Caterpillar. Dealer service tools catalog (2018)

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Spring Compressor, Adapter Set

Essential Tool

• Used to replace parking brake activation

• Center to center pin distance: 38.1 mm

spring

(1.50 in)

Model Usage: D250, D300, D350, D400

Articulated Truck

• Spring compressor is used with adapter set

• Set includes all items in Figure 2

Warranty: Caterpillar ^®Six Months

• Used on Wabco parking brake actuator

Reference

• Square drive for guide (3): 1/2 inch

• HENR8086, Service Manual

Item

Description

Thrust Pad

Guide

Guide, 1/2in square drive

Item

Part Number

Description

045-5106

—

200-4422

Spring Compressor

Piston Press

Model Usage: 910, 920, 930 and 950 Wheel

• Used to facilitate installation of caliper disc

• Minimizes seal damage during piston

Loaders; 518 and 528 Logskidders; and Tree

brake pistons

installation

Harvesters

Part Number

Description

Warranty: Caterpillar ^®Six Months

5P-3569

Piston Press

Brake Piston Puller

Model Usage: 769D, 771D, 773D, 775D, 776D,

• Used to remove and install 114-9306 Brake

• SENR1422, 769D Truck and 771D Quarry Truck

and 777D Off-Highway Trucks

Pistons located in back side of brake caliper

Machine Systems

Warranty: Caterpillar ^®Six Months

• Can be used on other pistons having same

Specifications

shape and size (refer to specifications)

• For use on brake pistons with:

References

- Groove width: 2.54 mm (0.1 in)

- Groove outside diameter: 75.1 mm (2.96 in)

• SENR1421, 773D Truck and 775D Quarry Truck

- Piston outside diameter: 79.25 mm (3.12 in)

Machine Systems

Part Number

Description

1U-9003

Brake Piston Puller

Steering Spline Gauge

Essential Tool

• Used to inspect steering column spline which

• If gauge does not fit over spline, shaft is

fits into hydraulic metering unit

reusable

Model Usage: All compact, small, and medium

wheel loaders

• Gauge is a go/no-go style gauge

• If gauge fits over spline, shaft must be

replaced

Warranty: Caterpillar ^®Six Months

Part Number

Description

297-6383

Steering SplineGauge

7-8

JULY 2018 Vehicle System Tools

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Adapter Group, Brake Release for Towing

Model Usage: D4H, D5H, D6H and D7H Tractors;

• Adaptable to D4H, D5H, D6H and D7H

temporarily placed on the fender or deck.

later D8L, D9L, D8N and D9R Tractors

Tractors from first production; adaptable to

Replace the seat and floorboard, leaving

following the models, effective with serial

Warranty: None

floorboard bolts out on 1 side to allow space

numbers indicated: D9L - 4Y-3134 D8L

for hose.

- 3Y-3485 D8L S.A. - 4FB339NB D8N -

Place the FT1845 Pump Group in front of

5TJ1-Up and 9TC1-Up D9R - 7TL1-Up and

the operator in a position convenient for

8BL1-Up

observing the pressure gauge, working the

• Used with FT1845 Pump Group to release

pump handle and with ready access to the

brakes for towing and 123-0525 Brake

bypass valve. Place the tractor parking brake

Release Adapters and 123-0526 Brake

control in the “unlocked” position.

Release Adapters

Preparation for releasing the brakes is now

• See 8T-2857, 123-0525 and 123-0526

complete. Before towing, the operator

Adapters for machine usage; when tooling is

should fasten the seat belt for safety if an

installed, these adapters extend past spool

emergency requires brake re-application.

bores in tractor steering valve, isolating brake

circuit and allowing pump pressure to be

Brake Release and Re-application

applied directly to brake release pistons

Turn the bypass valve handle to the closed

• With leakage minimized, brake release can be

position.

maintained with low volume pump

Work the pump handle rapidly to produce

• Before connecting pump and adapter group

a large volume of oil flow. This flow is

to tractor steering valve, maximum pressure

sometimes necessary to cause the brake

relief valve opening pressure must be checked

piston seals to seat.

and adjusted in order to prevent possible

Brake piston seal seating will be evidenced

damage to brake piston seals

by a sudden rise in oil pressure. At this

point, oil flow will drop to near zero and

Checking Maximum Pressure Relief Valve

pressure will rise to maximum.

Opening Pressure

An occasional pump stroke will maintain

Plug the main pressure hose where it

maximum pressure.

connects to the FT1973 Adapter Group.

• Do not let pressure drop below 375 PSI

Turn the bypass valve handle to the closed

while towing. To do so will risk partial brake

position.

engagement which can result in serious

While building pressure with the pump

damage.

handle, observe the relief valve opening

To re-apply the brakes, turn the bypass valve

pressure.

90° to fully dump oil.

Adjust relief valve opening pressure to 410

• Do not use brakes to retard the tractor.

(10 PSI).

Absence of cooling oil flow will result in

Installing Tooling on Tractor

extensive damage to the brakes and system

The FT1973 Adapter Group is connected to the

contamination. Brakes must be fully released

steering valve under the tractor seat.

while the towed tractor is moving. If an

emergency calls for brake re-application,

Remove the quick-disconnect fittings from

apply brakes fully and allow tractor to come to

the ports marked BRK on the steering valve.

a stop before proceeding.

Install the adapters in the ports and connect

Brakes can be re-applied ONLY by turning

the remainder of the FT1973 Adapter Group

the bypass valve to the open position. Using

to the adapters and to the pressure hose

the steering levers and brake pedals is not

from the pump.

effective.

It is usually convenient to route the pressure

Be sure to follow all other towing instructions

hose under the floorboard (leaving the

and precautions published in the Operation and

floorboard loose) to the pump which is

MaintenanceManual.

JULY 2018 Vehicle System Tools

7-9

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Brake Release Adapters

Model Usage: D8N, D9N and D9R Track-Type

• D4H, D5H, D6H, D7H (all)

- 587

Tractors

• D5M: 4BR, 4JS, 3DR, 5FS

450-4258 Adapter

Warranty: Caterpillar ^®Six Months

• D8N: 9TC1-UP PIN, 1XJ1-UP PIN

• Adapter fits valve group 345-6789

• D6M: 9ZM, 2YS, 5WR, 2RN, 4GS

• Used for (refer to Operation and Maintenance

• D9N: 1JD1-UP PIN, 6XJ1-UP PIN

Manualforadditional information)

• D8L: 53Y-3485-UP

NOTICE

• D9L: 14Y-3134-UP

Before connecting pump and adapter group,

check and adjust maximum pressure setting on

• D8L S.A.: 4FB339NB-UP

relief valve to prevent possible damage to brake

• D9R: 8BL1-UP PIN

piston seals which could occur if the system is

over-pressurized.

123-0525 Adapter

Used for (refer to Operation and

• Used to supply oil from an external source

References

MaintenanceManual foradditional

to disengage spring applied parking brake

• SEBU6422 and SEBU6028, Service Manual

information)

whenever towing is required

Module, D8N Operation and Maintenance

• D8N: 5TJ1-UP PIN

• Used with FT1845 Pump Group, Brake System

• SEBU6029 and SEBU6668, Service Manual

and FT1973 Adapter Group, Brake Release for

• D8R (all)

Module, D9N Operation and Maintenance

Towing

123-0526 Adapter

• SEBU6892, Service Manual Module, D9R

• Tractors with disabled engine or power train

Used for tractors with differential steering

Operation and Maintenance [for tractors

hydraulic system cannot be moved without

control

(8BL1-UP) with steering clutch control]

supplying oil to release parking brake -

• D9R: 7TL1-UP

• SEBU6923, Service Manual Module, D9R

refer to Service Manuals and Operation

Operation and Maintenance [for tractors

and Maintenance Manuals for detailed

• Can also be used on D8N’s and D8R’s

(7TL1-UP) with differential steering control]

instructions

425-8104 Adapter

• SEBU6891, D8R Service Manual Module, D8R

• Adapters extend into control valve and isolate

• Adapter fits brake valve groups 389-1531,

Operation and Maintenance

brake circuit (applies pressure directly to

375-4096, 426-1510

brake release pistons)

• Used for (refer to Operation and Maintenance

• Requires two adapters installed into ports of

Manual for additional information):

brake control valve

- D6T

8T-2857 Adapter

- D8T

Used for tractors with steering clutch

- D9T

control

- 572

- 583

Engagement

Seal For

Seal for

Overall

Connection to

Connection To

Seal For Brake

Part Number

Description

Depth (spot face

#8 STOR

#10 STOR

Length

Brake Valve

Adapter Group

Valve Passage

to O-ring seal)

Connection

Brake Release

110 mm

7/8-14

3/4-16 (#8 JIC male

123-0525

74mm (2.91in)

2J-6274 Seal

2M-9780 Seal

Adapter

(4.3in)

(#10 STOR port)

connector)

Brake Release

85 mm

7/8-14

3/4-16 (#8 JIC male

123-0526

49mm (1.93in)

2J-6274 Seal

2M-9780 Seal

Adapter

(3.3in)

(#10 STOR port)

connector)

Brake Release

110 mm

3/4-16

3/4-16 (#8 JIC male

8T-2857

75.4mm (2.97in)

2J-6274 Seal

3K-0360 Seal

Adapter

(4.3in)

(#8 STOR port)

connector)

Brake Release

52.3 mm

3/4-16

3/4-16 (#8 JIC male

425-8104

22.5mm (.886in)

1H-1023 Seal

6V-6609 Seal

Adapter

(2.059 in)

(#8 STOR port)

connector)

Brake Release

52.3 mm

3/4-16

3/4-16 (#8 JIC male

450-4258

22.5mm (.886in)

1H-1023 Seal

6V-6609 Seal

Adapter

(2.059 in)

(#8 STOR port)

connector)

7-10 JULY 2018 Vehicle System Tools

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Displacement Gauge Assembly

Model Usage: 772B/773B, 776B/777B, 785 and

• Eliminates difficulty of making brake wear

• Allows serviceman to transport needed

789 Off-Highway Tractors and Trucks

measurements directly from 5P-9726 Gauge

dimension away from vehicle for easy reading

Plug (Brake wear on 772B/773B, 776B/777B,

of measurement; gauge assembly placed over

Warranty: Caterpillar ^®Six Months

785 and 789 Off-Highway Tractors and Trucks

gauge plug to allow easy measurement of

measured with 5P-9726 installed in service

5P-9726 rod piston; standard calipers or inside

brake hydraulic port; when installed, 5P-9726

micrometer can then be used to determine

can be reached with only one hand making

plug position within tube of 1U-7425

direct measurement very difficult)

References

• Brake piston travel, difference between

• Technical Information Bulletin 7-22-87

minimum (actuated) and maximum (retracted),

measured to determine brake wear

• Component Code 4250, Brake Wear

Measurement Procedures and Specifications

• Service Part: 6V-9028 O-ring Seal (2)

Service Manual

Part Number

Description

1U-7425

Displacement Gauge Assembly

Brake Disc Wear Gauges

Model Usage: 924G and 928G Wheel Loaders

• Measures usable thickness of brake disc

• Used by placing wear gauge through slot in

brake housing (amount of material between

Warranty: Caterpillar ^®Six Months

• Quickly and easily determines if replacement

step of tool and brake housing is the usable

is necessary

thickness of brake disc)

Item

Part Number

Model

221-6892

928G

221-6893

924G Standard

221-6894

924G Dual Disc

Brake Wear Gauge

Model Usage: 950G, 962G, and 966G Wheel

• Used to measure brake wear

• Easier to use and provides greater accuracy

Loaders

than tools previously available

Warranty: Caterpillar ^®Six Months

Part Number

Description

185-5784

BrakeWearGauge

Cylinder Spanner Wrench

Model Usage: 785, 789 and 793 Trucks

• Removal and installation of ball studs,

• Two C-4887 Pins (19.05 mm [3/4 inch]

particularly during installation, requires ball

diameter) (2), and two 4C-3387 Pins (9.53 mm

Warranty: Caterpillar ^®Six Months

stud to be held and kept from turning when

[3/8 in] diameter] (3) are easily positioned

nut is being torqued; usually friction of taper

into or out of the hex body and retained in the

alone is not enough to keep ball stud from

desired position with detent grooves and ball

turning

spring plungers (4)

• Wrench Assembly (1) consists of a 63.5 mm

• The 2 different sized pins allow the tool to be

(2 1/2 in) hex body that is easily held with a

used on all ball studs used on 785 and 789

63.5 mm (2 1/2 in) wrench or socket (5S-6078

Trucks

Socket shown)

• Currently the ball studs contain 9.52 mm

(3/8 in) diameter holes. Future ball studs will

have 19.05 mm (3/4 in) diameter holes.

Part Number

Description

4C-3386

Cylinder Spanner Wrench

JULY 2018 Vehicle System Tools

7-11

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Solid Taper Reamers

Essential Tool

• Repairs tapered steering arm linkage joints

• Can be resharpened for continued usage

Model Usage: 785, 789, 793, 797(A), and 797B

• 202-8960 and 202-8961 used on 785 through

Reference

Off-Highway Trucks

797(A) (up to 5YW-1) trucks

• SEBF8271, Guideline for Reusable Parts and

Warranty: Caterpillar ^®Six Months

• 258-5684 used on 797(A) (5YW-1 and UP) and

Salvage Operations, Salvage of Tapered

797B (JSM-1 and UP) trucks

Steering Bores (785-797B)

Large End

Small End

Flute

Overall

Item

Part No.

Description

Flutes

Taper

Shank

Diameter

Length

Solid Taper

84.14 mm

66.37 mm

142.2 mm

393.7 mm

Number5

202-8960

Reamer

1:8

(3.31 in)

(2.61 in)

(5.6in)

(15.5 in)

MorseTaper

(roughing)

Solid Taper

84.14 mm

66.75 mm

139.2 mm

393.7 mm

Number5

202-8961

Reamer

1:8

(3.31 in)

(2.63 in)

(5.48 in)

(15.5 in)

MorseTaper

(finishing)

Solid Taper

113.48 mm

92.12 mm

171.0 mm

349.0 mm

Number5

258-5684

1:8

Reamer

(4.47 in)

(3.63 in)

(6.73 in)

(13.75 in)

MorseTaper

Plug Gauges with Case

Essential Tool

• Used with Blueing Paste (sold separately) to

• Heat-treated and black-oxide coated for

inspect steering arm linkage joints with 1:8

added durability

Model Usage: 769, 770 (BZZ), 771, 772 (RLB),

ratio on steering/center arms

773, 773F (EED), 775, 775F (DLS), 777, 777F

References

(JRP), 784, 785, 789, 793, and 797 Off-Highway

• Gauges have incorporated a “Go” and “No

• SEBF9054, Guideline for Reusable Parts,

Truck

Go” step to determine wear condition of

Reusability of Tapered Steering Bores (769

specific steering joint tapered bores

Warranty: Caterpillar ^®Six Months

Through 777 Trucks and Tractors)

• Durable waterproof case included

• SEBF9055, Guidelines for Reusable Parts,

• Foam insert protects gauge from damage and

Reusability of Tapered Steering Bores (784

provides storage for Blueing Paste

Tractor Through 797B Trucks)

Part No.

Description

Model Usage

265-9215

Plug Gauge Group

769, 771, 772

265-9216

PlugGaugeAssembly (notservicedseparately)

769, 771, 772

265-9217

FoamBlockGroup(servicedseparately)

761,771, 772

265-9218

Plug Gauge Group

773, 775, 777

265-9219

PlugGaugeAssembly (notservicedseparately)

770 (BZZ), 772 (RLB)

265-9220

FoamBlockGroup(servicedseparately)

773F (EED), 775F (DLS), 777F (JRP)

265-9221

Plug Gauge Group

785

265-9222

PlugGaugeAssembly (notservicedseparately)

785

265-9223

FoamBlockGroup(servicedseparately)

265-9224

Plug Gauge Group

789, 793, 797(A)

265-9225

PlugGaugeAssembly (notservicedseparately)

789, 793, 797 (A)

265-9226

FoamBlockGroup(servicedseparately)

265-9227

Plug Gauge Group

797B

265-9228

PlugGaugeAssembly (notservicedseparately)

797B

265-9229

FoamBlockGroup(servicedseparately)

Disc Brake Alignment Group

Essential Tool

• Provides easy installation of disc brakes

• Aligns disc brake splines before brake

package installation onto wheel station

Model Usage: D350E and D400E Series II, 735

• Diameter across pins: 351.5 mm (13.84 in)

and 740 Articulated Dump Trucks

Item

Part Number

Description

Warranty: Caterpillar ^®Six Months

162-8231

Disc Brake Alignment Group

0S-1590

Bolt (English)

7-12 JULY 2018 Vehicle System Tools

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Lapping Tool (Ball Stud)

Model Usage: 769 through 797B Quarry and Off-

• Used to finish-lap tapered steering arm

• Used with 226-6624 Lapping Compound

Highway Trucks

linkage joints on steering arms, center arms,

• Laps bore to proper specifications

and steering boxes

Warranty: Caterpillar ^®Six Months

• Heat-treated for added durability

• Used with 176-6538 Ball Stud Spanner

Wrench (797) to rotate lapping tool or a

Reference

4C-3386 Cylinder Spanner Wrench, 5S-6078

• SEBF8271, Guideline for Reusable Parts and

Socket (2 1/2 inch), and 1 inch square drive

Salvage Operations,

ratchet is required to remove ball studs on

Salvage to Tapered Steering Bores (785-797)

•

769 through 793 Off-Highway Trucks

Part Number

Taper

Weight

Use

226-2378

1:8 ratio

7.4 kg (16.3 lb)

785 through 793 Off-Highway Trucks

265-9213

1:8 ratio

2.3 kg (5.1 lb)

769 through 777 Off-Highway Trucks

265-9214

1:8 ratio

10.6 kg (23.4 lb)

797 Off-Highway Trucks

Tooling Chart

Item

Description

Qty.

Used On

Fixture Assembly

All

Adapter Assembly

775 Rear (O.C.), 775 Rear (I.C.), 777 Rear (O.C.), 777 Rear (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 775 Rear

Plate Assembly

(O.C.), 777 Front (I.C.), 777 Rear (O.C.)

Plate Assembly

770 Rear (I.C.), 772 Rear (I.C.), 773 Rear (I.C.), 777 Front (I.C.)

Plate Assembly

777 Front (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 770 Rear (I.C.)

Rod

772 Rear (I.C.), 773 Rear (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 777 Front

Guide Pin Assembly

(O.C.)

Plate Assembly

775 Rear (I.C.), 777 Front (O.C.)

Plate Assembly

770 Rear (I.C.), 772 Rear (I.C.), 773 Rear (I.C.)

Socket Head Screw a

All - Quantity used varies per application

(O.C.) = Out-of-Chassis.

(I.C.) = In-Chassis.

a. McMaster-Carr part number 91251A346, 10-32 x 22.2 mm (.875 in) long.

Ball Stud Removers

Model Usage: 769 through 797B OHTs

• Used to separate ball stud from steering joint

• RENR3365, Disassembly and Assembly, 776D

and 777D Off-Highway Trucks

Warranty: Caterpillar ^®Six Months

• Reduces damage to steering components

(strike remover tool, no impact in steering

• SENR1500, Disassembly and Assembly, 784C

components necessary)

and 785C Off-Highway Trucks

• SENR1534, Disassembly and Assembly, 789C

References

Off-Highway Truck

• SENR1561, Disassembly and Assembly, 769D

and 771D Off-Highway Trucks

• RENR2535, Disassembly and Assembly, 793C

and 793C XQ Off-Highway Trucks

• SENR1584, Disassembly and Assembly, 773E

and 775E Off-Highway Trucks

• RENR2588, Disassembly and Assembly, 797B

Off-Highway Truck

Part Number

Use

Weight

231-4902

769 and 771 Off-Highway Trucks

1.827 kg (4.03lb)

231-4903

773 through 777 Off-Highway Trucks including 777 HAA

3.142 kg (6.93lb)

231-4904

785 Off-Highway Trucks including 785 HAA

7.119 kg (15.69lb)

231-4905

789 through 793 Off-Highway Trucks

8.506 kg (18.75lb)

287-5796

797 Off-Highway Trucks

12.600 kg (27.78 lb)

JULY 2018 Vehicle System Tools

7-13

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Brake Alignment Tool Group

Essential Tool

• Used to precisely align plates and friction

• Simplifies assembly, reduces installation time

discs; helps eliminate damage of brake

ModelUsage: 770, 772, 773, 775, & 777 OHTs

• For convenience, each component is attached

pack and mating components during brake

to main fixture assembly with a single size

Warranty: Caterpillar ^®Six Months

assembly-helps ensure proper brake operation

socket head cap screw

• Versatile tool group can be easily configured

References

to fit several different brake assemblies

• NEHS1004, Tool Operating Manual, 318-2943

• Lightweight aluminum, for ease of handling

Brake Alignment Tool for 773, 775, and 777

• For easy identification, aluminum components

Off-Highway Trucks

are stamped with the identification mark A, B,

• RENR8273, 770/772 Off-Highway Truck,

C, D, E, F, H, or J

Disassembly and Assembly Manual

• Tool assembly chart in NEHS1004 Tool

• RENR8286, 773/775F Off-Highway Truck,

Operating Manual provides precise assembly

Disassembly and Assembly Manual

instructions for each application

• RENR8312, 777F Off-Highway Truck,

• Tool Group includes protective storage case

Disassembly and Assembly Manual

51 x 51 x 51 cm (20.0 x 20.0 x 20.0 in)

• NEEG3102 Decal

Part Number

Description

Quantity

318-2943

Brake Alignment Tool Group

Service/Repair Parts a

292-3211

Brake Alignment Tool

318-2927

Storage Case Foam Insert

a. Includes: Brake Alignment Tool, Storage Case Foam insert, and NEEG3102 Decal.

Tooling Chart

Item

Description

Qty.

Used On

Fixture Assembly

All

Adapter Assembly

775 Rear (O.C.), 775 Rear (I.C.), 777 Rear (O.C.), 777 Rear (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 775 Rear

Plate Assembly

(O.C.), 777 Front (I.C.), 777 Rear (O.C.)

Plate Assembly

770 Rear (I.C.), 772 Rear (I.C.), 773 Rear (I.C.), 777 Front (I.C.)

Plate Assembly

777 Front (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 770 Rear (I.C.)

Rod

772 Rear (I.C.), 773 Rear (I.C.)

770 Rear (O.C.), 772 Rear (O.C.), 773 Rear (O.C.), 777 Front

Guide Pin Assembly

(O.C.)

Plate Assembly

775 Rear (I.C.), 777 Front (O.C.)

Plate Assembly

770 Rear (I.C.), 772 Rear (I.C.), 773 Rear (I.C.)

Socket Head Screw a

All - Quantity used varies per application

(O.C.) = Out-of-Chassis.

(I.C.) = In-Chassis.

a. McMaster-Carr part number 91251A346, 10-32 x 22.2 mm (.875 in) long.

Brake Alignment Tool

Model Usage: 797F Off-Highway Truck

• Used to align plates and friction discs to

Specifications

eliminate damage to brake pack and mating

Warranty: Caterpillar ^®Six Months

• O.D.: 793.7 mm (31.25 in)

components duringbrakeassembly.

Height: 218 mm (8.58 in)

•

• Simplifies assembly and reduces installation

• Weight: 19.39 Kg (42.75 lb)

time.

• Tool is black oxide coated to increase

corrosion resistance.

Part Number

Description

346-8608

Brake Alignment Tool

7-14 JULY 2018 Vehicle System Tools

Vehicle System Tools

BRAKE AND STEERING SYSTEMS

Brake Alignment Tool

Model Usage: 777G Off-Highway Truck

• Used to align plates and friction discs to

• Simplifies assembly/reduces installation time

eliminate damage to brake pack and mating

Warranty: Caterpillar ^®Six Months

• Tool is black oxide coated to increase

components duringbrakeassembly

corrosion resistance

Part Number

Description

366-6542

Brake Alignment Tool

Test and Adjust Manifold

Model Usage: 950G, 962G, 966H, 966G, IT62G

• Used with hydraulic test bench

Specifications

and 972H

• Allows for off-machine pressure setting of the

• Dimensions:60 X 60 X107.8 mm

Warranty: Caterpillar ^®Six Months

steering crossover relief valve (129-8222)

(2.36 X 2.36 X 4.24 in)

• Weight: 3.203 kg (7.06 lbs)

Reference

• RENR4314, Test and Adjust Procedures/Specs

Part Number

Description

378-4530

Test and Adjust Manifold

Adapter Bracket Assembly

Essential Tool

European Union compliant, CE marked

• Outside ends of adapter bracket attach to

brake cooler assembly with (8) 8S-4755 Bolts

Model Usage: 795F AC Off-Highway Truck

• Used to remove and install 291-6885 Brake

and (8) 7K-0897 Washers (dealer supplied) -

Cooler Group from 795F AC Off-Highway Truck

Warranty: Caterpillar ^®Six Months

tighten bolts to standard torque value

• Used with 226-2380 C-Frame Lifting Bracket

• Meets ANSI B30.20.2006, ASME AS 4991

Assembly and 226-2381 Short Slide Tube

2004standards

Assembly

• Adapter bracket is attached to slide tube

Specifications

assembly with two 8T-4779 Bolts and two

• Working load limit: 181.5 kg (400 lb)

3E-9402 Washers (dealer supplied) - tighten

• Weight:75 kg (165 lb)

bolts to standard torque value

• Length: 1132 mm (44.6 in)

• Provides stability during brake cooler removal

• Height: 213 mm (8.4 in)

and installation

• Width: 70 mm (2.7 in)

Item

Part Number

Description

226-2380

Multi-Purpose “C” Style Lifting Bracket Assembly

226-2381

Short Slide Tube Assembly (included with 226-2380 Lifting Bracket Assembly)

—

317-5304

AdapterBracketAssembly

Line Relief Test Block

Model Usage: F2 Series Backhoe Loaders

• Used to test and adjust line relief pressure

Specifications

• Made of steel

• Dimensions: 70 mm x 50.8 mm x 101.6 mm

Warranty: Caterpillar ^®Six Months

• One port for M28 X 1 relief valve (396-4902)

Reference

• Tested to 6,000 psi capacity of hydraulic pump

• UENR5025 backhoe loader machine systems,

or bench testing

hydraulic and steering system

• Inlet and outlets are SAE No. 6 ports

Part Number

Description

478-8367

Line Relief Test Block

JULY 2018 Vehicle System Tools

7-15

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Tools for Flushing Scraper Hydraulic Systems

Model Usage: Wheel Tractor-Scrapers

• When flushing contaminated oil from

Reference

hydraulic system, other parts are required to

Warranty: Caterpillar ^®Six Months

• FM055145

bypass cylinders to permit free flow of oil.

Item

Qty.

Part No.

Description

Size

1P-4579

Flange

(1 1/2 in) SAE

1A-1460

Bolt (1/2 - 13) (fork mounting hardware)

51.0 mm (1/2 in - 13 x 2 in)

1P-4578

Flange

(1 1/4 in) SAE

1D-4707

Bolt

57.0mm (7/16in - 14 x 2.25in)

1P-4576

Flange

(3/4 in) SAE

0T-0318

Bolt

25.0 mm (7/16 in - 14 x 1 in)

7F-0192

Bolt

51.0 mm (3/8 in - 16 x 2 in)

4H-4581

Plug

19.05 mm (3/4 in)

2D-1767

Plug

12.7 mm (1/2 in)

1D-4719

Nut

(1/2in - 13)

6H-1717

Bolt

29.0 mm (1/2 in - 13 x 1 1/8 in)

3H-5521

Plate

(1 1/4 in) SAE

1D-4718

Nut

(7/16 in - 14)

3H-5522

Plate

(3/4 in) SAE

1D-4717

Nut

(3/8in - 16)

9U-6219

Tool Box

Not Shown

2P-8289

Holder Block

—

6H-3621

Plug

Bolt

Model Usage: 225B, 229, 235C, 245B

• Used to provide way to manually engage

• Makes testing and adjusting a 1-person job

pilot-operated control valves when testing

instead of requiring 2

Warranty: Caterpillar ^®Six Months

and adjusting excavator hydraulic systems

• Grade 5 bolt, 10.16 mm (4 in) long and

• Installed directly into pressure tap hole in end

threaded 9/16 inch-18 to fit covers on

cover to allow variable positioning of valve

excavator control valves

without using pilot controls in cab

Part Number

Description

5P-7336

Bolt

Always remove the 5P-7336 Bolts immediately after completion of the testing or adjusting procedure and reinstall the 9/16 inch - 18 O-ring plug before

operating the machine in a normal manner. Injury to personnel and damage to equipment can result if this is not done.

7-16 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Fittings for 22 mm (7/8 in) JIC Connectors

Model Usage: Wain-Roy Backhoe

• 9S-0176 Tee and 9S-0177 Union used for tapping into 22.22 mm (7/8 in) JIC connectors on Wain-

Roy Backhoes to check pressure relief valve settings

Warranty: Caterpillar ^®Six Months

Item

Part Number

Description

9S-0177

Union

9S-0176

Adapter - Tee (37°)

Portable Hydraulic Tester

Model Usage: All Models Including E and MS

power-off feature

(0 - 125 gpm)

Series Excavators

• Use 9U-5229 Adapter or 9U-5228 Adapter

• External input socket for flow meters:

Warranty: Six Months

to reduce ports to 41.27 mm (1 5/8 in) or

0.2 - 795 lpm (0.05 - 210 gpm) range

33.33 mm (1 5/16 in) STOR (Straight Thread

• Used to test hydraulic flow, pressure, and

• Continuous working pressure (analog readout):

O-ring) respectively [makes a close-coupled

temperature in any hydraulic system (used in

0 - 500 bar (0 - 6,800 PSI)

connection with 41,000 kPa (6,000 PSI)

field or shop by simulating system working

• Pressure accuracy: ±1.6% full scale

pressure rating]

conditions)

• Temperature (analog readout): 10° to 120°C

• Range and versatility extended with use of

References

(50° to 250°F)

externally connected flow meters

• NEHS0565, Operating Manual, Portable

• Temperature accuracy: ±1°C (±2°F)

• Troubleshoot or adjust hydraulic circuits at

Hydraulic Tester

• Speed: 0 - 6000 RPM (digital readout)

low or high flows (“Interpass” protection

• NEHS0576, Operating Manual, Portable

prevents dangerous external oil spray in event

Hydraulic Tester Repair Manual

• Accuracy: ±1% full scale

of over-pressure)

• Ports: 1 7/8-12 UNF SAE O-ring

4C-9910 Portable Hydraulic Tester

• Unit is self contained and bi-directional (easily

• Flow range: 13.0 - 475.0 lpm

4C-9911 Flowmeter (typical)

installed into hydraulic circuit using hoses and

(3.5 - 125.0 gpm)

quick disconnects)

• Flow accuracy: ±1% full scale of normal

• Digital readout scales: Metric, US or British

range; ±2% full scale of extended range

• Uses discontinued 6V-3136 Photo Pickup and

6V-2198 Cable, saving tool accessory costs

• Accuracy: ±1% full scale over normal range

• Temperature: 10° to 120°C (50° to 250°F)

• Uses standard batteries with automatic

• Analog output: 0 - 1.5 VDC = 0 - 475.0 lpm

• Temperature accuracy: ±1°C (±2°F)

Part No.

Description

Normal Flow Range

Extended Flow Range

Max. Pressure

Port Size

Specifications for Flow Meters

Flow Meter, 795 lpm

30- 800lpm

4C-8686

60 - 700 lpm (15 - 180 gpm)

350 bar (5075 PSI)

1 1/2 SAE Flange

(210 gpm)

(7 - 210 gpm)

Flow Meter, 490 lpm

20- 500lpm

4C-8687

45 - 450 lpm (10 - 100 gpm)

350 bar (5075 PSI)

1 1/2 SAE Flange

(130 gpm)

(4 - 130 gpm)

Flow Meter, 110 lpm

5 - 150 lpm

4C-9436

12- 120lpm (3 -25 gpm)

420 bar (6090 PSI)

1 1/16-12, 12 SAE

(30 gpm)

(1 - 30 gpm)

Flow Meter, 55 lpm

2 - 60 lpm

4C-9911

8 - 50 lpm (2 - 12 gpm)

420 bar (6090 PSI)

1 1/16-12, 12 SAE

(15 gpm)

(0.5 - 15 gpm)

Flow Meter, 245 lpm

10- 300lpm

4C-9912

20- 220lpm (5 -50 gpm)

420 bar (6090 PSI)

1 5/16-12

(65 gpm)

(2 - 65 gpm)

Flow Meter, 380 lpm

10- 400lpm

4C-9913

30- 300lpm (8 -80 gpm)

420 bar (6090 PSI)

1 5/16-12

(100 gpm)

(3 - 100 gpm)

Flow Meter, 645 lpm

25- 650lpm

4C-9914

50 - 550 lpm (12 - 150 gpm)

350 bar (5075 PSI)

1 1/2 SAE Flange

(170 gpm)

(6 - 170 gpm)

JULY 2018 Vehicle System Tools

7-17

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Adapters for Portable Hydraulic Tester

• Working pressure rating: 41,000 kPa

• Burst pressure rating: 165 MPa (24,000 PSI)

(6,000 PSI)

• Size of hex across flats: 53.97 mm (2 1/8 in)

Part No.

Description

Size

Use

Adapts 1 7/8 12 STOR male fitting

9U-5228

Adapter

to 1 5/16-12male union

Adapts 1 7/8 12 STOR male fitting

9U-5229

Adapter

to 1 5/8-12male union

Service/Repair Parts

2S-4078

Seal— O-ring— STOR

41.27mm (15/8in)

6K-6307

Seal— O-ring— STOR

47.62mm (17/8in)

7M-8485

Seal— O-ring— STOR

33.33mm (15/16in)

Portable Hydraulic Tester

Item

Part Number

Description

127-9353

Disc— Burst

4C-9625

Pressure Gauge

4C-9922

Load Valve

—

4C-9910

Portable Hydraulic Tester

Not shown

—

4C-9626

Seal - Transducer

—

4C-9918

Seal Kit

Hydraulic Flow Testers

Model Usage: All Models

Hydraulic Flow Testers

• Accept Cat^®discontinued 6V-3136 Photo

Pickup and 6V-2198 Cable to read RPM; saves

Warranty: Caterpillar ^®Six Months

• Used to diagnose hydraulic flow, pressure

tool accessory costs

and temperature symptoms in any hydraulic

system, including E and MS Family Excavators

• Uses standard batteries with auto “power off”

• Allows testing in field or shop; built-in load

• 1U-8761 Hydraulic Flow Tester discontinued/

valve allows simulation of operation

replaced by 4C-9437; 1U-9551 Hydraulic Flow

Tester discontinued/replaced by 4C-9675

• Can be used to troubleshoot or set hydraulic

circuits to specifications at low or high flows

4C-9436 Flow Meter

• If over pressure, “interpass” protection

• When used with hydraulic flow testers,

protects from dangerous external oil spray

extends their range and versatility, keeping

• May be used in-line or for tee test operation

present tooling from becoming obsolete

• Self-contained, bi-directional, capable of

References

reading all parameters and loading systems

• NEHS0572, Tool Operating Manual, Portable

regardless of flow direction; easily installed

Hydraulic Tester

with hoses into a circuit; high-pressure quick

disconnects readily available from Dealer

• NEHS0573, Tool Operating Manual, Turbine

Service Tools to work with these units

Flow Meter

• Analog display of all parameters for quick

• NEHS0576, Tool Operating Manual, Repair of

check of system/component performance

Portable Hydraulic Tester

Item

Part Number

Description

4C-9625

Pressure Gauge

4C-9627

Load Valve, 4C-9437 Tester

Not Shown

4C-4083

Rupture Disc for 4C-9437 Tester

—

4C-4084

Rupture Disc for 4C-9675 Tester

4C-9626

Seal - Transducer

7-18 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Flowmeter (typical)

Item

Part Number

Description

—

4C-9911

Flowmeter (typical)

4C-9626

Seal - Transducer

Hydraulic Flow Testers

Specifications

4C-9675 Hydraulic Flow Tester

• Flow range: 0 - 100 gpm or 0 - 25 gpm metric

The 4C-9675 has the same design characteristics

or US scales

as the 4C-9437 except for flow capacity of 0-200

- Accuracy: ±2% full scale over normal

or 0-40 g/m and working pressure of 5000 PSI.

range External input socket calibrated

• Flow range (dual): 0 - 200 gpm or 0 - 40 gpm

for 4C-9436 Flow Meter only; use Cable

metric or US scales

to connect external flow meter. *Contact

- Accuracy: ±2% full scale over normal range

Webster Instruments for cable.

External input socket calibrated for 4C-9436 Flow

• Continuous working pressure: 0 - 420 bar

Meter only; use Cable to connect external meter.

(0 - 6,000 PSI)

• Contact Webster Instruments for cable.

- Accuracy: ±1.6% full scale

Continuous working pressure: 0 - 350 bar

•

• Temperature (dual scale): 10° to 120°C

FOR CABLE, CONTACT:

(0 - 5,000 PSI)

(50° to 250°F)

Webster Instruments

- Accuracy: ±1.6% full scale

1290 East Waterford Avenue

- Accuracy : ±2% full scale

Milwaukee, WI 53207

• Temperature (dual scale): 10° to 120°C

• Speed, will measure: 0 - 10,000 photo tach

Phone: 414-769-6400

(50° to 250°F)

Fax: 414-769-6591

0 - 3,000 mech. tach

- Accuracy: ±2% full scale

• Speed, will measure: 0 - 7,500 photo tach;

• Uses discontinued 6V-3136 Pickup and

0 - 2,500mech. tach

6V-2198 Cable Ports: 1 5/16 in-12 UNF SAE

- Accuracy: ±2% full scale

O-ring port

Uses disc. 6V-3136 Pickup/6V-2198 Cable

• Ports: 1 1/2 in SAE 4 bolt flange (XT-3)

Part Number

Description

4C-9437

Hydraulic Flow Testers

Flowmeter

Specifications

The 4C-9436 Flowmeter is not a standalone

flowmeter. It is a flow block with a flow/

• Flow range: 3 - 25 gpm

temperature transducer. It must be used with

(1 - 30 extended range)

a hydraulic flow tester or another device with

• Working pressure: 0 - 420 bar max.

readout capabilities. A Cable is used to couple

(6,300 PSI)

the flowmeter to a readout device. Contact

• Temperature: 10° to 120°C (50° to 250°F)

Webster Instruments for cable.

• Ports: 1 1/16 in-12 SAE O-ring (#12 port)

Item

Part Number

Description

—

4C-9436

Flowmeter

—

4C-9626

Seal - Transducer

JULY 2018 Vehicle System Tools

7-19

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Rupture Discs

Model Usage: Most Cat Models

• Replacement discs for 2 different portable

Reference

hydraulic testers; disc will blow out if over-

Warranty: Caterpillar ^®Six Months

• NEHS0508-01, instructions to replace discs

pressure conditions have occurred in portable

(designated as safety discs in instruction

hydraulic tester

manual)

Part No.

Outside Diameter

Nominal Rupture Pressure

Pkg. Qty.

Use

4C-9437 and 160-2513 Portable

4C-4083

15.875 mm (0.625 in)

41,343 kPa (6,000 PSI)

Hydraulic Tester

4C-9675 and 160-2515 Portable

4C-4084

19.913 mm (0.784 in)

41,343 kPa (6,000 PSI)

Hydraulic Tester

Flowmeter-Testers

Warranty: Caterpillar ^®Six Months

• Used to regulate hydraulic flow with built-in

• Used with DataView

load valve

Part Number

Flow Range

Maximum Pressure

Connections

160-2513

19- 190lpm (5 -50 gpm)

41,343 kPa (6,000 PSI)

1 5/16-12 (No. 16) O-ring ports

160-2514

15 - 474 lpm (4 - 125 gpm)

48,230 kPa (7,000 PSI)

1 7/8-12 (No. 24) O-ring ports

160-2515

57 - 682 lpm (15 - 180 gpm)

34,450 kPa (5,000 PSI)

38.1 mm (1.5 in) SAE 4-bolt flange

REPAIR INFORMATION

Webster Instruments

1290 East Waterford Avenue

Milwaukee, WI 53207

Phone: (414) 769-6400

Fax: (414) 769-6591

A “Return Material Authorization” number is required.

Adapter Flange

Model Usage: Large Excavators

• Used to connect large excavators to 348-6504

• Allows different sized code 62 to be

load valve during main hydraulic flow test

connected using SAE standard bolt patterns

Warranty: Caterpillar ^®Six Months

• Material: Steel

• Meets SAE J518 and ISO standards

Part Number

Dimensions

Weight

434-6930

133.35 x 101.6 x 50.8mm (5.25 x 4.0 x 2.0in)

4.15 kg (9.16 lb)

434-6931

133.35 x 114.3 x 57.15 mm (.25 x 4.5 x 2.25 in)

5.22 kg (11.5 lb)

7-20 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

DHCR1500 Flowmeter, HV1500 Load Valve

Model Usage: All Models

• Used together to measure hydraulic flow,

• Infra-red photo-tachometer with “on target”

pressure, temperature in any hydraulic system

indicator

Warranty: Caterpillar ^®Six Months

• Diagnosises problems in hydraulic systems

• Measures flow in both directions (uni-

directional when used with 348-9504 HV1500

• Meets EU requirements (No CE markings req.)

Load Valve)

348-9503 DHCR1500 Flowmeter

348-9504 HV1500 Load Valve

• Flow rated up to 1500 lpm (400 gpm)

Progressive pressure control

•

• Pressure rated up to 420 bar (6000 PSI)

High-strength aluminum body rated up to 420

•

• Code 62 four-bolt flange connections

bar (6000 PSI)

• Accuracy of ± 1% of indicated reading

• Includes connecting flange, seals, and bolts

• Remote inputs: flow, temperature - 2,

for use with 348-9503 DHCR1500 Flowmeter

REPAIR INFORMATION

pressure— 1, speed— 1

• Pilot operated, over-pressure internal bypass

Webster Instruments

• Quickly checks hydraulic pumps, motors,

valve

1290 East Waterford Avenue

valves, cylinders, hydrostatic transmissions

Milwaukee, WI 53207

• Includes spare burst discs

Phone: (414) 769-6400

• Low battery power consumption with

• Uni-directional flow

Fax: (414) 769-6591

automatic “power off” feature

A “Return Material Authorization” number is required.

348-9503 DHCR1500 Flowmeter

Item

Quantity

DHCR1500Unit

Cable HoseAssembly

LT1500-FR-F-S-6 Unit

Carry Case

348-9504 HV1500 Load Valve

Item

Quantity

HV1500Load ValveUnit

Spool

Carry Case

Part Number

Description

348-9503

DHCR1500 Flowmeter

348-9504

HV1500 Load Valve

Flowmeter Adapters

Model Usage: All Models

• Tests of pump flow rate without removing

• Connects flowmeter into a hydraulic circuit

pump from machine, saving time and money

Warranty: Caterpillar ^®Six Months

• 1 end of the through hole and intersecting

• Perform flow test on hydraulic systems of

port are SAE 16 O-ring ports (1 5/16-12),

Cat^®and competitive machines

making the ports compatible with Cat^®high

pressure fittings

• Through drilled with 90° intersecting port

• 1 series adapter has holes for 4-bolt flanges

• 3 ports allow the adapter to be used as a

straight through or 90° connection

• 1 series of adapter has tapped holes which

allow a flowmeter to be connected to pump

• 2 through ports can be connected into the

outlet hose

system, leaving third port for pressure or flow

rate tap

• Pressure rating: 41,340 kPa (6,000 PSI)

Item

Part Number

Description

9U-5273

Adapter, 25.4 mm (1 in) flange

9U-5272

Adapter, 31.75 mm (1.25 in) flange

9U-5936

T-Test Adapter, 31.75 mm (1.25 in) hose

Service/Repair Parts

1P-3703

D-ring used on 9U-5273

—

1P-3704

D-ring used on 9U-5272

JULY 2018 Vehicle System Tools

7-21

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Load Valve and Cable Tool Groups

Model Usage: All Models

• Used to allow accurate flow testing including

• Low-flow solution provides accurate flow

power testing of the 349 Excavators

measurement of small HEX

Warranty: Caterpillar ^®Six Months

• Equipped with same ports as 4C-9910

• Accuracy: Up to 1% of indicated reading

• Additional load valve allows for multiple load

• Top Ports: 7/16" -20UN #4 SAE ORB

testing and versatility in testing for the next

• 5 m cable included

generation of electronically controlled pumps

• Loadvalves to be used in tandem with

436-8662 or with the 4C-9910

Part No.

Description

Flow Range

Main Ports

Max Pressure

Load Valve and Cable

436-8661

5 - 210 gal/min

1-7/8" -12UN #24 SAE ORB

7000 PSI

ToolGroup

Load Valve and Cable

436-8663

2.5- 100 gal/min

1-5/16" -12UN #16 SAE ORB

6000 PSI

ToolGroup

Digital Hydraulic Testers

Model Usage: All Models

• Used to allow accurate flow testing including

• Internal Temp. Range: 0-120 degree celcius

power testing of the 349 Excavators

(32-250 degree fahrenheit)

Warranty: Caterpillar ^®Six Months

• Additional load valve will allow for multiple

• Remote Flow Input: external input is easily

load testing and versatility in testing for the

configured in the field to any LT series flow

next generation of electronically controlled

meter

pumps

Dimensions

• Load valve to be used in tandem with

• 436-8662: 246.4 x 226.1 x 226.1 mm

436-8662 or with the 4C-9910

(9.7 x 8.9 x 8.9 in)

• Low flow solution provides accurate flow

• 436-8664: 241.3 x 200.7 x 200.7 mm

measurement of small HEX

(9.5 x 7.9 x 7.9 in)

Part No.

Description

Flow Range

Main Ports

Max Pressure

436-8662

Digital Hydraulic Tester

5 - 210 gal/min

1-7/8" -12UN #24 SAE ORB

7000 PSI

436-8664

Digital Hydraulic Tester

2.5- 100 gal/min

1-5/16" -12UN #16 SAE ORB

6000 PSI

Hydraulic Test Adapter

Essential Tool

• Used to connect flowmeter return line into

Specifications

hydraulic circuit

Model Usage: M312, M315, M318, and M320

• Female connection (STOR): Dash Size - 16,

Wheeled Excavators

• Test pump flow rate without removing pump

1 5/16-12 thread

from machine

Warranty: Caterpillar ^®Six Months

• Through hole connection: Code 61 Split Flange

• Directs oil from flowmeter through oil cooler

• Hole size: 30.0 mm (1.181 in)

(prevents overheating during pump testing)

Fits flange dash size: 20

•

• Adapter is through-drilled with 90 degree

• Fits head size: 50.8 mm (2.0 in)

intersecting port

• Use 4J-0522: O-ring seal

Reference

• SENR6261, Testing and Adjusting M300

Family Excavators Hydraulic Systems

Part Number

Description

146-3661

Hydraulic Test Adapter

7-22 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Adapters for Hydraulic System Component Testing

• The same improved adapters are

• All adapter components are high pressure,

• For convenience, 5P-8687 Tool Group,

recommended for use with discontinued

103,500 kPa (15,000 PSI) minimum burst

consisting of an E-2 Tachometer Adapter,

5P-3600 Flow Meter and discontinued

pressure, fittings and, where convenient,

blocking plate assemblies, and certain special

9S-2000 Flow Meter, with one additional C-2

duplication of components has been

tools, is available

hose assembly being required with 9S-2000

eliminated

• Oil flow should always be from a nipple into a

Flow Meter; refer to following tool lists and

• Some components are seldom used and have

valved coupler and never from a coupler into a

Tee Test Tool Chart for adapter components

been removed from “recommended” status to

valved nipple.

required for each machine

an “available if needed status”

Always make certain that the valved coupler on the C5 and C8 Connecting Hose Assemblies are connected to the valved nipple on the pump adapter

before starting the diesel engine. If this connection is not made properly, injury to personnel or damage to the machine can occur when performing the

pump test. Refer to Form REG00791-01 for procedural information for testing hydraulic systems and components.

Tee Test Tool Group

Model Usage: See Charts

Item

Part No.

Description

Qty.

—

5P-8687

Tee Test Tool Group

Warranty: Caterpillar ^®Six Months

2P-9697

Plug (7/8in— 14 thd)

3R-6789

Cap (1 5/16 in - 12 thd)

5P-2299

Plug (1 5/16 in— 12 thd)

5P-2909

Plug (3/4in— 16 thd)

5P-4299

Plug (1 3/16 in— 12 thd)

6J-7366

Cap (7/8 in - 14 thd)

8L-9137

Cap (1 3/16 in - 12 thd)

8S-4950

Cap (9/16 in - 18 thd)

8S-4951

Cap (3/4 in - 16 thd)

9L-8493

Cap (7/16 in - 20 thd)

9S-8895

Plug (1 1/16in— 12 thd))

9S-8896

Cap (1 1/16 in - 12 thd))

9S-8927

Plug (9/16 in - 18 thd))

1W-2316

Adapter Assembly

4M-8303

Seal - O-ring (outside)

5P-0537

Hard Washer

5P-1758

Shaft Assembly

• For use with 1U-8761 and 1U-9551

4N-0538

Coupling

Portable Hydraulic Testers (all blocking

9U-7419

Bit, 19.05 mm (3/4 in)

plate assemblies, most needed tachometer

1P-3566

Bit, 14.28 mm (9/16 in)

adapters, and 2 tool bits available under 1

4F-7391

Seal

4F-7952

Seal

part number)

4J-8996

Seal

• All parts stored in compact box with decal in

5F-1678

Seal

lid for quick parts reference

5F-7054

Seal

7F-8267

Seal

8F-6711

Seal

9S-7358

Plate Assembly, 12.7 mm (1/2 in)

9S-7359

Plate Assembly, 19.05 mm (3/4 in)

9S-8092

Plate Assembly, 25.4 mm (1 in)

9S-8093

Plate Assembly, 31.75 mm (1 1/4 in)

9S-8094

Plate Assembly, 38.1 mm (1 1/2 in)

9S-8095

Plate Assembly, 50.8 mm (2 in)

9S-8894

Plate Assembly, 15.87 mm (5/8 in)

6V-3073

Case - Plastic

6V-7029

Block-Top

JULY 2018 Vehicle System Tools

7-23

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

5P-8687 Tee Test Tool Group Assemblies (Continued)

Part No.

Description

Qty.

A-1 Assembly

2P-8336

Nipple As - High Pressure (Valved) a b

2S-4078

Seal - O-Ring STOR (SAE 1 5/8 - 12) (Part of 8S-9967) c

9S-9967

Adapter

A-2 Assembly

2P-8336

Nipple As - High Pressure (Valved) a b

3D-2824

O-Ring Seal c

9S-7336

Adapter

A-4 Assembly

030-7976

Adapter - 45° Union

1P-5596

Pipe Nipple

2P-8336

Nipple As - High Pressure (Valved) a b

3D-2824

O-Ring Seal c

A-5 Assembly

031-5744

Adapter - Elbow, 90°

1P-5597

Nipple - Pipe, 25.4 x 31.75 mm (1 x 1 1/4 in) b

2P-8336

Nipple As - High Pressure (Valved) a b

5P-2242

Tee— Swivel- 37°Flared

5P-2244

Union - Adapter - 37° Flared Swivel

A-6 Assembly

004-3099

Fitting

2P-8337

Valved Coupler

3B-7257

Bushing

9S-0247

Hose

A-7 Assembly

030-7980

Adapter, 90°

1P-5598

Pipe Nipple 31.75 x 31.75 mm (1 1/4 x 1 1/4 in)

2P-8336

Nipple As - High Pressure (Valved) a b

2S-7078

O-ring Seal

A-8 Assembly

1D-4717

Nut

1P-5597

Nipple - Pipe, 25.4 x 31.75 mm (1 x 1 1/4 in) b

2P-8336

Nipple As - High Pressure (Valved) a b

4F-7391

O-Ring Seal

5P-3032

Adapter,25.4 mm (1in) hose

8S-9191

Bolt (4)

A-9 Assembly

1D-4718

Nut

1P-5597

Nipple - Pipe, 25.4 x 31.75 mm (1 x 1 1/4 in) b

2P-8336

Nipple As - High Pressure (Valved) a b

4F-7952

O-Ring Seal

5P-3033

Adapter,31.75 mm (11/4in)hose

7H-3472

Bolt

A-10 Assembly

1D-4719

Nut

1P-5598

Pipe Nipple 31.75 x 31.75 mm (1 1/4 x 1 1/4 in) a

2H-6488

Bolt

2P-8336

Nipple As - High Pressure (Valved) a b

5P-3034

Adapter,38.1mm (11/2in) hose

7F-8267

O-Ring Seal

A-11 Assembly

004-4977

Elbow, 45°

2P-8336

Nipple As - High Pressure (Valved) a b

8S-9967

Adapter

a. Use from A-7 Assembly No.

b. Use from A-8 Assembly No.

c. Recommended spare parts

7-24 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

B - Return Line Assemblies

• To determine assembly number required for a

machine model, refer to Section B of Tee Test

• Return oil to hydraulic tank

Tool Chart and following list

Part Number

Description

Quantity

B-6 Assembly

2P-8335

Coupler As - High Pressure

6V-0001

Seal Kit (Part of 2P-8337)

8S-9967

Adapter

B-7 Assembly

2P-8337

Valved Coupler a

3B-7750

Pipe Nipple

4J-3815

Gasket

6V-0001

Seal Kit (Part of 2P-8337)

B-8 Assembly

2P-8337

Valved Coupler a

3B-6555

Street Ell

3B-7257

Bushing

3B-7749

Nipple

6V-0001

Seal Kit (Part of 2P-8337)

9H-6454

Gasket

B-10 Assembly

030-7980

Adapter, 90°

1P-5598

Pipe Nipple

2P-8335

Coupler As - High Pressure

2S-4078

O-Ring Seal

6V-0001

Seal Kit (Part of 2P-8337)

a. Use 2P-8337 Valved Coupler instead of discontinued 8S-9974

JULY 2018 Vehicle System Tools

7-25

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

C - Tachometer Drive Group

• Required to attach Flow Meter Tachometer

• To determine assembly number required for a

Generator to all machines which are

machine model, refer to Section C of Tee Test

adaptable to “Tee Testing”

Tool Chart and thento list below

Part Number

Description

Quantity

C-1 Assembly (Used on very early 988 and 992 only)

1B-9575

Bolt

1M-5061

Tachometer Drive Group

3B-4505

Lock Washer

C-2 Assembly

4M-8303

Seal (Part of 5P-1759)

4N-0538

Coupling(Partof5P-1759)

5P-1758

Shaft Assembly (Part of 5P-1759)

5P-1759

Tachometer Adapter (Included in 5P-8687 Tool Group)

9N-3018

Adapter Group (Part of 5P-1759)

9S-0211

Clamp (Part of 5P-1759)

9S-3032

Clamp (Part of 5P-1759)

C-3 Assembly (Used on 977H, 955H, 933F and G and 966 withserial numbers below 75A-1092 only)

1B-2714

Bolt (1/4 in-20 x 2 1/2 in)

1D-4539

Bolt (5/16 in-18 x 2 1/2 in)

3B-4504

Lock Washer, 6.35 mm (1/4 in)

3B-4505

Lock Washer

C-4 Assembly (Used on 977H machines not equipped with 2S424 Service Meters only)

1D-4539

Bolt (5/16 in-18 x 2 1/2 in)

2B-2695

Bolt (5/16in-18 x 7/8in)

2S-0424

Service Meter Group

3B-4505

Lock Washer

C-5 Assembly (Used on D3, 910 and 931 only)

1B-7182

Bolts

5P-0935

AdapterGroup

C-6 Assembly (Used on all U.S. production 3204 Engines)

0S-1617

Bolt

4M-8303

Seal (Part of 5P-1759)

8N-5945

Tachometer Drive Adapter

9M-1974

Washer

9S-3032

Clamp (Part of 5P-1759)

C-7 Assembly (Used on 3204 Engines 10X-2936-up)

0S-1617

Bolt

4M-8303

Seal (Part of 5P-1759)

5P-1758

Shaft Assembly (Part of 5P-1759)

6N-1345

Tachometer Drive Adapter

9M-1974

Washer

9S-3032

Clamp (Part of 5P-1759)

7-26 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

D - Blocking Plate Assemblies

• Available by ordering 5P-8687 Tool Group

• To determine assembly number required

for a machine model, refer to the Service

• Isolate various system components when

Manual for Testing Hydraulic Systems and

troubleshooting hydraulic system

Components, and then to the list below

Part Number

Description

Quantity

D-1 Assembly

5F-7054

Seal - O-Ring

2 a

9S-7358

Blocking Plate Assembly, 12.7 mm (1/2 in)

2 a

D-2 Assembly

4J-8996

Seal - O-Ring

2 a

9S-8894

Blocking Plate Assembly, 15.87 mm (5/8 in)

2 a

D-3 Assembly

5F-1678

Seal - O-Ring

2 a

9S-7359

Blocking Plate Assembly, 19.05 mm (3/4 in)

2 a

D-4 Assembly

4F-7391

Seal - O-Ring

2 a

9S-8092

Blocking Plate Assembly, 25.4 mm (1 in)

2 a

D-5 Assembly

4F-7952

Seal - O-Ring

9S-8093

Blocking Plate Assembly, 31.75 mm (1 1/4 in)

D-6 Assembly

7F-8267

Seal - O-Ring

4 a

9S-8094

Blocking Plate Assembly, 38.1 mm (1 1/2 in)

4 a

D-7 Assembly

8F-6711

Seal - O-Ring

1 a

9S-8095

Blocking Plate Assembly, 50.8 mm (2 in)

1 a

D-8 Assembly

9S-8895

Plug (1 1/16in— 12 thd))

2 a

9S-8896

Cap (1 1/16 in - 12 thd))

2 a

D-9 Assembly

2P-9697

Plug (7/8in— 14 thd)

2 a

6J-7366

Cap (7/8 in - 14 thd)

2 a

D-10 Assembly

8S-4950

Cap (9/16 in - 18 thd)

9S-8927

Plug (9/16in— 18 thd)

D-11 Assembly

5P-2909

Plug (3/4in— 16 thd)

2 a

8S-4951

Cap (3/4 in - 16 thd)

2 a

D-12 Assembly

3R-6789

Cap (1 5/16 in - 12 thd)

1 a

5P-2299

Plug (1 5/16 in— 12 thd)

1 a

D-13 Assembly

5P-4299

Plug (1 3/16 in— 12 thd)

1 a

8L-9137

Cap (1 3/16 in - 12 thd)

1 a

D-14 Assembly

9L-8493

Cap (7/16 in - 20 thd)

1 a

a. Included in 5P-8687 Tool Group

JULY 2018 Vehicle System Tools

7-27

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Tee Test Tool Charts: Hydraulic Implement System - A-1 thru A-11

Machine Model

A-1

A-2

A-3

A-4

A-5

A-6

A-7

A-8

A-9

A-10

A-11

D7G

D8K

D9H

D10L

613B

621

621B

623

623B

627

627B

631C

631D

633

633D

641B

650B

651B

657B

660B

666B

814

815

816

824

824B

826B

834

835

931

941

943, 953

951

955

- a

977

- a

983

518

528

910

920

930

950

966

980

988

992

2 b

992C

120G

130G

140G

12G

14G

- c

16G

- c

215

225

235

245

1 d

a. See “Adapter for Hydraulic System Component Testing”

b. Machines with ROPS cabs only

c. Required on early machines with “Tee Taps”

d. Machines with serial numbers 95V960-Up, 825X543-Up, 94L443-Up and 84X555-Up

JULY 2018 Vehicle System Tools

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Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Steering Systems - B thru C

Machine Model

B-6

B-9

C-2

920

930

966

988

992C

814

815

816

621B

623B

627B

631D

633D

637D

528

Tee Test Adapters

Model Usage: Most Cat^®Models

• Used to perform Tee Tests on Cat^®or

• Bolts listed with associated parts and nuts

competitive machines which are not equipped

which allow convenient storage of bolts in

Warranty: Caterpillar ^®Six Months

with Tee Test taps in pump outlet line

adapter

• Each adapter through-drilled with 90°

• Correct O-ring seal for inlet port of each

intersecting port which allows adapter to be

adapter given in figure below

used as straight-through or 90° connection

• Instructions for using adapters on future Cat^®

with remaining port being used for Tee tap

machines not equipped with Tee taps will be

• Intersecting port and one end of through-

covered in the Service Manual

drilled hole are tapped with NPTF threads

to facilitate installation of pipe nipples and

valved nipples for connection to Tee Test hose

• All 3 ports have 4 bolt holes for connecting

pump outlet hoses with 4 bolt flanges; since

the 4 bolt flange holes for through-drilled

passage are also through-drilled, longer bolts

are required to install adapters

7-32 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Typical Adapter and Associated Parts for Tee Test Adapters

Required Associated Parts

Part Number

Description

5P-3033 Adapter, 31.75 mm (1 1/4 in) hose

1D-4718

Nut (4)

1P-5597

Pipe Nipple, 25.4 x 31.75 mm (1 x 1 1/4 in)

2P-8336

Nipple As - High Pressure (Valved)

4F-7952

O-ring Seal

7H-3472

Bolt (4)

5P-3032 Adapter, 25.4 mm (1 in) hose

1D-4717

Nut (4)

1P-5597

Pipe Nipple, 25.4 x 31.75 mm (1 x 1 1/4 in)

1P-8336

Valved Nipple

4F-7391

O-ring Seal

8S-9191

Bolt (4)

5P-3034 Adapter, 38.1 mm (1 1/2 in) hose

1D-4719

Nut (4)

1P-5598

Pipe Nipple, 31.75 x 31.75 mm (1 1/4 x 1 1/4 in)

2H-6488

Bolt (4)

2P-8336

Nipple As - High Pressure (Valved)

7F-8267

O-ring Seal

Quick Disconnect Couplings for Hydraulic Test Equipment

Model Usage: Most Cat^®Models

• All quick disconnect couplings used for Cat^®

• Disconnects rated by operating pressure,

hydraulic test equipment summarized in chart

pressure at which no failure expected to

Warranty: Caterpillar ^®Six Months

occur in normal cyclic usage

• Couplings listed within each group are

interchangeable

Connection Thread

Item

Part No.

Description

Type

Nominal Size

Operating Pressure

(Type)

2P-8334

Nipple

Open

1 1/4 NPT (Int)

1 1/4 in

34,500 kPa (5000 PSI)

2P-8335

Coupler

Open

1 1/4 NPT (Int)

1 1/4 in

34,500 kPa (5000 PSI)

2P-8336

Nipple

Valved

1 1/4 NPT (Int)

1 1/4 in

34,500 kPa (5000 PSI)

2P-8337

Coupler

Valved

1 1/4 NPT (Int)

1 1/4 in

34,500 kPa (5000 PSI)

Not Shown:

Connection

Part No.

Description

Type

Nominal Size

Operating Pressure

Thread (Type)

Not Shown

69 000 kPa (10,000 PSI)

1P-2375

Nipple

Valved

3/8 NPT (Ext)

3/8in

(Normal Service Press coupled

operation only)

69 000 kPa (10,000 PSI)

1P-2376

Coupler

Valved

1/4 NPT (Int)

3/8in

(Normal Service Press coupled

operation only)

2P-8335

Coupler

Open

1 1/4 NPT (Int)

1 1/4 in

12,070 kPa (1750 PSI)

2P-8336

Nipple

Valved

1 1/4 NPT (Int)

1 1/4 in

12,070 kPa (1750 PSI)

12,070 kPa (1750 PSI) and

2P-8337

Coupler

Valved

1 1/4 NPT (Int)

1 1/4 in

34,500 kPa (5000 PSI)

3P-2232

Coupler

Valved

3/8 NPT (Int)

3/8in

20,700 kPa (3000 PSI)

3P-2233

Coupler

Valved

3/8 NPT (Ext)

3/8in

20,700 kPa (3000 PSI)

3P-2234

Nipple

Valved

3/8 NPT (Int)

3/8in

20,700 kPa (3000 PSI)

3P-2235

Nipple

Open

3/8 NPT (Int)

3/8in

20,700 kPa (3000 PSI)

3P-2236

Nipple

Open

3/8 NPT (Ext)

3/8in

20,700 kPa (3000 PSI)

6V-3965

Nipple

Valved

9/16 SAE (Ext)

1/4in

41,500 kPa (6000 PSI)

6V-3966

Nipple

Valved

1/4 NPT (Ext)

1/4in

41,500 kPa (6000 PSI)

6V-3989

Nipple

Open

1/4 NPT (Int)

1/4in

41,500 kPa (6000 PSI)

6V-4142

Nipple

Open

1/8 NPT (Int)

1/4in

41,500 kPa (6000 PSI)

6V-4143

Coupler

Valved

1/8 NPT (Int)

1/4in

41,500 kPa (6000 PSI)

6V-4144

Coupler

Valved

1/4 NPT (Int)

1/4in

41,500 kPa (6000 PSI)

JULY 2018 Vehicle System Tools

7-33

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Quick Disconnect Couplings

Model Usage:Most Cat^® Models with pressure

• Small quick disconnect couplings with good

• 2 types of valved couplers available for

up to 41,500 kPa (6000 PSI)

sealing ability for pressures up to 41,500 kPa

connecting gauges, hoses, and snubber valves

(6,000 PSI)

to valved nipples on machine

Warranty: Caterpillar ^®Six Months

• Valved nipples can be permanently installed in

• 2 additional plain nipples available for hose to

test points of current Cat^®hydraulic,

gauge or snubber valve to gauge connection

transmission, engine oil, or cooling systems so

• 6V-0852 Protective Dust Caps are available

that pressures can be quickly determined

for the 6V-3965 and 6V-3966 Valved Nipples

throughout machine

Item

Part No.

Description

Valved Couplers

6V-4144

Coupler Assembly Internal, 1/4 in NPT

301-7445

Valved Coupler, Internal, 9/16 in-18 STOR

6V-4143

Coupler Assembly Internal, 1/8 in NPT

Valved Nipples

—

8T-3613

Valved Nipple, External, 1/8 in NPT

6V-3965

Nipple Assembly, External, 9/16 in SAE thd

6V-3966

Nipple Assembly, External, 1/4 in NPT

Plain Nipples

6V-3989

Plain Nipple, Internal, 1/4 in NPT

6V-4142

Plain Nipple, Internal, 1/8 in NPT

High Temp. Valved Nipples

6V-4433

Valved Nipple, External, 9/16 in SAE thd

Auto Brake Fluid Valved Nipples

6V-7691

Valved Nipple, External, 1/4 in NPT

—

8T-3614

Valved Nipple, External, 1/8 in NPT

Auto Brake Fluid Valved Coupler

6V-7690

Valved Coupler, Internal, 1/4 in NPT

ORFC Valved Nipple

8C-6416

Valved Nipple, ORFC; use with 6V-8554 Nut

Quick Disconnect Couplings and Hoses

Model Usage: M300 Series Wheeled Excavators;

• Used to diagnostically test any component

Dust Cap and Plug

953C, 963C, 973C, 933, and 939 Track Loaders;

or machine requiring 68,950 kPa (10,000 PSI)

• Used to provide contamination protection

and D3C, D4C, D5C, D6R, D7R, D8R, and D9R

hoses and fittings

Used with 187-3546 Coupler and 183-3547

•

Differential Steering Track-Type Tractors

• Highest pressure-rated hose and fittings of

Nipple

Warranty: Caterpillar ^®Six Months

this type in the industry

•

Made of plastic compound

• Rated at 4:1 minimum burst pressure

Specifications

Quick Disconnect and Hoses

• Pressure rating: 68,950 kPa (10,000 PSI)

• Used to diagnostically test pumps and

• Minimum hose burst ratio rating: 4:1

transmissions rated at 68,950 kPa (10,000 PSI)

• Nipple threads: 9/16-18, male STOR

• Used with 344-7922, 344-7923, and 344-7924

Hose Assemblies

• Coupler threads: 9/16-18, female STOR

• Valved coupler and nipple will not interchange

• Hose end threads: 9/16-18, male STOR

with lower pressure 41,500 kPa (6,000 PSI)

• Hose inside diameter: 4.78 mm (0.188 in)

nipple and coupler

• Hoses made of tough thermoplastic material

Item

Part Number

Description

187-3546

Quick Disconnect Coupler

187-3547

Quick Disconnect Nipple

187-9010

Dust Plug

187-9008

Dust Cap

not shown

344-7922

Hose Assembly, 3.1 m (10.0 ft)

not shown

344-7923

Hose Assembly, 4.3 m (14.0 ft)

not shown

344-7924

Hose Assembly, 5.5 m (18.0 ft)

7-34 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Connector Plates for Hydraulic System Flushing

Model Usage: Most Cat Models

• Used for flushing hydraulic systems on Cat^®

• Used between hose flanges which are joined

machines

together during flushing process; provide

Warranty: Caterpillar ^®Six Months

sealing surface for O-ring seals in flange

faces

Plate

Bolt Hole Spacing

Bolt Hole Diameter

Center Hole Diameter

Thickness

5C-2268

23.80 x 50.80 mm (0.937 x 2.000 in)

10.49 mm (0.413 in)

19.05 mm (0.75 in)

5.99 mm (0.236 in)

5P-9707

36.50 x 79.38 mm (1.437 x 3.125 in)

16.66 mm (0.656 in)

38.10 mm (1.50 in)

6.35 mm (0.250 in)

8K-2574

31.75 x 66.68 mm (1.250 x 2.625 in)

13.13 mm (0.517 in)

31.75 mm (1.25 in)

6.35 mm (0.250 in)

8K-4977

27.76 x 57.15 mm (1.093 x 2.250 in)

11.99 mm (0.472 in)

25.40mm (1in)

6.71 mm (0.264 in)

Quick Disconnect Fittings

Model Usage: All Models

Quick Disconnect Couplers and Nipples

• 4C-5091 Coupling: 1 5/16 in-12 STOR

(M30 x 2)

Warranty: Caterpillar ^®Six Months

• Used to quickly connect high pressure hoses

(extensively used for hydraulic flow testing

Hose End Fittings

with hydraulic test benches and portable flow

• Used to make hydraulic hoses for field flow

meters, for hydraulic hammers on excavators,

testing, test benches, or shop oil filtering

and any application where high pressure quick

disconnects are needed)

• Used with 5P-1010 and 5P-0477 XT5 Sleeves

(assembled with Cat^®Hose Press Tooling)

• Designed as screw-to-connect high pressure

fittings (will not come uncoupled during

• Helps eliminate leaks and need for additional

rugged use or abuse)

thread adapters

• Burst pressure provides 3 1/2 to 1 safety

• Available with STOR (Straight Thread O-ring)

factor

style threads

• Valved for clean, non-spill field application

• Working Pressure: 41,340 kPa (6,000 PSI)

• Dust caps and dust plugs available where dirt

• 4C-8767 Coupling: 25.4 mm (1 in) XT5 Hose x

and other contaminates are present

1 5/16 in-12 External STOR with O-ring

• Repair kits available for all sizes and contain

• 4C-6461 Coupling: 31.75 mm (1 1/4 in) XT5

all seals to overhaul quick disconnects

Hose x 1 5/8 in-12 External STOR with O-ring

• Used with 1U-9551 Portable Hydraulic

• 4C-6462 Coupling: 31.75 mm (1 1/4 in) XT5

Flowmeter and 1U-8761 Portable Hydraulic

Hose x 1 5/16 in-12 External STOR with O-ring

Flowmeter

Connection

• Working pressure of all couplers and nipples:

• for 9U-5075 and 9U-5076: 19.05 mm (3/4 in)

41,340 kPa (6000 PSI)

NPT female port

• Flow rate: 303 lpm (80 gpm) with a 690 kPa

• for 4C-6481 and 4C-6482: 1 5/16 in-12 STOR

(100 PSI) pressure drop

• for 4C-5093 and 4C-5094: 1 5/8 in-12 STOR

• Operating pressure: 41,340 kPa (6000 PSI)

• Burst pressure: 137,800 kPa (20,000 PSI)

Thread Adapters

• Working pressure: 41,340 kPa (6,000 PSI)

Flow Test Fittings

• 4C-5092 Coupling: 1 5/16 in-12 Internal STOR

• Used to adapt various applications when

x 1 5/8 in-12 External STOR

STOR, ORFS, or metric threads are present

• 4C-5088 Coupling: 25.4 mm (1 in) NPT Internal

• Working pressure: 41,340 kPa (6,000 PSI)

Pipe thd x 1 5/8 in-12 External STOR

• 4C-5089 Elbow: 1 5/16 in-12 STOR x 1 3/16

• 4C-5087 Coupling: 1 5/8 in-12 x 1 5/8 in-12

in-12 ORFS 90° Swivel

STOR Male Union

• 4C-5090 Coupling: 1 5/16 in-12 STOR

(M30 x 2) Swivel

Reference

• NEHT5000, Tool Operating Manual

JULY 2018 Vehicle System Tools

7-35

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Couplers and Nipples Usage Chart

Coupler and Nipple Usage Chart

Size

Description

Part No.

Dust Cap

Dust Plug

Repair Kit

19.05 mm (3/4 in)

Coupler

9U-5076

9U-5083

19.05 mm (3/4 in)

Nipple

9U-5075

9U-5085

25.4 mm (1 in)

Coupler

4C-6481

9U-5084

9U-5078

25.4 mm (1 in)

Nipple

4C-6482

9U-5086

9U-5081

31.75mm (11/4in)

Coupler

4C-5094

9U-5079

31.75mm (11/4in)

Nipple

4C-5093

9U-5082

Item

Part Number

Description

Size

9U-5076

QDCoupler

19.05 mm (3/4 in)

9U-5083

Dust Plug

19.05 mm (3/4 in)

9U-5085

Dust Cap

19.05 mm (3/4 in)

9U-5075

QD Nipple

19.05 mm (3/4 in)

4C-6481

QDCoupler

25.4 mm (1 in)

9U-5084

Dust Plug

25.4 mm (1 in)

9U-5086

Dust Cap

25.4 mm (1 in)

4C-6482

QD Nipple

25.4 mm (1 in)

4C-5094

QD Coupler (263-2839 Dust Cap)

31.75mm (11/4in)

4C-5093

QD Nipple (201-8057 Dust Cap)

31.75mm (11/4in)

Not shown

9U-5078

Coupler Repair Kit

25.4 mm (1 in)

—

9U-5079

Coupler Repair Kit

31.75mm (11/4in)

—

9U-5081

Nipple Repair Kit

25.4 mm (1 in)

—

9U-5082

Nipple Repair Kit

31.75mm (11/4in)

Flow Test Fittings and Thread Adapters

Item

Part No.

Description

4C-5088

Coupling

4C-5087

Coupling

4C-5091

Coupling

4C-5090

Coupling

4C-5089

Elbow

4C-5092

Coupling

Hose End Fittings

Part No.

Description

4C-8767

Hose Coupling

7-36 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Dust Cap, Plug, and Nipple Assembly

Model Usage: All Cat^®Machines

• Used to seal valved and non-valved nipples

7X-7646 Nipple Assembly

and couplings

Warranty: Caterpillar ^®Six Months

• Low pressure quick disconnect nipple:

•

Provide positive sealing and padded

- Working pressure: 3000 PSI

protection for nipples and couplings

- Burst pressure: 12,000 PSI

Item

Part Number

Description

Use

7X-7646 Nipple Assembly,

7X-7645

Dust Cap

8C-9024 Nipple Assembly

Machines, tool groups, and dealer shop

7X-7646

Nipple Assembly

equipment

7X-7647

Dust Plug

8C-9025 Coupler

7X-7648

Dust Cap

8C-7545 Nipple Assembly

Tool Kit

Essential Tool

• Used to properly disconnect snap-to-connect

Reference

hydraulic fittings during service procedures

Model Usage: 450E Backhoe Loader

• KENR5485, Power Train Disassembly and

• Comes in pouch which includes 3 wrenches

Assembly Service Manual

Warranty: Caterpillar ^®Six Months

for 5 coupler sizes

Item

Part Number

Description

Size

—

304-1165

Tool Kit

Service/Repair Parts

1 a

304-1166

STCWrench

-06

2 a

304-1167

STCWrench

-08 and -10

3 a

304-1168

STCWrench

-12 and -16

Not Shown

304-2721

Tool Pouch

a. Not Serviced

Adapter Assembly, Hose Assembly

Model Usage: 205, 206, 211, 212, 213, 214 and

• Needed when pressure testing hydraulic

• 8T-5114 used with 6V-3965 Nipple makes

224 Excavators

excavators

8T-5115 Hose Assembly and pressure nipples

on machines compatible with standard Quick

Warranty: Caterpillar ^®Six Months

• Both have working capacity of 41,400 kPa

Disconnect Couplings used on Cat^®test

(6,000 PSI)

equipment; 8T-5114 Adapter Assembly and

• 8T-5115 Hose Assembly has M16X2-6H

6V-3965 Nipple must always be installed in

female threaded couplings, which are

one end of 8T-5115 Hose Assembly before

compatible with pressure nipples on the

attaching hose assembly to pressure nipple

hydraulic excavators

onmachines

• 8T-5114 Adapter Assembly has M16X2-6G

male threads and 9/16-18-2B female threads

Part Number

Description

8T-5114

Adapter Assembly

8T-5115

Hose Assembly

Hydraulic Hose for Diagnostic Testing

Model Usage: Most Cat^®Models

• For diagnostic test applications primarily with

• Lightweight, easy to coil and resist expansion,

5P-3600 Flow Meter and discontinued 6V-

minimizing accumulator effect

Warranty: Caterpillar ^®Six Months

4160 Transmission Test Groups

Part No.

Pressure Rating

Thread Connections

Hose Inside Diameter

HoseLength

177-7860

41,500 kPa (6,019.06 PSI)

1/8-27-NPTF (both ends)

3.2mm (0.13in)

304 cm (10 ft)

177-7861

41,500 kPa (6,019.06 PSI)

1/8-27-NPTF (both ends)

3.2mm (0.13in)

427 cm (14 ft)

177-7862

41,500 kPa (6,019.06 PSI)

1/8-27-NPTF (both ends)

3.2mm (0.13in)

549 cm (18 ft)

1U-5757

41,500 kPa (6,019.06 PSI)

1/8-27-NPTF 7/16-20-thread

2 mm(0.08 in)

183 cm (6 ft)

JULY 2018 Vehicle System Tools

7-37

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Test Adapter

Model Usage: M312, M315, M318, M320

• Used to test and adjust travel motor de-stroke

Reference

Wheeled Excavators

point

SENR6261, Testing and Adjusting M300 Family

Warranty: Caterpillar ^®Six Months

• Adapter has #6 SAE O-ring port for 6V-3965

Excavators Hydraulic Systems

Valved Quick Disconnect Nipple and 3J-1907

Specifications

O-ring Seal

• Working pressure: 41,500 kPa (6,000 PSI)

• Allows use of standard quick disconnect

couplers used on Cat^®test equipment

• Male end: M12 x 1.0 thread

• Female end: #6 SAE O-ring port

Part Number

Description

126-3993

Test Adapter

Track Blocks

Model Usage: 307C thru 349E Excavators

• Used to retain track movement on machines

• Material, steel

for testing relief pressure

Warranty: Caterpillar ^®Six Months

Part No.

Models Used

Dimensions

Weight

418-3610

311D, 312E/D, 313D, 314E/D

350x 60 mm (13.8 x 2.4in)

5.1 kg (11.2 lb)

315D, 316E, 318E/D, 319D, 320E/D, 321D,

418-3611

350x 65 mm (13.8 x 2.6in)

7.0 kg (15.4 lb)

323E/D, 324E/D, 325E/D, 326D, 328D, 329E/D

418-3612

336E/D, 340D, 345E/D, 349E/D

420x 75 mm (16.5 x 3.0in)

11.6 kg (25.6 lb)

421-2325

307C/D, 308C/D/E

350 x 52 mm (13.8 x 2.05 in)

4 kg (8.8 lb)

Blocking Covers for Hydraulic Components

Model Usage: Most Cat^®Models

• Used to provide correct fit in the 4 bolt

• With these covers installed, full system

flanges when disconnecting hydraulic hose

pressure can be applied without loss of

Warranty: Caterpillar ^®Six Months

on machines equipped with XT-5 Hose

hydraulic fluid or damage to seal

(34,500 kPa [5,000 PSI]) hydraulic system

• Can also be used to isolate relief valve

pressure readings

Item

Blocking Cover

Seal

Hydraulic Hose Size

5P-0045

1P-3700

12.70 mm (0.50 in)

5P-0046

1P-3702

19.05 mm (0.75 in)

5P-0047

1P-3703

25.40mm (1in)

5P-0048

1P-3704

31.75 mm (1.25 in)

5P-0049

1P-3705

38.10 mm (1.50 in)

5P-0050

1P-3709

50.80mm (2in)

Stop

Model Usage: 12G, 14G, 16G, 130G and 140G

• Used to block pump servo valve when testing

• Stop assembly can be modified, as indicated

Motor Graders

maximum pressure relief valve on 14G and

below, so it can be used to obtain maximum

16GMotor Graders

pressure relief valve setting when tee testing

Warranty: Caterpillar ^®Six Months

12G, 130G and 140G Motor Graders

Part Number

Description

5P-2683

Stop

7-38 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Medium Pressure Quick Disconnect Couplings

Model Usage: Most Cat^®Models

• Replacement parts for earlier adapters for

• Use of these components should be limited

hydraulic system component testing

to testing at pressures below 34,500 kPa

Warranty: Caterpillar ^®Six Months

(5,000 PSI)

Item

Part No.

Description

2P-8334

Nipple, 1 1/4 in Plain 1 1/4 in NPT

2P-8335

Coupler, 1 1/4 in Plain 1 1/4 in NPT

190-8317

Nipple, 1 in Valved with 1 1/4 in NPT

190-8319

Nipple

2P-8336

Nipple, 1 1/4in Valved with 1 1/4 in NPT

Coupler As - High Pressure Valved with 1 1/4 in NPT 190-8316 Coupler - 1 in

2P-8337

Valved with 1 1/4 in NPT 190-8318 Coupler - 1 in Valved with 1 in NPT

T Handle Hex Wrench

Model Usage: HH45, HH55, HH65, and HH75

• Adjusts bypass relief valve (both tools used

• Used in tight spaces where conventional tools

Skogsjan Tree Harvester Heads

together)

will not work

Warranty: Caterpillar ^®Six Months

• Easy one-hand operation makes adjustment

• Socket size: 14 mm (0.55 in)

procedure much faster and easier

• Hex wrench: 4 mm (0.15 in)

• Eliminates need for open end wrenches

Part Number

Description

173-0960

T Handle Hex Wrench

Needle Valve

Model Usage: All Challengers

• Used in circuit when testing and adjusting

Reference

hydraulic pump margin pressure

• SENR3346, Service Manual SENR4969,

Warranty: Caterpillar ^®Six Months

• Used with FT2220 Hydraulic System Test Hose

Service Manual

Assembly

Specifications

• May be used in any hydraulic circuit with

• Maximum flow: 57 lpm (15.0 gpm)

pressure of 34,450 kPa (5000 PSI) or less

• Maximum pressure: 34,450 kPa (5,000 PSI)

• Valve body made from steel; needle from

stainless steel

• Pressure at maximum flow: 330 kPa (48.0 PSI)

• Port size: 1/2-12 NPTF

Part Number

Description

9U-5841

Needle Valve

Fitting Groups - JIC and ORFS

Model Usage: All Models

• 4C-4890 JIC Fitting Group replaces

• Included with tees, plugs, caps, adapters,

discontinued 6V-4161 Pressure Gauge Kit;

hose, valve and quick disconnects are 3 oil-

Warranty: Caterpillar ^®Six Months

4C-4890 contains essentially the same fittings

filled gauges with test ranges of 4,000 kPa

as discontinued 6V-4161 but costs less

(580 PSI), 25,000 kPa (3600 PSI) and 60,000

kPa (8,700 PSI)

• 4C-4890 and 4C-4892 Fitting Groups used

to pressure test pilot, main hydraulic and

• Packaged in lightweight, durable carrying

steering systems on all Cat^®products; can be

case containing 2 modular fitting boxes;

used on competitive machines when JIC or

limited space for expansion of number and

ORFS fittings are needed

type of fittings; lid decals list each fitting part

number, description and location

• Groups 4C-4890 and 4C-4892 include all

items in figures

• Compact, time-saving fitting kits

JULY 2018 Vehicle System Tools

7-39

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

JIC Fitting Group

Item

Part No.

Description

—

4C-4890

JIC Fitting Group

4C-3975

Plastic Case

4C-3721

Foam Block

4C-3719

Foam Block

1U-5757

Hose Assembly

4C-3725

Utility Box

052-0572

Swivel Tee (7/16 JIC)

061-9258

Swivel Tee (9/16 JIC)

5P-2242

Swivel Tee (1 5/16 JIC)

5P-4982

Swivel Tee (1/2 JIC)

5P-4984

Swivel Tee (1 3/16 JIC)

5P-5003

Reducer (7/16 JIC Ext. x 1 5/16 JIC Int.)

5P-5004

Reducer (7/16 JIC Ext. x 1 3/16 JIC Int.)

5P-5005

Reducer (7/16 JIC Ext. x 1 1/16 JIC Int.)

5P-5006

Reducer (7/16 JIC Ext. x 7/8 JIC Int.)

5P-5007

Reducer (7/16 JIC Ext. x 3/4 JIC Int.)

5P-5008

Reducer (7/16 JIC Ext. x 9/16 JIC Int.)

5P-5009

Reducer (7/16 JIC Ext. x 1/2 JIC Int.)

6S-5693

Swivel Tee (3/4 JIC)

6V-4144

Valved Coupler, (1/4 NPT Int.)

7D-0978

Swivel Tee (1 1/16 JIC)

9S-0176

Swivel Tee (7/8 JIC)

2P-9697

Plug (7/8 JIC)

3R-6789

Cap (1 5/16 JIC)

5P-0405

Cap (1/2 JIC)

5P-2299

Plug (1 5/16 JIC)

5P-2909

Plug (3/4 JIC)

5P-4299

Plug (1 3/16 JIC)

5P-4996

Plug (1/2 JIC)

6J-7366

Cap (7/8 JIC)

8L-9137

Cap (13/16 JIC)

8S-4950

Cap (9/16 JIC)

8S-4951

Cap (3/4 JIC)

9L-8493

Cap (7/16 JIC)

9S-5518

Plug (7/16 JIC)

9S-8895

Plug (1 1/16 JIC)

9S-8896

Cap (1 1/16 JIC)

9S-8927

Plug (9/16 JIC)

4C-4463

Utility Box

4C-4464

Foam Block

1S-8937

Needle Valve

8T-0855

Gauge 4000 kPa (0 - 580 PSI)

8T-0859

Gauge 25,000 kPa (0 - 3600 PSI)

8T-0861

Gauge 60,000 kPa (0 - 8700 PSI)

1J-9671

O-ring Seal

2P-1314

Connector (7/16 JIC Ext. x 9/16 - 18 Ext.)

3J-1907

O-ring Seal

3J-7352

Connector (7/16 JIC Ext. x 7/16-20 Ext.)

3J-7354

O-ring Seal

3K-0360

O-ring Seal

4S-6399

Connector (7/16 JIC Ext. x 1/4 NPT Ext.)

7J-4026

Elbow (90°, 7/16 JIC Ext. x 9/16-18 Ext.)

8L-6557

Connector (7/16 JIC Ext. x 1/8 NPT Ext.)

5P-8998

Nipple (1/4 NPT Ext.)

6V-3966

Valved Nipple Assembly (1/4 NPT Ext.)

6V-3989

Non-Valved Nipple (1/4 NPT Int.)

6V-4143

Valved Coupler, (1/8 NPT Int.)

7-40 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

ORFS Fitting Group

Item

Part No.

Description

—

4C-4892

ORFS Fitting Group

4C-3975

Plastic Case

4C-3721

Foam Block

4C-3719

Foam Block

177-7860

Hose

4C-3725

Utility Box

4J-5477

O-ring Seal

5K-9090

O-ring Seal (not serviced)

6V-3966

Nipple, QD, (1/4 EXT NPT)

6V-8397

O-ring Seal

6V-8398

O-ring Seal

6V-9507

Plug (9/16 EXT ORFS)

6V-9508

Plug (11/16 EXT ORFS)

6V-9509

Plug (13/16 EXT ORFS)

6V-9510

Plug (1 EXT ORFS)

6V-9511

Plug (1 3/16 EXT ORFS)

6V-9512

Plug (1 7/16 EXT ORFS)

6V-9746

O-ring Seal

6V-9828

Cap (9/16 INT ORFS)

6V-9829

Cap (11/16 INT ORFS)

6V-9830

Cap (13/16 INT ORFS)

6V-9831

Cap (1 INT ORFS)

6V-9832

Cap (1 3/16 INT ORFS)

6V-9833

Cap (1 7/16 INT ORFS)

7J-9108

O-ring Seal

7X-0871

Swivel Tee (13/16 INT ORFS x 13/16 EXT ORFS x 9/16 INT SAE)

7X-0872

Swivel Tee (1 INT ORFS x 1 EXT ORFS x 9/16 INT SAE)

7X-0873

Swivel Tee(1 3/16INT ORFS x 1 3/16 EXT ORFS x 9/16INTSAE)

7X-2444

Swivel Tee(9/16INTORFSx9/16EXTORFSx9/16INTSAE)

8T-4834

Swivel Tee(1 7/16INT ORFS x 1 7/16 EXT ORFS x 9/16INTSAE)

8T-8902

Swivel Tee (11/16 INT ORFS x 11/16 EXT ORFS x 9/16 INT SAE)

1S-8937

Needle Valve

4C-4463

Utility Box

4C-4464

Foam Block

3J-1907

O-ring Seal

3K-0360

O-ring Seal

5P-6944

Adapter (3/4 EXT SAE x 9/16 INT SAE)

5P-8998

Nipple(1/4 EXT NPT x 1/4EXT NPT)

6V-3965

Nipple, QD, (9/16 EXT SAE)

6V-4143

Coupler, QD, (1/8 INT NPT)

6V-4144

Coupler, QD, (1/4 INT NPT)

8T-4188

Adapter Union (1/8 INT NPT x 1/4 INT NPT)

8T-0855

Gauge 4,000 kPa (0 - 580 PSI)

8T-0859

Gauge 25,000 kPa (0 - 3600 PSI)

8T-0861

Gauge 60,000 kPa (0 - 8700 PSI)

JULY 2018 Vehicle System Tools

7-41

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Hydraulic Testing Group

• Designed for general purpose pressure

• Liquid filled gauges, which are more durable

measurements

and accurate

• Provides versatile and simple method for

• Pressure tap assemblies equipped with

checking pressure in implement and steering

6V-3966 Nipple Assembly which allows a

hydraulic systems

single gauge to be quickly connected to

hydraulic system

• Replaces discontinued 6V-7940 Hydraulic Test

Group

• More flexible hose with higher working and

minimum burst pressure than former hose

• Also replaces discontinued 5S-5123 Hydraulic

Testing Group

• Group includes all items in figure

Item

Part No.

Description

Qty.

—

8T-5320

Hydraulic Testing Group

6V-7145

Case

8T-7686

Block - Tool Holder

3J-1907 a

Seal-O-Ring— STOR (SAE 9/16-18)

7M-8489

Adapter Assembly

8T-0859

Gauge, 25,000 kPa (3600 PSI)

8T-0857

Gauge, 13,800 kPa (2000 PSI)

1J-9671

Seal

3D-2824

Seal-O-Ring - STOR (SAE 1 1/16-12)

3J-7354

Seal

3K-0360

Seal-O-Ring - STOR (SAE 3/4-16)

5P-2937

Adapter - O-ring to Pipe

5P-3415

Adapter

5P-3501

Adapter - STOR

5P-4674

Adapter - Straight Thread - O-Ring

5P-4675

Adapter - STR

8S-7169

Coupling-Pipe Hexagon

6V-3965

Nipple Assembly

2N-2543

Plug

2S-4078

Seal-O-Ring - STOR (SAE 1 5/8-12)

2J-2668

Cover

4F-7391

Seal

4F-7952

Seal

4J-8996

Seal

5F-1678

Seal

5F-7054

Seal

5H-4017

Cover, 12.70 mm (0.50in) line

5H-4018

Cover, 19.05 mm (0.75in) line

5H-4019

Cover, 25.40 mm (1.00in) line

5H-4020

Cover, 31.75 mm (1.25in) line

7F-8267

Seal

8S-7668

Cover, 15.75 mm (0.62in) line

0S-1587

Bolt

0S-1591

Bolt

0T-0768

Bolt

1A-9579

Bolt

6V-7944

Plate Assembly, 33.3 mm (1.312 in) diameter 12.70 mm (0.50 in) hose

6V-7945

Plate Assembly, 41.4 mm (1.63 in) diameter 19.05 mm (0.75 in) hose

6V-7946

Plate Assembly, 47.5 mm (1.87 in) diameter 25.4 mm (1.0 in) hose

6V-7947

Plate Assembly, 54.1 mm (2.13 in) diameter 31.75 mm (1.25 in) hose

6V-7948

Plate Assembly, 63.5 mm (2.50 in) diameter 38.10 (1.50 in) hose

6V-7949

Plate Assembly, 38.1 mm (1.50 in) diameter 15.75 mm (0.62 in) hose

6V-3966

Nipple Assembly

177-7860

Hose Assembly

6V-4143

Coupler Assembly

a. Item 4 and item 7

7-42 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Test Kit

Essential Tool

• Used to test all Cat^®oil coolers for leaks

Reference

Model Usage: All Cat Oil Coolers

• Prevents unnecessary oil cooler replacement

• REHS1758, Test Procedure

136-3602 Drive Adapter

Warranty: Caterpillar ^®Six Months

Part Number

Description

NEEG2976

Decal

Part Number

Description

1P-3703

Seal, 38.66mm (1.52in) outside diameter

1P-3704

Seal, 44.75mm (1.76in) outside diameter

1P-3708

Seal, 64.2 mm (2.52in) outside diameter

210-6990

Digital Pressure Gauge (0 to 500 PSI)

242-7135

Test Kit

4C-7056

Hose

4C-8858

Coupler

6V-7145

Case

8T-2885

Seal, 83.4 mm (3.28in) outside diameter

Flushing Adapter

Model Usage: 245 Excavator

• Required for flushing stick cylinder

• Has 3 interconnecting ports so that a loop of 3

hoses can be connected to the three ports on

Warranty: Caterpillar ^®Six Months

stick cylinder

Part Number

Description

6V-0102

Flushing Adapter

Flowmeter

Model Usage: Most Cat^®Models

• Low cost flowmeters for measuring hydraulic

• Similar to 6V-7788 Flowmeter; all 3

flow in applications within their capacities

flowmeters incorporate a variable orifice

Warranty: Caterpillar ^®Six Months

which measures line flow with less restriction

• Can be installed in any position and are not

(pressure drop) than 5P-3600 Flowmeter

affected by shock or vibration

Maximum

Inlet/Outlet

Part Number

Description

Range

Length

Pressure

Connections

20 - 200 lpm

20,700 kPa

Approx. 300 mm

8T-0454

Flowmeter

1 1/4 in NPT

(5 - 50 gpm)

(3,002 PSI)

(12in)

50 - 550 lpm

20,700 kPa

Approx. 300 mm

8T-0456

Flowmeter

1 1/4 in NPT

(10 - 150 gpm)

(3,002 PSI)

(12in)

Adapter

Warranty: Caterpillar ^®Six Months

• Used to adapt fluid ports for measuring

• Low-cost adapters are used with other field

flow in hydraulic and cooling systems

service components

• Three sizes fit most Cat^®machines

Part Number

Male End

Female End

197-8947

1/4 NPTF

9/16-18 ORFS swivel

197-8948

1/2 NPTF

13/16-16 ORFS swivel

197-8949

3/4 NPTF

1 3/16-12 ORFS swivel

JULY 2018 Vehicle System Tools

7-43

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Tools needed for checking transmission cooler flow

Tools needed for checking transmission cooler

flow on 943, 953, 963 and 973 Track-Type

Loaders (Sold Separately)

Item

Part Number

Description

8T-0454

Flowmeter

1P-5598

Pipe Nipple, 1 1/4 in NPT

1Y-7453

Tee

9B-3523

Reducing Bushing

6V-3966

Nipple Assembly

6V-4144

Coupler Assembly

8T-0854

Gauge-Pressure,9-1000 kPa(1-150 PSI)

8F-8306

Reducing Bushing, 1 1/4 in NPT to 3/4 in NPT (2)

4S-6678

Flared Connector, 37° (2) (Use for 943 and 953)

9D-9262

Hose (Use for 943 and 953)

6K-3459

Flared Connector, 37° (2) (Use for 963 and 973)

134-8416

Hose (Use for 963 and 973)

Flowmeter

Model Usage: D8L, D9L and D10 Tractors

• Used for measuring flow when diagnosing

Reference

steering problems using a field test procedure

Warranty: Caterpillar ^®Six Months

• SMHS8284, Special Instruction

developed to determine amount of leakage in

steering clutch and brake compartments

Specifications

• Direct reading device installed in oil line

• Range: 5 - 60 lpm (2 - 15 gpm)

• Mounting position, shock, and vibration

• Max. pressure: 20,670 kPa (3,000 PSI)

have little or no effect on operation of new

• Accuracy: ±5% of full scale reading

flowmeter

Part Number

Description

6V-7788

Flowmeter

Cap Assemblies

Model Usage: Most Cat^®Models

• For 1 1/4 - 11 1/2 NPTF threaded quick

• Designed to prevent contamination when

disconnect nipples and couplers

fittings not in use

WWarranty: Caterpillar ^®Six Months

Part Number

Description

8T-5266

Cap Assembly

2P-8334

Nipple

2P-8336

Nipple

7-44 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Pressure Limiting Valve

Model Usage: Most Cat^®Models

• Protects gauges with maximum working

• Easy to install; uses common 1/4-18 FNPT

pressures ranging from 30 to 5000 PSI

thread

Warranty: Caterpillar ^®Six Months

• Prevents calibration failure, interior damage,

• Quickly pays for itself in savings from cash

and blow out caused by excessive pressure

repair and replacement charges

• Works in 3 pressure ranges: 30 to 120 PSI,

• Can also be used to set up 2-gauge system

100 to 1100 PSI, and 1000 to 5000 PSI

similar to 6V-7830 Tetragauge Group

• Supplied with 3 springs used for adjustment

• Adjustable from 30 to 5000 PSI

throughout 3 pressure ranges

(210 to 34,500 kPa)

• Whenever pressure pulses or overpressure

• 1/4-18 FNPT thread

occurs, valve automatically shuts off pressure

• Maximum working pressure: 5000 PSI

instrument at desired setting

(34,500 kPa)

• Needle built into valve for adjusting amount

of dampening and can alsobe used asmanual

shut off

Item

Description

Spring, black, 100 - 1,100 PSI (690 - 7,600 kPa)

Spring, gold, 1,000— 5,000 PSI (6,900— 34,500 kPa)

Item

Part Number

Description

Valve-Pressure Limiting [Spring, silver, 30 - 120 PSI

1U-9161

(210 - 830 kPa) installer at shipment]

Pressure Differential Gauge Group

Model Usage: See Below

• Required to verify and set margin pressure on

Reference

load-sensing hydraulic systems

Warranty: Caterpillar ^®Six Months

• 1U-7425 Displacement Gauge Assembly

• Typical examples for use are 416 and 426

SEHS8979, Special Instruction

Backhoe Loader hydraulic systems, D8N

Specifications

Track-Type Tractor differential steering, and all

current motor grader hydraulic systems

• Maximum line pressure: 52,400 kPa

(7,500 PSI)

• Can also be used in other applications

requiring measurement of differential

• Maximummeasurable pressure differential:

pressure (deltaP)

3,500 kPa (500 PSI)

• Eliminates need for using 2 gauges and then

• The differential gauge has a magnetic

subtracting to find difference between gauges

movement.

to obtain margin pressure

• Over pressure and pressure spikes will not

• Measures differential pressure continuously,

damage the unit.

regardless of fluctuations in system pressure

Part Number

Description

177-7861

Hose Assembly

1U-5793

Pressure Gauge

1U-5796

Pressure Differential Gauge Group

3J-1907

Seal-O-Ring - STOR (SAE 9/16 - 18)

6V-0484

O-ring Adapter

6V-3072

Case - Plastic

6V-3965

Nipple Assembly

6V-4143

Coupler Assembly

6V-4144

Coupler Assembly

6V-6105

Block

8C-8431

Tee

8T-0859

Gauge - Pressure

8T-0861

Gauge - Pressure

JULY 2018 Vehicle System Tools

7-45

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Drive Adapter

Model Usage: 205, 206, 211, 212, 213, 214, 224

• Used to connect drive shaft on hydraulic

• Also used with 1U-9359 Adapter and coupled

and Series B, Wheel-Type Excavators

pumps to drive shaft on test benches

with standard drive shaft (SAE 55)

Warranty: Caterpillar ^®Six Months

• Adapters bolt directly to 1U-9832 Drive Shaft

• Adapters are internally splined hubs

(SAE 27) found on test benches

Item

Part Number

Corresponding Splines

Model

9U-5277

45 x 2 x 21 x 9G DIN5480

211B, 212B, 213B, 214B, 224B

9U-5275

40 x 2 x 18 x 9G DIN5480

205B

9U-5230

B40 x 36 DIN5482 213, 214, 224

Splined Adapter

Model Usage: D4H

• Internally-splined drive hub used when bench

• Fits any pump shaft with spline size of

testing D4H hydraulic pumps

19-tooth, 24/48 pitch

Warranty: Caterpillar ^®Six Months

• Bolts directly to 1U-9832 Drive Shaft

Reference

(SAEsize 27) or when used with1U-9359

• SEHS6022, “9T-0290 Pump, D4H Implement”

Adapter can be coupled to size SAE 55 drive

Test Procedure, adapter and other required

shaft supplied standard on large hydraulic test

tooling to bench test D4H implement pump

center

Part Number

Description

4C-4385

Splined Adapter

Drive Adapter

Model Usage: 14H and 16H Motor Graders

• Used to connect test bench drive shaft to

Specifications

tapered end of hydraulic pump

Warranty: Caterpillar ^®Six Months

• Adapter taper: 44.45 mm (1 3/4 in), SAE J501

• Works on any pump with a SAE J501

• Outside diameter: 97.5 mm (3.84 in)

44.45 mm (1 3/4 in) diameter tapered pump

• External keyway width: 16.2 mm (0.637 in)

shaft

• Material: Steel

Part Number

Description

136-3602

Adapter

Splined Adapter

Model Usage: Backhoe Loaders

• Internally-splined drive hub used when bench

References

testing backhoe loader hydraulic pumps

Warranty: Caterpillar ^®Six Months

• NEHT6022, Test Procedure; 9T-6857 Pump,

• Fits any pump shaft with spline size of

416/428 Backhoe Loader

15-tooth, 16/32 pitch

• NEHT6027, Test Procedure; 9T-4833 Pump,

• Bolts directly to 1U-9832 Drive Shaft

426, 436, 438 Backhoe Loader (adapter and

(SAEsize 27) or when used with1U-9359

other required tooling to bench test Backhoe

Adapter can be coupled to standard drive

Loader pump)

shaft (SAE size 55) on lg. hydraulic test center

Part Number

Description

4C-4088

Splined Adapter

7-46 JULY 2018 Vehicle System Tools

Vehicle System Tools

HYDRAULIC SYSTEM TOOLS

Drive Adapter

Model Usage: D3C Track Type Tractor and 933C

• Used to connect test bench drive shaft to

• Pressure angle: 30 degrees

Track Type Loader

spline shaft of pump

• Pitch diameter: 20.638 mm (0.8255 in)

Warranty: Caterpillar ^®Six Months

Specifications

• Keyway width: 16.2 mm (0.64 in)

• Number of spline teeth: 21

• Spline pitch: 16/32

Part Number

Description

133-2329

Drive Adapter

Bolt Mounting Group

Model Usage: Most Cat Models

• Provides way to secure 1U-9130 Pump Stand

• Improves speed and ease of mounting and

or Transmission Mounting Group to hydraulic

moving components on hyd. test bench bed

Warranty: Caterpillar ^®Six Months

test bench bed

• Accepts any mounting rail within 63.5 mm

• Bolt weldment slides inside rail mounting

(2.50 in) inside clearance and 20.6 mm

grooves on most test beds

(0.81 in) clearance slot

• Comes complete w/speed bar knob & washer

Part Number

Description

4C-4103

Bolt Mounting Group

Adapter Fitting

Warranty: Caterpillar ^®Six Months

• Used for high pressure testing

Specifications

• Used with 68,900 kPa (10,000 PSI) high

• Maximum working pressure: 68,900 kPa

pressure hoses

(10,000 PSI)

• Threaded at each end to adapt 1 thread size

• Burst ratio: 4:1

to another

• Thread size: 1/4-18 NPT

• Thread size: #6 port, 9/16-18

Part Number

Description

171-1879

Adapter Fitting

Hydraulic Test Fittings and Adapters

Model Usage: “MS” and “E” Family Excavators

• Used to connect Cat^®hydraulic service tools

• All fittings rated at 6000 PSI working pressure

to hydraulic ports on excavators

Warranty: Caterpillar ^®Six Months

• Eliminate time spent searching for, and then

• Hydraulic fittings and ports on these

“stacking” fittings to convert port

excavators are British standard connections;

• BSPT = British Standard Pipe Tapered Threads

Cat^®service tools use SAE standard

BSPP = British Standard Pipe Parallel Threads

connections

• Fittings and adapters available for both flow

and pressure measurements

JULY 2018 Vehicle System Tools

7-47

Caterpillar. Dealer service tools catalog (2018) - page 30