Caterpillar. Dealer service tools catalog (2018)

Engine Tools

FUEL SYSTEMS

Common Rail Assembly Reseal and Flushing Group

Model Usage: All C175s

• Complete bench assembly for resealing and

• Configurable to provide leak test of low

flushing of C175 Common Rail Groups. (All

pressure return tubes and seals

Warranty: Caterpillar ^®Six Months

Applications)

• Assembly table, two assembly fixtures, and

• Provides a stable, adjustable and safe

adjustable holding jigs included

platform to reliably reseal, assemble, align

• Separate quill tube flushing manifold included

and flush a C175 Common Rail Fuel Group

• All necessary plugs, alignment tools and

• Reuse, salvage, resealing and flushing of the

adapters included

fuel rail provides significant cost savings and

• May be adapted to additional tubes and

offers an attractive component repair option

other fuel system components such as low

to the customer.

pressure supply/return lines or 3500 series

• Flushing system is designed to provide

fuel manifold groups

reliable and repeatable flushing results

• Two assembly fixtures improves technician

to help the dealer conform to Caterpillar

efficiency by allowing a second rail to be

Contamination Control cleanliness guidelines

assembled while the other is being flushed.

for fuel system components after rebuild.

• Reseal, assembly, and flushing time is

• Sampling port for flushing flow allows

approximately 4 man hours per rail.

monitoring of component cleanliness during

flushing process.

• Contamination monitor/particle analyzer is

required but not included.

• Twoselectable 225 L (60 gal) fluid tanks

allows for off-line filtration while rail is being

• Contact your Cat^®Dealer Service Tools

flushed.

representative for assistance and ROI

analysis.

• Two-stage off-line kidney loop filtration

utilizing Caterpillar Clean Fuel Module^®.

Reference

• Sampling ports for off-line tanks allow

• M0072382 Inspection, Salvage, Reuse, and

monitoring of fluid cleanliness before the

Cleaning of the C175 Engine Fuel Rails

flushing process.

Part No.

Description

502-0889

C175CommonRailAssemblyReseal andFlushing Group

Flushing Bench:

Dimensions

3550 x 1260 x 508 mm (139 x 49 x 20 in)

Weight

545 kg (1200 lb)

Fluid Capacity

457 L (120 gal) 2 x 227 L(60 gal) tanks

Electrical

100/230 VAC / 50/60 HZ /1 PH

Air

760 kPa (110 psi)

Acceptable Flushing Fluid

Diesel (non-bio), mineral spirits, 6V6067 calibration fluid

Assembly Table and Fixture:

Dimensions

3184 x 903 x 508 mm (125 x 36 x 20 in)

Weight

87 kg (195 lb)

Radial Fixture Adjustment

180° / 30° increments

JULY 2018 Engine Tools

3-171

Engine Tools

FUEL SYSTEMS

Fuel Injection Tube Assemblies

Model Usage: Cat^®Fuel Injection Test Bench

• Bend-to-fit lines that reduce need for special

References

(FITB) and Fuel Injection Equipment Test Stand

fuel injection lines

• NEHS0594, Tool Operating Manual, Using TMI

(FIETS)

• Data available in TMI uses 9U-6705 Master

to Find Pump Specifications

Warranty: Caterpillar ^®Six Months

Nozzles and 9U-5298 and 9U-5299 lines (see

• LEBQ0724, TechnicalMarketing Information

SEHS0594)

(TMI)

Part Number

Overall Length

Use

9U-5298

76 cm (30 in)

Used for testing all in-line pumps and 3208

9U-5299

127 cm (50 in)

Used for testing all 3400 Vee pumps

Master Nozzle Group

Model Usage: Cat^®Fuel Injection Test Bench

• Replaces discontinued 1U-5500 Master Valve

• Required when using new pump performance

(FITB) and Fuel Injection Equipment Test Stand

Assembly, 9U-5024 Master Valve Assembly,

test specifications available in TMI

(FIETS), AVM

and 6V-9470 Master Valve Assembly

• Use with 9U-5298 and 9U-5299 Tube

Warranty: Caterpillar ^®Six Months

• Used to test fuel pump delivery rates on FITB

Assemblies (high pressure fuel lines)

and FIETS

References

• Has improved accuracy of ±1% with four-

• NEHS0594, Tool Operating Manual, Using TMI

orifice tip (greatly improved over former valve

to Find Off-Engine Test Specs

assemblies with ±5% accuracy)

• LEBQ0724, TechnicalMarketing Information

(TMI)

Part Number

Description

9U-6705

Nozzle Master

Service/Repair Parts

7W-4486

Sealing Washer

9U-5037

Bleed Fitting

Storage Bags

Warranty: None

• Keep fuel lines sealed and protected from

• Transparent so the parts can be visibly

dust and dirt

identified

• Ziplock closure prevents oil and other greases

• May be used for a variety of purposes

from leakage

• 3 sealed hang holes on top of bag spaced to

• Printed with 2-color Cat^®logo, black part

fit standard one inch pegboard hooks

number, and a white area that can be written

on to identify the parts inside the bag

Clear Vinyl Back

Item

Part Number

Outside Dimensions

Ziplock Closure

and Front

Top of bag

152-0789

55.9 x 76.2 mm (22x30in)

10.0 mm

(55.9mm [22in])

Top of bag

152-0788

45.7 x 60.0 mm (18x24in)

10.0 mm

(45.7mm [18in])

Injection Pump Off Engine Test Specification Determination

Model Usage: Fuel Injection Equipment Test

• Contains complete instructions to obtain test

• Data can be obtained using injection pump

Stand

specifications through TMI on Caterpillar^®

and governor group part number, or engine

Network

arrangement number

Warranty: None

• New data format gives larger selection of

• Most current data is always available on line

data for each pump (does not require resetting

Reference

pump)

• LEBQ0724, TMI Technical Marketing

Information

3-172 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Pressure Gauge

Model Usage: All Models with Pump and Line

• Used to replace original gauges on the

• Diameter: 102 mm (4.0 in)

Fuel Systems

discontinued 6V-7900, discontinued 1U-8212,

• 1/4 inch NPT lower back connection

and discontinued 1U-8213 Fuel Injection Test

Warranty: Caterpillar ^®Six Months

• Liquid-filled, chrome-plated cast brass case

Benches, and discontinued 132-9753 and

discontinued 139-1437 (AVM)

•

Clamp and profile ring included for panel

mounting

• Replaces without modifying test stand

• Displays both kPa and PSI

Part Number

Replaces Hartridge Gauge

4C-4617

0 to 7000 kPa (0 to 1000 PSI)

8T-7637

0 to 1400 kPa (0 to 203 PSI)

9U-6099

-100 to 4000 kPa (-14 to 580 PSI)

9U-6100

0 to 700 kPa (0 to 101 PSI)

Calibration Fluid Tool Group

Model Usage: FIETS, FITB, AVM, All Cat Engines

• Used to measure viscosity and specific gravity

Reference

of SAE J967D (IS04113) calibration fluid

Warranty: Caterpillar ^®One Year

• NEHS0607, Tool Operating Manual

• Used with fuel injection equipment test stand

• NEHS0631, Tool Operating Manual, General

(FIETS) and fuel injection test bench (FITB) -

Maintenance for FIETS

helps to maintain accuracy of test equipment

NEHS0640, Tool Operating Manual, Installing

•

• Performs test to make sure calibration fluid in

Fuel Suction Port on the FIETS

test equipment is within specifications

Specifications

• Saves money - fluid is not changed

prematurely

• Case: 470 x 395 x 203 mm (18.5 x 15.6 x 8 in)

• Beakers made from durable Nalgene and

• Weight: 2.3 kg (5 lb)

Pyrex

• Viscosity Cup: Individually serialized (includes

• Hydrometers are filled with a non toxic

calibration sheets)

biodegradable measurement fluid

• Beaker Material: Nalgene or Pyrex

• Viscosity cup is individually calibrated for

• Also included (not shown) NEEG3148 Decal

eachtest 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

Item

Part No.

Description

—

398-9680

Calibration Fluid ToolGroup

Serviceable Parts

398-9676

Hydrometer Instrument

398-9677

Hydrometer Instrument

398-9678

Beaker Instrument

9U-7839

Stopwatch

9U-7841

Viscosity Cup

9U-7842

Beaker

6V-9449

Case

JULY 2018 Engine Tools

3-173

Engine Tools

FUEL SYSTEMS

Basic Mounting/Setup Group (Not Serviced)

Model Usage: All Fuel Injection Equipment Test

• Replaces discontinued 1U-7426 Pump Adapter

References

Stands (FITB, FIETS, and AVM)

Group

• NEHS0594, TMI Specification

Warranty: Caterpillar ^®Six Months

• Used to adapt injection pump mounting and

• NEHS0624, 4C-8192 Heavy Duty Coupling

drive groups to test stand

Group (Hartridge Bench UpGrade)

• Used with fuel injection equipment test

• NEHS0625, Tool Operating Manual, 3408/12,

stands (FITB, FIETS, and AVM)

PEEC NSFS

• Group has been updated to eliminate non-

• NEHS0631, FIETS General Maintenance and

current tooling and add new required tooling

Trouble Shooting

• Tooling is required for off-engine testing of

• NEHS0639, Tool Operating Manual, 3406B

injection pumps and governors

and 3406C, PEEC NSFS

• Parts are serviced separately to reduce dealer

• NEHS0640, Tool Operating Manual,

cost (no need to purchase tools already in

Calibration Fluid Suction Port

inventory)

• SEHS8024, 6V-6070 Governor Adjustment

Tool Group

• SEHS9318, 3161 Woodward Test and

Adjustment

• SMHS7013, 5P-4203 SMFS Tool Group

Item

Part Number

Description

Quantity

Basic Mounting/Setup

—

136-8330

Group (not serviced)

Mounting Hardware

6V-6103

Screw Assembly

6V-9134

Screw Assembly

6V-9138

Clamp Assembly

6V-9132

Fixture Assembly

Lines and Testing Hardware

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

Quantity

Lines and Testing Hardware

126-1827

Rod

7G-7105

Hose Assembly

3V-2744

Hose Assembly

031-2125

Hose Assembly - Hyd

Tube As-Fuel

9U-5299

Injection Test

Tube As-Fuel

9U-5298

Injection Test

3-174 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Additional Service/Repair Parts

Warranty: Caterpillar ^®Six Months

Item

Part No.

Description

Qty.

WhereUsed

Additional Hardware (Dependent on Pump Model)

1U-5223

Fitting

bleed return for 1P-1795 (discontinued)

1.60 mm (0.063 in) ID x 533.4 mm (21.0 in)

—

3P-1539

Tube Assembly

long

drive adapt Hartridge 20.00 mm (0.787 in)

6V-7793

Coupling Group

jaw

Injection Pump

1.60 mm (0.063 in) ID x 431.8 mm (17.0 in)

4L-5937

Fuel Line Assembly

long

Additional Parts

6V-9138

Clamp Assembly

fixture assembly to rail system

6V-9134

Screw Assembly

fixture assembly to bench rails (short)

6V-6103

Screw Assembly

fixture assembly to bench rails (long)

6V-9132

Fixture Assembly

target/fixture assembly to bench rails

—

126-1827

Rod

drive coupling rotation (Cat^®heavy duty)

—

1U-5223

Fitting

bleed return for 1P-1795 (discontinued)

1.60 mm (0.063 in) ID x 533.4 mm (21.0 in)

—

3P-1539

Tube Assembly

long

drive adapt Hartridge 20.00 mm (0.787 in)

6V-7793

Coupling Group

jaw

9U-6705

Nozzle Master

for master nozzle

Tube As-Fuel

1.83 mm (0.072 in) ID x 1270.0 mm (50.0 in)

—

9U-5299

Injection Test

long

Tube As-Fuel

1.83 mm (0.072 in) ID x 762.0 mm (30.0 in)

—

9U-5298

Injection Test

long

Hose Assembly

#4 (37 degree) [7/16 - 20 thdx 1016 mm

—

031-2125

- Hyd

(40 in)long]

—

1T-0416

Bolt

for master nozzle

#4 (37 degree) [7/16 - 20 thd x 610 mm

—

3V-2744

Hose Assembly

(24.0in)long]

Injection Pump

1.60 mm (0.063 in) ID x 431.8 mm (17.0 in)

4L-5937

Fuel Line Assembly

long

—

8N-5132

Clamp

for master nozzle

JULY 2018 Engine Tools

3-175

Engine Tools

FUEL SYSTEMS

Mounting Drive Group (Not Serviced)

Model Usage: 3406B, 3406C, and 3406 PEEC

• Replaces discontinued 6V-4990 Adapter Group

References

Engines

• Used to mount and test fuel injection pumps

• NEHS0594, TMI Specification

Warranty: Caterpillar ^®Six Months

• Used with fuel injection equipment test

• NEHS0624, Tool Operating Manual

stands (FITB, FIETS, and AVM)

• NEHS0639, Tool Operating Manual

• 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 Number

Description

Qty.

—

135-2916

Mounting Drive Group (not serviced)

6V-6101

Plate Assembly a

6V-8801

Nut

1J-8668

Stud

0L-1143

Bolt

9U-7709

Drain Tube

5D-1026

Hose Clamp

7G-7105

Hose Assembly

5P-6661

Fitting

6V-6102

Support Assembly

1S-0004

O-ring Seal

0S-1591

Bolt

3J-1907

O-ring Seal for 5P-9617 Adapter

8S-5953

O-ring Seal

3B-1915

Bolt

14a

2A-0762

Bolt

9U-5297

Cover

4W-0435

QuadRingSeal

4W-4616

QuadRingSeal

7H-2069

Bolt

8T-2848

Plug

8T-2849

Plug

030-7947

Elbow Fitting

1W-3151

Orifice Fitting

6N-3646

Lever

5P-0537

Hard Washer

9M-3858

Spring

6V-8918

Bolt

a. Some later 6V-6101 Plate Assemblies do not include shield.

b. 2A-0762 Bolt, is item 14 (Qty. 2) and item 22 (Qty. 1)

3-176 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Additional Required Hardware for Mounting Drive Group

Warranty: Caterpillar ^®Six Months

The following list of hardware is required, but

Drive Group (not serviced). This tooling can be

not included as part of the 135-2916 Mounting

purchased as needed.

Drive Adapters for 4C-8723 Jaw Assembly

Item

Part No.

Description

WhereUsed

Qty.

Camshaft Drive Adapter

camshaftdrive (10 degreehelix

6V-6097

Assembly

with 50 teeth)

Camshaft Drive Adapter

camshaftdrive (15 degreehelix

1U-8700

Assembly

with 50 teeth)

Camshaft Drive Adapter

camshaft drive (15.615 degree

4C-8249

Assembly

helix with 52 teeth)

Camshaft Drive Shield

6V-6099

Assembly a

4L-7124

Bolt - Hex Socket Head c

bolt, drive adapter to injection

0L-1143

Bolt

pump cam

a. Some later 6V-6101 Plate Assemblies do not include shield.

b. Part of 1P-0520 Driver Group

Adapter Part Numbers and Usage

4C-8723 Jaw

Usage

Assembly

3406 Truck Engine - 7FB and 4MG3600-DOWN, 10

6V-6097

degree Helix with 50 teeth

3406B PEEC Engine - 3ZJ, 3406B Truck Engine -

4C-8249

4MG3600-UP, 15.615 degree Helix with 52 teeth

3406B PEEC Engine - 8TC, 3406B Truck Engine -

1U-8700

4MG3600-UP, 15 degree Helix with 50 teeth

c. Requires 126-1826 Oil Shield Assembly on 6V-6101 Plate Assembly.

d. Requires 4C-8189 Drive Tube.

e. Attach the 4C-8723 Jaw Assembly onto the discontinued 4C-8192 Heavy-Duty Coupling Group.

Test Hardware (PEEC and Non-PEEC Engines)

Item

Part Number

Description

Qty

8T-1002

Position Probe (X4)

5P-4160

Point - Indicator Contact, 19.05 mm (0.75 in) long

5P-4814

Collet As - Clamp

7B-2742

Bolt

8T-9198

Rack Indicator Bracket Assembly

0S-1615

Bolt d

9U-6705

Nozzle Master

9U-5298

Tube As - Fuel Injection Test

6V-4186

Pin - Fuel Pump Timing

9U-5296

Rack Positioning Assembly a

4F-7957

Bolt

a. Parts serviced separately.

b. Non-PEEC, 3406B and 3406C Rack Adjustment

Rack Positioning Hardware (3406 PEEC Engines)

Item

Part Number

Description

9U-5292

Rack Pre-load Assembly

9U-5295

Rack Positioning Assembly

9U-5120

Spanner Wrench

JULY 2018 Engine Tools

3-177

Engine Tools

FUEL SYSTEMS

Fuel Pump and Governor D&A Tools, Zexel and Nippondenso

Model Usage: 3046, 3064 and 3066 Engines

• Used to disassemble and assemble fuel

References

injection pump and governor

Warranty: Caterpillar ^®Six Months

• SENR6572, Supplement for Fuel Injection

• Makes overhaul of pump and governor simpler

Pumps for 3064 and 3066 Engines

and faster

• SENR6573, Supplement for Fuel Injection

• Using this specialized tooling reduces the risk

Pumps for 3046 Engines

of part and component damage

Part Number

Description

Use

keep parts organized (reduces chance of

4C-6608

Holding Tray

lost or damaged parts)

Fixture Group/Mounting Plate

Item

Part Number

Description

Use

hold pump in any position for ease of repair (can greatly

4C-5602

FixtureGroup

increase mechanic’s efficiency during overhaul)

boltsto fuelinjection pump and attaches to 4C-5602

4C-5603

MountingPlate

Fixture Group; allows attachment of Nippondenso, Zexel,

and Stanadyne pump, all to the same plate

Assemble Tools for Zexel and Nippondenso Fuel Pump

Item

Part Number

Description

Use

4C-5567

Torque Adjusting Socket

remove and adjust torque control spring

126-2370

Wrench (3046 only)

remove and adjust torque control spring

4C-5085

Wrench (3064and3066 only)

remove and adjust torque control spring

5P-1720

Seal Pick

remove shims under plunger springs

remove and install delivery valve (care must

4C-6605

Tweezers

be taken not to damage this part)

install bearing on camshaft (reduces bearing

4C-4025

Bearing Installer

damage and part replacement cost)

4C-4098

Seal Installer

install sealsin front pump cover

3-178 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fuel Pump and Governor T&A Tools, Zexel and Nippondenso

Model Usage: 3046, 3064 and 3066 Engines

• Used to test and adjust fuel pump and

References

governor after an overhaul

Warranty: Caterpillar ^®Six Months

• NEHS0622, Tool OperatingManual, Testing

• Used with discontinued 8T-1001 Electronic

and Adjusting Fuel Injection Pump and

Position Indicator, 8T-1002 Indicator Probe,

Governor on 3064 and 3066 Engines

6V-3075 Indicator, and 5P-4163 Indicator Tip

• SENR6573, Supplement, Nippondenso Fuel

System

Item

Part Number

Description

Use

Mounting Tools

8S-2264

Puller Group

helps remove drive adapter from pump

9U-7493

Drive Adapter

attaches pump to test stand drive spindle

0T-0722

Bolt

attaches pump to test stand base plate

4S-9191

Flat Washer

attaches pump to test stand base plate

9U-7494

PumpMountingPlate

attaches pump to test stand base plate

pumpmountingbase (partofFuelInjection

6V-9138

Clamp Assembly

Test Stand)

0T-0924

Bolt

attaches pump to test stand base plate

3B-4506

Lock Washer

attaches pump to test stand base plate

pumpmounting base (partof Fuel Injection

6V-9134

Screw Assembly

Test Stand)

pumpmounting base (partof Fuel Injection

6V-9132

Fixture Assembly

Test Stand)

118-1713

Washer

attaches pump to test stand drive spindle

118-1711

Nut

attaches pump to test stand drive spindle

2A-4639

Bolt

attaches pump to test stand drive spindle

9U-7501

Drive Adapter

attaches pump to test stand drive spindle

Not shown

146-7767

Guard Assembly

—

2H-0191

Bolt

a. Item 13 includes: item 8, 3B-4506 Lock Washers (2)

Adjustment Tools

Item

Part Number

Description

Use

Adjustment Tools

8T-1001

Electronic Position Indicator

obtain measurement specifications

8T-1002

Position Probe (X4)

obtain rack measurement specifications

6V-3075

Indicator - Dial

obtain measurement specifications

Point - Indicator Contact,

5P-4163

obtain measurement specifications

120.65mm (4.75in)long

4C-2982

Indicator Collet

as an assembly to measure plunger lift

allows mechanic to see when fuel stops

4C-5713

Nozzle Overflow Assembly

flowing and then check timing angle

4C-5085

Wrench (3064and3066 only)

adjusts the setting of torque idling screw

4C-5567

Torque Adjusting Socket

adjusts the setting of torque idling screw

replace adjustment shims (holds plunger

4C-6509

Plunger Spring Retainer

spring off top of roller)

replace adjustment shims (holds plunger

5P-1720

Seal Pick

spring off top of roller)

4C-6605

Tweezers

helps to remove and install delivery valve

9Y-6051

Locknut

as an assembly to measure plunger lift

4C-5604

Copper Washer (2)

as an assembly to measure plunger lift

4C-4658

J-tube Fitting

as an assembly to measure plunger lift

4C-4766

Plunger Adapter

as an assembly to measure plunger lift

JULY 2018 Engine Tools

3-179

Engine Tools

FUEL SYSTEMS

Calibration Fluid and Lube Line Tooling

Item

Part Number

Description

Use

connect injection pump to

127-4365

FuelInjector Test Tube Assembly (6)

master nozzle

coverstransfer pumpopening

4C-4909

Transfer Pump Cover

during testing

returns test oil from pump

4C-5708

Copper Washer (2)

back to test stand

4C-5707

Copper Washer (2)

supplies test oil to fuel pump

4C-5706

Copper Washer (2)

supplies lube oil to pump

4C-6609

Lube Oil Supply Fitting

supplies lube oil to pump

4C-5711

Calibration Fluid Supply Fitting

supplies test oil to fuel pump

returns test oil from pump

4C-5710

Calibration Fluid Return Fitting

back to test stand

Disassemble Tools for Zexel and Nippondenso Fuel Pump

Item

Part Number

Description

Use

compresses plunger spring and roller so

4C-5601

Plunger Compressor

plunger holders can be installed and removed

designed to reach through pump case and

4C-6381

Lower Plier

remove/install plungers

hold plungers off camshaft so it can be

4C-6597

Plunger Holder

removedorinstalled

removes 4C-4024 Camshaft Holder from

4C-5580

Pulling Adapter

camshaft

hold camshaft while removing andinstalling

4C-4024

Camshaft Holder

retaining nut that holds flyweights to camshaft

makes removal and installation of roller much

4C-6380

Plunger Holder

easier

removes and installs flyweight retaining nut

4C-4956

Nut Socket

(specially designed)

Indicator Tools

Item a

Part Number

Description

Use

Indicator Tools

Electronic Position Indicator

obtain rack measurement specifications

8T-1002

Position Probe (X4)

obtain rack measurement specifications

Point - Indicator Contact,

5P-4160

obtain rack measurement specifications

19.05mm (0.75in)long

3P-1567

Indicator

obtain rack measurement specifications

attachesindicator to pump for rack

4C-5569

Measurement Adapter b

measurement

4C-2982

Indicator Collet

as an assembly to measure plunger lift

a. Item 1: Electronic Position Indicator, Use: obtain rack measurement specifications

b. Used for FIETS and AVM with heavy duty coupling

3-180 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Rack Position Bracket Group (not

serviced)

Item

Part Number

Description

Qty.

Rack Position Bracket

—

146-7780

Group (not serviced)

146-7777

Arm Assembly a

6V-2057

Contact Point

5B-9324

Set Screw a

3P-1565

Collet Clamp

Rack Measurement

146-7771

Adapter a

Not Shown

—

6V-2030

Extension a b

a. Used for FIETS and AVM with

heavy duty coupling

b. Part of 6V-6042 Indicator Con tact Point Group

Thread Adapter

This adapter is used to adapt the 4C-5601

To remove existingM26 thread adapter:

Plunger Compressor to Zexel pumps with M28

Remove block with spring fingers (heat

threaded plugs.

may be required to loosen thread lock

compound).

Remove washer and current M26 thread

adapter (silver).

Install new M28 thread adapter (black

oxide).

Install washer and block with spring fingers

(use 4C-4030 Thread Lock to secure block

with spring fingers).

Item

Part Number

Description

4C-5601

Plunger Compressor

195-0768

Thread Adapter

Engine Governor Adjustment Tools

Essential Tool

• Used to adjust governor on specific model

Reference

Industrial engines

Model Usage: C0.5, C0.7, C1.1, C1.5, C1.6 and

• KENR6228-00, Testing and Adjusting C0.5,

C2.2 Engines

• Used with 8C-4982 Allen Head Screw

C0.7, C1.1, C1.5, C1.6 and C2.2 Industrial

(M4x 20 x 0.70 mm)

Engines

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

Use

graduated in 0.01 mm increments and

330-7396

Dial Indicator

has a 20 mm (.8 in) long extension tip

fits over indicator shaft and collet locks

330-7397

Dial Indicator Holder

it in position

installs in cylinder block and allows

330-7398

Engine Block Adapter

dialindicator holder to threadinto

adapter

JULY 2018 Engine Tools

3-181

Engine Tools

FUEL SYSTEMS

Injection Pump

Model Usage: Early 3054 and 3056 Pre-Emission

• Used to disassemble and assemble Stanadyne

References

Engines

DB2 and DB4 fuel injection pump and

• SENR6574, Stanadyne Fuel System

governor used on pre-emission 3054 and 3056

Warranty: Caterpillar ^®Six Months

(Supplement)

engines

ENG95-1 IRM, for 3054 and 3056 Engine Fuel

•

• Makes adjustments to fuel pump and

Systems

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

Part Number

Description

Use

keep parts organized (reduces

4C-6608

Holding Tray

chance of lost or damaged parts)

Disassembly and Assembly Tools for Injection Pump Off-Engine

Item

Part Number

Description

Used

4C-5602

FixtureGroup

disassembly and assembly

4C-5603

Plate

hold pump during disassembly and assembly

3-182 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Bench Mounting Tools and Testing Tools

Item

Part Number

Description

Use

Qty

Bench Mounting Tools and Testing Tools

remove 9U-7493 Drive Adapter

8S-2264

Puller Group

from pump

connect fuel injection pump to

0T-0772

Bolt

mounting plate

connect fuel injection pump to

4S-9191

Flat Washer

mounting plate

118-1713

Washer

connect 9U-7493 to pump

118-1711

Nut

connect 9U-7493 to pump

connect 9U-7501 Drive Adapter

9U-7493

Drive Adapter

to bench drive

8T-6864

Valve Shut-off

9U-7501

Drive Adapter

2A-4639

Bolt

bolt 9U-7501 to 9U-7493

11a

5M-2894

Washer

bolt 9U-7501 to 9U-7493

6V-9134

Screw Assembly

secure base plate to rails

6V-9132

Fixture Assembly

6V-9138

Clamp Assembly

secure base plate to rails

0T-0924

Bolt

146-7767

Guard Assembly

2H-0191

Bolt

a. Item 11: 2M-2894 Flat Washer (Qty. 2) is also Item 15: 2M-2894 Flat Washer (Qty. 4)

Air Supply and Test Group

Item

Description

9.53 mm (3/8 in) Tubing, 0.46 m (1.5 ft)

Air Bulb (W.A. Baum Co. Inc. Catalog No. 1890)

Item

Part Number

Description

Size

Qty.

Air Supply and Test

—

4C-8740

Group

8T-0841

Plastic Case

Diff Pressure

8T-0839

Gauge

9U-6100

Gauge

4C-3974

Union Fitting

1U-5469

Pressure Gauge

Not Shown a

3J-7354

O-ring Seal

3.18 x 3.18 mm

—

4C-3973

Fitting

(1/8 x 1/8 in)

—

8T-0821

Tubing

16 m (52.5 ft)

—

5D-9231

Fitting

a. Also not shown: Male Connector, 6.35 x 3.18 mm (1/4 x 1/8 in) (Qty. 2) and Bulkhead Union, 3.18 mm (1/8 in) (Qty. 2)

JULY 2018 Engine Tools

3-183

Engine Tools

FUEL SYSTEMS

Governor Torque Control Tool Group, 3161

Model Usage: Multiple Engine Models

• Used to perform variety of in-vehicle engine

• With correct combination of lever arms and

governor and fuel system settings for D11

weights, a specific torque is applied to 3161

Warranty: Caterpillar ^®Six Months

Track-Type Tractor and the 777, 785 and 789

WoodwardGovernor speeder and terminal

Off-Highway Trucks

shafts; allows for setup of governor, setting

fuel injection timing, derating of governor for

• Easily installed on governor without removing

high altitude applications, and evaluation of

surrounding components such as alternator or

governor schedule

water hoses

Item a

Part Number

Description

Weight

Tool Group, 3161 Governor

—

4C-6100

Torque Control

4C-3975

Plastic Storage Case

a. Not shown: NEEG2435 Decal

Governor Torque Arm

Model Usage: 3500 Marine and Industrial

• Used to test and adjust 3161 governor

• Arm applies 10.3 N·m (7.60 ft-lb) of torque to

Generator Sets

governor linkage when torque arm is installed

• Applies consistent torque to governor and fuel

with center line of cylinder-shaped weight in

Warranty: Caterpillar ^®Six Months

system linkage for more accurate fuel system

horizontal position

adjustments

• Can be installed on terminal shaft of 3161

Reference

governor

• SEHS9240-01, Special Instruction

Item

Part Number

Description

—

1U-9361

Governor Torque Arm

3F-7147

Bolt

Calibration Fluid and Lube Line Tooling

Item

Part Number

Description

Use

Fuel Injector Test Tube

connect injection pump

127-4365

Assembly

to master nozzle

3-184 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Injector Sleeve

Model Usage: D11N, 3508, 3512, 3516, 777B,

• Used to cover fuel ports when cleaning

785, 789, 3500

injectors on D11N. 777B, 785, 789, and 3500

Series Engines

Warranty: Caterpillar ^®Six Months

Part Number

Description

6V-4172

Injector Sleeve

Injection Nozzle Test Kit

Model Usage: C3.3B, C3.8

• Used to accurately test Bosch and Denso

• Connects directly to the 442-1747 Pop Test e

electronic fuel injectors on C3.3B and C3.8

(not included)

Warranty: Manufacturer’s

engines

Part Number

Description

440-6907

Injection Nozzle Test Kit

Nozzle Tester Group

Model Usage: 1100, 3100, 3208, 3400

• Used to test all fuel nozzles, including pencil-

Reference

type nozzles on 1100 and 3100 Series and

Warranty: Caterpillar ^®Six Months

• SEHS7292, Special Instruction

3208 Engines, direct injection capsule-type

fuel nozzles on 3400 Series Engines, and

capsule-type nozzles used on all other engines

Item

Part Number

Description

Notes

—

5P-4150

Nozzle Tester Group

If desired, quick disconnect fittings

may be installed for faster

5P-8744

Adapter Assembly

changingof nozzleadapters; refer

to Engine News of October 3, 1979,

for installation instructions

6000 kPa (870 PSI) SEHS7605

8T-0856

Gauge

Caution Label

End fittings notincluded;included

5P-4721

Tube

with 5P-4719 and 5P-4720

5P-4244

Adapter

Includes connecting fitting for

5P-4719

Fitting

5P-4721

5P-4243

Fitting

8T-5313

Filter

4J-7533

Seal

one on each hand valve, qty. 5

6V-0183

Gasket

between reservoir and pump

8T-0859

Gauge - Pressure

25000 kPa (3600 PSI)

Available separately (not shown)

—

1U-9578

Repair Kit

JULY 2018 Engine Tools

3-185

Engine Tools

FUEL SYSTEMS

Service/Repair Parts for 5P-8744 Adapter Assembly (Sold Separately)

Item

Description

Adapter

Retainer

Item

Part Number

Description

5P-4720

Fitting d

5P-8742

Piston Assembly

2S-4663

Seal

a. Includes connecting fitting for 5P-4721

Nozzle Tester Repair Kit

Model Usage: Cat^®Engines

• Used to disassemble and assemble 5P-4150

• Allows worn or broken 5P-4150 Nozzle

Nozzle Tester Group

Tester Group to be repaired and put back into

Warranty: Caterpillar ^®Six Months

operation when used along with other service

• Contains gaskets, seals, O-rings, steel balls

parts listed in Tool Guide

and filter, along with printed parts breakdown

if parts not included in the kit are needed

Part Number

Description

1U-9578

Repair Kit

Adapter

Model Usage: Flat Seat Fuel Injection Valves

• Used to test and adjust flat seat fuel

injection valves on 5P-4150 Tester and also

Warranty: Caterpillar ^®Six Months

discontinued 1P-1795 Master Valve from fuel

injection test bench

Part Number

Description

5P-7448

Adapter a

a. Not included with tube assemblies, must be ordered separately

Fuel Ratio Control Adjusting and Synchronizing Wrench

Essential Tool

• Used to adjust fuel ratio control (similar to

• Overall length: 145.9 mm (5.74 in)

1U-6673)

Model Usage: 3114, 3116, 3126 MUI Engines

• Hex wrench size: 2 mm

Used in Challenger 35, 45, and 55 Tractors

• Shorter length provides necessary clearance

References

for Challengers

Warranty: Caterpillar ^®Six Months

• SENR6454, Service Manual, Governor

• Maybeused in place of 1U-6673 formost

applications

Part Number

Description

159-1783

Fuel Ratio Control Adjusting and Synchronizing Wrench

3-186 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fuel Collector, Extension Tube and Extension

ModelUsage: All Fuel Systems

1U-8857 Extension Tube

• Increases height of 8S-2270 Fuel Collector to

prevent splashing of test fluid; made of plastic

Warranty: Caterpillar ^®Six Months (U-8857)

• Used with 8S-2270 Fuel Collector to collect

spray from 5P-4150 Nozzle Tester or 8S-2242

Nozzle Tester

Part Number

Description

1U-8857

Extension Tube

8S-2270

Fuel Collector

Tube Assemblies

Model Usage: D6D, 528, 3300, 3046, 3054, 3056,

• Used with 5P-4150 Nozzle Tester and 5P-7448

• 6V-2170 and 5P-7448 are used on 3054, 3056,

3064, 3066

Adapter to test fuel nozzles in 3300 Series DI

3064 and 3066 Engines (14 mm x 1.5 thd)

Engines

Warranty: Caterpillar ^®Six Months

• 5P-4718 Adapter is used for, 3034 and 3046

Engines (12 mm x 1.5 thd)

Item

Part Number

Description

Used to Test

6V-2171

Tube Assembly

7N-0449 Fuel Nozzle

3J-1906

Nut (Part of 6V-2170 and 6V-2171)

3J-1905

Sleeve (Part of 6V-2170 and 6V-2171)

5P-7448

Adapter b

Not

Adapter (not included with tube

5P-4718

shown

assemblies; must be ordered separately)

b. Not included with tube assemblies, must be ordered separately

JULY 2018 Engine Tools

3-187

Engine Tools

FUEL SYSTEMS

Wrench

Model Usage: 3116 Engines

• Replaces discontinued 131-5009 Wrench

• Tamper resistant plugs protect load stop and

fuel air ratio control settings on some Type

Warranty: Caterpillar ^®One Year

• Removes and installs tamper-resistant plugs

IV governors and fuel air ratio control setting

on 3116 governors installed after 01/01/96

only on some Type V governors

• Used with standard socket and ratchet or flat

• Hex head diameter: 22.23 mm ( 7/8 in)

wrench

• Short hex design for confined spaces

Reference

• 3/8 square drive (required for dual HP

• SENR6454, Service Manual Module,

governors)

3114/3116 and 3116 Engine Governors (MUI)

Part Number

Description

148-3605

Wrench

Nozzle

Essential Tool

• Used to connect fuel leak kit to 297-7658

• M14 x 1.5 threaded end installs into manifold

Manifold Block (for measuring test fuel

block

Model Usage: C6.4 Engines

system leaks)

• Barbed end fits 8.25 mm (5/16 in) ID hose

Warranty: Caterpillar ^®Six Months

• Used with 300-4988 Fuel Leak Kit

from fuel leak kit

Part Number

Description

334-3221

Nozzle

Governor Adjust Tool Group (Not Serviced)

• Used to calibrate governors

• 1U-7431Adjusting Tool— adjusts low power

load stop setting on Type VI governors (used

• 1U-7299 Adjusting Wrench - adjusts

with 1U-7300)

governor output (load stop) position and fuel

ratio control setting on Type V and later model

• 1U-7316 Calibration Pin Group - used to

governors (used with 1U-7300)

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)

Item

Part Number

Description

—

1U-9087

Governor Adjust Tool Group

4C-9594

Wrench, 1/2 in (low idle adjustment)

1U-5548

Wrench, 8 mm (high idle adjustment)

5P-4205

Wrench b

Wrench - Fuel Ratio Control Adjusting and

4 a

1U-6673

Synchronizing

1U-6672

Rack Adjusting Wrench

Adjustment (FRC) Wrench (“Type V” 1994 and

1U-7299

later Trucks)

1U-7300

Wrench (3 mm Hex)

1U-8815

Point - Indicator Contact

1U-7316

Calibration Pin Group

1U-7431

Adjusting Tool (dual horsepower screw)

a. Warranty: Six Months

b. 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

3-188 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Adapter

Model Usage: 3114, 3116

• Used on governor transfer pump outlet fitting

• Use 3K-0360 or 8M-5260 O-ring Seal with

adapter

Warranty: Caterpillar ^®Six Months

Reference

• SEHS8868, Special Instruction

Part Number

Description

4C-9309

Spanner Pin Group

Fuel System Tools

Essential Tool

300-4988 Fuel Leak Kit

• Eliminates risk of damaging injector or inlet

rocker arm

Model Usage: C4.4 and C6.6 Engines

• Used to measure fuel leak rates on C4.4 and

C6.6 engines

• 3/8 inch square drive with T40 Torx bit

Warranty: Caterpillar ^®Six Months, except

298-5564 which is Manufacturer’s Lifetime

• Aids in diagnosing faulty fuel injectors on

• Overall length: 114.3 mm (4.5 in)

hard-to-start engines

References

298-5564 T40 Torx Socket

• SEBD9416, Service Manual (298-5564)

• Used to install injector hold down bolt on C4.4

TIBU4874, Bulletin (300-4988)

and C6.6 engines

Part Number

Description

298-5564

T40 Torx Socket

300-4988

Fuel Leak Kit

Air-in-Fuel Test Kit

• Used to check for air in fuel in C4.4 and C6.6

engines

Item

Part Number

Description

301-1501

Air-In Fuel Test Kit

Service/Repair Parts

2P-8278

Fuel Flow Tube

3P-2233

Coupler Assembly

102-5758

Hose End

3P-2234

Nipple

215-9513

Connector

124-6275

Hose Clamp

Pressure Adapter

• Used to check transfer pump pressure on C4.4

and C6.6 engines

Item

Part Number

Description

—

304-3107

Pressure Adapter

Service/Repair Parts

8T-0854

Gauge

6V-1739

Pipe Reducing Tee

3P-2236

Nipple

3P-2233

Coupler Assembly

JULY 2018 Engine Tools

3-189

Engine Tools

FUEL SYSTEMS

Fuel System Priming Group

Model Usage: CT660 with C11 and C13 Engines

• Used to prime the fuel system

• Assists in priming the fuel filter housings

and the high pressure fuel pump after either

Warranty: Manufacturer’s

component has been replaced

Part Number

Dimensions

446-7641

609.6 x 304.6 x 1219.2mm (2.0 x 1.0 x 4.0 ft)

Fuel Delivery Test Kits

Model Usage: C4.4, C6.6, C9.3 Engines

• Used to check volumetric flow rates for high-

• Volumetric fuel flow (volume over a specific

pressure rail fuel systems

time) from each outlet, can be compared to

Warranty: Caterpillar ^®Six Months

determine if fuel pump output is acceptable

• Provides a method to flush fuel outlet ports on

high-pressure rail fuel systems

Reference

• Steel fitting, orifice, and tube assembly

• KENR6938 High Leakoff of the Electronic Unit

connects to each outlet individually

Injector on C4.4 and C6.6 Engines

• Includes five high-pressure cap assemblies to

• KENR9307, UENR3402 Injector Bypass Fuel

block fuel outlets not being tested

Flow - Test, for C9.3 Engines

• Drilled orifice meters fuel flow at precise rate

Part Number

Description

323-3949

Fuel Delivery Test Kit for C9.3 Engines

362-9754

Fuel Delivery Test Kit

356-2470

GraduatedCylinder

362-9749

Discharge Orifice Assembly

362-9751

Rail Plug Assembly

362-9752

Nut

362-9753

Pin Gauge

Engine Timing Pin

Model Usage: C7.1, C6.6, C4.4

• Determines when crankshaft is positioned at

Specifications

top dead center

Warranty: Caterpillar ^®Six Months

• Dimensions: 87 x 22 x 22 mm

• Locks crankshaft in TDC position

(3.4 x 0.87 x 0.87 in)

• Weight: 0.14 kg (0.31 lb)

Part Number

Description

367-8608

Engine Timing Pin

3-190 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Connector Assemblies

Essential Tool

• Used to back flush common rail fuel system

• PEBJ0002, Caterpillar Dealer Contamination

on C175 Engines

Control Guidelines

Model Usage: C175-16 Engine - S/N WYB1-UP

• Used with 295-5490 Filter Cart, 170-8500

• PEBJ9180, Contamination Control Guideline,

Warranty: Caterpillar ^®Six Months

Particle Analyzer, and various cap/plugs (part

Diesel Fuel Cleanliness By Particle Analyzer

of 276-7018 Cap and Plug Kit)

• RENR7466, Disassembly and Assembly,

• Provides a method of flushing fuel systems on

C175-16 Generator Set Engine

C175 engines with out removing fuel system

• RENR9338, Systems Operation, Testing and

components

Adjusting, C175-16 Generator Set Engine

Reference

• RENR9339, Troubleshooting, C175-16

• SEBF9107, Reuse and Salvage Guideline,

Generator Set Engine

Procedure for Back Flushing the Common Rail

• NEHS0799, 170-8500 Analyzer Group Tool

Fuel System of C175 Engines

Operating Manual

• SEBF9109, Reuse and Salvage Guideline,

Handling Procedures for the Components

of the Common Rail Fuel System for C175

Engines

Item

Part Number

Description

Use

installed in place of high pressure fuel

330-7185

Connector Assembly

line on number two cylinder

installed in place of high pressure fuel

334-4442

Connector Assembly

line at pump outlet

301-1501

Air-In Fuel Test Kit

304-3107

Pressure Adapter

Timing Fixture Plates

Model Usage: Cat^®Engines

• Used to time accessory drive shaft to engine

with fuel pump housing and governor removed

Warranty: Caterpillar ^®Six Months

Part Number

Engine

5P-0143

3204 Engine

5P-4240

D8K Engine (14 degree 17 in timing)

8S-4625

951B Traxcavator with 4.5 in Bore engine and hydraulic governor

8S-5417

4.75 in Bore, 4- and 6- Cylinder 2-valve engines (scroll pumps)

Timing Decal

Model Usage: 1100, 3100

• Attach to crankshaft pulley or damper

pulley on 1100 and 3100 Series Engines as

Warranty: Caterpillar ^®Six Months

alternate method for flow checking static

timing without removing rocker arm shaft and

injection nozzle

Part Number

Description

2P-8256

Timing Decal

JULY 2018 Engine Tools

3-191

Engine Tools

FUEL SYSTEMS

Engine Timing Indicator Group

Model Usage: Multiple Engine Models

• Used to determine piston true top dead center

• Components for timing each engine in

(TDC) and fuel injection pump timing of most

accordance with procedure described in

Warranty: Caterpillar ^®Six Months

Cat^®engines

Special Instruction SMHS7083 listed in

application chart below

• Replaces discontinued 3S-2954 Indicator

Group

• 6V-2056 Rod and 6V-2057 Contact Point

available separately for 3300 Series DI

Engines

Model

Adapter

Rod

Contact Point

Dial Indicator and Collet

D336,1676

8T-5340

3S-3264

9S-8883

6V-3075, 5P-4814

1100 and 3100 Series 3208,

8T-3206

8S-2296

9S-8883

6V-3075, 5P-4814

3204 and 3406 DI b

3204 PC a

8T-5339

3S-3264

9S-8883

6V-3075, 5P-4814

3300 Series DI b

8T-3206

6V-2056

6V-2057

6V-3075, 5P-4814

3400 Series DI

8T-5340

3S-3264

5P-7261

6V-3075, 5P-4814

3400 Series PC a

8T-5340

3S-3264

5P-2393

6V-3075, 5P-4814

D353, D379, D398, D399

8T-5338

3S-3264

5P-6531

6V-3075, 5P-4814

Engines Not Listed Above a

8T-5338

3S-3264

5P-7261

6V-3075, 5P-4814

3406A

8T-3205

3S-3264

6V-3075, 5P-4814

3406B, 3408B, 3412B

8T-3206

5S-8090

6V-2057

6V-3075, 5P-4814

a. DI - Direct Injection

b. PC - Precombustion Chamber

Item b

Part Number

Description

Size

—

8T-5246

Engine Timing Indicator Group

5P-7276

Container

3S-3269

Contact Point

25.40mm (1in)

5P-4809

Point Indicator

50.80mm (2in)

5P-2393

Contact Point

38.10 mm (1.50 in)

9S-8883

Contact Point

12.70 mm (0.50 in)

3S-3268

Point - Indicator Contact

6.35mm (0.25in)

5P-6531

Point

57.20 mm (2.25 in)

5P-7261

Contact Point

31.80 mm (1.25 in)

6V-2057

Contact Point

3.17 mm (0.12 in) a

8S-3675

Point - Indicator

3.10mm (0.12in)

3S-3270

Point - Indicator Contact, 44.45 mm (1.75 in) long

44.50 mm (1.75 in)

6V-3075

Indicator - Dial

5P-4814

Collet As - Clamp

6V-6105

Block

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

8T-5247

Block (not serviced)

8T-5339

Adapter

8T-5340

Adapter

8T-5338

Adapter

3S-3264

Rod

180.90 mm (7.12 in)

8S-2296

Rod

133.40 mm (5.25 in)

8T-3206

Adapter

9S-0239

Adapter Assembly

5S-8090

RodAssembly

6V-2056

RodAssembly

1T-0416

Bolt

8N-5132

Clamp

8T-3205

Adapter

a. Item 6: 8T-5247 Block (Not serviced)

b. 9.52 mm (0.375 in) diameter flat face

3-192 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Torque Adapter

Model Usage: D25C, 3304B, 3306B

• 4C-9874 replaces discontinued 6V-6176

• 6V-6175 Adapter used on standard engines;

Torque Adapter

4C-9874 Adapter used on engines with

Warranty: Caterpillar ^®Six Months

automatic timing advance

• Bolted to fuel pump drive gear on 3300 Series

Engines so that specific torque can be applied

• Both adapters have 1/2 inch square drive

to gear by tightening center bolt to specified

torque value

Part Number

Description

4C-9874

Torque Adapter

6V-6175

Torque Adapter

Timing Plate

Model Usage: 1100, 3100, 3208

• Used to time fuel injection pump and governor

with front cover removed

Warranty: Caterpillar ^®Six Months

Part Number

Description

5P-0950

Timing Plate

Low-Height Fuel Injector Adjustment Tool

Model Usage: All EUI andMUI Engines 3500B

• Used to test and adjust fuel systems,

• Used on mechanical and electrical unit

1U-8869 and up

including fuel timing, rack, synchronization

injector engines

and fuel setting

Warranty: Caterpillar ^®Six Months

Specifications

• Used with digital dial indicator 369-2607

• Dimensions: 155 x 40 mm (6.1 x 1.6 in)

(preferred method)

• Weight: 0.18 kg (0.4 lb)

• Used on No. 2 cylinders or injector

adjustments on MT4400 trucks

Reference

• Built-in collets hold digital dial indicator

• NEHGE2013-030

Part No.

Description

443-4177

Low-Height Fuel Injector Adjustment Tool

443-4174

Magnetic Fixture used in the 443-4177 Timing Group

JULY 2018 Engine Tools

3-193

Engine Tools

FUEL SYSTEMS

Timing Advance Holding Tool

Model Usage: 3406B

• Used when pin timing 1988 and newer 3406B

• Required to hold timing advance at bottom of

Engines, serial numbers 4MG3600 and up,

its travel (retarded position) while pin timing

Warranty: Caterpillar ^®Six Months

that have large cone-type retainer on fuel

engine; if not used, position can slip and

timing advance

proper timing is not achieved

• Mounted on timing advance

Reference

• SEBR0544-02, Truck Engine Manual

Part Number

Description

4C-9287

Timing Advance Holding Tool

Timing Pin

Model Usage: 3054 and 3056 Engines

• Usedto setengine piston at100° before top

• Installs into nozzle bore and is held in place

dead center (BTDC) when timing Lucas fuel

with nozzle clamp

Warranty: Caterpillar ^®Six Months

pump (at this location, the piston can be more

• Material: SAE 1020 steel

accurately set to a specific position)

Reference

• Whistle on top of timing pin confirms that

piston is on compression stroke

• SENR6525, Supplement, Lucas Fuel System

Part Number

Description

127-1069

Timing Pin

Timer Tool Assembly

Essential Tool

• Used to remove and install balancer

• Also used during disassembly and assembly

(maintains timing)

of balancer

Model Usage: 3054B Engine

• Black oxide coated for corrosion resistance

Warranty: Caterpillar ^®Six Months

Part Number

Description

329-6925

Timer Tool Assembly

Timing Setting Tool

Essential Tool

Item

Part Number

Description

230-6283

LockingPin - Locks the crakshaftin the TDC position

Model Usage: C4.4, C6.6, C7.1 3054E and 3056E

231-8848

Balancer Fitting Pin

Engines

Balancer Locking (Timing) Pin - Locks driveshaft of balancer in correct

231-8849

Warranty: Caterpillar ^®Six Months

position for removal and installation (not for C6.6 or C7.1)

230-6284

Locking Pin - Locks the camshaft in the TDC position

Timing Tool - Installs in fuel injector port of 3056 and uses contact with the

226-2270

piston to determine TDC. Refer to RENR2427

226-2268

Tappet chamber oil plug tool

3-194 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Timing Pin

Model Usage: C4.4, C6.6, C7.1, 1.1L, 1.2L, 3300,

• Used to determine when crankshaft is

• 208-9388 adapter has male ½-20 thread on

3176 and 3400 Engines

positioned at top dead center

one end, 9/16 - 18 male thread on other end

STOR to replace stock adapter in the 136-

Warranty: Caterpillar ^®Six Months

• Spring loaded pin presses against flywheel;

4632 timing pin. Used for flywheel housings

as engine is rotated pin will drop into hole as

with ½ - 20 threads.

number one cylinder reaches TDC

• Hardened pin to resist bending

• Adapters furnished to fit models listed with

sufficient clearance behind timing hole

• No adapter needed for 3300 and 3400

• Easier to use than a bolt— allows one man

• Requires 268-1966 adapter for C4.4, C6.6, and

operation

C7.1 engines

• Adapters are installed onto the existing

• 220-2793 timing pin is used as replacement

adapter on pin assembly, based on thread

for the pin that comes with the 136-4632.

size in flywheel housing of your engine.

Part No.

Description

Male End Size

Female End Size

Use

136-4632

Timing Pin Adapter

1/4- 18 NPFT

9/16 - 18 STOR

139-7063

Timing Pin Adapter

7/16 in - 20

1/4- 20 NPFT

1.1 and 1.2 L Engines

139-7064

Timing Pin Adapter

1/2 in - 20

1/4- 18 NPFT

3176 C10/12 Engines

220-2793

Timing Pin

117 mm approx. length

268-1966

M18 x 1.5

1/4- 18 NPFT

Timing Pin, Adapter

Essential Tool

• Pin and adapter allows use of 136-4632

• Used for flywheel housings with ½ - 20

Timing Pin with D6R and D7R flywheel

threads.

Model Usage: 3176C Engine, D7R Track-Type

housings

Tractor and C-9 Engine, D6R Track-Type Tractor

• Spring loaded pin presses against flywheel.

• Used with 208-0888 Crankshaft Turning Tool

As engine is rotated pin drops into hole when

Warranty: Caterpillar ^®Six Months

number one cylinder reaches TDC

• Easily determines when crankshaft is

positioned at top dead center

• Easy to use - allows 1-man operation

• 208-9388 adapter has male ½-20 thread on

• Hardened pin resists bending

one end, 9/16 - 18 male thread on other

• 208-9387 pin is used as replacement for pin

end STOR to replace stock adapter in the

that comes with the 136-4632.

136-4632.

Item

Part No.

Description

208-9388

Adapter

136-4632

Timing Pin

208-9387

Pin (133 mm approx. length (127 mm from shoulder of pin to the tip)

Spring (part of timing pin)

PIN (Camshaft Timing)

Model Usage: C3.4B

• Used to keep camshaft from rotating when

Specifications

the idler gear is removed

Warranty: Caterpillar ^®Six Months

• Dimensions: 82 x 11.5 mm (3.22 x .45 in)

• Used to maintain timing of fuel injection pump

• Weight: .05 kg (.11 lb)

Part Number

Description

435-3146

PIN (Camshaft Timing)

JULY 2018 Engine Tools

3-195

Engine Tools

FUEL SYSTEMS

Timing Pin Assembly

Model Usage: Machines with Tier 4 Engines

• Used to pin engine without removing extra

• Material: Steel

components needed for Tier 4 compliance

Warranty: Caterpillar ^®Six Months

• Black oxide finish for corrosion resistance

• Shorter pin allows pinning of engine when

Specifications

space is limited

• Dimensions: 19 x 105 mm (.75 x 4.1 in)

• Used with existing adapter, 208-9388

• Weight: .12 kg (.26 lb)

• Adapter fits flywheel housing thread size of

¼-18 NPFT

Part Number

Description

433-7100

Timing Pin Assembly

Timing Pin

Model Usage: 14M and 16M Motor Graders

• Used on either the C11 equipped 14M, or the

• Constructed of steel

C13 equipped 16M Motor Grader, with a 277-

Warranty: Caterpillar ^®Six Months

Specifications

4434 Flywheel Housing

• Length: 105.8 mm (4.2 in)

The technician is not required to remove the

•

ECM or engine oil dipstick to perform timing

• Diameter: 7.5 mm (0.3 in)

• Spring-loaded timing pin allows the

• Weight: 0.1 kg (0.2 lb)

technician to install the timing pin and then

rotate the engine by himself.

Part No.

Description

456-7526

Timing Pin

Timing Adapter Pin

Essential Tool

• Allows use of a timing pin

Model Usage: C4.4, C6.6, C7.1 Engines

Part Number

Description

268-1966

Timing Adapter Pin

Warranty: None

High-Pressure Fuel Pump Removal and Installation Tools

Model Usage: C3.8 T4 Final Engines

• Allows the removal and installation of the

gear for the high pressure fuel pump

Warranty: Manufacturer’s

Part No.

Description

Dimensions

Weight

506-3178

Puller

Hex, 41 x 40.5 mm (1.6 x 1.6in)

0.227 kg (0.5lb)

506-3179

Installation Jig

54 x 42 x 13 mm (2.13 x 1.65 x 0.5 in)

0.454 kg (1 lb)

506-3179

3-196 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fuel Pump Locking Pin

Model Usage: C7.1, C6.6, C4.4

• Used to lock the fuel injection pump in the

• Engages into rear of pump drive gear

correct timing position

Warranty: Caterpillar ^®Six Months

Part Number

Description

364-9107

Fuel Pump Locking Pin

Open Socket (17 mm)

Model Usage: C6.6 and C7.1 Engines

• Accesses fuel line connectors/fuel line nuts

• Thin-walled, 3/8" drive, 12-point crowfoot

provides easy access near fuel line

Part Number

Description

367-2771

Open Socket (17 mm)

Timing Fixture Group

Model Usage: 3054 and 3056 Engines

• Four separate tools used in combination to

Reference

check accuracy of timing mark location on fuel

Warranty: Caterpillar ^®Six Months

• SENR5547, Service Module in SENR5555

injection pump or engine

Service Manual

• Needed to determine location of timing mark

on engine if front cover is replaced

Item

Part Number

Description

—

9U-6188

Timing Fixture Group

9U-6189

Drive Adapter

9U-6191

Pointer

Pump Timing Tool Group

Essential Tool

• Used to set timing of common rail fuel pump

• Required for installation to ensure proper

operation of fuel pump

Model Usage: C6.6 Engines

Warranty: Caterpillar ^®Six Months

Part Number

Description

338-1054

Pump Timing Tool Group

JULY 2018 Engine Tools

3-197

Engine Tools

FUEL SYSTEMS

Fuel Spanner

Model Usage: 3054 and 3056 Engines with

• Used to remove and install Bosch fuel

• Square drive: 3/8 inch

Bosch Fuel Pumps

injection pumps

• Socket size: 13 mm, 12-point

Warranty: Caterpillar ^®Six Months

• Built-in ratchet mechanism reduces removal/

installation time

Part Number

Description

157-3719

Fuel Spanner

Timing Gauge

Model Usage: 3056 Engines with Bosch Pumps

• Replaces discontinued 136-3113 Timing

• Used to hold dial indicator while checking

Gauge

injection pump timing on engines with Bosch

Warranty: Caterpillar ^®Six Months

EPVE fuel pump

Part Number

Description

192-3331

Timing Gauge

Crankshaft Turning Group

Essential Tool

• Used to rotate engine crankshaft

• Designed with internal bearings for smooth

rotation

Model Usage: C4.2, C6.4, 3054, and 3096

• Used with 1/2 inch drive

Engines

• Bolts to access hole in flywheel housing

Warranty: Caterpillar ^®Six Months

Part Number

Description

299-9126

Crankshaft Turning Group

Engine Turning Group

Model Usage: 3516, 3520, and 3524 Large

• Used to rotate engine crankshaft

• Heavy-duty design uses two needle bearings

Mining Truck Engines

for smoother rotation

• Used with 1 inch socket

Warranty: Caterpillar ^®Six Months

• Bolts to access hole in flywheel housing

Part Number

Description

285-5989

Engine Turning Group

Engine Turning Tool

Essential Tool

• Used to turn crankshaft in engines with rear

• Heat-treated for added durability

PTO flywheel housing (engages forward spline

Model Usage: 3176C and C-9 Engines

• To install: remove cover plate or hydraulic

of upper PTO gear)

pump as needed

Warranty: Caterpillar ^®Six Months

• Used in applications where no flywheel

Specifications

turning tool access is provided

• Square drive: 3/4 in

• Spline: 14-tooth

Part Number

Description

208-0888

Engine Turning Tool

3-198 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Engine Turning Handle, Engine Turning Pinion

Model Usage: C3.4B

• Used to turn engine over by hand using a

Specifications

common wrench

Warranty: Manufacturer’s

• Assembled Dimensions: 76.2 x 76.2 x 127 mm

(3.0 x 3.0 x 5.0 in)

442-7300

Part Number

Description

442-7300

Engine Turning Handle

445-2702

Engine Turning Pinion

445-2702

Barring Group

Model Usage: 3500, 3600, and C175 Engines

• Used to rotate engine during valve setting and

• Opposing male/female disconnects between

timing procedures

air motor and control pendant for easy

Warranty: Caterpillar ^®Six Months

assembly and to ensure consistent directional

• Used with shop air supply and dealer-supplied

control (rotation)

connectors

• Control pendent group and air motor group

• Makes engine rotation much easier and

disconnects can be coupled together to

enables one-person operation

provide air line contamination control when

• Rugged design provides maximum durability

tooling is not assembled

and dependability

Depending on engine, use access cover or

•

• 620 kPa (90 PSI) air pressure produces more

remove starter to install barring tool

than 203 N·m (150 ft-lb) of torque

Air motor mounting flange can be positioned

•

• Reversible-vane, air motor provides

through 360 degrees of rotation for different

precise control in both clockwise and

applications

counterclockwise directions

328-2307 Muffler offered as serviceable part

•

• Incorporates pull pin locking device that

• 334-3258 Service Kit available for air motor

engages/disengages barring motor

rebuild

• Air supply and lock-out valves prohibit

unintentional tool operation

• Dual pendent levers control direction (CW/

CCW) and speed (pressing lever farther down

increases rotation speed)

Part Number

Description

329-3831

Barring Group

Service/Repair Parts

328-2307

Muffler

334-3258

Service Kit

Barring Device

Model Usage: C175 Engines

• Manually rotates crankshaft on C175 Engine

• Bolts to starter access hole in flywheel

housing

Warranty: Caterpillar ^®Six Months

• Used with M34 Socket

Part Number

Description

279-3473

Barring Device

JULY 2018 Engine Tools

3-199

Engine Tools

FUEL SYSTEMS

Rotating Crankshaft Tools

Model Usage: C15, C16, 3400, 3508, 3512

Item

Part Number

Description

Use

Engines and 5.4 inch Bore Engine

Position 1P-7410 Timing Plate on discontinued

9S-9114

Spacer

8S-2346 Shaft Assemblywhen settinglifters

Warranty: Caterpillar ^®Six Months

off engine

9S-9082

Turning Tool, 1/2 in drive

Rotate crankshaft

Containsinternal needle bearings; bolts

238-9586

Turning Tool, 1/2 in drive

to flywheel housing for easier rotation of

crankshaft

Rotating Crankshaft Tools

Model Usage: 3114, 3116 and 3126 Engines

• Used to rotate crankshaft (makes setting

• Fastens to starter mounting hole using starter

valves and engine timing procedures easier)

mounting bolts

Warranty: Caterpillar ^®Six Months

• Used with 5P-7305 Engine Turning Gear and

• Rotate gear shaft housing assembly until

1/2 inch square drive ratchet

5P-7305 Engine Turning Gear engages

flywheel gear before tightening starter

mounting bolts

Part Number

Description

Size

Measure dimension X on starter housing to determine which part to use

5P-7305

Engine Turning Gear

6/8 and 8/10 pitch

9U-6943

Shaft Housing Assembly

146mm(5.75in)

9U-7336

Shaft Housing Assembly

127mm(5.00in)

Crankshaft Turning Tool

Model Usage: C4.4, C6.6, C7.1, 3054, 3056

• Used to rotate crankshafts (connects directly

Reference

Engines

to front of crankshafts)

• SENR5555, Service Manual

Warranty: Caterpillar ^®Six Months

• Has 1/2 inch drive in center to connect ratchet

or breaker bar

• Dimensions: 50 x 140 mm (2.0 x 5.5 in)

Part Number

Description

9U-6198

Crankshaft Turning Tool

Socket

Model Usage: 3114, 3116, 3126 MUI, HEUI, and

• Used to turn engine crankshaft by hand

• Prevents over-tightening or loosening of a

3126B Engines

single bolt when it used to turn crankshaft

• Socket crossbars engage all four bolt heads in

clockwise or counterclockwise

Warranty: Caterpillar ^®Six Months

front pulley hub

• Square drive: 3/4 inch

• Overall length: 90 mm (3.5 in)

Part Number

Description

178-8615

Socket

3-200 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Socket Assembly (C9.3 Engine)

Essential Tool

• Used to rotate crankshaft by hand

• Socket cross-bars engage four front pulley

hub bolts eliminating need for removal to

Model Usage: All C9.3 Engines

• Used with 3/4 inch square drive ratchet

attach turning tool

Warranty: Caterpillar ^®Six Months

Part Number

Description

Size

Overall diameter: 79 mm (3.11in) x

350-7549

SocketAssembly (C9.3Engine)

87 mm (3.43in)long

Gear Shaft Housing Assembly, Engine Turning Gear

Model Usage: Cat^®Engines

• Makes engine rotation much easier for valve

• Piniongear has 6/8 pitch gear on one end and

setting and timing procedures, especially on

8/10 pitch on other

Warranty: Caterpillar ^®Six Months

engines with no compression release

• Both ends of pinion have 1/2 inch square drive

• Any engine that will accept standard short

hole to accommodatestandard ratchet

and long nose electric starters can be rotated

Part Number

Description

5P-7305

Engine Turning Gear

5P-7306

Gear Shaft Housing Assembly

Cap, Plug

Model Usage: D5B, D6D, D9N, IT28, 943, 953,

• Used to protect fuel pumps (cap) and lines

963, 973

(plug) when removing them from engine

Warranty: Caterpillar ^®Six Months

Part Number

Description

2F-2990

Plug

5F-2807

Cap

Reamer Assembly

Model Usage: 1100, 3100, 3200 and 330 Series

• Removes carbon deposits from bores of

Direct Injection Engines

pencil-type fuel nozzles

Warranty: Caterpillar ^®Six Months

Part Number

Description

6V-4089

Reamer Assembly

Extractor

Model Usage: 3400 Series Direct Injection

• Used to remove fuel nozzle adapter body on

Engine

3400 Series Direct Injection Engines and most

other engines with precombustion chambers

Warranty: Caterpillar ^®Six Months

Part Number

Description

5P-6229

Extractor

JULY 2018 Engine Tools

3-201

Engine Tools

FUEL SYSTEMS

Fuel Injection Valve Nut Removal Tools

Model Usage: Cat^®Engines

• Used for fuel injection valve nut removal on

early engines

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

Size

9B-2029

Wrench

13/4in hex

Wrench

17/8in hex

Cleaning Tool Group

Model Usage: 1100, 3100, 3208

• Used to properly service pencil-type injection

Reference

nozzles used in 1100 and 3100 Series and

Warranty: Caterpillar ^®Six Months

• SEHS7292

3208 Engines

Part No.

Description

546-3323

Cleaning Tool Group

Included in 8S-2245 Cleaning Tool Group:

Part No.

Description

2P-8279

5P-0958 and 8S-2254

2P-8279

Locknut Adapter

5P-0958

Retractor Assembly-V

5P-4813

Socket

6V-4979

Seal Tool

8S-2246

Wire Assembly, 0.20 mm (0.008 in)

8S-2247

Wire Assembly, 0.28 mm (0.011 in)

8S-2249

Cleaning Pad

8S-2250

Holding Tool

8S-2251

Drill -Sac Hole

5P-4813

6V-4979

8S-2254

Retractor Assembly-V

8S-2255

Scraper - Tip Seat

8S-2256

Vise Assembly - Pin

8S-2257

Loupe

8S-2258

Brass Wire Cleaning Brush

8S-2260

HoningStone

8S-2246 and 8S-2247

8S-2249

8S-2250

8S-2251 and 8S-2255

8S-2258

8S-2259

8S-2257

8S-2260

8S-2256

3-202 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fuel Injection Nozzle Tool Tester

Model Usage: C3.3B, C3.8 Engines with Bosch or

• Pop Tester connects directly to the 440-6907

Specifications

Denso Injectors

injector test kit for testing Bosch and Denso

• Dimensions: 660.4 x 146.05 x 285.75

electronic fuel injectors

Warranty: Manufacturer’s

(26 x 5.75 x 11.25 in)

Part Number

Description

442-1747

Fuel Injection Nozzle Tool Tester

Nozzle Puller Group

Model Usage: D5B, D6D, 225B, 225B-3208,

• Used to remove direct injection fuel nozzles

3208, 518

from 1100, 3100, 3200 and 3300 Series DI

Engines

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

—

6V-4061

Nozzle Puller Group

1B-4206

Nut

2S-5658

Washer

6V-4153

Plate

4 a

6V-4152

Screw

6V-4150

Leg

6V-4149

Jaw

6V-4151

Leg

a. Also part of 6V-4061 Puller Group

Nozzle Puller Group

Model Usage: D5B, D6D, 225B, 225B-3208,

• 6V-4054 Puller Group used with 6V-4061

3208, 518

Group to remove 7N-0449 Nozzles in 3300

Series DI Engines (all parts of 6V-4061 Puller

Warranty: Caterpillar ^®Six Months

Group, except 6V-4153 Plate, needed)

Item

Part Number

Description

—

6V-4054

Nozzle Puller Group

0S-1618

Bolt

Nozzle Puller Group

Model Usage: 3406

• Used for removal of 8N-7006 Direct Injection

• Uses several parts from earlier 6V-4061

Fuel Nozzles from 3406 Engines

Nozzle Puller Group

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

—

6V-6981

Nozzle Puller Group

1B-4206

Nut

2S-5658

Washer

6V-4152

Screw

4 a

6V-6982

Sleeve Assembly

5 a

6V-6983

Adapter

a. These parts are needed to make the 6V-6981 Nozzle Puller Group from the earlier 6V-4061 Nozzle Puller Group.

JULY 2018 Engine Tools

3-203

Engine Tools

FUEL SYSTEMS

Nozzle Puller Group

Model Usage: 3300

• Replaces discontinued 6V-3129 Puller

NOTE: The 6V-6980 Puller Group should only

be used when less than 150 pound-inches torque

Warranty: Caterpillar ^®Six Months

• Used for removing 8N-7003 and 8N-7005

is required to pull the nozzle. The nozzle stem will

Nozzles used in 3300 Series Engines; can also

bend or break if more than 150 pound-inches

be used for removal of discontinued 8N-7001

torque is applied with the 6V-6980 Puller. For

and 8N-7002 Nozzles

nozzles that are extremely difficult to remove,

• Required because carbon build-up around

the 1P-0074 Slide Hammer is still recommended.

nozzle stems prevent nozzles from being

Whenusing these tools, it is often necessary to

removed by hand

remove various engine components.

Item a

Part Number

Description

—

6V-6980

Nozzle Puller Group

6V-6197

Screw

6V-6198

Clip

6V-6199

Button

4 b

6V-6130

Puller

a. Item 4: 6V-6130 Puller (not serviced)

b. Not serviced

Puller Group

Model Usage: 3204

• Used to remove discontinued 1W-3996 Direct

NOTE: As indicated in the parts list, several

Injection Fuel Nozzles on 3204 Engines;

parts of the 6V-6976 Puller Group are also

Warranty: Caterpillar ^®Six Months

nozzles tend to stick in their bores due to

used in the existing 6V-4061 Nozzle Puller Group.

carbon deposits, etc.

If the dealer already has the 6V-4061 Group, only

the last 4 parts (items 5, 6, 7 and 8) are needed

to assemble the 6V-6976 Group.

Item

Part Number

Description

—

6V-6976

Nozzle Puller Group

1B-4206

Nut

2 a

2S-5657

Washer

3 a

6V-4153

Plate

4 a

6V-4152

Screw

6V-6979

Leg

6V-6978

Head

6V-6977

Leg

1D-4716

Nut

Nozzle Puller Assembly

Model Usage: 3306 Engine

• Used to remove 104-9450 Direct Injection Fuel

• Using specialized puller makes nozzle removal

Nozzle Assembly

faster, easier, and helps prevent damage

Warranty: Caterpillar ^®Six Months

• Requiredfor nozzle removal (carbon build-up

• As of June 1, 1994 the 104-9450 Fuel

around nozzle stems prevents removal by

Injection Nozzle is used only in the European

hand)

market

Part Number

Description

4C-8175

Nozzle Puller Assembly

3-204 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Nozzle Puller Group

Model Usage: Cat^®Engines

• Combines all components of 5 nozzle puller

Reference

groups listed below without duplicating

Warranty: Caterpillar ^®Six Months

• SEHS8094, Special Instruction

commonly-used components

• Also included are various maintenance items,

such as 6V-4979 Carbon Stop Seal Too, 25

extra carbon stop seals and 6V-4089 Reamer

for carbon removal; socket, extension and

handle included for removal of 5/16 inch-12

point hold down screws used on some nozzle

clamps

Nozzle Puller Group

Engine Used On

Nozzle Part Number

6V-6981

3406

8N-7006

6V-6980

3300 Series

8N-7005, 8N-7003

6V-6976

3204

9N-2366, 9N-3299, 1W-5829,

6V-4061

1100, 3100 and 3200 Series

9L-6969, 9N-3299

6V-4054

3300 Series

7N-0449

Part Number

Description

Quantity

6V-7020

Nozzle Puller Group

Service/Repair Parts

5P-7276

Container

Case - Plastic, NEEG2574 Group

6V-3072

Decal on lid

6V-4054

Nozzle Puller Group

6V-4089

Reamer Assembly

6V-4149

Jaw

6V-4150

Leg

6V-4151

Leg

6V-4979

Carbon Stop Seal Tool

6V-6976

Nozzle Puller Group

6V-6980

Nozzle Puller Group

6V-6982

Sleeve Assembly

6V-6983

Adapter

6V-7031

Block

9L-9098

Carbon StopSeal

9S-1715

Socket

9S-1721

Extension

Fuel Nozzle and Fuel Nozzle Adapter Tools, 3406B Engine

Model Usage: 3406B

• Smaller tools required to remove and install

cylinder heads on 3406B Engines, which

Warranty: Caterpillar ^®Six Months

were redesigned with smaller diameter fuel

injection nozzle adapters

Item

Part Number

Description

1B-4206

Nut

8T-3199

Screw

6V-6983

Adapter

8T-3198

Sleeve Assembly

JULY 2018 Engine Tools

3-205

Engine Tools

FUEL SYSTEMS

Injector Puller Connector

Model Usage: 3054, 3056, 3064, and 3066

• Used to remove stuck injector nozzles due to

• Used with 1U-7600 Puller Group

Engines

carbon deposit build-up in bore

• 1/2 - 20 thread (female) on one end and

Warranty: Caterpillar ^®Six Months

M12 x 1.5 thread (female) on other end

Part Number

Description

9U-6278

Injector Puller Connector

Nozzle Retainer Spanner Wrench

Model Usage: 3406B, 3406C, 3408, 3408B, and

• Replaces discontinued 8T-3139 Spanner

Specifications

3412 Engines with P and L Fuel Systems

Wrench and 9U-5840 Spanner Wrench

• Hex size: 14.28 mm (9/16 in)

Warranty: Caterpillar ^®Six Months

• Used to remove and install 7W-2315 Fuel

• Overall height: 20.5 mm (0.81 in)

Injection Nozzle Retainer

• Overall diameter: 41.0 mm (1.61 in)

• Provides additional clearance for 3406B and

• Distance between pins: 28.5 mm (1.12 in)

3406C Engines equipped with Jacobs Engine

Brake

• Made from SAE 4140 steel and heat-treated

for long tool life

Part Number

Description

134-2570

Nozzle Retainer Spanner Wrench

Wrench

Model Usage: See below

• Used on following engines to remove and

• Works on both 7W-1645 (old style) and

replace nozzle adapters

7W-5435 (new style) Nozzle Adapters

Warranty: Caterpillar ^®Six Months

• Larger and stronger to eliminate breakage

• Has 1/2 inch square drive for normal usage,

when removing tight adapters

and 28.57 mm (1 1/8 in) hex so larger drive

socket can be used when removing tight

adapters

Engine

Serial No.

3406B

All

3408

S/N 78Z-1277-up

S/N 67U-11092-up (DI only)

3412

S/N 81Z-4579-up

S/N 38S-13223-up

—

S/N 60M-2477-up

Part Number

Description

1U-9725

Wrench

Guide

Model Usage: 3406

• Replaces discontinued 5P-4755 Guide

• Used to properly install 5P-2060 Seal onto

4N-3761 Direct Injection Capsule Valve

Warranty: Caterpillar ^®Six Months

Adapter on 3406 Engines

Part Number

Description

6V-7025

Guide

3-206 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Injector Height Setting Gauge, Spacer Sleeve

Model Usage: 3406E Engines

9U-7227 Injector Height Setting Gauge

247-5377 Torque Screwdriver

Warranty: Caterpillar ^®Six Months

• Used to adjust injector Prestroke

• Tightens torx screws to the proper torque

without damaging the injector

• Leaves both hands free to make adjustments

• Torque range of 5-40 in lbs

187-0482 Spacer Sleeve

• Accepts all standard screwdriver bits

• Used to help prevent improper injector height

settings

References

• Used with 9U-7227 Injector Height Gauge

• SENR5580, Service Manual

with a straight indicator pin (spacer sleeve

• SENR6421, Service Manual Module,

can be ordered separately)

Disassembly and Assembly 3406E Engines

• Sleeve rests against injector spring to keep

gauge square on spring retainer

• Earlier gauges with a support flare machined

onto the indicator pin do not need this spacer

• All new gauges include a spacer sleeve

Item

Part Number

Description

9U-7227

Injector Height Gauge Assembly

187-0482

Spacer Sleeve

4L-5966

Setscrew

1U-9084

Flag

247-5377

Torque Screwdriver

Tool Group, 3408 PEEC and 3412 PEEC

Model Usage: 3408 and 3412 PEEC Engine

• Replaces discontinued 4C-9579 Tool Group

• 90 mm (3.54 mm) long timing pin

Warranty: Caterpillar ^®Six Months

• Used to test and adjust fuel pump timing on

• Two 89 mm (3.50 in) long rack zero pins

3408 and 3412 PEEC Engines

• Modified 19.05 mm (3/4 in) crowsfoot with

• Increased accuracy

3/8 inch drive

• On-engine field adjustments expand capability

• Slotted 1 5/16 inch socket with 1/2 inch drive

of field service mechanics

• Solenoid spanner wrench with 3/8 inch

• Increases service revenue opportunities

square drive

• Durable, high quality design - convenient

• 6V-2112 Pin for Haliburton Engines

case protects tool investment

Item

Part Number

Description

—

9U-5127

Tool Group, 3408 PEEC and 3412 PEEC

9U-5120

Spanner Wrench

136-3124

Socket-Sensor (rack)

6V-2112

3 and6

6V-4186

Pin - Fuel Pump Timing

4C-9581

4C-9582

CrowfootWrench,19.05 mm (3/4in)

Not Shown

9U-5128

Foam

6V-3073

Case - Plastic

JULY 2018 Engine Tools

3-207

Engine Tools

FUEL SYSTEMS

Nozzle Puller Group

Model Usage: 3200, 3300

• Works to pull all 7000 Series Fuel Nozzles on

• Replaces two nozzle pullers: 6V-6980 Nozzle

3200 and 3300 Series Engines; short enough

Puller Group for 3300 Series Engines and

Warranty: Caterpillar ^®Six Months

to use on rear cylinders on 3208 Engines in

6V-6976 Nozzle Puller Group for 3204 Engines

highway trucks

• Has two adapters, one with full clamp for

• Strong enough to pull stuck nozzles on 3300

3300 Series Engines and one with half clamp

Series Engines

for 3200 Series Engines

Part Number

Description

1U-8780

Nozzle Puller Group

Tool Group 3406 PEEC Engines

Model Usage: 3406B PEEC Engine

• Replaces discontinued Tool Group (to update

• Remove and install 6T-9675 Solenoid (fuel

former1U-5540, order 9U-5103 Slotted

shutoff)

Warranty: Caterpillar ^®Six Months

Socket, and NEEG2516 Decal

• Set timing position sensor, necessary before

• Used to set clearance dimension between

8T-5282 DDT and/or discontinued 8T-8697

engine speed sensor and 4W-2485 Slotted

ECAP can be used to calibrate timing position

Retainer (pulse wheel)

sensor

• Establish zero rack position, necessary before

• Remove and install water temperature sensor

discontinued 8T-8697 ECAP can be used

Reference

to calibrate rack position sensor without

breaking governor seals

• SEHS8746, Special Instruction

Item

Part Number

Description

Size

—

9U-5219

Tool Group 3406 PEEC Engines

8T-9198

Rack Indicator Bracket Assembly

5P-4814

Collet As - Clamp

9U-5120

Spanner Wrench

6V-4186

Pin - Fuel Pump Timing

90mm (3.54in)

1U-5426

Zero Rack Compressor Assembly

6D-3982

Nut

7F-2359

Spring

9S-8903

Point

2.4mm (0.094in)

9U-5103

Slotted Socket

5P-0326

Crowfoot Wrench

19.05mm ( 3/4in)

1U-5536

Crowfoot Wrench

33.33mm (15/16in)

1U-5425

Timing Gauge Assembly

Not shown

Decal

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

a. 12.7 mm (0.5 in) diameter flat face with a bevel to 9.7 mm (0.38 in) diameter

Rack Preload Assembly (3400 PEEC)

Model Usage: 3406, 3408, and 3412 Series NSFS

• Used to set the PEEC injection pump rack

• Fits in place of pumps electronic control unit

(PEEC) Engines with Fuel Injection Pump and

position without an electronic control system

(BTM)

Governor Group

• Fluted knob provides easy adjustment

9U-5292 Rack Preload Assembly

Warranty: Caterpillar ^®Six Months

• Used to hold pressure against (preload) rack in

• Outside diameter: 82.6 mm (3.25 in)

plus direction

• Knob: 1V-5044

Part Number

Description

9U-5292

Rack Pre-load Assembly

3-208 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Rack Position Group (3400 PEEC)

9U-5295 Rack Positioning Group

• Parts are serviced individually

• Used to limit travel of rack and make precision

References

rack adjustments

NEHS0625, Tool Operating Manual

•

• Fits in place of the rack shut-off solenoid

•

NEHS0639, Tool Operating Manual

• Knurled surfaces provide better grip while

adjusting rack position

Part Number

Description

9U-5295

Rack Positioning Assembly

Rack Positioning Group Consists of:

3S-2713

Full Hardened Nut

Gas Regulator Setting Tool Group

Model Usage: All gas engines with Fisher Gas

• Used to adjust gas line pressure regulator on

• Allows adjustment of gas regulator spring

Regulators

entire current and non-current lines of spark

with no leakage at air side of regulator; air

ignition engines

leakage during adjustment causes incorrect

Warranty: Caterpillar ^®Six Months

settings

• Can service engines equipped with both

smaller regulator used on 3304 and 3306

and 2 of the larger regulators used on larger

engines

Item

Part Number

Description

Quantity

—

8T-5160

Gas Regulator Setting Tool Group

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

8T-5149

Fitting

6L-7141

Gasket

3H-8012

Gasket

6V-6105

Block

Assembled Setting Tool

Model Usage: All gas engines with Fisher Gas

Application Procedure

• 3400, 3500 Positive Pressure Regulator,

Regulators

1 each:

Select appropriate tool, adapter and gasket

- Adapter

Warranty: Caterpillar ^®Six Months

for regulator being set and assemble using

- Tool

8T-5149 Fitting

- 8T-5149 Fitting

To install, remove gas regulator cap and

- Gasket

thread adapter into regulator in place of

• 3400, 3500 Vacuum Regulator, 1 each:

cap; push tool shaft down until it engages

- Adapter

adjustment screw or nut and tighten fitting

- Tool

just enough to seal off any air leaks around

- 8T-5149 Fitting

shaft

- Gasket

Specifications

• 379, 398, 399 Positive Pressure Regulator,

• 03304, 3306 Positive Pressure Regulator,

2 each:

1 each:

- Adapters

- Adapter

- Tools

- Tool

- 8T-5149 Fittings

- 8T-5149 Fitting

- Gaskets

- Gasket

• 379, 398, 399 Vacuum Regulator, 2 each:

• 3304, 3306 Vacuum Regulator, 1 each:

- Adapters

- Adapter

- Tools

- Tool

- 8T-5149 Fittings

- 8T-5149 Fitting

- Gaskets

– Gasket

JULY 2018 Engine Tools

3-209

Engine Tools

FUEL SYSTEMS

Gas Regulator Cap Assembly

Model Usage: All Models with discontinued 7E-

• Used to adjust gas line pressure on

• Eliminates costly engine downtime

3407 Gas Regulators

discontinued 7E-3407 Gas Regulators

• Allows adjustment of regulator with no

Warranty: None

• Adjust regulator while engine is running

leakage

Item

Part Number

Description

Gas Regulator Adjusting Tool

155-3062

Regulator Adjusting Tool

8T-5149

Fitting

123-5974

O-ring

Fuel Injection Pump Extractors

Model Usage: All Models with discontinued 7E-

• Use the extractor and wrenches to remove

Buttress Taps

3407 Gas Regulators

and install fuel injection pumps and retaining

• Bottoming

bushings

Warranty: None

• For cleaning threads on 3300 NSFS and 3400

NSFS fuel system pumps

Size

Threads Per Inch

Part Number

Pitch Diameter

1.375 in

1U-6725

33.746 ± 0.090 mm (1.329 ± 0.004 in)

1.750 in

1U-6726

43.276 ± 0.090 mm (1.704 ± 0.004 in)

Item

Part Number

Description

Use

8S-2244

Extractor

With 8S-2244 Extractor to remove and install fuel

8S-2243

Wrench

injection pumps on 1100 and 3100 Series Engines and

engines with Sleeve Metering Fuel Systems

With 8S-2244 Extractor to remove and install fuel

8T-5287

Wrench

injection pumps on engines with compact fuel systems;

replaces discontinued 8S-4613 Wrench

Remove and install fuel pump retaining bushings where

Wrench, 3/8 in

5P-1668

space does not permit use of 8S-2243 Wrench on 1100,

drive

3100 and 3200 Series Engines

Compressor Group

Model Usage: 3406

• Used for servicing fuel pump plunger and

Reference

barrel assemblies on 3406 Engines with New

Warranty: Caterpillar ^®Six Months

• SMHS8278, Special Instruction

Scroll Fuel System

• Needed to compress heavier pump lifter

springs on these engines when plunger and

barrel assemblies are removed and installed

Item

Part Number

Description

—

6V-7050

Compressor Group

2N-3476

Screw (4)

5M-7418

Nut

4B-1228

Screw

4B-2046

Nut

Not shown a

148-5675

Case

—

148-5677

Block

a. Also not shown: Block

3-210 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Off-Engine Lifter Setting Tool Group

Model Usage: All Engines with Forged Body or

• Replaces 5P-6600 Tool Group

• Tools required for individual engines are

Compact Fuel Systems

listed in the application chart below

• Includes lifter setting tools for all current

Warranty: Caterpillar ^®Six Months

engines, including 3400 Series Engines

• Additional tools needed, but not included,

with 6V-4180 Group are also illustrated

• Also included are shaft assemblies which

clamp positively to camshafts, eliminating

movement between camshaft and degree

wheel

6V-4180 Off-Engine Lifter Setting Tool Group

Item

Part Number

Description

—

6V-4180

Off-Engine Lifter Setting Tool Group

9S-6332

Box Assembly

9S-8105

Liner

Application Charts for 6V-4180 Tool Group

Components of 6V-4180

Tool Group (Fig. 1)

D311, D312, D315, D318, D339, D342, D364, D375, D386, D397, D468,

D326, D337,

D346,

D379, 641, 650,

Item

Part No.

Description

D3400, D4400, D4600, D6100, D6600, D7700, D8800, D11000, D13000,

D343, 619C,

D348,

D349

D398, 651, 657,

D17000

824A, 1693

D349

D399

660, 666

Forged Body Fuel System

2S-6160

Washer

0S-1594

Bolt

0S-0509

Bolt (3/8 - 16)

0S-1617

Bolt

1P-7410

Degree Wheel

JULY 2018 Engine Tools

3-211

Engine Tools

FUEL SYSTEMS

Compact Fuel System

Components of 6V-4180 Tool

Group (Fig.1)

D311H, D320,

D330D, D333,

1140, 1145, 1150,

D334, D343,

Item

Part Number

Description

1670, 1673, D8,

D336, 1676

1160, 3145, 3150,

3406

3408, 3412

1674, 6193

583, 3204, 3304,

3160

3306

CompactFuel System

5P-4158

Gauge

1F-1375

Bolt

2S-6160

Washer

2S-0932

Washer

0S-1594

Bolt

0S-0509

Bolt

0S-1517

Bolt

Pointer

6V-6019

1J-6298

Bolt

2M-5218

Shaft

24b

5P-1768

Pointer

9S-4446

Shaft

5P-3601

Adapter

31b

1P-7410

Plate

b. The 7.14 mm (0.281 in) diameter hole must be increased to 8.5 mm (0.328 in) diameter for use on later 3408 and 3412 fuel pump housings.

Additional Tools Needed But Not Included in 6V-4180 Group

Item

Part Number

Description

1B-3680

Bolt

3F-1417

Washer

36a

6V-2012

Gauge Group

6V-7926

Indicator Group

38a

9M-4567

Wrench

9M-4568

Wrench

a. Optional

3-212 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fixture Group

Model Usage: Cat^®Engines

• Designed with adjustable clamp and

for other engines with fuel pumps having reverse

5-position turret

flow check valves

Warranty: Caterpillar ^®Six Months

• 1 position used for 3406B Engines with New

Reference

Scroll Fuel Systems and remaining 4 positions

• SMHS8378, Special Instruction

Item

Part No.

Description

—

6V-7870

FixtureGroup

4B-6060

Setscrew (2)

4B-2046

Nut

2N-3476

Screw (4)

Sockets for Special Applications

Model Usage: 3208, 1100, D379, D398, D399

Item

Part Number

Description

Size

Use

Required for tachometer drive adapter shaft removal

Warranty: Caterpillar ^®Six Months

Deep Well

5/8in,

on 1100 and 3100 Series Engines equipped with

9S-5031 a

Socket

3/8 in drive

hydraulic governors; also used for removal and

tightening cap on 9L-6969 Nozzle for 3208 Engines

Required to loosen bolt which retains automatic timing

Deep Well

9/16 in,

8S-2357

advance unit to fuel injection pump camshaft on 1100

Socket

3/8 in drive

Series Engines equipped with max-min governor

Socket

Turning injection pump camshaft when setting lifters

9S-6054

3/4 in drive

Assembly

on D379, D398 and D399 Engines

a. Comes with insert for removing spark plugs

Timing Pin

Model Usage: 1100, 3100, 3406, 3408, 3412,

Item

Part Number

Description

Model

3306, 3304 D.I.

6V-2112

1100 and 3100 Series and 3406 Engines

6V-6019

3408and3412 Engines

Warranty: Caterpillar ^®Six Months

6V-4186

Pin - Fuel Pump Timing

3306 and 3304 D.I. Engines

Not Shown

3P-1544

328 SMFS

—

4C-9581

3408/12 PEEC

Timing Pin

Model Usage: 3054 and 3056 Engines

• Used to install injection pumps on 3000 Series

engines

Warranty: Caterpillar ^®Six Months

Part Number

Description

Use

150-3992

Timing Pin

Required to install Bosch injection pumps

150-3993

Timing Pin

Required to install Lucas and Stanadyne injection pumps

Hook

Model Usage: Cat^®Engines

• Used to pull rack against rack centering pin on

• On some of these engines, overfueling spring

engines with negative rack settings

may not move rack against centering pin

Warranty: Caterpillar ^®Six Months

Part Number

Description

6V-7942

Hook

JULY 2018 Engine Tools

3-213

Engine Tools

FUEL SYSTEMS

Decal for Degree Wheel

Model Usage: 3406B

• Used to time 3406 Direct Injection Truck

• Decal, SEHS7306, must be applied to early

Engines (1978 Truck Model Year) with static

1P-7410 Degree Wheels for accurate timing

Warranty: Caterpillar ^®Six Months

fuel injection timing

• Decal provides timing marks in increments

less than one degree

Part Number

Description

1P-7410

Degree Wheel

Spring Compressor

Model Usage: 3406, 3408 and 3412 Engines

• Works on all three engines - 3406, 3408

• Clamps on side of pump housing and

and 3412

eliminates need to attach to adjoining pump

Warranty: Caterpillar ^®Six Months

• Used to compress heavier lifter springs in

References

pump when fuel pump plunger and barrel

• SENR5148, Service Manual

assemblies are removed and installed

• SENR4658, Service Manual

Part Number

Description

9U-5692

Spring Compressor

Rethreading Die

Essential Tool

• Used to cut additional threads on 214-5491

• Current threads align die onto filler neck

Filler Neck

during use

Model Usage: 613C II, DV-613C II Scraper

• Used with large wrench (dealer supplied)

Warranty: Caterpillar ^®Six Months

Specifications

• Additional threads allow gasket in fuel cap

• Thread size (inch): 4-12

to seal against filler neck and prevent fuel/

• Hex size: 178 mm (7.0 in)

vapor leaks

• Material: steel

Part Number

Description

318-6237

Rethreading Die

Fixture, Bearing Driver

Model Usage: 3408, 3412

• Used to install tanged fuel rack bearings on

3408 and 3412 Engines

Warranty: Caterpillar ^®Six Months

Part Number

Description

5P-6217

Fixture

5P-6218

Bearing Driver

Rack Setting Gauge

Model Usage: D333, D330, D320, D311H

• Replaces 8M-0530 Gauge

• Measures rack travel in both fuel on and fuel

off directions

Warranty: Caterpillar ^®Six Months

Part Number

Description

7S-7113

Rack Setting Gauge

3-214 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Driver, Plate

Model Usage: 3406B

• Used to install D-shaped rack bearing in fuel

• Assure bearing installation to correct depth

injection pump housing on 3406B Engines

and angle

Warranty: Caterpillar ^®Six Months

• 6V-4825 Plate, bolted to pump housing, pilots

Reference

bearing as it is driven into position with

• 3406B Service Manual

6V-4824 Driver

Part Number

Description

6V-4824

Driver

6V-4825

Plate

Overfueling Spring Compressor

Model Usage: Cat^®Engines

• Used to make fuel rack and fuel ratio control

• Plunger travel in former 6V-2128 Compressor

settings on engines with New Scroll Fuel

was limited by mechanical stops and would

Warranty: Caterpillar ^®Six Months

Systems

not permit checking full range of rack settings

on above engines; 6V-7941 Compressor

• Replaces discontinued 6V-2128 Overfueling

does not have internal stops, and thus will

Spring Compressor

accommodate full range of rack settings

Part Number

Description

6V-7941

Compressor Assembly

Rack Set Tool

Model Usage: 3034 Engines

• Used to adjust maximum fuel setting if timing

Reference

case or fuel pump linkage are removed or

Warranty: Caterpillar ^®Six Months

• SENR5013, Disassembly and Assembly of

repaired

3034 Engine

Part Number

Description

158-8665

Rack Set Tool

Rack Positioning Assembly

Model Usage: 3204, 3300, and 3406 Series NSFS

• Used to set injection pump rack while pump is

Specifications

(Non-PEEC) Engines

being tested on test bench

• Overall length: 171.4 mm (6.75 in)

Warranty: Caterpillar ^®Six Months

• Used with FITB, FIETS, and AVM test benches

• Thread size: 1/4 - 28

Reference

• Bolt hole diameter: 7.5 mm (0.30 in)

• NEHS0639, Tool Operating Manual

• Distance between holes: 63.6 mm (2.50 in)

• Service part: 6V-8187 Nut

Part Number

Description

9U-5296

Rack Positioning Assembly b

a. Non-PEEC, 3406B and 3406C Rack Adjustment

JULY 2018 Engine Tools

3-215

Engine Tools

FUEL SYSTEMS

Body Group

Model Usage: 3208

• Used to remove fuel pump drive gear from

• Replaces 5P-2371 Puller Plate (provides more

taper on drive shaft before removing sleeve

pulling force than 5P-2371)

Warranty: Caterpillar ^®Six Months

metering fuel system on 3208 Engines

• Needed because of lack of space in vehicle

Item

Part Number

Description

—

6V-4069

Body Group

5L-4041

Bolt (2)

2H-0191

Bolt

6V-4088

Washer

Rack Position Tool Group

Model Usage: Cat^®Engines

• Provides convenient and accurate way to set

• Replaces discontinued 9S-0240 Rack Position

or check rack position on Cat^®Engines

Tool Group; both groups are identical, except

Warranty: Caterpillar ^®Six Months

new group contains metric dial indicators and

• Used to measure fuel rack position during

low cost plastic case

normal operation of engine, or measure

fuel rack position and make any necessary

Reference

adjustments while engine is shut down

• SEHS8436, Special Instruction

• Rack setting can be made or checked without

removing injection pump

Item

Part Number

Description

Size

RackPosition Tool

—

6V-9128

Group

6V-9127

Liner

6V-7145

Case

0S-1616

Bolt

25.4 mm (1/4in - 20 x 1.00in)

3 c

9S-0239

Adapter Assembly

4 d

5S-8086

Contact Point

6.35mmOD(0.25inOD)

5S-8090

RodAssembly

9S-8521

Rod

Light - Continuity

8T-0500

Testing

6V-3075

Indicator - Dial

6V-6106

Dial Indicator

177-9037

Block

Spring

2A-0762

Bolt

16.0 mm (1/4in - 20 x 7/8in)

9S-7343

Bracket Assembly

9S-0227

Bracket Group

2H-0191

Bolt

16.0mm(10 -24 x0.625in)

9S-0225

Bracket Assembly

3P-1565

Collet Clamp

5P-4814

Collet As - Clamp

5P-7276

Container

9S-0229

Contact Point

9.5 mm (0.4 in)

9S-8518

Plug

9S-8519

Plug

9S-8903

Point

9.50mm (0.4in)

3S-3269

Contact Point

25.4mm (1.0in)

9S-8883

Contact Point

12.7mm (0.5in)

Point - Indicator

3S-3268

6.35mm (0.25in)

Contact

8S-3675

Point - Indicator

3 mm(0.12 in)

Not Shown

4C-3474

Cap

a. Also Item 13

b. Also Item 10 and 19

3-216 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Bracket Group

Item

Part No.

Description

—

9S-0227

Bracket Group

Bracket Assembly

Plug

Rod

Service/Repair Parts

2A-0762

Bolt

5S-7348

Screw

Service/Repair Parts for Rack Position Tool Group

Item

Part No.

Description

Bracket Assembly

Plug

Hole Attachment

Service/Repair Parts

2A-0762

Bolt

5S-7348

Screw

3F-9190

Dowel

Tool Group

Model Usage: Cat^®Engines

Part Number

Description

Qty.

6V-6070

ToolGroup

Warranty: Caterpillar ^®Six Months

6V-6070 Tool Group Contains

021-7956

Bolt

0S-1614

Bolt

0S-1615

Bolt a

2A-0762

Bolt

2P-8264

Socket

2P-8265

Socket

5B-5689

Gasket

5P-4814

Collet As - Clamp

6V-2014

Bracket Assembly

6V-2017

Tool

6V-2030

Extension b c

• Used to check and adjust rack and fuel ratio

6V-2105

Tool As. - Rack ADJ

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

control linkage on all engines with New Scroll

6V-3075

Indicator - Dial

Fuel Systems (NSFS) - new procedure

6V-4186

Pin - Fuel Pump Timing

now used to check and adjust rack on these

6V-6104

Block

engines

6V-6105

Block

6V-6106

Dial Indicator

Reference

6V-6151

Adapter (Overfueling Spring Compressor)

• SEHS8024, Special Instruction

6V-7941

Compressor Assembly

6V-7942

Hook

• Form SEHS8024

8H-3128

Bolt - Hex Socket Head

• Form NEEG2119 (Label)

8H-9178

Bolt

8T-9198

Rack Indicator Bracket Assembly

• Form SEES5641 (Layout Chart)

9S-0229

Contact Point

9S-8903

Point

—

Arm

—

Arm (Part of 6V-2014)

a. Parts serviced separately.

b. Used for FIETS and AVM with heavy duty coupling

c. Part of 6V-6042 Indicator Contact Point Group

JULY 2018 Engine Tools

3-217

Engine Tools

FUEL SYSTEMS

Sleeve Metering Field Service Tool Group

Model Usage: Cat^®Engines

Item

Part Number

Description

Size

Qty.

Sleeve Metering Field Service

Warranty: Caterpillar ^®Six Months

—

5P-4203

ToolGroup

3P-1549

Block

5P-0301

Driver

1P-0529

Handle

4B-4280

Washer

1D-4538

Bolt

1D-4533

Bolt

3K-4910

Screw

0S-1603

Bolt

8B-8817

Plug (Not shown)

8T-0853

Gauge, 0 - 400 kPa (0 - 60 PSI)

5P-0318

Driver

1P-0463

Plate

1.000in Diameter

6L-5551

Bolt

2 1/4 in long

4L-7124

Bolt - Hex Socket Head a

1 1/4 in long

4B-4276

Flat Washer

76.2 long (1/8in

3B-7734

Adapter STR

NPT x 3 in)

• Used for disassembly, assembly, testing and

Seal - O-ring - STOR for 8C-3446

3J-7354

adjusting Sleeve Metering Fuel System; used

(not pictured)

17b

5D-9231

Connector

for fuel setting

6J-3958

Coupling

• Metric tools; values for testing and adjusting

3P-2210 c

Socket

given in metric pressures

19 d e

5P-6602

Adapter

20d

5P-4205

Wrench f

• As a result of changes and improvements in

3P-1544

test and adjust procedures, the discontinued

4H-0553

Fitting

3P-1550 Sleeve Metering Field Service

19.2831 mm

5P-0299

(0.7592 in)

Tool Group was converted to the 5P-4203

17.8587 mm

S.M.F.S. Tool Group. Dealers should check

5P-0298

(0.7028 in)

the list to determine what tools are required

25 f

5P-4209

Gauge

to convert their discontinued 3P-1550 Group

3J-6956

Spring

to the 5P-4203 Group. Some parts of the

8S-7271

Setscrew

discontinued 3P-1550 Group are no longer

8S-2243

Wrench

3P-1565

Collet Clamp

needed, but a number of items should be

5P-0302

Bar (Injector Removal)

retained in case of the need for dynamic

33b

6V-3071

Seal Guide

checking of sleeve shaft movement.

3P-1567 Indicator, Includes:

3P-1567

Indicator

Reference

30d

5P-4228

Spring

• SMHS7013, Special Instruction

30d

5P-6531

Point

57.2mm (2.25in)

The following parts which, were in the discontinued 3P-1550 Tool Group, should be retained in case

of the possible need for dynamic checking of sleeve shaft movement

0S-1616

Bolt

—

7B-2742

Bolt

—

3K-6896

Gasket

a. Part of 1P-0520 Driver Group

b. Not included in early 5P-4203 Groups

c. Special socket

d. Tools which must be procured to convert the discontinued 3P-1550 Tool Group to the 5P-4203 Tool Group. The 3P-1567

Indicators from discontinued 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.

e. NOTE: The discontinued 5P-4226 Adapter was replaced by the 5P-6602 Adapter, which is required for 3208 Engines with EGR

systems.

f. Warranty: Six Months

3-218 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Sleeve Metering Calibration Tool Group

Model Usage: Cat^®Engines

• Used for calibrating (similar to lifter setting)

Metric tools; values for testing and adjusting are

sleeve metering fuel pumps in shop

given in metric terms, with exception of torque

Warranty: Caterpillar ^®Six Months

values and pressures

• Several tools from 5P-4203 Tool Group also

needed for this operation

Reference

• SMHS6988, Special Instruction

Item

Part Number

Description

Size

Sleeve Metering

—

3P-2200

Calibration Tool Group

7W-8120

Bushing

1P-7379

Microgauge

3P-1568

Indicator

6V-3185

Base

6V-3186

Collet

3P-1546

15.9410 mm (0.62 in)

3P-1545

17.3734 mm (0.68 in)

10a

5P-6557

Spring

a. Part of pump assembly

Additional Calibration Tools

Item

Part Number

Description

Additional Tools from 5P-4203 Tool Group Required forPump Calibration

8S-2243

Wrench

5P-6602

Adapter

5P-4205

Wrench a

5P-4206

Wrench

1D-4533

Bolt

1D-4538

Bolt

5P-4209

Gauge

8S-7271

Setscrew

2P-8264

Socket

6V-0190

Clamp (2)

a. Warranty: Six Months

Reaming Tool Group

Model Usage: 225B, 225B-3208, 3208, 613C

• Used to ream 5P-4810 Camshaft Bearing when front bearing requires replacement in sleeve

metering fuel system pump housings

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

5P-3516

Reaming Tool Group

5P-3515

Reamer

5P-3057

Fixture Assembly

Driver, Bit

Model Usage: Cat^®Engines

• Capable of applying torque required to remove and install mounting bolts for later 8N-2663

Flyweight Carrier in sleeve metering fuel systems

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

Size

6V-4164

Driver

1/4 in Hex, 3/8 in Square Drive

6V-4163

Bit

1/4 in and 1/8 in Hex

JULY 2018 Engine Tools

3-219

Engine Tools

FUEL SYSTEMS

Fuel Setting Tool Group

Model Usage: Cat^®Engines

• Contains only those tools needed for checking

• All tools in this group also contained in

and adjusting fuel setting on engines with

5P-4203 Field Service Tool Group

Warranty: Caterpillar ^®Six Months

Sleeve Metering Fuel Systems

Item

Part Number

Description

—

5P-6577

Fuel Setting Tool Group

1D-4533

Bolt

1D-4538

Bolt

5P-4205

Wrench a

3P-1544

3J-6956

Spring

5P-0299

5P-0298

3P-1565

Collet Clamp

3P-1567

Indicator

5P-6602

Adapter

8S-7271

Setscrew

8 b

5P-6531

Point

5P-7319

Box

a. Warranty: Six Months

b. Part of 3P-1567

Sleeve Metering Calibration Tool Group

Model Usage: 3208

• Makes adjustment of sleeve levers easier on

• Formerly, tolerances on sleeve lever had

Sleeve Metering Fuel Systems

to be exact to 0.002 mm (0.00008 in); it

Warranty: Caterpillar ^®Six Months

was necessary to use 3P-2220 Calibration

• When used with 6V-4980 Torque Screwdriver

Tool Group to make an adjustment this

Tool Group, adjustment to sleeve levers on

exact; tolerances were changed to 0.05 mm

3208 Engine takes about 5 minutes instead of

(0.002 in) with a maximum of 0.05 mm

15 to 30 minutes

(0.002 in) between each lever, and 6V-4141

Tool Group can make this adjustment

accurately and faster

Reference

• MHS7835, Special Instructions

Item

Part Number

Description

Size

Sleeve Metering

—

6V-4141

Calibration Tool Group

6V-4137

FixtureGroup

3P-1545

17.3734 mm (0.68 in)

8T-0888

Washer

3P-1546

15.9410 mm (0.62 in)

Fixture Group

Model Usage: Cat^®Engines

• Used for disassembly and assembly of unit injectors, and to check assembled injectors for free rack

movement

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

—

6V-4830

FixtureGroup

5L-1100

Bearing

2N-7229

Spring

Screw

3-220 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Calibration Tools

Model Usage: 3208 Engines with Heavy Sleeve

• Used to set, test, and adjust heavy sleeve

• 146-5068 Hex Key required for on engine

Metering Fuel System

metering fuel pumps - these tools are not

adjustment for aftercooled engines

available as a group and should be ordered to

Warranty: Caterpillar ^®Six Months

• All tools can be stored in a 6V-3073 Case; 6V-

supplement existing tool groups

4094 foam (convoluted) is used in the lid; two

• Used with 3P-2200 Sleeve Metering

foam blocks are required in the case bottom,

Calibration Tool Group, 5P-4203 Sleeve

6V-4873 topped with 2P-8289 (convoluted); all

Metering Field Service Tool Group, and

foam is cut to fit the case

5P-6577 Fuel Setting Tool Group

References

• The 3P-1565 Collet, 8S-7271 Setscrew, and

• REHS0063, Special Instructions, Sleeve

3J-6956 Spring are required for this operation

Setting

and are part of 5P-4203 Sleeve Metering Field

Service Tool Group or 5P-6577 Fuel Setting

• SENR3688, Service Manual

Tool Group

• A 6V-6082 Bit, 5/64 Hex, part of 6V-4980

Torque Screwdriver Tool Group, is required

for 8S-7271 Setscrew to adjust the injection

pumps

Item

Description

Original Load Stop Cover Bolts

Item

Part Number

Description

Used with

Used to

3P-2200 Calibration Tool

Set sleeve lever position

Calibration Pump

141-6727

Group for sleeve lever

on control shaft during

Assembly, 3208 HSMFS

setting

injection pump assembly

Preset sleeve lever

position before final

3P-2200 Calibration Tool

calibration (use a

141-6737

Adjustable Micro-Gauge

Group for sleeve lever

wicking sealant to lock

setting

screw in place the first

time this gauge is used)

Hold calibrating and

3P-2200 Calibration

zero pins for rack setting

Tool Group for sleeve

and positioning control

145-1853

Calibration Fixture

lever setting 5P-4203 or

shafts for sleeve setting

5P-6577 for fuel setting

(required for all 3208

adjustments

HSMFS and 3208 SMFS

injection pumps)

3P-1565

Collet Clamp

8S-7271

Setscrew

Position sleeve during

pump disassembly and

131-3459

Sleeve Holder

assembly - simplifies

assembly and protects

sleeve from damage

146-5068

HexKey-Ball End

5P-4809

Point Indicator

3J-6956

Spring

Service parts for 141-6727 Calibration Pump Assembly

5P-6557

Spring

8T-0116

O-ring

Recommended but not shown

2P-8289

Holder Block

—

6V-3073

Case - Plastic

—

6V-4094

Foam - Convoluted

—

6V-4873

Foam-Block

JULY 2018 Engine Tools

3-221

Engine Tools

FUEL SYSTEMS

Cleaning Tray

Model Usage: Cat^®Engines

• Holds specific parts of unit injectors in groups

• Plungers, bushings, tips and needles

while they are cleaned in ultrasonic cleaner

arranged in sequence so that parts which fit

Warranty: Caterpillar ^®Six Months

tank

together and must be kept together can be

cleaned but not mixed

• Tray fits in tank of either ultrasonic cleaner

group

Part Number

Description

6V-6188

Cleaning Tray

Tip Driver

Model Usage: Cat^®Engines

• Used to separate tip assembly from nut during

• Can be used as alignment tool during

disassembly of injector

assembly

Warranty: Caterpillar ^®Six Months

Part Number

Description

6V-4822

Tip Driver

Seal Protector, Backup Ring Installer

Model Usage: 3126B Engines

• Used to quickly install stiff O-ring and both

backup rings in top groove of HI300 injector

Warranty: Caterpillar ^®Six Months

• Prevents steel backup ring from deforming or

damaging injector case during ring installation

Outside Diameter

Inside Diameter (of

Inside Diameter of

Part Number

Description

Overall Length

Inside Diameter

(large end)

large end)

taper

149-2955

Seal Protector

121mm(4.76in)

40mm (1.57in)

37.6mm (1.48in)

25.2mm (0.99in)

Backup Ring

149-2956

105mm(4.13in)

40.75 mm (1.60 in)

Installer

Service Part

5F-9657

O-ring seal

Hose Removal Tool

Model Usage: 3126B Engines

• Used to easily separate hose from fitting

• Separates fitting from hose collar (insert

beveled edge between hose collar and fitting)

Warranty: Caterpillar ^®Six Months

• Used on #10 fitting on 192-2963 Oil Supply

Hose on HEUI high-pressure pump

• For #6 fitting use 180-0186 Hose Tool

Part Number

Description

192-5092

RemovalTool

3-222 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Hose Removal Tool

Model Usage: 3126B HEUI Engine

• Used to quickly and easily separate 175-3236

• Insert beveled edge between fitting collar and

High-Pressure Hose from fitting

hose collar; hose should release from fitting

Warranty: Caterpillar ^®Six Months

Part Number

Description

180-0186

RemovalTool

Hose Removal Tool

Essential Tool

• Used to quickly and easily separate a hose

• Helps prevent hose damage - angled end of

from a #8 fitting

tool allows hose to be pushed off of fitting

Model Usage: C15 and 3456 Engines

• Used on C15 Engine turbocharger supply line

• Other hose release tools also available: #6

Warranty: Caterpillar ^®Six Months

and 3456 Engine crankgear

180-0186 and #10 192-5092

• Insert edge of tool between fitting and hose

collar to release hose from fitting

Part Number

Description

250-6092

RemovalTool

Injector Installation and Removal Tooling

Essential Tool

• Used to push injector into bore (attaches to

• Order parts separately

rocker shaft bolt)

Model Usage: 3126B, C7, C9 Engines

References

• Used with 1/2 inch drive ratchet to apply force

Warranty: Caterpillar ^®Six Months

• SENR9664, C9 Marine Engine

to raise or lower injector

• RENR9218, C7 Engine for Cat Built Machines

• Lever action provides fast and easy

installation

• RENR9579, C9 Engine For Cat Built Machines

• Eliminates injector damage which can occur

• RENR7458, C7 On Highway Engine

when using other installation methods

Item

Part Number

Description

Used with

Used To

Used On

Injector Installation and Removal Tooling

152-1057

Injector Installation Tool

Install injectors

3126B

152-1057 Injector

Installation Tool

191-6077

Bracket

Install injectors

(replaces standard

bracket assembly)

152-1057 Injector

Installation Tool

C7, C9 (after

272-1149

Leg (2 pieces)

Install injectors

(replaces standard

06/2004)

legs)

152-1057 Injector

Remove

C7, C9 (after

293-7624*

Rod (2 required)

Installation Tool

injectors

06/2004)

*Replaces 274-9198

Injector Installation and Removal Tooling

Model Usage: C7, C9 Engines

• Used to safely remove and install injector

• M8 nuts supplied

Warranty: Caterpillar ^®Six Months

• Threaded tabs captured between injector

• Lubricant suggested on threaded rods to

clamp and head, allowing threaded rod to

reduce friction

be turned with 4 mm hex wrench to jack out

Specifications

injector clamp

• Threaded Rods: M8 x 1.25

• Threaded rods can be installed into head

thread end down and injectors can be pulled

• Hex Wrench: 4 mm

into head with M8 nuts

Part Number

Description

367-3070

Injector Installation and Removal Tooling

JULY 2018 Engine Tools

3-223

Engine Tools

FUEL SYSTEMS

Injector Sleeve Installation and Removal Tooling

Model Usage: C7, C9 Engines

Part Number

Description

221-9777

Injector Sleeve Installer

Warranty: Caterpillar ^®Six Months

221-9778

Injector Sleeve Puller

221-9778

221-9777

Timing Tool Group

Model Usage: 3500 EUI and MUI Engines

• Replaces discontinued 6V-7880 Tool Group

• Tool group can be used for both MUI

(to upgrade 6V-7880 to 9U-5132, order

(Mechanical Unit Injector) and EUI (Electronic

Warranty: Caterpillar ^®Six Months

6V-3072 Plastic Case, 9U-5138 Set Gauge,

Unit Injector) engines

9U-5233 Timing Fixture, 9U-5136 Foam Insert,

• 136-4587 Collet Extension and 136-4588

129-8602 Solenoid Nut Driver, and Decal

Collet Extension can also be used with this

NEEG2515)

tool group (use 136-4587 for 9U-6273 and

• Used to test and adjust fuel systems,

136-4588 for 122-0449)

including fuel timing, rack synchronization,

Reference

and fuel setting

• NEHS0666, Tool Operating Manual

Set Gauge Step

Rod Sleeve Extension

Extension 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 (7.12in)long]

Item

Part Number

Description

Size

—

9U-5132

Timing Tool Group

6V-3075

Indicator - Dial

2 a

9U-5137

Timing Fixture

5P-7276

Container

5P-7263

Indicator Contact Point

76.2mm (3.0in)

9S-8883

Contact Point

12.7mm (0.5in)

4C-8753

Extended Collet

8T-2684

Rack Synchronization Gauge

12.7mm (0.5in)

6V-7918

Wrench

5/8in

8S-3675

Point - Indicator

3 mm(0.12 in)

129-8602

Solenoid Nut Driver

9U-5138

Set Gauge

13d

9U-6273

Rod Sleeve Extension

14d

9U-6272

Nylon Screw

17d

122-0449

Rod Sleeve Extension

Optional Tooling

369-2607

Digital Indicator

5P-4814

Collet As - Clamp

136-4588

Collet Extension

136-4587

Collet Extension

Not shown

122-0451

Extension Rod Assembly

19.0 mm (0.75 in) (for

—

5P-4160

Point - Indicator Contact, 19.05 mm (0.75 in) long

digital indicator)

6V-3072

Case - Plastic, NEEG2574 Group Decal on lid

—

9S-9082

Turning Tool, 1/2 in drive

1/2 in drive

—

9U-5136

Foam Insert

—

9U-5220

Extension Rod Assembly

a. Part of 9U -5233 Magnetic Fixture Group

b. Additional tooling required, but not part of 9U-5132

3-224 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Plate, Socket

Model Usage: Cat^®Engines

• Used with 6V-4830 Fixture Group and 6V-4822

Reference

Tip Driver to remove and install nozzle on type

Warranty: Caterpillar ^®Six Months

• SEHS8993, Special Instruction

2 3500 Engine unit injector

• Make it possible to replace nozzle assemblies

that plug or fail; with 1U-9395 Plate installed

on 6V-4830 Fixture Group, injector can remove

and install nozzle assembly

Part Number

Description

1U-8701

Socket

1U-9395

Plate

Collet Extensions

Model Usage: 3500 and 3500B Engines

• Used to hold a dial indicator in 9U-5233

• Use 136-4587 Extension-Collet with 5P-4814

Fixture Group with 5P-4814 Collet Clamp and

Collet-Clamp, instead of 9U-6273 Rod Sleeve

Warranty: Caterpillar ^®Six Months

two (2) 6V-7918 Collet Wrenches

Extension, to check and adjust fuel timing on

3500 MUI Engines

• Released to provide an alternative to the

nylon screw-type indicatormount

• 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

Part Number

Overall Length

Diameter

Extension Length

External Thread

Internal Thread

136-4587

56.5mm (2.2in)

19 mm (0.7 in)

47mm (1.85in)

7/16 - 20

3/8 - 16

136-4588

23 mm (0.9 in)

19 mm (0.7 in)

13.5mm (0.53in)

7/16 - 20

3/8 - 16

Low Height Fuel Injector Adjustment Tool

Model Usage: 3516 Engines

• Tests and adjusts fuel systems, including fuel

• Used on Mechanical and Electrical Unit

timing, rack, synchronization, and fuel setting

Injector Engines

Warranty: Caterpillar ^®Six Months

• Used with digital dial indicator 1U-8869

Specifications

(preferred method)

• Length: 155 mm (6.1 in)

• Used on No. 2 cylinders or injector

• Width: 40 mm (1.6 in)

adjustments on MT4400 trucks

• Weight: .18 kg (.4 lb)

• Collets to hold digital dial indicator

Part Number

Description

443-4177

Low Height Fuel Injector Adjustment Tool

Lapping Plates

Model Usage: Cat^®Engines

• Lapping set permits distribution of lapping

• Makes it possible to lap plates against each

work between the 3 plates

other to make them flat after a period of use

Warranty: Caterpillar ^®Six Months

• All parts need to be ordered separately

Part No.

Description

6V-6999

Lapping Plate

JULY 2018 Engine Tools

3-225

Engine Tools

FUEL SYSTEMS

Fuel System and Governor Tool Group, 3114-3116

Model Usage: 3114, 3116, and 3126 Engines

• Used to simplify the required testing and

9U-7264 Linkage Lever

adjusting operations

Warranty: Caterpillar ^®One Year

• Used to actuate linkage when zeroing rack

• Allows more precise fuel system

position at each injector

adjustments in significantly less time, at less

• Includes 1U-6235 Knob Fuel Setting

cost, than using previous tooling

128-8827 Governor Pin Assembly

• Improvements to tool group are described

below

• Used to properly position injector control

linkage relative to governor housing face

References

when making static rack power setting

• NEHS0610, Tool OperatingManual

• Required for 1994 and later governors where

• SEBR0551, Service Manual, 3116 Diesel Truck

calibration pin connection is not accessible

Engine

from rear of governor (also works for earlier

version governors)

• SENR3583, Service Manual, Systems

Operation, Testing and Adjusting, Basic

136-4149 Governor Connection Sleeve

Engine Components - 3114 and 3116

Pliers

Engines Timing

• Used to move linkage cover tube between

123-4940 Magnetic Base Indicator Group

governor and head to gain access to governor/

rack linkage connection

• Attaches directly to tappet on top of each unit

injector

• Pliers have more gripping force than former

6V-0006 Pliers (easier to move stubborn cover

• Saves time - moves from cylinder to cylinder

tubes)

quickly and easily

• Pliers have self-locking feature of Vice-Grip

• Use with 9U-7274 Contact Point

type pliers

369-2607 Digital Indicator

• Coated with vinyl material to prevent damage

• Has a programmable preset feature

to sleeve (refer to Modifications section for

reworking older pliers)

• Allows direct reading of published timing

dimensions

NOTE: The discontinued 1U-6681 Holding

Tool (not included) is still needed for some

• Used with the 9U-7269 Timing Gauge Block

model governors. The following list of tools is

9U-7270 Synchronization Gauge Block

broken down into essential tools, recommended

tools and improved tools. Many tools used in

• Used to set #1 injector to 3.5 mm (0.14 in)

the discontinued 1U-6680 Tool Group are used

rack (gives more accurate and consistent

again in 223-2454 Tool Group. See footnotes for

results)

status of tool. If desired, the discontinued

• Used on 127-8207Injector

1U-6680 Tool Group can be updated to a

223-2454 Tool Group by ordering those items

220-0123 Synchronization Gauge Block

with footnotes 1 and 2. Unless otherwise

• Used to set #1 injector to 3.0 mm (0.12 in)

specified, quantity required is one of each item.

rack (gives more accurate and consistent

results)

• Used on 127-8213Injector

• 128-9640 Injector Synchronization Fixture

Group

• Used to hold linkage in synchronizing position

for all cylinders

• Allows both hands to be free when making

adjustments

• Provides more consistent results by applying a

constant spring load to the linkage

3-226 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Fuel System and Governor Tool Group, 3114-3116 (Continued)

Item

Part Number

Description

Size

Fuel System and Governor Tool

—

223-2454

Group, 3114-3116

Injector Synchronization Fixture

1 a

128-9640

Group

128-8706 Spring Plunger (serviceable part)

220-0123

Sync Gauge Block

3.0mm (0.12in)

2 a

9U-7270

Sync Gauge Block

3.5mm (0.14in)

9U-5120

Spanner Wrench

4 a

369-2607

Digital Indicator

5 a

128-8823

Locking Long Nose Pliers a

238 mm(9.375in)long

1U-6675

Injector Spring Compressor

8T-4177

Bolt (spring compressor)

9U-7282

Indicator Fixture Group

9U-6272 Nylon Screw (serviceable part)

8C-4984

Bolt, (indicator stand)

10a

9U-7263

Contact Point

18.5mm (0.73in)long

Fuel Timing Tooling

11a

9U-7269

Timing Gauge Block

12 a a

123-4940

Magnetic Base Group

13a

128-8824

DeepOffsetWrench

(16 and 18 mm)

DeepOffsetWrench

14a

128-8825

(17 and 19 mm)

9U-7274

Contact Point

85 mm (3.35in)long

Miscellaneous Engine Tools

16b

5P-0302

Bar (Injector Removal)

17 a b

123-4941

Valve Setting Gauge

18 a b

194-3542

Hex Socket Bit Driver

5 mm

Fuel Setting Tooling

130-2711

Fuel Setting Holding Tool

136-4149

Governor Connection Pliers

21a

128-8827

Fuel Setting Pin Assembly

22 a b

1U-7523

Pilot— Pin Insertion

Adjustment (FRC) Wrench

23a

1U-7299

(“Type V” 1994 and later Trucks)

24a

1U-7300

Wrench (3 mm Hex)

3 mm

Wrench - Fuel Ratio Control

25a

1U-6673

Adjusting and Synchronizing

Not shown

128-8828

Foam Insert Group

6V-7145

Case

Decal

NEEG2688

a. Recommended or improved tools.

b. Some of the former 9U-7305 Groups used the new 123-4940 Magnetic Base; check your specific tool group.

c. Early 128 -8823 were 150 mm (6.0 in)

d. Refer to the appropriate engine Service Manual for additional information on use of these tools.

e. 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.

Governor Connection Pliers

The 136-4149 Governor Connection Pliers can be used for inspection procedures as outlined in Special

Instruction REHS0601, if modified. Remove 10 mm (0.4 in) of rubberized coating from tips of pliers to

expose metal teeth. This modification will not affect the original function of pliers, and it will allow

pliers to fit onto rivet head.

Part Number

Description

136-4149

Governor Connection Pliers

JULY 2018 Engine Tools

3-227

Engine Tools

FUEL SYSTEMS

Swivel Jaws Pliers

Model Usage: T4 Engines (Engines Without Fuel

• Swiveljaws allow even clamping pressure on

• 504-3766 is 1/2 inch and works well on fuel

Shut-Off Valves Near Fuel Filters)

flexible fuel lines.

lines 20 - 30 mm OD.

Warranty: Manufacturer’s

• Pliers clamp onto fuel lines and lock into

• 504-3767 is 1/4 inch and works well on fuel

position preventing fuel from spilling when

lines 20 mm OD and smaller.

changing fuel filters.

504-3766

Part No.

Description

Length

Weight

504-3766

Swivel Jaws Pliers 19.05 mm (0.75 in)

139.7 mm (5.5 in)

0.12 kg (0.5 lb)

504-3767

Swivel Jaws Pliers 31.75 mm (1.25 in)

234.95 mm (9.25 in)

0.12 kg (0.5 lb)

504-3767

Offset Wrench

Model Usage: 3114, 3116

• Replaces disc. 1U-8771 Offset Wrench

sizes, 17 mm and 19 mm; world standards for

metric fasteners changed and affected 1.1 liter

Warranty: Caterpillar ^®Six Months

• Special wrench required for adjusting valve

engine; for example, early engines have 17 mm

lash and injection timing on 3114/3116 Engine

and 19 mm locknuts; later engines have 16 mm

• 4 necessary socket sizes - 16, 17, 18, 19 mm

and 18 mm locknuts; interim period of engines

• Offset for clearing intake manifold

may have combination of sizes of locknuts; no

special serial number break exists for different

• Has all metric socket sizes required to

size locknuts

adjust valve lash on any 1.1 liter engine;

discontinued 1U-8771 Offset Wrench had 2

Part Number

Description

1U-9563

Offset Wrench

3-228 JULY 2018 Engine Tools

Engine Tools

FUEL SYSTEMS

Offset Wrench, 18 mm

Model Usage: 793C

• Allows technician to properly tighten hose

flange mounting bolts on the brake pump

Warranty: Caterpillar ^®Six Months

without removing other components

Part Number

Description

468-0551

Offset Wrench, 18 mm

Seal Remover

Model Usage: 3176

• Used to remove copper combustion gas seal

• Has short chisel points that indent copper

from unit injector tip on 3176 Engines

seal when tool is struck with small hammer;

Warranty: Caterpillar ^®Six Months

chisel points are shorter than seal thickness

• Designed for quick removal without damaging

to prevent damage to injector

injector; stretches copper seal so it can be

removed by hand (pliers or chisels would

likely damage injector)

Part Number

Description

9U-5129

Seal Remover

Air Regulator Assembly

Model Usage: 16G

• Enables use of shop air pressure to activate

References

air-fuel ratio controls for checking or setting

Warranty: Caterpillar ^®Six Months

• SMHS7083, Special Instruction

fuel rack or rack limiter

•

SEHS7465, Special Instruction

• Applicable to both mechanical and

hydraulically operated controls

Item

Part Number

Description

—

5P-2413

Air Regulator Assembly

3B-7262

Nipple

4H-0553

Fitting

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Caterpillar. Dealer service tools catalog (2018) - page 9