Caterpillar. Dealer service tools catalog (2018)

Vehicle System Tools

Hydraulic System Tools

Cat^® Filtration Skid

Model Usage: Hydraulic Mining Shovels

The offboard filtration skid is specifically

Specifications

(HMS 6015-6090)

designed to offer the most efficient, cost-

• Dimensions: 1.6 x 1.5 x 1.1 m (65 x 60 x 42 in)

effective method to clean oil on Cat^® mining

Warranty: Caterpillar ^®Six Months

• Weight of base skid: 620 kg (1,366 lb)

shovels, improving equipment uptime.

• Required external electric power source (not

included): 3 phase, 40 kW (recommended)

Standards Compliance

• Oil Types: SAE 10W, 20W, 30W

• ISO 19/16/13 cleanliness spec

• Flow Rate: 454/367 liters per minute (at

• CE compliant

60/50Hz)

• AU compliant

• Operating temperature range: 30-66 °Celcius

Flexibility

• Operating pressure: approx 130 psi

• Sample interval: continuous/auto shut-off

• Electric 3Ph 230/415/460VAC, 60/50 Hz

when cleanliness level achieved

• Dealer-supplied hoses

• On-board particle counter with auto shut-off

Reference

Reliability

• M0073390 Tool Operating Manual

• M0080900 Contamination Control

• Designed for use at a mine site

Guidelines for HMS

• Equipped with fork pockets and lifting eyes

Standards

Part No.

Description

Power Settings

Compliance

514-4590

Base Filtration Skid

230VAC, 50Hz

514-4591

Base Filtration Skid

230VAC, 60Hz

514-4592

Base Filtration Skid

460VAC, 60Hz

514-4593

Base Filtration skid with on-board contamination sensor

230VAC, 50Hz

514-4594

Base Filtration skid with on-board contamination sensor

230VAC, 60Hz

514-4595

Base Filtration skid with on-board contamination sensor

460VAC, 60Hz

514-4596

Base Filtration skid with on-board contamination sensor

415VAC, 50Hz

Serviceable Parts

Part No.

Description

514-4600

5 Micron Filter Element

514-4601

10 Micron Filter Element

514-4602

5 Micron Filter Housing

514-4603

10 Micron Filter Housing

525-7232

Contamination Sensor

514-4597

Polycarbonate Top Cover

526-6467

Suction Header - 6040 (Retrofit)

527-3199

Block Tee - Suction Hose Connection

537-6068

Canvas Cover for Filtration Skid

Additional Equipment Required for Machine Connection

Part No.

Description

Where Required

FT3321

Hose Group - Suction and Return Lines

All HMS

FT3322

Return Hose Adapter Group

All HMS

FT3333

Suction Hose Adapter Group

6040

FT3325

Suction Hose Adapter Group

6060

526-6467

Modified Suction Header

6040

527-3199

Flanged Run Tee

6050/6060

7-68 JULY 2018 Vehicle System Tools

Hydraulic System Tools

Hydraulic Filter Cart Group, Hydraulic Filter Cart in Kit Form

Model Usage: All Cat^® Models

• Used to flush and clean hydraulic tanks or

Reference

hydraulic systems; can also be used in any

Warranty: Caterpillar ^®Six Months

• NEHS0778, 188-3242 Hydraulic Filter Cart

filtering application for oil contamination

Group

control

Specifications

• Allows oil filtering directly from hydraulic tank

- eliminates placing oil in separate filtering

• Operating pressure: 138 - 827 kPa

cart/container

(20 - 120 PSI)

• Filters hydraulic fluids from 5W to 90W

• Variable delivery: 0 - 409 lpm (0 - 90 gpm)

• Easily moved around in field conditions on

• Supply air consumption: 0.47 L/s (1 cfm) per

three 30 cm (12.0 in) pneumatic tires

4.55 lpm 1 gpm) of fluid pumped

• Oil is pumped through the filter cart using an

• Suction lift: Up to 5.5 m (18 ft)

air-powered, diaphragm pump

• Operating temperature: 0° to 93°C

• Maximum output pressure of fluid being

(2° to 200°F)

pumped is equal to air inlet air pressure

• Liters (gallons) per cycle: 1.9 L (0.5 gal)

• Differential pressure gauge (dirty filter

• Four (4) gang parallel filter head: Permits 4

indicator) indicates filter element change time

times filter area to capture particulates and

• All hose assemblies are made from Cat^® 844

extends filter life

wire-reinforced hose (will not collapse when

• Standard filtration: 10-microns

filtering hot oil)

• Outlet hose (one): 30 cm (10 ft) long with a

• Extra tall hose hook for ease of hose storage

female quick-disconnect end

• Built-in storage box to hold optional adapter

• Inlet hose (one): 30 cm (10 ft) long with a male

fittings

quick-disconnect end

227-2479 (Not European Union Compliant)

• Storage box: 736 x 406 x 305 mm

(29 x 16 x 12 in)

• Includes every part needed to build 188-3242

Hydraulic Filter Cart

• Noise level: 82 dB @ 758 kPa (110 PSI) air

pressure

• Frame provided as item-numbered, unpainted

steel pieces to be assembled and welded

• Overall dimensions: 1295 x 889 x 1143 mm

together

(51 x 35 x 45 in) with hook bar 1956 mm

(77 in)

• Hoses not assembled

• Weight: 163 kg (360 lb)

• Prints provided for welding and assembly

Part Number

Description

188-3242

Hydraulic Filter Cart Group

188-7019

Pump

188-7027

Water Removal Element, optional

195-3164

Air Muffler

227-2479

Hydraulic Filter Cart in Kit Form

3H-0976

O-ring (Element to Head)

8T-0846

Working Pressure Gauge

9U-5870

Filter Element, 10-Micron

9U-6983

Filter Element, 5-Micron, optional

9U-6984

Filter Element, 25-Micron, optional

9U-6985

Pre-filter Element, 100-Mesh

9U-6986

Differential Gauge

Dust Caps/Plugs Used with 188-3242 Hydraulic Filter Cart Group

66.8 mm diameter plastic/rubber plug used on 190-8316 and 190-8318 Quick

201-8057

Disconnect Coupler (female end)

44 mm diameter plastic/rubber cap used on 190-8317 and 190-8319 Quick

201-8059

Disconnect Coupler (male end)

8C-3451

1/2 in diameter rubber cap for S·O·S port

JULY 2018 Vehicle System Tools

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Vehicle System Tools

Hydraulic System Tools

Filter

Model Usage: All Cat^® Service Vehicles

• Used to filter oil in high-volume applications

Specifications

Warranty: Caterpillar ^®Six Months

• Provides extended time between element

• Working pressure: 9,650 kPa (1,400 PSI)

changes

• Burst pressure: 27,573 kPa (4,000 PSI)

• Uses synthetic fiber filter elements

• Nominal flow: 64 lpm (17 gpm)

• Filter head is made of cast aluminum and

• In/out ports: SAE #12

bowl is made of steel for strength and

• Dirty element indicator: Pop-up style

durability

• Material: Aluminum head, steel housing with

• Visual dirty element indicator shows when to

3-micron cellulose media

change element

• Overall dimension: 239 x 89 mm (9.4 x 3.5 in)

• Elements contain no metal

• Weight: 1.4 kg (3.0 lb)

• Elements can be incinerated, crushed, or

shredded

• Body-style: Canister

Nominal

Dirt Holding

Height /

Media Material

Part No.

Description

Micron Rating

Capacity

Diameter

—

192-6432

Filter Group

Barrel Adapter

Essential Tool

• Used to attach filtering units to 208 L (55 gal)

• Inserts into 2 inch NPT port of 208 L (55 gal)

barrels

barrel

Model Usage: All Models

• Used with 204-7392 Kidney Loop Filter Cart or

• Top port is return side (1 inch NPT male), and

Warranty: Caterpillar ^®Six Months

equivalent

side port is suction side (1 inch NPT female)

• All steel design is easy to clean

• Unit does not come with quick disconnect

fittings

Part Number

Description

274-6783

Barrel Adapter

Flow Indicator with Tempered Sight Glass

Warranty: Caterpillar ^®Six Months

• Used to provide a means of viewing flow

• Does not restrict flow away from pump

• Made of brass with tempered sight glass on

• Viton seals provide long life

opposing sides

• Female NPT ports at each end

• Installs down stream of pump

• Stainless steel flapper shows the movement

of fluid and prevents back flow to pump

Inlet and

Sight Glass

Maximum

Operating

Maximum

Part No.

Outlet

Overall Size L x H x W

Diameter

Pressure

Temp.

Thread Size

69.0 mm

141.0 x 79.0 x 70.0 mm

1034 kPa

-17° to 121°C

204°C

257-8843

1 1/2 in NPT

(2.72 in)

(5.6 x 3.125 x 2.75 in)

(150 PSI)

(1° to 250°F)

(400°F)

7-70 JULY 2018 Vehicle System Tools

Hydraulic System Tools

Hydraulic Tank Adapters

Essential Tool

• Used to connect oil filter cart to hydraulic tank

Reference

on excavator

Model Usage: All 311 through 375 Hydraulic

• NEHS0778, Tool Operating Manual, 188-3242

Excavators

• Used with 188-3242 Oil Filter Cart

Filter Cart Group (Used on Hydraulic Tanks or

Hydraulic Systems)

Warranty: Caterpillar ^®Six Months

• Provides a quick-disconnect feature to quickly

hook up filter cart

• SEBF8446, Procedure for Filtering 300 Series

Excavator Hydraulic Oil

• Suction and return stand pipes are easily

adjusted depending on depth of hydraulic tank

• SEBF8447, Procedure for Filtering Excavator

(311-375) Hydraulic Oil

• For more efficient operation, permanently

install 198-1053 Cover Assembly on each 345

and 365 Excavator

Item

Part No.

Description

Parts for 345 and 365 Excavators

198-8796

Return Line Group

198-1052

Adapter Assembly (return)

198-1053

Cover Assembly (return)

462-4312

Cover Assembly 320D GC

462-7502

Cover Assembly 326D 2 and 329D 2

464-6025

Cover Assembly 316F

464-6026

Cover Assembly 312F

465-2945

Cover Assembly 355F

467-0289

Cover Assembly 336F

467-3471

Cover Assembly 349F

480-7274

Cover Assembly 314F

198-8795

Suction Line Group

198-1052

Adapter Assembly (suction)

4I-0722

Plug

381-8839

Adapter for E-Series tanks (use in place of item 3)

Parts for 311 through 375 Excavators (excluding 345 and 365)

Item

Part Number

Description

198-8796

Return Line Group

198-1051

Adapter Assembly (return)

199-1003

Seal Assembly (return)

198-8795

Suction Line Group

198-1052

Adapter Assembly (suction)

Model Usage: All Cat^® Service Vehicles

• Used to provide no-bypass filtering of

Inlet and outlet ports: 3/4 NPT

hydraulic oils

-–

Operating temperature range: -29° to

Warranty: Caterpillar ^®Six Months

107°C (-20° to 225°F)

• Used in service bays with drop-down oil lines

Material: Aluminum head with steel

or any other application requiring filtered,

housing

petroleum-based oil

Overall size: 90.0 mm (3.5 in) square x

• Non-collapsible filter elements work well with

238.0 mm (9.4 in) long

higher viscous hydraulic oils

• Filter Elements

• Filter head is made of cast aluminum with

Filter media: Synthetic

steel bowl for strength and durability

-–

Overall size: 50 mm (2 in) diameter x

150 mm (6 in) long

Specifications

Collapse rating: 206.8 bar (3000 PSI)

• Filter Head

Body-style: Canister

Mounting holes: 5/16-18

Part Number

Description

249-2931

Filter Housing

249-2932

Filter Element, 10-Micron

JULY 2018 Vehicle System Tools

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Vehicle System Tools

Hydraulic System Tools

Filter Head Kidney Loop Group

Model Usage: 301.5 (3YW), 301.6 (BDH),

• Used to kidney loop filter a hydraulic

• Optional components enable filtering for

301.8 (BFA), 302.5 (4AZ), 303 (DMA), 303.5

system or filter hydraulic oil returning from

specific machines (refer to charts)

(AFW), 304.5 (ANR), 305 (DSA) Mini Hydraulic

detachable work tools

Specifications

Excavators; All Skid Steer Loaders, and All Small

• Hoses attach to a rectifier head which allows

Wheel Loaders

• Weight of filter unit: 15.88 kg (35 lb)

input flow from either 26.98 mm (1 1/16 in)

Warranty: Caterpillar ^®Six Months

O-ring ports

• Maximum working pressure rating: 31,716 kPa

(4,600 PSI)

• Handle for easier carrying; hooks allow filter

group to be hung on machine near work area

• Maximum flow rating: 151.4 lpm (40 gpm)

• Comes with 225-3116 Filter Element

• Collapse pressure rating: 20,995 kPa

(3 micron) - optional 225-3115 Filter Element

(3,045 PSI)

(6-micron) can be purchased separately

• Dirty filter rating: 517 kPa (75 PSI)

• Dirty filter indicator shows when to change

element

Part Number

Description

Quantity

301.8 (BFA) and 302.5 (4AZ) Mini Hydraulic Excavator

030-8190

Adapter (-12 to -10)

152-8181

Male Coupler

152-8182

Female Coupler

165-0018

XT-3 ES Bulk Hose 15.9 mm (-10) ID

305 cm (10 ft)

221-0575

Permanent Hose Coupling

225-3114

Filter Housing

3D-2824

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

3J-1907

O-ring Seal for 5P-9617 Adapter

6V-4362

Adapter (-10 to -6)

301.5 (3YW), 301.6 (BDH), and 303.5 (AFW) Mini Hydraulic Excavator

030-8190

Adapter (-12 to -10)

152-2996

Male Coupler

152-2997

Female Coupler

165-0018

XT-3 ES Bulk Hose 15.9 mm (-10) ID

305 cm (10 ft)

221-0575

Permanent Hose Coupling

225-3114

Filter Housing

2P-7636

Adapter (-10 to -8)

3D-2824

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

3K-0360

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

303 (DMA), 304.5 (ANR), 305 (DSA, 3YS), Mini Hydraulic Excavator; All Skid Steer Loaders, and All

Small Wheel Loaders

030-8190

Adapter (-12 to -10)

153-2994

Female Coupler

153-2995

Male Coupler

165-0018

XT-3 ES Bulk Hose 15.9 mm (-10) ID

305 cm (10 ft)

221-0575

Permanent Hose Coupling

225-3114

Filter Housing

2M-9780

Seal - O-ring - STOR (SAE 7/8 - 14)

3D-2824

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

9M-4584

Adapter (-10 to -10)

7-72 JULY 2018 Vehicle System Tools

Hydraulic System Tools

Adapters and Extensions

Recommended Tool

• Used to filter oil directly from hydraulic tank

• Uses an S·O·S fitting to release pressure

(eliminates placing oil in separate filtering

buildup prior to removing adapter assembly

Model Usage: All Models with hydraulic tanks

cart/container)

(in some cases as oil heats up inside hydraulic

having 2 or 4 inch filler caps

tank, pressure can build up, resulting in

• In tight places the extensions will extend the

Warranty: Caterpillar ^®Six Months

possible hot oil spray, if pressure is not

adapters for easy access

released before adapter is removed)

• Used with 188-3242 Filter Cart Group

• Made from lightweight aluminum for easier

• Easy-to-use; simply remove filler cap and

handling and steel fittings for added durability

screen, and then screw adapter onto neck of

• Requires dealer supplied length of 25.4 mm

filler tube

(1 in) ID suction hose (hose length should

• 2 adapters (1 for 50.8 mm [2 in] and 1 for

allow end of hose to be within 15.24 cm [6

101.6 mm [4 in] hydraulic tank filler necks)

in] from bottom of tank) and S·O·S Sampling

• Designed with quick disconnect fittings

Adapter

for quick hookup of hoses from filter cart

• Overall size (W x L x H): 12.7 x 15.2 x 38.1 cm

(designed to prevent incorrect hookup)

(5 x 6 x 15 in)

• Oil is removed and replaced through adapter

Reference

into tanks filler hole

• NEHS0778, Using the 188-3242 Filter Cart

Group

Part Number

Description

Weight

193-5900

Adapter

5 kg (11 lb)

193-5903

Adapter

4 kg (9 lb)

197-4626

Extension

1.58 kg (3.5 lb)

197-4627

Extension

0.68 kg (1.5 lb)

Hydraulic Tank Adapters for 554 and 574B Forwarders

Essential Tool

• Used to connect oil filter cart or kidney loop

References

cart to hydraulic tank

Model Usage: 554 and 574B Forwarders

• NEHS0848, Tool Operating Manual, 204-7392

• Used with 204-7392 Kidney Loop Cart (Air

(Air Motor Driven) Filter Cart (Use on All

Warranty: Caterpillar ^®Six Months

Motor Driven), CE

Caterpillar Products)

• Provides a quick-disconnect feature to quickly

• SEBF8788, Contamination Control Guideline,

hook up filter cart

Procedure for Kidney Looping Forwarder

Power Train and Hydraulic Oil

• Suction and return stand pipes are easily

adjusted depending on depth of hydraulic tank

• Another adapter is listed in the table which

works on any hydraulic tank with correct

thread specifications

ID of Sch 40

Replaceable

Part No.

Description

Model

Thread Size

Black Pipe

O-ring

Adapter

198-1052

Assembly

1 in

M42 x 2

095-1608

(suction)

Adapter

228-6507

554

3/4 in

1 5/16-12

7M-8485

Assembly

Adapter

236-2516

574B

1/2 in

1 1/16-12

3D-2824

Assembly

Adapter

337-8034

1 in

M52 x 2

095-1610

Assembly

JULY 2018 Vehicle System Tools

7-73

Vehicle System Tools

Hydraulic System Tools

Adapter Assembly

Model Usage: Forwarders

• Used to connect machine to filter cart for

Reference

kidney loop cleaning of hydraulic system

Warranty: Caterpillar ^®Six Months

• SEBF8788, Procedure for Kidney Looping

• Used with 5P-7701 or 7M-8485 O-ring

Forwarder Hydraulic Oil

• Provides easy, clean connection to hydraulic

Specifications

tank (helps to meet Contamination Control

• Tank connecting thread: SAE 1 5/16-12

Initiative)

• Tube size: 3/4 in ID pipe

• Made of durable steel with rubber locking

mechanism (allows tube to be locked in

• Overall length: 63.4 mm (2.50in)

desired location)

• See reference manual for additional parts

required for procedure

Part Number

Description

228-6507

Adapter Assembly

Fluid Recovery Unit

Model Usage: All Models

• Safe operation - tank safety relief valve and

• Drain pan - lightweight aluminum, 469.9 x

wheel locking device are standard

520.7 x 76.2 mm (18 1/2 x 20 1/2 x 3 in) drain

Warranty: Caterpillar ^®Six Months

pan; equipped with quick coupling connection;

• Compact - storage and job accessibility is

steel ball type rollers permit rolling on floor;

no problem due to compact design of the unit

low profile gets where other pans cannot

• Environmentally safe - although it will not

• Filtration - serviceman has the option of

turn “bad” fluids into “new” fluid, it will

filtering fluids three separate times (three

convert contaminated fluids into clean, ready-

filters: suction, recycle and discharge; all have

to-use fluids; this eliminates hazardous waste

visual “dirty filter” indicators)

and landfill problems

When fluid is initially being vacuumed from

• Air supply - requires 65 to 80 PSI shop

the sump or pan to the unit; the fluid passes

compressed air

into the tank through dual filters at a rate of

• Pump unit - vacuum 60.6 to 68.1 lpm (16 to

European Union compliant, CE marked

60.6 to 68.1 lpm (16 to 18 gpm).

18 gpm); discharge 60.3 lpm (16 gpm)

• Designed to reduce time and trouble

While the fluid is in the holding tank it

• Easy to clean - large 20.32 x 25.4 cm (8 x

associated with the handling and filtration

can be continually circulated through the

10 in) cleanout door allows cleaning of unit

of contaminated petroleum-based fluids and

dual recycle filters until the acceptable

water glycol

• Tank unit - 567.8 L (150 gal) holding tank is

contamination level is attained.

mounted on rubber tired wheels and caster;

• Sized to handle most hydraulic, transmission,

When fluid is being pumped back into the

completely portable with fold-away tow bar

crankcase or cooling system filtering/handling

vehicle, it goes through yet another set of

jobs on construction equipment

• Hoses - 31.75 mm x 6.10 m (1 1/4 in x 20 ft)

dual discharge filters at a rate of 60.6 lpm

clear industrial suction hose is lightweight

(16 gpm)

• Efficient - everything is there! No extra

and flexible; equipped with a quick 25.4 mm

pans, drop cords, hoses, buckets or barrels are

Reference

x 3.66 m (1 in x 12 ft) black discharge hose

needed; short term fluid storage is no longer a

with quick coupling and fluid shutoff fill nozzle

• NEHS0648, Tool Operating Manual

messy problem

(standard)

• Portable - operates on shop or portable air

Part Number

Description

systems; easily moved by 1 person when full;

173-8839

Fluid Recovery Unit

fold-away tow bar is standard

140-7992

Pump Group for 173-8839

• Easily operated - 3 quick operating ball

Standard Replacement Filters a

valves change operation of unit from vacuum

Recirculating and Discharge Filter Element, 13-micron absolute,

9U-5870

synthetic media, spin-on

to discharge to recycling - easily changed

9U-6985

Suction Filter Element, 100-mesh, stainless steel media, spin-on

spin-on filters are used throughout

Optional Replacement Filters

• Economical - eliminates time consuming

9U-6983

Replacement Filter, 5-micron absolute

handling and disposal of seemingly

9U-6984

Replacement Filter, 22-micron absolute

contaminated fluids; eliminates the purchase

All spin-on filters listed have synthetic filtering media for compatibility with petroleum-based and water-based fluids.

of new fluids in many cases; decreases

disposal and permit expenses

7-74 JULY 2018 Vehicle System Tools

Hydraulic System Tools

Filter Cart Group

Model Usage: All Cat^® Products

• Used to flush and clean final drive, rear

References

axle, differential, small hydraulic tanks, and/

Warranty: Caterpillar ^®Six Months

• SEBF8797, Procedure for Filtering Final Drives,

or hydraulic systems with less than 110 L

Rear Axles, and Differentials on Caterpillar

(30 gal) capacity; can also be used in any

Machines

filtering application for oil contamination

• NEHS0899, Tool Operating Manual, Using the

control

231-6284 30 Gallon Filter Cart

• Allows oil filtering directly from hydraulic tank

- eliminates placing oil in separate filtering

Specifications

cart/container

• Capacity: 114 L (30 gal)

• Filters hydraulic fluids from 5W to 90W

• Maximum free flow: 159 lpm (42 gpm)

• Easily moved around in field conditions on

• Maximum size of pumpable solids: 3.0 mm

two 30 cm (12 in) pneumatic tires

(0.12 in)

• Oil is pumped through the filter cart using an

• Air inlet: 12.7 mm (0.5 in)

air-powered, diaphragm pump

• Recommended operating pressure: 414 kPa

• Maximum output pressure of fluid being

(60 PSI)

pumped is equal to air inlet air pressure

• Maximum air pressure: 827 kPa (120 PSI)

• A dirty filter indicator indicates when to

• Minimum air pressure: 138 kPa (20 PSI)

change filter elements

• Overall size (H x D x W): 953.0 x 762.0 x

• Protective rails help prevent damage during

673.0 mm (37.5 x 30.0 x 26.5 in)

transportation

• Weight: 82.6 kg (182 lb)

• A 161-7059 Diaphragm Repair Kit and a

196-9504 Air Valve Repair Kit are sold

separately

Part Number

Description

231-6284

30 Gallon Filter Cart

Diesel Fuel Flushing Cart

Model Usage: All Cat^® Products

• Used to flush and clean diesel fuel systems;

Specifications

with an additional quick disconnect added to

Warranty: Caterpillar ^®Six Months

• Capacity: 114 L (30 gal)

the cart it can be used to filter fuel tanks

• Maximum free flow: 159 lpm (42 gpm)

• Easily moved around in field conditions on

• Maximum size of pumpable solids: 3.0 mm

two 30 cm (12.0 in) pneumatic tires

(0.12 in)

• Oil is pumped through the filter cart using an

• Air inlet: 12.7 mm (0.50 in)

air-powered, diaphragm pump

• Recommended operating pressure:

• Maximum output pressure of fluid being

137 - 276 kPa (20 - 40 PSI)

pumped is equal to air inlet air pressure

• Maximum air pressure: 310 kPa (45 PSI)

• A dirty filter indicator indicates when to

change filter elements

• Minimum air pressure: 138 kPa (20 PSI)

• Protective rails help prevent damage during

• Overall size (H x D x W): 953.0 x 762.0 x

transportation

673.0 mm (37.5 x 30.0 x 26.5 in)

• A 161-7059 Diaphragm Repair Kit and a

• Weight: 89.4 kg (197 lb)

196-9504 Air Valve Repair Kit are sold

Reference

separately

• NEHS0969, Tool Operating Manual

Part Number

Description

292-8713

Diesel Fuel Flushing Cart

JULY 2018 Vehicle System Tools

7-75

Vehicle System Tools

Hydraulic System Tools

Filter Cart Group

Essential Tool

• Used to clean diesel fuel systems by removing

Specifications

contaminants in fuel

Model Usage: Diesel Fuel Engines

• Air diaphragm pump: 138 to 414 kPa

• Lightweight, portable design for easy

(20 to 60 PSI) (operating pressure range)

Warranty: Caterpillar ^®Six Months

transport to work site

• Pressure air relief valve: 483 kPa (70.0 PSI)

• Maximum output pressure: Pressure of the

• Use before engine re-start, or after

fluid pumped should be equal to the air inlet

replacement of a failed fuel system

pressure

component

• Tank capacity: 18.9 L (5.0 gal)

• Kidney loop fuel through filter element,

• Fluid cycle: 0.57 lpm (0.15 gpm)

reservoir tank, and engine fuel system until

• SOS valve: Standard

desired level of cleanliness is achieved

• Operating temperature: 4.4° to 65.5°C

• Air powered diaphragm pump for dependable

(40° to 150°F)

pumping action

• Noise level: 78 dB at 483 kPa (70 PSI) air

pressure

• Dirty filter indicator shows when filter

• Overall dimensions (W x D x H): 365.0 x 466.0

elements require service

x 535.0 mm (14.37 x 18.35 x 21.06 in)

• Includes basic suction/return hose and

• Ground strap length: 305 cm (10 ft)

discharge/pressure hose assemblies

• Suction/return hose length: 427 cm (14 ft)

(additional dealer-supplied adapters are

• Discharge/pressure hose length: 671 cm

required)

(22 ft)

• Weight: 13.6 kg (30 lb)

Reference

• NEHS0989, Tool Operating Manual, 295-5490

Portable Diesel Fuel System Filtration Unit

Item

Part Number

Description

—

295-5490

Filter Cart Group

Service/Repair Parts

295-5589

Pump (Not Serviced)

295-8469

Dust Cap

295-8468

Dust Cap

Not Shown

295-5590

Air Repair Kit

—

295-5591

Diaphragm Repair Kit

Pump Test Fittings

Model Usage: See Chart

• Fittings adapt expanded mining pumps to

hydraulic test bench

Warranty: Six Months

Fitting

Thread (Male x Female)

Pump Usage

Model Usage

533-1169

M33 STOR x ½” NPTF

471-5739

6018

468-9838

533-1170

M33 STOR x 1” NPTF

417-9308

6015, AP300F AP300D

417-9312

437-0161

437-0159

485-8432

484-6741

533-1171

M42 STOR x 1” NPTF

467-9656

6015, 6018, 6030, 6050, 6060, 6090

468-9837

468-9838

468-9840

471-5739

533-1172

M22 STOR x M14 STOR

437-0163

6040, 6050

162-9592

MTC735, MTC745, MTC755, MTC765,

180-0459

MTC835, MTC845, MTC855, MTC865,

533-1173

M26 STOR x ¾” NPTF

233-6702

MT735, MT745, MT755, MT765, MT835,

484-6741

MT845, MT855, MT865, 6030, 554

485-8432

437-0161

533-1174

¾ JIC x M20 Swivel

6015, 6018, 6030

467-9658

7-76 JULY 2018 Vehicle System Tools

Hydraulic System Tools

Heavy Weight Oil Filter Cart

Model Usage: Hydraulic Systems on 785, 789,

• Replaces discontinued 201-8131 and

Specifications

793 Off-Highway Trucks and Power Train Oils

discontinued 183-9301 Carts

• Prime mover: Air diaphragm pump

Warranty: Caterpillar ^®Six Months

• Used to filter fluids from 5W (lightweight oils)

• Operating pressure: 138 - 689 kPa

to 90W (final drive lubricants)

(20 - 100 PSI)

• Variable pump delivery

• Variable delivery: 0 - 340 lpm (0 - 90 gpm)

• Powered by compressed air

• Supply air consumption: 0.47 liter/s (1 cfm)

• A differential pressure gauge is provided to

per 3.78 liter/m (1 gpm) of fluid pumped

monitor filter element condition

• Maximum output pressure of fluid being

• Extra large capacity filter for extended time

pumped equals: Air inlet pressure

between dirty element change

• Hydraulic fluids: 5W to 90W

• Wire-reinforced hoses; will not collapse with

• Operating temperature: 0° to 66°C

“hot” oil

(0° to 150°F)

• Built-in tool box

• Standard filtration: 10-micron, absolute

• Convenient hose caddy for ease of storage

• Extra large filter: 27.3 cm diameter x 82.5 cm

• Mobile cart on hard plastic casters

(10.7 in diameter x 32.5 in)

• Outlet hoses: Two #844, 38.1 mm (1 1/2 in)

Reference

diameter x (25 ft) long (1 1/2 in Cam-lok

• NEHS0847, Tool Operating Manual

fittings)

Performance Note:

• Inlet hose: #844, 50.8 mm (2 in) diameter x

• Fluid flow through filter for maximum

4.27 m (14 ft) long (1 1/2 in Cam-lok fittings)

efficiency is dependent upon fluid

• Tool box: 40.6 x 25.4 x 22.8 cm (16 x 10 x 9 in)

temperature, fluid viscosity, supply air

• Overall dimensions: 122 x 157 x 102 cm

pressure, supply air volume, and filter media

(48 x 62 x 40 in)

rating.

• Noise level: 82dB (at 110 PSI air pressure)

• Weight: 318 kg (700 lb)

Part Number

Description

245-1769

Oil Filter Cart

161-7059

Diaphragm Repair Kit

185-1375

Filter Element, 25-micron absolute

188-7020

Filter Element, 5-micron absolute

192-1560

Filter Element, 10-micron

196-9504

Air Valve Repair Kit

212-7125

Filter Element, 3-micron

3H-0976

O-ring (Element to Head)

4C-6786

Pump (complete)

Dust Caps/Plugs Used with245-1769

63.5 mm (2 1/2 in) diameter aluminum male plug used with 190-8321 Quick

201-8128

Disconnect Coupler or suction line

50.8 mm (2 in) diameter aluminum male plug used with 190-8321 Quick

201-8129

Disconnect Coupler or return line

63.5 mm (2 1/2 in) diameter aluminum female cap used with the following

201-8552

adapters: 190-9936, 190-9938, 190-9940, 190-9942, or 190-9944

50.8 mm (2 in) diameter aluminum female cap used with the following

201-8553

adapters: 190-9935, 190-9937, 190-9939, 190-9941, or 190-9943

8C-3451

Dust Cap (not pictured)

JULY 2018 Vehicle System Tools

7-77

Vehicle System Tools

Hydraulic System Tools

Spanner Kit

Essential Tool

• Used to remove and install relief valve in

References

259-6758 Valve Group

Model Usage: 416E Backhoe Loader

• RENR7164, Service Manual, 414E, 416E,

• Used with 6mm socket wrench (dealer

420E, 422E, 428E, 430E, 432E, 434E, 442E,

Warranty: Caterpillar ^®Six Months

supplied)

and 444E Backhoe Loaders Machine Systems

• Spanner head fits inside hydraulic valve body

• KENR7659, Service Manual, 416E, 420E, and

430E Backhoe Loaders Machine Systems

• Four equally spaced teeth engage relief valve

for proper removal and installation

• RENR8043, Service Manual, 422E, 428E,

432E, 434E, 442E, and 444E Backhoe Loaders

• Includes sealable rust inhibitor bag for proper

Machine System

tool storage

Part Number

Description

341-4073

Spanner Kit

Valve Adjuster

Model Usage: E-Series Backhoe Loaders

• Used to manually lower boom during engine

• Slowly turn knob to depress internal valve

stall

stem and relieve oil back into reservoir tank

Warranty: Caterpillar ^®Six Months

• Temporarily replaces boom lower pilot line on

• Allows controlled lowering of boom without a

main control valve

power source

• Remove pilot line and thread plug into control

valve

Part Number

Description

308-4547

Valve Adjuster

Nitrogen Booster System

Model Usage: 336E, D7E

European Union compliant, CE marked

• Comes with Manual start & stop, safety relief

valve, gas inlet and outlet gauges

Warranty: Caterpillar ^®Six Months

• Used to charge Nitrogen accumulators

requiring pressures up to 3,100 psi

• Provides an efficient and quick way to charge

accumulators where high pressure Nitrogen

• Runs on compressed shop air or using the gas

bottles are not available

from nitrogen bottle

Part Number

Description

Dimensions

Weight

455-0126

Nitrogen Booster System

762 X 305 X 305 mm (30 X 12 X 12 in)

27.2 kg (60 lb)

Service Repair Parts

455-0127

Seal Kit - Gas booster Air section

0.4 kg (1 lb)

455-0129

Seal Kit - Gas booster Air section

0.4 kg (1 lb)

7-78 JULY 2018 Vehicle System Tools

HYDRAULIC COMPONENT DISASSEMBLY AND ASSEMBLY

Hose Assembly

Essential Tool

• Used to test and adjust high-flow, hydraulic

Reference

systems

Model Usage: 248B, 268B, 246C, 256C, 262C,

• RENR8747, Service Manual (248B, 268B)

272C, 277C, 287C, and 297C Skid Steer Loaders

• Used on both B and C-Series models

• KENR5113, Service Manual (246C, 256C,

Warranty: None

262C, 272C)

• KENR5196, Service Manual (277C, 287C,

297C)

Item

Part Number

Description

8C-8835

Bulkhead Adapter

218-5843

Nipple

218-5845

Coupler

153-0785

Coupling Assembly

6V-8397

O-ring Seal

161-1815

Hose, 152 cm (60 in)

3K-0360

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

Spanner Tool, Sleeve

Model Usage: 994 Wheel Loaders

9U-5919 Spanner Tool

• Use of any other tool can result in damage to

piston or rod, and result in improper assembly

Warranty: Caterpillar ^®Six Months

• Used to disassemble and assemble 6E-0512

and 101-9571 Threaded Piston in 9T-9021,

• Provides positive, non-slip engagement of

9T-9022, 9T-9024, and 9T-9025 Tilt Cylinder

spanner pins

Groups

Specifications

• Used with torque wrench

• Construction: Steel

• Plastic ID of spanner to prevent damage to

• Outside diameter: 203 mm (8 in)

cylinder rod threads during use

• Inside diameter: 114.0 mm (4.5 in)

• Enables required piston assembly torque

of 816 N·m (600 ft-lb) to be achieved (not

• Length: 152 mm (6 in)

possible with conventional spanner tools)

• Weight: 15 kg (33 lb)

• Square drive: 1 in

Part Number

Description

9U-5919

Spanner Tool

9U-5920

Sleeve

Lock Nut

Model Usage: D6T

• Required for removal and installation of the

• Set screws are provided for securing the

angle cylinder piston on D6T VPAT Track-Type

spanner to the piston when using a manual

Warranty: Caterpillar ^®Six Months

Tractors

torque wrench

• Features replaceable 7.5 mm diameter pins

Specifications

458-3598

• OD: 114 mm (4.9 in)

• Can be used with a standard 46 mm socket

• ID: 30 mm (1.2 in)

(matching the piston locknut) for manual

torque wrenches

• Overall Height: 85 mm (3.3 in)

• The spanner can also be used with a hydraulic

• Weight: 2.16 kg (4.8 lb)

cylinder bench for R&I of the piston

Part Number

Description

455-7436

Lock Nut

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Piston Spanner Assemblies

Model Usage: D25C and D, D30C and D, D35C

• Removes/installs pistons on cylinder rods

• Pins inside of tool provide positive non-slip

and HP, D40D, D44B, D250B, D300B and D,

engagement during torquing (using standard

• Used with 3/4 inch square drive torque

D350C and D, D400, D400D, D550B Articulated

adjustable-type spanner is ineffective and

wrench, ratchet, or breaker bar

Trucks

usually results in damaged rod or piston)

• Quick and easy assembly and disassembly

Warranty: Caterpillar ^®Six Months

• ”Tubular” design provides slip fit around

• Maintains positive engagement and

piston; 3 set screws also provide assurance

eliminates damage to rod surface

wrench will not become disengaged during

• Saves part replacement costs by eliminating

tightening or loosening

damage by destructive methods such as

Reference

cutting torch or welding

• SENR8220, Service Manual, D300D Vehicle

9U-6110 Spanner Wrench

Systems Disassembly and Assembly

• Used to remove and install threaded

pistons in 6U-3247 and 5U-6864 Suspension

Cylinders

Inside

Length (to end

Number of

Square

Part No.

Description

Depth

Width

Pin Size

Bolt Circle of Pins

Weight

Diameter

of handle)

Pins

Drive

101.6 mm

61 mm

3L-3324 Pin;

9U-6110

Spanner

72.00 mm (2.834 in)

2 kg (4.5 lb)

3/4 in

(4.00 in)

(2.4 in)

9.50 mm (0.375 in)

Spanner Wrench

Spanner Wrench Usage Chart

Spanner Wrench Part

9U-6110

Piston Serviced

6U-3247

Type Cylinder

Suspension

D250B

D35C

Vehicle Models

D25C

D300B

D300D

Adjustable Cylinder Spanner Wrench

Essential Tool

• Used to remove threaded glands from

• Maximum gland adjustment: 139.70 mm

hydraulic cylinders

(5.500 in)

Model Usage: Duece

• Used with torque wrench (installation only)

• Square drive: 3/4 in

Warranty: Caterpillar ^®Six Months

• Adjustable for different diameter heads (must

• Maximum installation torque: 510 N·m

have 4 radial holes on outer diameter)

(375 ft-lb)

• Setscrew: 9X-6405

Specifications

• Minimum gland adjustment: 104.78 mm

(4.125 in)

Part Number

Description

160-0261

Adjustable Cylinder Spanner Wrench

7-80 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Repair Tools for Backhoes and B-Series Telehandlers

Model Usage: TH220B, TH330B, TH350B,

242-0780 Spanner Wrench

• Replaces canceled 208-5524 Brake Gauge

TH360B, TH460B, TH560B, TH580B, and Backhoe

• Used to service B-series Telehandlers only

• Used to check brake disk wear and determine

Loader

whether disk replacement is needed

• Used to disassemble and assemble tow hitch

Warranty: Caterpillar ^®Six Months

cylinder

• Checks for minimum thickness between brake

disks

• Used with a 1/2 inch square drive ratchet

• Gauge is inserted through inspection port in

• Comes with 4 dowels (1/4 in, 5/16 in, 4.5 mm,

axle housing

and 5.5 mm) to fit pin holes

• Fits Nut Sizes up to 84.5 mm (3.327 inch) max

242-0779 Socket

spread

• Used to service B-series Telehandlers only

242-0992 Brake Gauge

• Used to remove/install tilt cylinder lock valve

• Used to service B-series Telehandlers and

• 36 mm deep socket with 1/2 inch square drive

Backhoe Loaders

Item

Part Number

Description

242-0780

Spanner Wrench

242-0992

Brake Gauge

242-0779

Socket

Cylinder Spanner Wrench

Model Usage: 525 Log Skidders Equipped

• Used to disassemble and assemble grapple

• Using other tools to remove glands and piston

with ESCO Series 2000 Sorting and Bunching

boom and tong cylinders (1 wrench removes

can cause part damage resulting in increased

Grapples

gland from cylinder tube, the other removes

machine downtime

piston from rod)

Warranty: Caterpillar ^®Six Months

• HEX for socket to apply specified torque

• Designed to clear cylinder rod guard

• Two 9.6 mm (0.38 in) pins provide positive

engagement with gland or piston

Distance

Part No.

Pin Diameter

Overall Width

Overall Length

Hex Size

Between Pins

68.3 mm

406 mm

126-5759

9.6 mm (0.38 in)

93 mm (3.66 in)

1 1/8 in

(2.69 in)

(15.98 in)

92.2 mm

406 mm

126-5760

9.6 mm (0.38 in)

117 mm (4.61 in)

1 5/16 in

(3.63 in)

(15.98 in)

JULY 2018 Vehicle System Tools

7-81

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Spanner Wrench

Essential Tool

• Used to disassemble and assemble tilt and lift

cylinders

Model Usage: 246C (JAY1-UP), 256C (DWS1-UP),

262C (MST1-UP), 272C (RED1-UP) Skid Steer

Loader, 277C (JWF1-UP), 287C (MAS1-UP), 297C

(GCP1-UP) Multi-Terrain Loader

Warranty: Caterpillar ^®Six Months

Part No.

Description

Capacity

Overall Length

Pin Diameter

Square Drive

Spanner

31.8 - 76.2 mm

204.7 mm

4.8 mm

292-9213

Wrench

(1.25 - 3.00 in)

(8.06 in)

(0.188 in)

Spanner

50.8 - 120.7 mm

285.6 mm

6.0 mm

292-9214

Wrench

(2.00 - 4.75 in)

(11.24 in)

(0.250 in)

Offset Spanner

31.8 - 76.2 mm

4.8 mm

292-9215

135 mm (5.31 in)

1/2 in

Wrench

(1.25 - 3.00 in)

(0.188 in)

Offset Spanner

50.8 - 120.7 mm

6.0 mm

292-9216

162 mm (6.38 in)

1/2 in

Wrench

(2.00 - 4.75 in)

(0.250 in)

Hydraulic Cylinder Rod Seal Guides

Warranty: Caterpillar ^®Six Months

• Needed for installation of hydraulic cylinder

heads with polyurethane seals used on square

shoulder rods

• Chart correlates guides with cylinder rod

diameter, thread size, and application

Seal Guide

Rod Larger Outer

Rod Smaller Outer

Rod Thread Inner

Length

Cylinder Where Used

Number

Diameter

129-4539

137.16 mm (5.40 in)

130.05 mm (5.12 in)

120.73 mm (4.75 in)

101.60 mm (4.00 in)

992G Tilt Cylinder

129-4541

146.05 mm (5.75 in)

139.70 mm (5.50 in)

127.07 mm (5.00 in)

99.06 mm (3.90 in)

132-5139

114.30 mm (4.50 in)

99.57 mm (3.92 in)

82.55 mm (3.25 in)

114.30 mm (4.50 in)

5230 Bucket Dump

132-5141

152.40 mm (6.00 in)

132.59 mm (5.22 in)

82.55 mm (3.25 in)

152.40 mm (6.00 in)

5130 Front Shovel

134-9803

88.65 mm (3.49 in)

76.20 mm (3.00 in)

63.50 mm (2.50 in)

88.90 mm (3.50 in)

D10N Bulldozer Lift

134-9804

88.65 mm (3.49 in)

81.79 mm (3.22 in)

76.20 mm (3.00 in)

99.06 mm (3.90 in)

D11N Bulldozer Lift

CS531, CS533, CS563, CS583, CP533, CP Eccentric

158-0511

44.96 mm (1.77 in)

25.40 mm (1.00 in)

31.75 mm (1.25 in)

128 mm (5.0 in)

Group

162-7704

121.00 mm (4.76 in)

105.40 mm (4.15 in)

76.20 mm (3.00 in)

125.00 mm (4.92 in)

187-1054

127.00 mm (5.00 in)

95.25 mm (3.75 in)

88.90 mm (3.50 in)

157.48 mm (6.20 in)

D11R Carrydozer Tilt

1P-0763

38.10 mm (1.50 in)

34.29 mm (1.35 in)

31.75 mm (1.25 in)

57.15 mm (2.25 in)

950 Steering

1P-0765

57.15 mm (2.25 in)

53.34 mm (2.10 in)

38.10 mm (1.50 in)

57.15 mm (2.25 in)

834 Steering; 657 Hitch; 920 Bucket Lift

1P-0766

57.15 mm (2.25 in)

53.34 mm (2.10 in)

44.45 mm (1.75 in)

57.15 mm (2.25 in)

966, 980, 977K Logging Fork

1P-0767

57.15 mm (2.25 in)

56.00 mm (2.20 in)

44.50 mm (1.75 in)

57.15 mm (2.25 in)

769B Steering

992 Steering; 983 Demolition Bucket; 8R, 9R Blade

1P-0768

63.50 mm (2.50 in)

59.18 mm (2.33 in)

50.80 mm (2.00 in)

57.15 mm (2.25 in)

Rip Tooth; 950, 955K, 966C Bucket Lift; 950, 988, 966C

Bucket Tilt; Pitch; 988B Logging Fork

1P-0769

69.85 mm (2.75 in)

63.50 mm (2.50 in)

57.15 mm (2.25 in)

977K Bucket Tilt

1P-0770

76.20 mm (3.00 in)

71.70 mm (2.82 in)

57.15 mm (2.25 in)

980 Bucket Tilt

1P-0772

82.55 mm (3.25 in)

78.05 mm (3.07 in)

57.15 mm (2.25 in)

8D Ripper Lift

1P-0773

82.55 mm (3.25 in)

78.05 mm (3.07 in)

63.50 mm (2.50 in)

57.15 mm (2.25 in)

983 Ripper Lift, 988B Bucket Tilt

1P-0774

82.55 mm (3.25 in)

78.05 mm (3.07 in)

69.85 mm (2.75 in)

57.15 mm (2.25 in)

983, 988 Bucket Lift, 9D Ripper Lift

1U-8606

89.97 mm (3.54 in)

82.00 mm (3.23 in)

72.15 mm (2.84 in)

196.00 mm (7.72 in)

MS240-8, E240

221-5385

101.60 mm (4.00 in)

92.66 mm (3.65 in)

82.55 mm (3.25 in)

211.00 mm (8.31 in)

854G, D11R Tilt

233-7206

44.40 mm (1.75 in)

38.00 mm (1.50 in)

32.00 mm (1.26 in)

82.00 mm (3.23 in)

TH360B, TH460B Rear Frame Lock

233-7207

44.40 mm (1.75 in)

38.00 mm (1.50 in)

32.00 mm (1.26 in)

100.00 mm (3.94 in)

TH460B Frame Level

233-7208

50.75 mm (2.00 in)

46.00 mm (1.81 in)

38.25 mm (1.51 in)

87.30 mm (3.44 in)

TH350B, TH360B Frame Level

485-0088

129.97 mm (5.12 in)

105 mm (4.13 in)

90 mm (3.54 in)

248 mm (9.76 in)

988K

7-82 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Hydraulic Cylinder Rod Seal Guides (Continued)

Seal Guide

Rod Larger Outer

Rod Smaller Outer

Rod Thread Inner

Length

Cylinder Where Used

Number

Diameter

233-7209

64.95 mm (2.56 in)

54.00 mm (2.13 in)

44.60 mm (1.76 in)

92.00 mm (3.62 in)

TH360B, TH460B Stabilizer Cylinder

233-7211

74.95 mm (2.95 in)

62.00 mm (2.44 in)

52.15 mm (2.05 in)

118.00 mm (4.65 in)

TH360B/460B Fork Cylinder

233-7213

101.55 mm (4.00 in)

69.00 mm (2.72 in)

57.20 mm (2.25 in)

97.00 mm (3.82 in)

TH360B Boom Raise Cylinder

233-7215

101.55 mm (4.00 in)

69.00 mm (2.72 in)

57.20 mm (2.25 in)

117.00 mm (4.61 in)

TH360B Boom Raise Cylinder

244-8857

79.95 mm (3.15 in)

54.00 mm (2.13 in)

44.45 mm (1.75 in)

93.00 mm (3.66 in)

TH330B Boom Raise

2P-8284

69.85 mm (2.75 in)

66.04 mm (2.60 in)

50.80 mm (2.00 in)

57.15 mm (2.25 in)

988 Bucket Tilt

2P-8301

63.50 mm (2.50 in)

59.18 mm (2.33 in)

44.45 mm (1.75 in)

57.15 mm (2.25 in)

623 Ejector

365-1766

64.95 mm (2.56 in)

59.21 mm (2.33 in)

50.80 mm (2.00 in)

57.15 mm (2.25 in)

420E Stick Cylinder

4C-6746

101.60 mm (4.00 in)

95.25 mm (3.75 in)

162.56 mm (6.40 in)

162.05 mm (6.38 in)

D10N Tilt Cylinder

4C-8122

107.95 mm (4.25 in)

101.60 mm (4.00 in)

82.55 mm (3.25 in)

57.15 mm (2.25 in)

994

4C-8123

139.70 mm (5.50 in)

133.10 mm (5.24 in)

82.55 mm (3.25 in)

430-4385

84.95 mm (3.34 in)

75 mm (2.95 in)

64.5 mm (2.54 in)

150 mm (5.91 in)

950K Wheel Loader

J613 Steering and Bowl Lift; 920, 930, 951B; 920, 930,

5P-0320

50.80 mm (2.00 in)

46.48 mm (1.83 in)

38.10 mm (1.50 in)

57.15 mm (2.25 in)

951B Multi-Purpose Bucket; Side Dump Bucket; 920,

930 Bucket Tilt

5P-3537

38.10 mm (1.50 in)

34.29 mm (1.35 in)

28.58 mm (1.13 in)

57.15 mm (2.25 in)

920, 930 Steering

5P-5191

76.15 mm (3.00 in)

72.39 mm (2.85 in)

50.80 mm (2.00 in)

57.15 mm (2.25 in)

623B Elevating Scraper; D9H Dozer Lift

5P-6155

66.04 mm (2.60 in)

50.80 mm (2.00 in)

44.45 mm (1.75 in)

57.15 mm (2.25 in)

D8 Bulldozer Tilt

5P-6156

88.90 mm (3.50 in)

85.09 mm (3.35 in)

63.50 mm (2.50 in)

57.15 mm (2.25 in)

225 Clamshell; 980C Lift

5P-7382

101.60 mm (4.00 in)

97.10 mm (3.82 in)

69.85 mm (2.75 in)

57.15 mm (2.25 in)

988B Bucket Lift

5P-8565

63.50 mm (2.50 in)

59.18 mm (2.33 in)

44.45 mm (1.75 in)

57.15 mm (2.25 in)

D7F, D7G Dozer Lift

5P-8725

101.60 mm (4.00 in)

97.10 mm (3.82 in)

63.50 mm (2.50 in)

57.15 mm (2.25 in)

D10 Bulldozer Lift

6V-3036

82.55 mm (3.25 in)

78.05 mm (3.07 in)

50.80 mm (2.00 in)

57.15 mm (2.25 in)

D9L Bulldozer Lift

6V-3038

95.25 mm (3.75 in)

88.90 mm (3.50 in)

63.50 mm (2.50 in)

57.15 mm (2.25 in)

963 Bucket Tilt

6V-4938

95.25 mm (3.75 in)

88.90 mm (3.50 in)

69.85 mm (2.75 in)

57.15 mm (2.25 in)

227 Stick

6V-6013

76.20 mm (3.00 in)

71.70 mm (2.82 in)

44.45 mm (1.75 in)

57.15 mm (2.25 in)

D8L Bulldozer Lift

6V-6159

28.58 mm (1.13 in)

21.84 mm (0.86 in)

16.00 mm (0.63 in)

38.10 mm (1.50 in)

6V-9052

59.94 mm (2.36 in)

50.80 mm (2.00 in)

38.10 mm (1.50 in)

6V-9072

44.45 mm (1.75 in)

43.94 mm (1.73 in)

39.62 mm (1.56 in)

38.10 mm (1.50 in)

8T-9156

53.34 mm (2.10 in)

33.02 mm (1.30 in)

74.93 mm (2.95 in)

8T-9158

45.72 mm (1.80 in)

36.32 mm (1.43 in)

32.26 mm (1.27 in)

45.47 mm (1.79 in)

8T-9159

50.80 mm (2.00 in)

30.48 mm (1.20 in)

44.70 mm (1.76 in)

83.82 mm (3.30 in)

9U-7456

127.00 mm (5.00 in)

119.89 mm (4.72 in)

97.00 mm (3.82 in)

299.72 mm (11.80 in)

9U-7953

101.60 mm (4.00 in)

97.10 mm (3.82 in)

82.55 mm (3.25 in)

57.15 mm (2.25 in)

992C Bucket Lift

445-4924

84.95 mm (3.34 in)

75.0 mm (2.95 in)

64.5 mm (2.53 in)

150.0 mm (5.90 in)

980K Wheel Loader

JULY 2018 Vehicle System Tools

7-83

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Sensor Installation Tools

Essential Tool

265-4177 Service Group

• Reduces possibility of damage to seal on

sensor

Model Usage: D8T (KPZ, J8B); D9T (RJS); D10T

• Used to install sensors in clevis-mounted,

(RJG) Track -Type Tractors 416E (SHA); 420E

position-sensing hydraulic cylinders (PCS)

• Reduces chances of damaging cylinder bore

(HLS, KMW); 430E (EAT, DDT); 432E (BXE); 434E

during installation

• Ensures accurate alignment of sensor

(FSH); 442E (GKZ) Backhoe Loaders 988G (BNH);

980H (JMS) Wheel Loaders 824H (ASX); 834H

Item

Part Number

Description

Qty.

—

4C-9662

Instrument Case, 355 x 832 x 115 mm (14.0 x 32.8 x 4.5 in)

(BTX); 825H (AZW); 826H (AWF); 836H (BXD)

265-4180

Installer Group

Wheel Dozers

265-4181

Sleeve

Warranty: Caterpillar ^®Six Months

265-4182

Sleeve Removal Tool

265-4183

Driver Group (includes driver cap and bolt)

265-4184

Extension Tube, 50.0 cm (19.7 in)

265-4185

Extension Tube, 75.0 cm (29.5 in)

265-4186

Coupler Group

8T-0269

M6 x 1 Bolt

265-4187

Support Collar Group

265-4188

Support Disc, 266.50 mm (10.49 in)

265-4189

Support Disc, 253.80 mm (9.99 in)

265-4190

Support Disc, 234.75 mm (9.24 in)

265-4191

Support Disc, 219.80 mm (8.65 in)

265-4192

Support Disc, 196.65 mm (7.74 in)

265-4193

Support Disc, 179.80 mm (7.08 in)

265-4194

Support Disc, 158.55 mm (6.24 in)

265-4195

Support Disc, 149.80 mm (5.89 in)

265-4196

Support Disc, 139.80 mm (5.50 in)

265-4197

Support Disc, 133.05 mm (5.24 in)

265-4198

Support Disc, 129.80 mm (5.11 in)

265-4199

Support Disc, 126.80 mm (4.99 in)

265-4200

Support Disc, 120.45 mm (4.74 in)

265-4201

Support Disc, 119.80 mm (4.72 in)

265-4202

Support Disc, 114.10 mm (4.49 in)

265-4203

Support Disc, 107.75 mm (4.24 in)

265-4204

Support Disc, 95.05 mm (3.74 in)

265-4205

Support Disc, 88.70 mm (3.49 in)

265-4206

Support Disc, 84.80 mm (3.34 in)

265-4207

Support Disc, 76.00 mm (2.99 in)

265-4208

Wire Guide Group

Sensor Installation Tools

265-4209 Service Group

Reference

• Used to install sensors in trunnion-mounted,

• NEHS0935, Tool Operating Manual, Using

position-sensing hydraulic cylinders (PCS)

the 265-4177 and 265-4209 Service Tool

Groups to Install Sensors in Position-Sensing

• Ensures accurate alignment of sensor

Hydraulic Cylinders

• Reduces possibility of damage to seal on

sensor

Item

Part Number

Description

Qty

—

265-4211

Foam Insert

—

4C-9662

Instrument Case, 355 x 832 x 115 mm (14.0 x 32.8 x 4.5 in)

265-4212

Slide Hammer Group

265-4180

Installer Group

265-4181

Sleeve

265-4182

Sleeve Removal Tool

7-84 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Position Sensor Cylinder (PSC) Gauge Tools

Essential Tool

• Used to precisely measure center-to-center

• Each gauge group includes two pins; a

distances between rod ends of steering

stepped gauge pin for cylinder rod ends and a

Model Usage: 12M, 14M, 16M, and 24M Motor

cylinders

straight gauge pin for cylinder tube ends and

Graders 120M, 140M, 160M Motor Graders,

a precision measuring tape

966K, 966L, 972K, 980K

• Used with two 5P-8637 V-Blocks

Warranty: Caterpillar ^®Six Months

• Measures cylinders in closed and open

Reference

position

• NEHS1038, Tool Operating Manual, 307-7586

• Obtaining accurate measurements are

PSC Gauge Group, 321-5932 PSC Gauge

necessary after servicing cylinders

Group, Used For Manual Length Measurement

of Position Sensing Steering Cylinders on

• Measurements are necessary to input trim

M-Series Motor Graders

values into ECM (controls steering logic)

307-7586 PSC Gauge Group for 120M, 140M, and 160M Motor Graders

Item

Description

Not shown

NEEG3106 Decal

Not shown

NEHS1038 Tool Operating Manual

Item

Part Number

Description

—

307-7586

Gauge Group

—

321-5932

Gauge Group

307-7586 PSC Gauge Group for 120M, 140M, and 160M Motor Graders

307-6222

Gauge Pin Assembly

307-6223

Gauge Pin Assembly

307-6224

Pi Tape (with case)

4C-3975

Storage Case

307-7585

Foam Insert

Gauge Group for 24M Motor Grader

321-5932 PSC Gauge Group for 24M Motor Grader

Item

Description

Not shown

NEEG3107 Decal

Not shown

NEHS1038 Tool Operating Manual

Item

Part Number

Description

321-5932 PSC Gauge Group for 24M Motor Grader

321-5644

Gauge Pin Assembly

321-5646

Gauge Pin Assembly

307-6224

Pi Tape (with case)

4C-3975

Storage Case

307-7584

Foam Insert

Gauge Group for 966K, 966L, 972K Wheel Loaders

384-3757 PSC Gauge Group for 966K, 966L, 972K Wheel Loaders

Item

Part Number

Description

Not Shown

NEEG3126 Decal

Not Shown

NEHS1138 Tool Operating Manual

384-3758

Pin Assembly

384-3758

Pin Assembly

384-3759

Pin Tape

4C-3975

Storage Case

Foam Insert

JULY 2018 Vehicle System Tools

7-85

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Gauge Group for 980K Wheel Loaders

384-3760 PSC Gauge Group for 980K Wheel Loaders

Item

Part Number

Description

Not Shown

NEEG3126 Decal

Not Shown

NEHS1139 Tool Operating Manual

384-3761

Pin Assembly

384-3761

Pin Assembly

384-3759

Pin Tape

4C-3975

Storage Case

Foam Insert

Position Sensor Tools for Hydraulic Sensors

Model Usage: 950M, 962M, 966M, 972M,

• Ensures accurate alignment of sensor

• Reduces chance of damaging cylinder bore

980M, 982M

during installation

• Reduces possibility of damage to seal

Warranty: Caterpillar ^®Six Months

• Plastic construction

Part Number

For Sensor Number

Diameter

Length

Weight

476-3486

395-0395, 395-0388, 388-4776

85 mm (3.34”)

1015 mm (39.9”)

1.58 Kg (3.48 lbs)

476-3487

384-8716, 399-8901, 424-3491

85 mm (3.34”)

850 mm (33.4”)

1.34 Kg (2.95 lbs)

476-3488

387-0838 and 387-1119

85 mm (3.34”)

1260 mm (49.6”)

1.94 Kg (4.27 lbs)

Sensor Installer Group

Essential Tool

• Used to install sensor into position-sensing

• Includes protective storage case

hydraulic cylinder (PCS)

Model Usage: 430E (DDT1-Up, EAT1-Up)

Reference

Backhoe Loaders

• Ensures accurate alignment of sensor

• RENR6485, Service Manual

Warranty: Caterpillar ^®Six Months

• Reduces possibility of damage to seal or

• NEHS0999, Tool Operating Manual, 301-9788

cylinder bore

Sensor Installer Group

Item

Part Number

Description

—

301-9788

Sensor Installer Group

—

302-1472

Foam Inserts (for case)

—

6V-3073

Case

302-1474

Alignment Pin (with handle)

302-1475

Installer

7-86 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Seal Installer Group

Essential Tool

• Used to install 096-7803 Seal onto 4I-3614

Specifications

Cylinder Piston

Model Usage: 318B, 320, 320B, 322, 322B, and

• Tapered Seal Guide:

325 Excavators

• Inside diameter of pusher can be used to size

O.D.: (large end): 121.0 mm (4.76 in)

outside diameter of seal after installation

-–

O.D.: (small end): 105.4 mm (4.15 in)

Warranty: Caterpillar ^®Six Months

-–

Counterbore diameter: 119.6 mm (4.71 in)

• Helps prevent seal damage during installation

-–

Inside diameter: 76.2 mm (3.00 in)

• Made from durable plastic

• Pusher:

Inside diameter: 120.1 mm (4.73 in)

-–

Length: 152.4 mm (6.00 in)

Items with no Part Number

Item

Part Number

Description

—

162-7704

Seal Installer Group

130-8364

Extension Spring

Piston Seal Installation Tool for Hydraulic Cylinder

Model Usage: Hex Machines

• Installs the seal in one quick movement

Specifications

without damaging the seal

Warranty: Caterpillar ^®Six Months

• Tapered Seal Guide

• Inside diameter of pusher can be used to size

O.D. large end: 154 mm (6.06 in)

outside diameter of seal after installation.

O.D. small end: 94 mm ( 3.70 in)

• Installs the plastic portion of the 096-1570

-–

Counter bore diameter: 150 mm (5.90 in)

two-piece piston seal on 105-2593 and 247-

8873 pistons

Inside diameter: 76.2 mm (3.00 in)

-–

Length : 215 mm (8.46 in)

• Sealing Ring Pusher

Inside diameter: 154 mm ( 6.06 in)

-–

Length: 247.4 mm ( 9.74 in)

Part No.

Item

Description

473-9443

Piston Seal Installation Tool for Hydraulic Cylinder

Tapered Seal Guide

Sealing Ring Pusher

130-8364

Extension Spring

JULY 2018 Vehicle System Tools

7-87

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Seal Installer Group

Model Usage: 312B to 385B, 312C, and 330C

• Used to install hydraulic cylinder piston seals

• Inside diameter of sealing ring pusher (2) can

Excavators

be used to “size” outside diameter of seal

• Tapered mandrel (1) stretches seal over

after installation

Warranty: Caterpillar ^®Six Months

piston - helps prevent seal damage during

installation

• Sealing ring pushers are made from

durable plastic, tapered mandrels are steel

• Sealing ring pusher (2) uniformly pushes seal

construction

over mandrel (1) and into piston groove

• Two different length mandrels (1) are required

to install seals on double groove pistons

Tapered Mandrel (Item 1)

Outside

Counter Bore

Inside

Counter Bore

Overall

Part No.

Diameter

Length

Large End

Small End

52 mm

36.9 mm

50.03 mm

33.9 mm

15 mm

60 mm

318-2322

(2.05 in)

(1.45 in)

(1.98 in)

(1.33 in)

(0.59 in)

(2.36 in)

62 mm

41.9 mm

60.03 mm

38.9 mm

13 mm

72 mm

318-2323

(2.44 in)

(1.65 in)

(2.37 in)

(1.53 in)

(0.51 in)

(2.83 in)

72 mm

50.3 mm

70.03 mm

47.3 mm

17 mm

82 mm

318-2324

(2.83 in)

(1.98 in)

(2.77 in)

(1.86 in)

(0.67 in)

(3.23 in)

77 mm

54.6 mm

75.03 mm

51.6 mm

20 mm

85 mm

318-2325

(3.03 in)

(2.15 in)

(2.96 in)

(2.03 in)

(0.79 in)

(3.35 in)

82 mm

58.7 mm

80.03 mm

55.7 mm

20 mm

90 mm

318-2326

(3.23 in)

(2.31 in)

(3.16 in)

(2.19 in)

(0.79 in)

(3.54 in)

92 mm

67.2 mm

90.03 mm

64.2 mm

20 mm

95 mm

318-2327

(3.62 in)

(2.65 in)

(3.55 in)

(2.53 in)

(0.79 in)

(3.74 in)

102 mm

75.6 mm

100.03 mm

72.6 mm

20 mm

100 mm

318-2328

(4.02 in)

(2.98 in)

(3.95 in)

(2.86 in)

(0.79 in)

(3.94 in)

132 mm

100.9 mm

130.03 mm

97.9 mm

24 mm

114 mm

318-2329

(5.20 in)

(3.97 in)

(5.13 in)

(3.85 in)

(0.94 in)

(4.49 in)

52 mm

36.9 mm

50.03 mm

33.9 mm

35 mm

80 mm

318-2972

(2.05 in)

(1.45 in)

(1.98 in)

(1.33 in)

(1.38 in)

(3.15 in)

62 mm

41.9 mm

60.03 mm

38.9 mm

31 mm

90 mm

318-2973

(2.44 in)

(1.65 in)

(2.37 in)

(1.53 in)

(1.22 in)

(3.54 in)

72 mm

50.3 mm

70.03 mm

47.3 mm

35 mm

100 mm

318-2974

(2.83 in)

(1.98 in)

(2.77 in)

(1.86 in)

(1.38 in)

(3.94 in)

77 mm

54.6 mm

75.03 mm

51.6 mm

40 mm

105 mm

318-2975

(3.03 in)

(2.15 in)

(2.96 in)

(2.03 in)

(1.57 in)

(4.13 in)

82 mm

58.7 mm

80.03 mm

255.7 mm

40 mm

110 mm

318-2976

(3.23 in)

(2.31 in)

(3.16 in)

(2.19 in)

(1.57 in)

(4.33 in)

92 mm

67.2 mm

90.03 mm

64.2 mm

40 mm

115 mm

318-2977

(3.62 in)

(2.65 in)

(3.55 in)

(2.53 in)

(1.57 in)

(4.53 in)

102 mm

75.6 mm

100.03 mm

72.6 mm

40 mm

120 mm

318-2978

(4.02 in)

(2.98 in)

(3.95 in)

(2.86 in)

(1.57 in)

(4.72 in)

132 mm

100.9 mm

130.03 mm

97.9 mm

45 mm

135 mm

318-2979

(5.20 in)

(3.97

(5.13 in)

(3.85 in)

(1.77 in)

(5.31 in)

Sealing Ring Pusher (Item 2)

Part Number

Inside Diameter

Length

318-2314

43.4 mm (1.70 in)

44 mm (1.73 in)

318-2315

49.3 mm (1.94 in)

48 mm (1.89 in)

318-2316

59.2 mm (2.33 in)

60 mm (2.36 in)

318-2317

64.2 mm (2.53 in)

64 mm (2.52 in)

318-2318

69.1 mm (2.72 in)

72 mm (2.83 in)

318-2319

79.0 mm (3.11 in)

80 mm (3.15 in)

318-2320

88.9 mm (3.50 in)

88 mm (3.46 in)

318-2321

118.7 mm (4.67 in)

120 mm (4.72 in)

7-88 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Clamp Assembly

Compressor Assemblies

• Used to expand or compress hydraulic cylinder

seals before installation

Model Usage: All models with hydraulic

cylinders

Part Number

Size

Description

4S-9446

Clamp Assembly

Warranty: Caterpillar ^®Six Months

Compressor Assemblies

4S-9450

114.3 - 120.7 mm (4.5 - 4.75 in)

4S-9453

152.4 - 158.8 mm (6.0 - 6.25 in)

9S-0289

38.1 - 72.2 mm (1.5 - 3.0 in)

Wiper Seal Installation Tool

Model Usage: 740 Articulated Truck

• This tool is used to install the 506-5669 wiper

• Designed for use with a common shop press

seal in the front suspension cylinder.

Warranty: Caterpillar ^®Six Months

Part No.

Description

Diameter

Weight

515-8207

Wiper Seal Installation Tool

150 x 30 mm (6 x 1.2 in)

3 kg (6.6 lb)

Relief Valve Tool Assembly

Essential Tool

• Used to repair/recondition worn valve seats in

hydraulic control valve body (line relief valve

Model Usage: Cat^® Hydraulic Control Valves

seats only)

Warranty: Caterpillar ^®Six Months

• Restores valve seat to factory specifications

• No need to remove valve; repair is performed

“in-chassis”

• In most cases, valve assembly is repaired and

not replaced - saves time and expense

JULY 2018 Vehicle System Tools

7-89

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Sleeves, Impact Rod

Model Usage: Cat Worktool Auto Connect-40

• Sleeves 416-8216 and 416-8217 are used to

Reference

install seals onto sleeve assembly

Warranty: Caterpillar ^®Six Months

• KENR6576, Assembly and Disassembly

Procedures

Part Number

Dimensions

Weight

416-8216

145 x 45 mm (5.7 x 1.8 in)

.67 kg (1.5 lb)

416-8217

163.52 mm (6.4 x 2.1 in)

.67 kg (1.5 lb)

Cutter, Adapter Assembly

Essential Tool

• Used to repair/recondition worn valve seats in

• 361-1591 Cutter features 10 teeth at a

hydraulic control valve body (line relief valve

117 degree angle with a zero degree rake

Model Usage: 311C, 312C, 313C, 314C, 315C,

seats only)

311D, and 314D Excavators

• 361-1593 adapter assembly threads into

• Used with 229-3612 relief valve tool assembly

229-3612 relief valve tool then attaches to

Warranty: Caterpillar ^®Six Months

line relief port on main hydraulic control valve

• Restores valve seat to factory specifications

• No need to remove valve; repair is performed

Reference

“in-chassis”

• NEHS0871, Repairing Line Relief Valve Seats

• In most cases, valve assembly is repaired and

using the 229-3612 Hydraulic Valve Seat

not replaced - saves time and expense

Repair Kit

Part Number

Description

361-1591

Cutter for M27 threaded port

361-1593

Adapter Assembly for M27 x 1.5 mm threaded port

Sling Assembly

Model Usage: 992 Wheel Loader

• Removes/installs lift cylinders without heavy

crane or removing lift arms and bucket

Warranty: Caterpillar ^®Six Months

Part Number

Description

9S-9101

Sling Assembly

Auto Connect Seal Installers

Model Usage: Work Tools with Auto Connect

• Required for the Auto Connect Seal Installers

• Replaces existing 416-8216 and 416-8217

on Cat^® work tools

Warranty: Caterpillar ^®Six Months

• Improves installation quality of the seals

• Nylon-type material construction

Part No.

Part Name

Dimensions

Weight

529-7617

Tool Group (Piston-Seal Installer) 3/4 in

65 x 415 mm (2.6 x 16.3 in)

3.1 kg (7 lb)

529-7621

Tool Group (Piston-Seal Installer) 1/2 in

57.5 x 389 mm (2.3 x 15.3 in)

2.4 kg (5.3 lb)

Serviceable Parts

For Part No.

Part No.

Description

529-7617

529-7618

Sleeve-Distant

529-7617

529-7619

Sleeve

529-7617

529-7620

Sleeve-Slitted

529-7621

529-7622

Sleeve-Distant

529-7621

529-7623

Sleeve

529-7621

529-7624

Sleeve-Slitted

529-7625

Sleeve-Resizing Tool (1/2 in Sleeve Assembly-Female)

529-7626

Sleeve-Resizing Tool (3/4 in Sleeve Assembly-Female)

7-90 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Puller Plate

Model Usage: 793 and 793B, 795F AC and 797

• Hydraulically separates lower eye of body lift

Reference

Off-Highway Trucks

cylinder from 8X-1213 Shaft (part of frame) -

• Service Magazine, 6/28/93 “Puller Holes

very difficult to remove without puller tooling

Warranty: None

Added to Hoist Rod Assembly for Easy

• Used with three 9X-6151 Bolts, 1 cylinder, 3

Removal”

7X-0533 Washers, and hydraulic power source

Specifications

• Current lift cylinders have puller holes to

• Diameter: 365 mm (14.37 in)

accommodate tooling - former cylinders

without puller holes can be reworked per

• Thickness: 40 mm (1.57 in)

Service Magazine article 6/28/93

• Weight: 29.7 kg (13.5 lb)

Part Number

Description

463-0278

Puller Plate

Model Usage: 784, 785, and 789 Off-Highway

• Used to hydraulically separate lower eye of

• Used with dealer-supplied hardware and

Truck

9T-2807 Hoist Cylinder from 6G-6499 Axle

components: three 4J-7945 Bolts, three

Group

5P-8248 Washers, one single acting, spring

Warranty: None

return hydraulic lifting cylinder, 6G-8221

• Material: A36 Plate Steel

Retainer Plate, and a hydraulic power supply

and hose

Part Number

Description

465-4092

Puller Plate

Hoist Cylinder Puller Assembly

Essential Tool

• Used to separate lower eye of hoist cylinder

• Used with 6V-3160 Hydraulic Cylinder Group

from axle group

Model Usage: 770, 772, 773F, 775F, and 777F

• Make puller plate from SAE 4140 Steel,

Off-Highway Trucks

hardened to RKW C27-33

Warranty: None

Item with no Part Number

Item

Description

Part Number

Puller Plate

465-4093

Item

Part Number

Description

Quantity

6V-6546

Bolt, 1/2-13 x 356 mm (14 in) long

1F-7958

Full Nut, 1/2-13

5P-1076

Hard Washer, 13.5 mm ID x 30 mm OD

5P-8245

Hard Washer, 13.5 mm ID x 25.5 mm OD

6V-1943

Bolt, 3/8-16 x 28.6 mm (1.13 in) long

Telehandler Boom Support

Essential Tool

European Union compliant, CE marked

• Bolts in place of rubber bumper pad centered

Model Usage: All Telehandler Models

on top of telehandler machine body

• Used to support main boom in a raised

Warranty: Caterpillar ^®Six Months

position during maintenance and service

• Designed to clear tubes on bottom of boom

• Designed with heavy-duty square tubing

Part Number

Description

174-7525

Telehandler Boom Support

JULY 2018 Vehicle System Tools

7-91

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Hydraulic Filter Removal Adapter

Model Usage: All 300B Series Excavators

• Used to take out hard-to-remove hydraulic

• 3/8-16 threaded hole for eyebolt

filter capsules

Warranty: Caterpillar ^®Six Months

• 1/2 inch square drive for ratchet wrench

• Eliminates possible damage to filter capsule

during removal

Item

Part Number

Description

—

191-3557

Hydraulic Filter Removal Adapter

1H-5403

Bolt

9M-1974

Washer

3W-9402

Plate Assembly

Model Usage: Cat^® Designed Hydraulic Piston

• Plate assembly holds rotating group,

• Bolt plate assembly in place using 2 customer-

Pumps

swashplate, and shaft together as one unit

supplied bolts and washers

while removing or installing this assembly

Warranty: Caterpillar ^®Six Months

• Black oxide coated

from/into the pump housing

• Material: steel

Part Number

Application

Center Distance Between Bolt Holes

129-1028

250 cc pump

188.7 mm (7.43 in)

424-6902

180 cc Pump

173 mm (6.81 in)

Gauge Tool Group

Model Usage: 225 and 235 Excavators

• Used to set pump drive bearing clearance to

• Can also be adapted to outer 2 gears of 235

an accuracy of ±0.03 mm (±0.0001 in)

Excavator pump drive, which have larger

Warranty: Caterpillar ^®Six Months

splines, by using 38.0 mm (1.5 in) length piece

• Fits directly into all 3 gears of 225 Excavator

of 25.0 mm (1.0 in) internal diameter XT-3

pump drive and center gear of 235 Excavator

Hose which has been cut through on 1 side

pump drive

• When used in outer gears of 235 Excavator

pump drive, dial indicator stylus must be

placed directly on gear hub, rather than the

end of tool group, to achieve desired accuracy

Item

Part Number

Description

—

5P-2390

Gauge Tool Group

1B-4330

Nut

1K-6872

Locknut

5H-6554

Setscrew

Wrench Assembly

Model Usage: MP318, MP324

• Used to torque nuts to correct amount by

• 436-6653 - used to tighten or R&I

placing wrench assembly on top

conversion ring 382-4931 (MP324)

Warranty: Caterpillar ^®Six Months

• 436-6651 - used to tighten or R&I nut

• Made of steel

399-4290 (MP318) or nut 386-9836 (MP324)

• Easy to install

• 436-6652 - used to tighten or R&I

conversion ring 394-3428 (MP318)

Part Number

Dimensions

Weight

436-6651

200 x 180 mm (7.87 x 7.08 in)

3.24 kg (7.15 lb)

436-6652

182 x 106 mm (7.16 x 4.17 in)

5.15 kg (11.36 in)

436-6653

162 x 106 mm (6.37 x 4.17 in)

5.65 kg (12.47 in)

7-92 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Timing Tools for Scrap Shear Rotators

Essential Tool

• Used to provide accurate timing of 190 degree

• Use locator screws, timing ring assemblies,

rotating scrap shears after repair

and pointer groups on specific models only

Model Usage: All Scrap Shears

• Two spiral gears are timed to obtain 95

• Tools serviced separately to help lower cost

Warranty: Caterpillar ^®Six Months

degree rotation from zero in each direction

Reference

• Makes installation and timing process quicker

• RENR4423, Service Manual, Scrap Shear

and easier

Rotators

• Use 170-0545 Degree Wheel and Alignment

Stud Group on all models

Item

Part Number

Description

Models

170-0544

Locator Screw

S80, S90, S280, S290

170-0545

Degree Wheel

All Models

Timing Ring Assembly

Part Number

Description

Models

170-0550

Timing Ring Assembly

S80, S280

Service Repair Parts: Timing Ring Assembly

095-7992

Dowel

8T-4200

Bolt

8T-4224

Washer

Pointer Group

1D-4669

Carriage Bolt

1F-1739

Wing Nut

Locator Screw

6V-8188

Nut - Full

8T-4223

Washer - Hard M12

Wear Sleeve Driver (Install), Wear Sleeve Driver (Remove)

Essential Tool

• Used to remove and install 275-0756 Wear

• Heat-treated for strength and durability

Bushing in main body of hydraulic hammer

Model Usage: PH 126 Hydraulic Hammer

• Hex end of driver fits ID of hex bushing

• Used with hydraulic press to remove and

Warranty: Caterpillar ^®Six Months

• Made from alloy steel

install bushing

Reference

• 283-9441 Driver is used to install and

283-9442 Driver is used to remove hex-shaped

• RENR6996, Hydraulic Hammer Disassembly

bushing

and Assembly

Part Number

Description

283-9441

Wear Sleeve Driver (Install)

283-9442

Wear Sleeve Driver (Remove)

JULY 2018 Vehicle System Tools

7-93

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Bushing Puller Plates

Essential Tool

• Used to remove upper and lower tool

Reference

bushings from hydraulic hammers

Model Usage: H75E, H95E, H115, H120, H130,

• RENR4422, Service Manual, H140 and H160

H140, H160, and H180 Hydraulic Hammers

• Used with hydraulic cylinder, power pack, and

Hammers

threaded rod (see Service Manuals)

Warranty: Caterpillar ^®Six Months

Specifications

• Various sizes fit each model of hydraulic

• Maximum pulling capacity: 27,216 kg

hammer

(60,000 lb)

Part Number

Description

193-1169

Puller Plate, H140 (Upper Bushing)

193-1214

Puller Plate, H115 (Upper Bushing)

193-1217

Puller Plate, H120 (Upper Bushing)

193-1218

Puller Plate, H130 (Upper Bushing)

193-1229

Puller Plate, H160 (Upper Bushing)

442-8460

Puller Plate, H75E (Upper Bushing)

442-8461

Puller Plate, H95E (Upper Bushing)

Typical Puller Plate

Part Number

Description

193-1230

Puller Plate, H115 (Lower Bushing)

193-1231

Puller Plate, H120 (Lower Bushing)

193-1232

Puller Plate, H130 (Lower Bushing)

193-1236

Puller Plate, H180 (Lower and Upper Bushing)

Part Number

Description

193-1233

Puller Plate, H140 (Lower Bushing)

193-1234

Puller Plate, H160 (Lower Bushing)

Washer

Part Number

Description

112-9837

Washer (all models)

Sleeve Driver Assemblies, Driver Handle

Essential Tool

• Used to remove and install piston sleeves

• Threaded portion of sleeve driver is made

without damage to cylinder

from steel to provide extended tool life

Model Usage: H35D, H45D, H55D, and H65D

Hydraulic Hammer

• Used with threaded driver handle

Reference

Warranty: Caterpillar ^®Six Months

• Head of sleeve driver is made from nylon to

• RENR4478, Service Manual, Hydraulic

eliminate scratching/damage to cylinder wall

Hammer Disassembly and Assembly

Item

Part Number

Description

Used On

Outer Diameter

293-6551

Sleeve Driver

H35D

40.0 mm (1.57 in)

293-6552

Sleeve Driver

H45D

50.0 mm (1.97 in)

293-6553

Sleeve Driver

H55D

65.0 mm (2.56 in)

293-6554

Sleeve Driver

H65D

75.0 mm (2.95 in)

293-6555

Driver Handle

7-94 JULY 2018 Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Oil Loss Control Tools

Model Usage: Most Cat^® Models

• Used to minimize oil loss when hydraulic

• With 3.5 kg/cm² (50 PSI) air pressure applied,

system must be disassembled for some

transducer uses 4.65 CFM of compressed air

Warranty: Caterpillar ^®Six Months

reason other than failure

and pulls 8.75 CFM of vacuum flow at 0 PSI

• Several sizes of blocker plates available

• Maximum of 406 mm (16 in) Hg is pulled at

(Figure 2) for use in pump suction line and/or

5.6 kg/cm² (80 PSI) or 254 mm (10 in) Hg at

tank return line joints

3.5 kg/cm² (50 PSI)

• Special vacuum cap assembly, consisting of

• For use on hydraulic systems onl

parts illustrated in Figure 1, is installed in

place of hydraulic tank filler cap; by applying

pressure air to 5P-0306 Vacuum Transducer,

continuous vacuum is produced in tank

Item

Part Number

Description

5P-0306

Transducer - Vacuum

5K-5068

Nipple - Pipe Hexagon

6V-4142

Nipple, Unvalved (for 42000 kPa)

Blocker Plates

Item

Part Number

Description

Size

5P-1750

Plate

31.8 mm (1.25 in) ID line

5P-1751

Plate

38.1 mm (1.5 in) ID line

5P-1752

Plate

50.8 mm (2.0 in) ID line

5P-1753

Plate

63.5 mm (2.5 in) ID line

5P-1754

Plate

76.2 mm (3.0 in) ID line

5P-1755

Plate

88.9 mm (3.5 in) ID line

5P-1756

Plate

101.6 mm (4.0 in) ID line

Plug Vacuum Assembly

Essential Tool

• Used to create a vacuum within the hydraulic

• Applying air pressure to transducer creates a

tank and hydraulic system (minimizes oil loss

continuous vacuum in hydraulic system

Model Usage: M-Series Motor Graders and

during repairs)

C-Series Skid Steer Loaders

• Used at maximum pressure of 138 kPa (20 PSI)

• Used with shop air supply

to prevent damage to hydraulic tank

Warranty: Caterpillar ^®Six Months

• Used when hydraulic system is disassembled

• Install tool in place of hydraulic tank filler plug

for reasons other than component failure

• Requires a dealer-supplied 1/4 inch NPT

adapter to connect air supply

Item with no Part Number

Item

Description

Safety Valve (not serviced separately)

Item

Part Number

Description

—

311-1362

Plug Vacuum Assembly

308-6636

Plug Assembly

5P-0306

Transducer - Vacuum

3B-6552

Elbow - 90° Pipe

6K-1019

Pipe Nipple

3B-7762

Tee Fitting

5P-8998

Nipple - Pipe

4C-8852

Air Regulator

JULY 2018 Vehicle System Tools

7-95

Vehicle System Tools

Hydraulic Component Disassembly and Assembly

Air Pressurizer Assembly

Model Usage: 300E Series

• Used to pressurize hydraulic tank to purge air

Specifications

from new installations on hydraulic pumps

Warranty: Caterpillar ^®Six Months

• Dimensions: 342.9 x 106.7 x 88.9 mm

• Sets air pressure to a safe 7 PSI when

(13.5 x 4.2 x 3.5 in)

connecting to an external source

• Weight: 1.6 kg (3.5 lb)

• Connects to almost any air source

Part Number

Description

440-0524

Air Pressurizer Assembly

Implement Pump 90 Degree Custom Wrench (30 mm)

Model Usage: Medium Wheel Loaders

• Used to aid in removing the implement pump

Specifications

that is installed on medium wheel loaders

Warranty: Caterpillar ^®Six Months

• Length: 189 mm (7.44 inches)

• Block oxide-coated hardened steel

• Width: 99.75 (3.92 inches)

• Thickness: 20 mm (0.78 inches)

• 3/4-inch square drive

• Weight: 1.0 kg (2.2 lbs)

• 6.5 inch offset with a 90 degree head

Part Number

Description

472-7514

Implement Pump 90 Degree Custom Wrench (30 mm)

Hole Finder Tool (Bushing Style)

Model Usage: 299D, 272D

• Used to mark new hole when installing

• Light weight made of steel

394-6140 auxiliary cooker kit, 430-9628 new

Warranty: Manufacturer’s

Specifications

debris kit, or 345-5840 debris kit

• Dimensions: 342.9 mm (13.5 in)

Part Number

Description

434-6932

Hole Finder Tool (Bushing Style)

Brace Assembly

Model Usage: 943, 953 to 953D Track Loaders

• Should be used on lift cylinder to support lift

• Has bar to hold it to extended lift cylinder rod

arms during repair work

Warranty: Caterpillar ^®Six Months

• Only 1 brace needed to hold lift arms in raised

• Made from high strength alloy steel

position

Part Number

Description

6V-3155

Brace Assembly

Lift Cylinder Brace Assembly

Model Usage: 963 and 973 Track-Type Loaders

• Used to support weight of linkage arms and

• Made from high-strength alloy steel

loader bucket, in raised position, during

Warranty: Caterpillar ^®Six Months

• Only 1 brace assembly required

machine maintenance and repair

• Built-in cross bar keeps brace assembly

• Prevents lift arms and bucket from lowering

attached to cylinder rod

due to an accidental loss of hydraulic pressure

Part Number

Description

236-1192

Lift Cylinder Brace Assembly

7-96 JULY 2018 Vehicle System Tools

Caterpillar. Dealer service tools catalog (2018) - page 32