0.5lb)

Cable Assembly, Adapter HEUI Injector Test

Model Usage: 3116 and 3126 HEUI Engines

• Used to test injector and/or injector harness

• overall length: 1.52 m (5 ft)

Warranty: Caterpillar ^®One Year

• Allows wiring to an individual injector to be

bypassed (helps to isolate problem between

injector or harness)

Part Number

Description

127-6359

Cable Assembly, Adapter HEUI Injector Test

Probe Group

Model Usage: All Models

• Used with discontinued 6V-7070 Digital

• Eliminates need for new breakout “T” cable

Multimeter to measure voltages in wiring

for each new connector

Warranty: Caterpillar ^®One Year

harnesses without disconnecting them

• Wire: 18-gauge

• Multimeter leads plug into probe cable jacks;

• Length: 18 inches

probes then slide along appropriate wires

into rear of connector until they contact pin or

socket of interest

Part Number

Description

7X-1708

Probe, Red

7X-1709

Probe, Black

7X-1710

Probe Group

Pin and Socket Probes

Model Usage: All models

• Used to probe Deutsch pins and/or sockets

• Length: 46 mm (18 in) terminals Creates

during testing

a “hands-free” method for connecting

Warranty: Caterpillar ^®One Year

multimeter to Deutsch terminals

• Used with multimeter test leads

• Red and black color-coded for easy connection

• Can also be used to measure voltage signals

to multimeter test leads

when using a breakout “T” harness

• Wire: 18 gauge

• Multimeter leads plug into probe cable jacks

and probes are inserted into Deutsch

Item

Part Number

Description

9X-1314

Red - Wire Assembly

9X-1315

Black - Wire Assembly

309-6081

Socket Probe, Red

309-6082

Socket Probe, Black

1-58 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Cable-Breakout Tee (Engine Throttle)

Model Usage: CT660

• Tests the 2015 13L engine throttle valve

Reference

Warranty: Manufacturer’s

• Eliminates the need to probe wires, reducing

• NEHGE2015-136

potential damage

Part No.

Description

Dimensions

Weight

485-8922

Cable-Breakout Tee

76.2 x 203.2 mm (3 x 8 in)

0.227 kg (0.5lb)

Meter Pressure Tester (Coolant Cap)

Model Usage: CT660

• Used for testing the coolant cap for proper

Reference

pop off pressure

Warranty: Manufacturer’s

• NEHGE2015-136

Part No.

Description

Dimensions

Weight

485-8923

Meter Pressure Tester

101.6 x 203.2 x 254 mm (4 x 8 x 10 in)

2.268 kg (5 lb)

Leak Detection Tool

Model Usage: 3500 Marine Applications and

• This diagnostic tool is used to smoke test

• Special adapters for CT660

Various Other Engines Sizes

engines in the field to look for hard-to-find

• Tool Group Includes: storage case, two 3.9”

intake system leaks, boost leaks and exhaust

Warranty: Caterpillar ^®Six Months

intake bladders, block off coupler, exhaust

leaks in the engine exhaust systems.

stack retention hoop, smoke wand, tip

• Various sized bladders can be used for wide

adapter, halogen inspection light, temperature

variety of engine sizes.

sensor port adapter, and pressure sensor

adapter.

• Can also be used for operator cab leak

detection

• 110-250 V AC or 12v DC

• Cab is pressurized with HVAC system, and the

• Additional bladder sizes and adapters

wand is moved around the cab to look for air

available

leaks.

• Inspection light allows the vapor to be more

visible when looking for leaks.

S.No

Part No.

Description

CE Complaint

Weight

533-1177

Detector-Leak (Hd Unit)

Yes

8.12 kg (17.9 lb)

Optional Parts:

541-9345

Tool-Bladder (2.9 in Intake)

Yes

0.9 kg (2 lb)

541-9346

Adapter-Fixed (CT660)

Yes

0.3 kg (0.7 lb)

541-9347

Adapter-Coolant (CT660)

Yes

0.5 kg (1.1lb)

541-9348

Tool-Bladder (1.5 in Intake)

Yes

1.4 kg (3 lb)

541-9349

Tool-Bladder(1.9 in Intake)

Yes

1.4 kg (3 lb)

541-9350

Tool-Bladder (5.9 in Intake)

Yes

3.2 kg (7 lb)

541-9362

Tool-Bladder (3.9in Replacement)

Yes

1.4 kg (3 lb)

541-9363

Light-Halogen (Inspection)

Yes

0.9 kg (2 lb)

JULY 2018 Diagnostic Tools

1-59

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Press Plate Assembly

Model Usage: MT4400, CST45, CST65

• Second plate assembly may be purchased to

• Used when not feasible to use a single

allow use of two cylinders for pulling using

cylinder in center of H-bar such as when

Warranty: Caterpillar ^®Six Months

515-4614 modular H-bar.

pulling bearing race from MT4400 wheel hub

• Made as ordered

Part No.

Description

Diameter (L x W x H)

Weight

WLL

50 Metric Ton

517-0934

Press Plate Assembly

165 x 165 x 147 mm (6.5 x 6.5 x 5.8 in)

10 kg (22 lb)

(100,000 lb)

Pressure Test Fitting

Model Usage: CT660

• Used for engine oil pressure test on the 2013

Reference

13L engine

Warranty: Manufacturer’s

• NEHGE2015-136

• The engine has a new thread pitch and

location for testing the oil pressure

Part No.

Description

Dimensions

Weight

485-8924

Pressure Test Fitting

25.4 x 50.8 mm (1 x 2 in)

0.113 kg (0.249lb)

Cable, TDC; Adapter, SI TDC

Model Usage: All Engines with Electronic

7X-1695 Top Dead Center (TDC) Cable

• Used with ECAP/DDT

Controls

• Used on captive engine applications

• 7X-1395 Adapter allows 7X-1695 Cable to

Warranty: Caterpillar ^®One Year

be used on industrial and spark ignited (SI)

• Allows magnetic sensor to be connected to

engines

engine to input timing information to ECM

(Electronic Control Module)

Part Number

Description

7X-1395

Adapter, SI TDC

7X-1695

Timing Probe Cable

ECAP and DDT Connectors

Model Usage: All 3176 and 3406 Electronic

• Connect 8T-5275 T-Harness cable on ECAP or

• Use 1U-5805 Removal Tool (green) and

Engines

DDT to connector on dash of truck cabs

1U-5804 Crimp Tool

Warranty: Caterpillar ^®One Year

• Allow ECAP or DDT to be connected to

• Locks onto highway truck in-cab diagnostic

electronic engine control from inside cab,

connector

instead of having to open engine compartment

7X-1686 Adapter Cable

7X-1873 Connector

• Service Part: 3E-5226 Socket

• Used to replace present six-pin Deutsch

connector on older 7X-1686 Adapter Cables

(present 7X-1686 Adapter Cable manufactured

with 7X-1873 Connector)

Part Number

Description

3E-5226

Socket-Connector

7X-1403

Harness As— Adapter

7X-1686

Harness As— Adapter

7X-1873

Plug As - Connector

1-60 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Engine Adapter Cable, 3116

Model Usage: Electronically Controlled 3116

• Used to setup and test electronic engine

• Connects between under dash Packard

Engines

controls on 3116 Engines in General Motors

connector and 8T-5275, 139-4166, and

on-highway trucks

275-5122 T-Harness cable on ECAP or DDT

Warranty: Caterpillar ^®One Year

Part Number

Description

7X-1714

Engine Adapter Cable, 3116

Adapter Cable Assembly (SAE to CAT^®CAN/ATA)

Essential Tool

• Used to connect 139-4166 Diagnostic Cable to

J1939 Under-Dash Diagnostic Connector

Model Usage: On-Highway Trucks

Part Number

Description

Warranty: Caterpillar ^®One Year

157-4829

Adapter Cable Assembly (SAE to CAT^®CAN/ATA)

Adapter Cable Assembly

Model Usage: Marine engines

• Used to join 2 Cat^®electronic marine engines

• Reduces ET recording time by 50%

together to record data

Warranty: Caterpillar ^®One Year

• Provides easier data reduction by having both

• Used with Cat^®electronic technician sea trial

engines’ data on same time scale

state and transient data recorder

• Allows simultaneous data recording from both

engines using 1 laptop

Part Number

Description

211-4988

Adapter Cable Assembly

Truck Adapter Cable

Model Usage: On-Highway Trucks

European Union Compliant, CE marked

• Works with all on-highway truck models with

round 9-pin connectors, including those with

Warranty: Caterpillar ^®One Year

• Used to connect between communication

500K baud communication

adapter cable and on-highway trucks J1939

diagnostic port

• Replaces discontinued-157-4829

• SAE to CAT CAN/ATA - 500K Baud

Part No.

Description

Dimensions

Weight

507-1011

Truck Adapter Cable

50 x 50 x 200mm(2 x 2x 8in)

0.5 kg (1 lb)

JULY 2018 Diagnostic Tools

1-61

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Extension Cable Assembly (Monitor)

Model Usage: All B-Series Excavators (Except

• Used to extend monitors viewing position to

• Canbe used intraining of technicians by

307)

outside of operators compartment

allowing monitor to be viewed by more than 1

person at a time

Warranty: Caterpillar ^®One Year

• Overall length: 6.1 m (20 ft)

Part Number

Description

102-7965

Female Terminal

111-4815

Plug Connector

121-1173

Male Terminal

125-4838

Plug Lock Wedge (7)

128-8951

Receptacle Connector (Not serviced)

136-7205

Extension Cable Assembly (Monitor)

Three-Pin Packard Break-Out Cable

Model Usage: 3116 HEUI Engines in General

• Used to provide test points, for individual

• Standard multimeter probe tips can be

Motors On-Highway Trucks

wires in wiring harness, to help troubleshoot

inserted into the break out cable tip jacks

electronic engine control system

allowing service technician to check voltage

Warranty: Caterpillar ^®One Year

on any 1 wire or between 2 wires of a circuit

Sold separately and as part of 125-2580 HEUI

•

Tool Group

Part Number

Description

124-5643

Three-Pin Packard Break-Out Cable

Breakout Harness Assembly

Model Usage: 3126E and C-9 Engines

• Used to check actual current to engine-

• Cable has red and black banana plugs for

mounted hydraulic pump

multimeter connection

Warranty: Caterpillar ^®One Year

• Used with a digital multimeter that has

• Connects to any component with 2-pin,

current measuring capability

Deutsch connectors (designed with both plug

and receptacle connectors)

• Connects digital multimeter into machine

harness

• Overall length: 30.5 cm (12 in)

Part Number

Description

224-9282

Breakout Harness Assembly

Breakout Cable

Essential Tool

• Checks governor for proper voltage supply

Model Usage: 320C Excavator

Part Number

Description

248-4754

Breakout Cable

Warranty: Caterpillar ^®One Year

1-62 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Sensor Bypass Cable

Model Usage: 3116 and 3126 HEUI Engines

• Isolates sensors when testing for faults

• Also used to test for bad sensor wiring in

wiring harness

Warranty: Caterpillar ^®One Year

Part Number

Description

125-3662

Sensor Bypass Cable

Ampseal Cable Assemblies

Model Usage: All Ampseal connector

• Used to troubleshoot sensors, solenoids, or

• Universal key allows use on Key 1 (Red), Key 2

applications

controllers that use ampseal connectors

(Grey), and Key 3 (Yellow) ampseal connectors

Warranty: Caterpillar ^®Six Months

• Allows circuit to be monitored while in

• Color coded and labeled for easy identification

operation using a multimeter or scopemeter

• Each cable has a 300 mm (11.8 in) cable

• 2, 3, 4, 6, 8, and 12 pin configurations

length, a 900 mm (35.4 in) breakout length,

available

and is made from 18 AWG wire

Part Number

Pin Configuration

305-0603

2-position

305-0604

3-position

305-0605

4-position

305-0606

6-position

305-0607

8-position

305-0608

12-position

Cable Assemblies

Model Usage: All Deutsch connector applications

• Used to troubleshoot sensors, solenoids, or

• 2, 3, 4, 6, 8, 12, and 18 pin configurations

controllers that use Deutsch connectors

Warranty: Caterpillar ^®One Year

• Cables are color coded and labeled for easy

• Used with a multimeter or scopemeter

identification

• Allows circuit to be monitored while in

• Key 1 type Deutsch connectors used on many

operation

applications

Part Number

Pin Configuration

326-4903

2-Pin Connector

326-4904

3-Pin Connector

326-4905

4-Pin Connector

326-4906

8-Pin Connector

326-4907

12-Pin Connector

326-4908

18-Pin Connector

330-4424

6-Pin Connector

Cable, M300 to PC RS-232

Model Usage: M300 Excavators

• Used to setup and test electronic hydraulic

• Connects to hydraulic controls and RS-232

controls using a personal computer

computer port

Warranty: Caterpillar ^®One Year

Part Number

Description

126-7877

M300 to PC RS-232 Cable

JULY 2018 Diagnostic Tools

1-63

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Test Cable Group

Model Usage: Various engine models with three-

• Used to test three-wire, active analog circuits

Item 1

wire, active analog sensor circuits

• Used with Cat^®Electronic Technician (ET)

• Light emitting diode (LED) in test cable

Warranty: Caterpillar ^®One Year

assembly indicates sensor is receiving power

• One test cable assembly and two adapter

cable assemblies allow testing of sensor

• Test cable generates a Voltage signal that can

circuits on various Caterpillar engines

be read by Cat^®ET

• Process of elimination helps to diagnose bad

Items 2 and 3

wiring quickly

• Adapter cable assemblies connect 3-pin

Deutsch or 3-pin Amp connectors to test cable

assembly

Item

Description

Test Cable Assembly with LED Indicator and Connector

Two-Connector Adapter Cable Assembly

Three-Connector Adapter Cable Assembly

Part Number

Description

288-4325

Test Cable Group

Repair Tools for 9-Pin Amp Connector

Model Usage: 3176, 3406B

• Makes simple repairs possible on 9-pin Amp

• 4C-4704 used to insert and remove contacts

circular connector on 8T-5275 Adapter Cable

from connectors when they are being replaced

Warranty: Caterpillar ^®One Year

Assembly and on port #1 of discontinued

8T-8697 (ECAP)

Part Number

Description

4C-4704

Insertion/Removal Tool

7T-4577

8C-4145

T-Harness Connector

8C-4146

ECAP/DDT Connector

8C-4147

Endbell

8C-4148

Strain Relief

8C-4797

Socket

Top Dead Center Tool

Model Usage: C2.4 T4 Final Engines used in the

• Locks the crankshaft into the TDC position for

• Installs in place of crankshaft position sensor

304E2, 305E2, 305.5E2 Mini Hex

various service procedures

Warranty: Caterpillar ^®Six Months

Part Number

Diameter

Weight

Description

483-5054

21 x 107 mm (0.83 x 4.21”)

0.15 kg

Top DeadCenterTool

1-64 JULY 2018 Diagnostic Tools

Diagnostic Tools

TOOLS FOR ELECTRONIC ENGINES

Communication Adapter 3 Group

Essential Tool

European Union compliant, CE marked

• Flash program allows adapter firmware

upgrades as additional features become

Model Usage: All Cat^®models with electronic

• Used to monitor communication, between

available

controls

engine and PC, using service tool programs

such as Cat^®Electronic Technician on

• Uses J1939/11, high-speed data link (part

Warranty: Caterpillar ^®One Year

J1939/11 high-speed data link, Cat^®DataLink,

of ADEM III controls), substantially reducing

or J1708 (ATA) vehicle networks, or Dual

flash times

DataLink

• Automatically selects J1939/11 when

• Comes complete with cables, software CD,

flashing the engine (reduces the flash time

manual (included on CD), and carrying case

approximately 80%, from 14 minutes to 3

minutes)

• Lightweight and portable

• RP1210A compliant

Reference

• Group includes all items in Figure 1

• NEHS1032, Tool Operating Manual

• Machine data cable works with 9- and 14-pin

Specifications

diagnostic connectors.

Figure 1

• Data Links: J1708 American Trucking

Association (ATA), Cat^®Data Link (CDL), and

Software

J1939-11 high-speed data link

• Works with Microsoft Windows

• PC Connection: USB 1.1 Full Speed

• Ready to use, just install software program

onto PC using provided CD

• Operating Voltage: 9-32 VDC

• Operating Temperature: -18° to 65°C (0° to

Communication

149°F)

• Allows communication between service tools

• Size: 470 x 396 x 127 mm (18.5 x 15.6 x 5 in)

and engine controls using various data links

such as J1939/11, Cat^®DataLink, and J1708

• Weight: 2.53 kg (5.59 lb)

(ATA) vehicle networks, or Dual DataLink

Item

Part Number

Description

—

538-5051

Communication Adapter 3 Group

6V-7145

StorageCasewith317-7513 Protective Foam Pad

370-4617

PC USB Cable

457-6114

Data Link Cable, 51 cm (20 in) - use with ATA, CDL, and J1939-11

478-0235

Electronic Control Group

NETG5057, CD ROM (not available separately)

Optional Cables (Sold Separately)

In-Cab Adapter Cable; ATA, CDL, and J1939-11

157-4829

(9-pin to 9-pin applications typically found in Freightliner)

7X-1686

In-Cab Adapter Cable (ATA only)

Cat^®5 Ethernet Cable (used on machines with 14-pin diagnostic

—

385-8492

connector)

Cable, Software Flash

Model Usage: AP300D Asphalt Pavers

• Allows the existing 436-3873 cable assembly

and 436-3874 software to be flashed to the

Warranty: Manufacturer’s One Year

machine ECU that is installed on certain

AP300D pavers

Part No.

Description

Dimensions

Weight

509-7110

Software Flash Cable

101.6 x 203.2 x 50.8 mm (4 x 8 x 2 in)

0.226 kg (0.5 lb)

JULY 2018 Diagnostic Tools

1-65

Caterpillar. Dealer service tools catalog (2018) - page 2