Engine Tools 03

Diagnostic and Repair Tools Engine Tools
Fuel System Repair and Adjust
6V-2023 Flow Checking Adapter Group

SMCS Code: 1250-025, 1250-036, 1251-082
Model: Caterpillar Engines
• Used when flow checking all engines that have reverse flow check valves in fuel
injection pump bonnets
• Has variable length pin for opening check valve; replaces 5P-3564, 5P-3565
and 5P-3566 Flow Check Assemblies which had fixed pins
• Pin can be removed entirely from 6V-2023 Group, allowing it to be used instead
of 7M-1999 Tube Assembly, to flow time engines which do not have reverse flow
check valves Item Part No. Description
1 6V-2018 Pin
ID: ph2, A90378T1
Reference 2 6V-2019 Nut
SMHS7083 Special Instruction 3 6V-2020 Adapter
4 6L-3921 Sealing Washer (three)
5 6F-0612 Jam Nut
6 6V-2021 Fitting
7 5P-2948 Connector
8 4K-9822 Nut
9 4K-9821 Sleeve
10 5P-5630 Tube, 20 cm (8 inch)
4C-8180 Timing Tool Group

SMCS Code: 0701, 0706, 1251
Model: 3408C and 3412C High Performance Marine Engines
• Required tooling used to set engine timing — improves fuel injection Item Part No. Description Quantity
pump-to-engine timing accuracy
1 6V-3073 Plastic Case 1
• Group includes tooling to accurately set timing gauge to zero
2 4C-8185 Foam Block Group 1
• Tools within this group are serviced separately to help lower dealer cost
3 4C-8182 Gauge Collar 1
(some tools may already be on hand at dealership or can be made from
used engine parts) 4 6V-7918 Collet Wrench 2
• Works on engines with serial numbers of 8RG, 3JK, and 7BL 5 4C-8184 Gauge, 66.512 mm (2.6186 in 1
• Can also be used to verify fuel pump cam profile 6 5P-4814 Clamp Collet 1
7 4C-2982 Collet Assembly (with nylon screw) 1
8 4C-8183 Gauge Plate 1
9 8J-3819 Spring 1
10 1N-3257 Retainer Ring 1
11 4C-8181 Timing Tool Assembly 1
12 4C-8178 Indicator Mount Bonnet 1
13 9U-5120 Spanner Wrench 1
14 4C-8179 Bonnet Nut 1
15 NEEG2651 Decal 1
Not Shown
6V-6106 Dial Indicator 1
8T-1000 Electronic Position Indicator Group 1
5P-7262 Contact Point 1
ID: ph2, C55111T1
Reference
NEHS0638 Tool Operating Manual
TSPG 2002 2-269

Engine Tools Diagnostic and Repair Tools
1P-0540 Flow Checking Tool Group

Discontinued — Service Parts Available
Service Parts
Item Part No. Description
1 8S-4600 Nipple
2 8S-4599 Coupling Assembly
3 5K-2408 Fitting
4 3B-6488 Pipe Coupling
5 5J-4634 Hose Assembly
6 4M-5317 Bushing
7 7M-1999 Tube Assembly
8 5P-2413 Regulator Assembly
Reference
ID: il2, C09469T1 SMHS7083 Special Instruction
3P-2239 Timing Plate

5P-0294 Crowfoot Wrench
SMCS Code: 1250-025
Model: D8H, D8K
• 3P-2239 Timing Plate used to time accessory drive shaft when fuel pump housing
is removed and reinstalled on later D8H Tractor engines with compact fuel systems
and 16.5 degree timing
• 5P-0294 Crowfoot Wrench used to tighten accessory drive gear retaining nut when ID: ph2, 92949T1
timing later engines by fuel flow method
Timing Fixture Plates

SMCS Code: 1000-025
• Used to time accessory drive shaft to engine with fuel pump housing and governor removed
Part No. Engine

8S-5417 4.75 inch Bore, 4 and 6 Cylinder
two valve engines (Scroll pumps)
8S-4625 951B Traxcavator with 4.5 inch
Bore engine and hydraulic governor
5P-0143 3204 Engine ID: ph2, 77209T1
5P-4240 D8K Engine (14° 17 inch timing)
8T-5246 Engine Timing Indicator Group

SMCS Code: 1250-025, 1250-036, 1251-081, 1251-082
Model: Multiple Engine Models
• Used to determine piston true top dead center (TDC) and fuel injection pump timing of most Caterpillar engines
• Replaces discontinued 3S-2954 Indicator Group
• Components for timing each engine in accordance with procedure described in Special Instruction SMHS7083 listed in application chart below
• 6V-2056 Rod and 6V-2057 Contact Point available separately for 3300 Series DI Engines
2-270 TSPG 2002


1 5P-7276 Container (contact points not included)
8S-3675 Contact Point, 3,0 (0.12 in)
6V-2057 Contact Point, 3,17 (0.125 in)
9S-8883 Contact Point, 12,7 (.50 in)
5P-7261 Contact Point, 31,5 (1.25 in)
2 6V-3075 Indicator
3 5P-4814 Collet
4 6V-6105 Block
5 6V-3072 Case
ID: ph2, C80209T1
6 8T-5247 Block
7 8T-5339 Adapter
Contact Dial Indicator
Model Adapter Rod Point and Collet 8 8T-5340 Adapter
D336 8T-5340 3S-3264 9S-8883 6V-3075 9 8T-5338 Adapter
1676 5P-4814 10 3S-3264 Rod, 180,9 (7.12 in)
1100 and 3100 8T-3206 8S-2296 9S-8883 6V-3075 11 8S-2296 Rod, 133,4 (5.25 in)
Series 3208, 3204 5P-4814
and 3406 DI1 12 8T-3206 Adapter
3204 PC 2 8T-5339 3S-3264 9S-8883 6V-3075 13 9S-0239 Adapter Assembly

5P-4814 14 5S-8090 Rod Assembly
3300 Series DI1 8T-3206 6V-2056 6V-2057 6V-3075 15 6V-2056 Rod Assembly
5P-4814 16 1T-0416 Bolt
3400 Series DI 8T-5340 3S-3264 5P-7261 6V-3075 17 8N-5132 Clamp
5P-4814
18 8T-3205 Adapter
3400 Series PC2 8T-5340 3S-3264 5P-2393 6V-3075
5P-4814
D353, D379 8T-5338 3S-3264 5P-6531 6V-3075
D398, D399 5P-4814
Engines Not 8T-5338 3S-3264 5P-7261 6V-3075
Listed Above2 5P-4814
3406A 8T-3205 3S-3264 6V-3075
5P-4814
3406B, 3408B, 8T-3206 5S-8090 6V-2057 6V-3075
3412B 5P-4814
1 DI — Direct Injection
2 PC — Precombustion Chamber
6V-6175 Torque Adapter 2P-8256 Timing Decal

SMCS Code: 1000-025
4C-9874 Torque Adapter Model: 1100, 3100
SMCS Code: 1162-010, 1206-010, 1251-010, 1264-017, 1250-025, 1272-010,
1250-025
Model: D25C, 3304B, 3306B • Attach to crankshaft pulley or damper pulley on 1100 and 3100 Series
Engines as alternate method for flow checking static timing without removing
rocker arm shaft and injection nozzle
• 4C-9874 replaces discontinued 6V-6176 Torque Adapter
• Bolted to fuel pump drive gear on 3300 Series Engines so that specific torque
can be applied to gear by tightening center bolt to specified torque value
• 6V-6175 Adapter used on standard engines; 4C-9874 Adapter used on
engines with automatic timing advance
• Both adapters have 1/2 inch square drive
ID: ph2, 57327T1

ID: ph2, B38448
TSPG 2002 2-271

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

SMCS Code: 1000-025 SMCS Code: 1000-025
Model: D397, D386, D375, D364 Model: 1100, 3100, 3208
• Used with 1F-8743 Adapter Assembly or 1P-7415 Pointer Assembly to time • Used to time fuel injection pump and governor with front cover removed
fuel injection pump camshaft to engine
ID: ph2, 79085T1
ID: ph2, T97397T1
6V-9145 Adapter Group

SMCS Code: 1000-025
• Used to add top dead center (TDC) hole in flywheel; 6V-3100 Engine Timing Indicator Group can
then be used for timing and 6V-3100 Multitach can be used to determine RPM on these engines
• 6V-9143 Transducer Adapter is first placed in timing pin hole to align center punch and drill for
6.35 mm (1/4 in) hole, 3.1 mm (1/8 in) deep at No. 1 TDC mark on flywheel; after this operation,
6V-2197 Transducer is used in adapter for connecting to 6V-3100 Group ID: ph2, B76503T1
Reference 1 6V-9142 Drill, 1/4 in
SEHS7742 Special Instruction 2 6V-9143 Transducer Adapter
2D-6392 Seal (Part of 6V-9145)
6M-5062 Seal (Part of 6V-9145)
5B-3254 Nut (Part of 6V-9145)
3 6V-9141 Center Punch
4C-9287 Timing Advance Holding Tool

SMCS Code: 1272-025
Model: 3406B
• Used when pin timing 1988 and newer 3406B Engines, serial numbers 4MG3600
and up, that have large cone-type retainer on fuel timing advance
• Mounted on timing advance
• Required to hold timing advance at bottom of its travel (retarded position) while
pin timing engine; if not used, position can slip and proper timing is not achieved
Reference
SEBR0544-02 Truck Engine Manual ID: ph2, B83722
127-1069 Timing Pin

SMCS Code: 1250-025
Model: 3054 and 3056 Engines
• Used to set engine piston at 100° before top dead center (BTDC) when timing Lucas fuel
pump (at this location, the piston can be more accurately set to a specific position)
• Whistle on top of timing pin confirms that piston is on compression stroke Reference
• Installs into nozzle bore and is held in place with nozzle clamp SENR6525 Supplement, Lucas Fuel System
ID: il2, C66730T1

2-272 TSPG 2002
136-4632 Timing Pin

220-2793 Timing Pin
SMCS Code: 1000-531
Model: 1.1L, 1.2L, 3300, 3176 and 3400 Engines
• Used to determine when crankshaft is positioned at top dead center

• Spring loaded pin presses against flywheel; as engine is rotated pin will drop into hole
as number one cylinder reaches TDC
ID: il1, D00179T1
• Adapters furnished to fit models listed with sufficient clearance behind timing hole
• Easier to use than a bolt—allows one man operation Part No. Description Size Use
• Hardened pin to resist bending 139-7064 Timing Pin Adapter 1/2 inch-20 3176 C10/12 Engines
• No adapter needed for 3300 and 3400 139-7063 Timing Pin Adapter 7/16 inch-20 1.1 and 1.2 L Engines
208-9387 Timing Pin

208-9388 Adapter
SMCS Code: 1000-531
Model: 3176C Engine, D7R Track-Type Tractor and C-9 Engine, D6R Track-Type Tractor
Essential Tool
2 5
• Pin and adapter allows use of 136-4632 Timing Pin with D6R and D7R flywheel housings
• Used with 208-0888 Crankshaft Turning Tool
• Easily determines when crankshaft is positioned at top dead center 1
4
• Spring loaded pin presses against flywheel. As engine is rotated pin drops into hole
when number one cylinder reaches TDC
• Easy to use — allows one-man operation 3
• Hardened pin resists bending
1 208-9388 Adapter
2 136-4632 Timing Pin ID: il2, C80526T1; 208-9388, 136-4632, 208-9387
3 208-9387 Pin
4 Spring (part of timing pin)
5 Spring (part of timing pin)
9U-6188 Timing Fixture Group

SMCS Code: 1251-036, 0766
Warranty: One Year
• Four separate tools used in combination to check accuracy of timing mark location
on fuel injection pump or engine
• Needed to determine location of timing mark on engine if front cover is replaced
Reference
SENR5547 Service Module in SENR5555 Service Manual

1 9U-6189 Drive Adapter
2 9U-6190 Gear Adapter
3 9U-6192 Timing Fixture
4 9U-6191 Pointer
ID: il3, C55195T1
TSPG 2002 2-273

157-3719 Fuel Spanner 192-3331 Timing Gauge

Model: 3054 and 3056 Engines with Bosch Fuel Pumps Model: 3056 Engines with Bosch Pumps
• Used to remove and install Bosch fuel injection pumps • Replaces discontinued 136-3113 Timing Gauge
• Built-in ratchet mechanism reduces removal/installation time • Used to hold dial indicator while checking injection pump
• Square drive: 3/8 timing on engines with Bosch EPVE fuel pump
• Socket size: 13 mm (12-point)
ID: il2, C79246T1
ID: ph2, C78528T1
5.4 inch Bore, 6 Cylinder Vehicle Engine Lifter Setting Tools

SMCS Code: 1209-025
Model: 5.4 inch Bore Engine, 3412, 3500 and G3500
Item Part No. Description Use

1 9S-9114 Spacer Position 1P-7410 Timing Plate on 8S-2346 Shaft Assembly
when setting lifters off engine
2 9S-9082 Turning Tool, 1/2 inch drive Rotate crankshaft when setting fuel pump lifters
ID: ph2, 92947T1
Tools for Rotating Crankshaft

SMCS Code: 1202-018, 0701
Model: 3114, 3116 and 3126 Engines
• Used to rotate crankshaft (makes setting valves and engine timing procedures easier)
• Used with 5P-7305 Engine Turning Gear and 1/2 inch square drive ratchet
• Fastens to starter mounting hole using starter mounting bolts
• Rotate gear shaft housing assembly until 5P-7305 Engine Turning Gear engages
flywheel gear before tightening starter mounting bolts
Measure dimension “X” on starter housing to determine which part to use.

Part No. Description Size ID: ph2, C80362T1
9U-6943 Shaft Housing Assembly 146 mm (5.75 in)

9U-7336 Shaft Housing Assembly 127 mm (5.00 in)
5P-7305 Engine Turning Gear 6/8 and 8/10 pitch
ID: il1, C66628T1
9U-6198 Crankshaft Turning Tool

SMCS Code: 1202-024, 0714
• Used to rotate crankshafts (connects directly to front of crankshafts)

• Has 1/2 inch drive in center to connect ratchet or breaker bar Reference
• Dimensions: 50 x 140 mm (2.0 x 5.5 inch) SENR5555 Service Manual
ID: il2, C54937T1

2-274 TSPG 2002
208-0888 Engine Turning Tool

SMCS Code: 1202-024, 0714
Model: 3176C and C-9 Engines
Essential Tool
• Used to turn crankshaft in engines with rear PTO flywheel housing (engages forward
spline of upper PTO gear)
• Used in applications where no flywheel turning tool access is provided
• Heat-treated for added durability
• To install: remove cover plate or hydraulic pump as needed
Square drive 3/4 inch

Spline 14 tooth
ID: il2, C80115T1; 208-0888
178-8615 Socket
SMCS Code: 1000-018, 0700, 0701
Model: 3114, 3116, 3126 MUI, HEUI, and 3126B Engines
• Used to turn engine crankshaft by hand

• Socket crossbars engage all four bolt heads in front pulley hub
• Prevents over-tightening or loosening of a single bolt when it used
to turn crankshaft clockwise or counterclockwise
• Square drive: 3/4 inch
• Overall length: 90 mm (3.5 in)
ID: il2, C79845T1
5P-7306 Gear Shaft Housing Assembly

5P-7305 Engine Turning Gear
SMCS Code: 1000-025
• Makes engine rotation much easier for valve setting and timing procedures, especially
on engines with no compression release
• Any engine that will accept standard short and long nose electric starters can be rotated
• Pinion gear has 6/8 pitch gear on one end and 8/10 pitch on other
• Both ends of pinion have 1/2 inch square drive hole to accommodate standard ratchet
ID: il2, A42403T1
5F-2807 Cap 9S-1743 Ferrule Nut Wrench

SMCS Code: 1252-010
2F-2990 Plug Model: Caterpillar Engines
SMCS Code: 1107-010, 1252-010
Model: D5B, D6D, D9N, IT28, 943, 953, 963, 973
• Used to remove and install fuel injection lines
• 3/4 inch x 1 inch
• Used to protect fuel pumps (cap) and lines (plug) when removing them
from engine
ID: ph1, C05383T1
ID: ph1, 76011-1T1
TSPG 2002 2-275

5P-0166 Crowfoot Wrench, 3/8 inch 5P-5195 Fuel Line Wrench

Square Drive SMCS Code: 1100-010, 1202-010, 1252-010, 1254-011, 1254-012
Model: 3406
SMCS Code: 1254-010, 1254-012
Model: D3B, 215, 910, 931B
• Special wrench to tighten inside fuel line nuts at through-head connectors
on 3406 Engines
• Used to torque fuel line nut at precombustion chamber on 3204 Engine
• Nuts are tightened to 41 N·m (30 lb.ft.)
in D3 Tractors, 910 Wheel Loaders and 931 Track Loaders
• Because of its small size, wrench can be damaged if used in any application
• Use Torque Computer, SEHS7150, to apply correct torque
where applied torque exceeds 41 N·m (30 lb.ft.)
ID: ph2, 77215T1
ID: ph2, A30728T1
5P-7260 Socket 5P-0144 Socket

Model: D346, D348 and D349 Model: D3, 910, 931, 1100, 3100
• Used with 9S-7353 Torque Wrench to remove and install • Used for removal and installation of fuel lines
fuel nozzle retaining nuts on D346, D348 and D349 Engines on 1100 and 3100 Series, 3208, 3406 and
with Fuel Leak Detection System 3204 Engines in D3 Tractors, 910 Wheel
Loaders, and 931 Track Loaders
ID: ph2, , A37348-1T1 ID: ph2, 80139T1
6V-4089 Reamer Assembly

SMCS Code: 1106-010, 1250-012, 1254-010, 1254-012
Model: 1100, 3100, 3200 and 330 Series Direct Injection Engines
• Removes carbon deposits from bores of pencil-type fuel nozzles
ID: ph2, B32114T1
5B-1401 Fuel Injection Valve Orifice Cleaning Tool Group

SMCS Code: 1254-070
• Used to remove carbon from orifice in nozzle end of flat seat-type fuel injection valves
1
• Chuck has hollow handle to store drills
• Do not use these tools to clean capsule-type valves.
1 5B-1254 Chuck
2 5B-2177 Drill 0.5 mm (.0197 in)
5B-2178 Drill 0.610 mm (.024 in)
7B-5724 Drill 0.445 mm (.0175 in)
7F-1522 Drill 0.711 mm (.028 in)
6H-8639 Drill 0.813 mm (.032 in) 2
8M-4813 Drill 0.965 mm (.038 in)
ID: il2, C79315T1
2-276 TSPG 2002

8S-2245 Cleaning Tool Group

SMCS Code: 1254-010, 1254-012, 1254-025, 1254-036, 1254-038, 1254-081
Model: 1100, 3100, 3208
• Used to properly service pencil-type injection nozzles used

in 1100 and 3100 Series and 3208 Engines
Reference
SEHS7292
1 8S-2262 Case Assembly
2 8S-2256 Vise Assembly
3 5P-0958 Retractor Assembly
4 8S-2249 Pad ID: ph2, B16378-1T1 Item Part No. Description
5 8S-2246 Wire Assembly 0,20 (.008 in) 12 8S-2250 Holding Tool
6 8S-2247 Wire Assembly 0,28 (.011 in) 13 6V-9124 Screwdriver
7 5P-4813 Socket 14 8S-2254 Retractor Assembly
8 8S-2259 Lapping Compound 15 8S-2255 Scraper
9 8S-2257 Loupe 16 8S-2251 Drill
10 6V-4979 Seal Tool 17 8S-2258 Brass Wire Brush
11 2P-5487 Adapter 18 8S-2260 Honing Stone
5P-6229 Extractor
SMCS Code: 1106-010, 1254-010
Model: 3400 Series Direct Injection Engine
• Used to remove fuel nozzle adapter body on 3400 Series Direct Injection Engines
and most other engines with precombustion chambers
ID: ph2, A30058T1
Fuel Injection Valve Nut Removal Tools

SMCS Code: 1254-011
Model: Caterpillar Engines 1
• Used for fuel injection valve nut removal on early engines
2 3
Item Part No. Description Size
1 9B-2029 Wrench 1-3/4 inch hex
2 7B-4973 Wrench 1-7/8 inch hex
3 4B-9918 Handle
ID: ph2, 13474T1
FT1533 Nozzle Adapter

SMCS Code: 1254-010, 1254-011
Warranty: None
• Recommended for use with 1P-0074 Slide Hammer for nozzles that are difficult to remove
ID: il2, B34211
TSPG 2002 2-277

6V-4061 Nozzle Puller Group

6V-4054 Nozzle Puller Group 1 1B-4206 Nut
SMCS Code: 1254-010 2 2S-5658 Washer
Model: D5B, D6D, 225B, 225B-3208, 229-3208, 3208, 518 3 6V-4153 Plate
4 6V-4152 Screw
5 6V-4150 Leg
• 6V-4061 Nozzle Puller Group used to remove direct injection fuel nozzles from 1100,
6 6V-4149 Jaw
3100, 3200 and 3300 Series DI Engines
7 6V-4151 Leg
• 6V-4054 Puller Group used with 6V-4061 Group to remove 7N-0449 Nozzles in 3300
Series DI Engines (all parts of 6V-4061 Puller Group, except 6V-4153 Plate, needed)

ID: ph1, B31919-1T1
1 0S-1618 Bolt
ID: ph3, B31906T1
FT1663 Fuel Nozzle Holder

SMCS Code: 1254-040
Warranty: None
• Holds and identifies up to 8 fuel injection nozzles

• Fabricated from 9L-7276 Cover
ID: ph2, B11806-1T1
6V-6026 Pump Group, 230V, 50Hz

6V-6027 Pump Group, 110V, 60Hz
SMCS Code: 1254-070
• Used with 6V-4022 Injector Tester to remove air from injector at faster rate during
injector test procedure
• After injector installed on tester, electric priming pumps can be turned on and run
during engine test procedure; pump protected from high pressures by check valve
• Includes fittings and hardware needed for installation on tester; 6V-6026 Pump Group
also includes 230V lamp for replacement of original 110V lamp in 6V-4022 Tester
Reference ID: ph2, B60374-1T1

SEHS8065 Special Instruction
8T-2854 Nozzle Retainer Handle

SMCS Code: 1252-012
Model: 3408, 3412
• When used with 5P-0328 Crowfoot Wrench, provides means to hold fuel nozzle
in place while installing fuel lines
• Can be used as handle (10 inch long) for any 3/8 inch drive socket ID: ph2, B96379
2-278 TSPG 2002


SMCS Code: 1254-011
Model: 3300
• Replaces discontinued 6V-3129 Puller

• Used for removing 8N-7003 and 8N-7005 Nozzles used in 3300 Series Engines;
can also be used for removal of former 8N-7001 and 8N-7002 Nozzles
• Required because carbon build-up around nozzle stems prevent nozzles
from being removed by hand
ID: ph2, B59013
NOTE: The 6V-6980 Puller Group should only be used when less than 150 pound-inches 1 6V-6197 Screw
torque is required to pull the nozzle. The nozzle stem will bend or break if more than
2 6V-6198 Clip
150 pound-inches torque is applied with the 6V-6980 Puller. For nozzles that are extremely
difficult to remove, the FT1533 Adapter and 1P-0074 Slide Hammer are still recommended. 3 6V-6199 Button
When using these tools, it is often necessary to remove various engine components. 4 6V-6130 Puller, not serviced
6V-6976 Puller Group

SMCS Code: 1254-011
Model: 3204
• Used to remove 1W-3996 Direct Injection Fuel Nozzles on 3204 Engines; Item Part No. Description
nozzles tend to stick in their bores due to carbon deposits, etc. 1 1B-4206 Nut (also part of 6V-4061 Puller Group)
2 2S-5657 Washer (also part of 6V-4061 Puller Group)
NOTE: As indicated in the parts list, several parts of the 6V-6976 Puller Group 3 6V-4153 Place (also part of 6V-4061 Puller Group)
are also used in the existing 6V-4061 Nozzle Puller Group. If the dealer already 4 6V-4152 Screw (also part of 6V-4061 Puller Group)
has the 6V-4061 Group, only the last four parts (items 5, 6, 7 and 8) are needed 5 6V-6979 Leg
to assemble the 6V-6976 Group.
6 6V-6978 Head
7 6V-6977 Leg
ID: ph2, B51767 8 1D-4716 Nut

SMCS Code: 1254-010 Part No Description Quantity
Model: Caterpillar Engines 6V-3072 Case 1
Warranty:
6V-6982 Tube Assembly 1
6V-7031 Block 1
• Combines all components of 5 nozzle puller groups listed below without
duplicating commonly-used components 6V-6980 Nozzle Puller Group 1
• Also included are various maintenance items, such as 6V-4979 Carbon 6V-6983 Adapter 1
Stop Seal Too, 25 extra carbon stop seals and 6V-4089 Reamer for 5P-7276 Container 1
carbon removal; socket, extension and handle included for removal 6V-4979 Carbon Stop Seal Tool 1
of 5/16 inch-12 point hold down screws used on some nozzle clamps 9L-9098 Carbon Stop Seal 25
6V-4089 Reamer 1
Reference 6V-6976 Nozzle Puller Group 1
6V-4151 Leg 1
ID: ph2, B51775T1 6V-4150 Leg 1
Nozzle Engine Nozzle 6V-4054 Nozzle Puller Group 1
Puller Group Used On Part No.
6V-4149 Jaw 1
6V-6981 3406 8N-7006
5P-4199 Handle 1
6V-6980 3300 Series 8N-7001, 8N-7005, 8N-7003
9S-1715 Socket 1
6V-6976 3204 1W-3996
9S-1721 Extension 1
6V-4061 1100, 3100 9L-8965, 9N-2366, 9N-3299,
and 3200 Series 1W-5829, 9L-6969, 9L-7883
9N-3299
6V-4054 3300 Series 7N-0449
TSPG 2002 2-279

6V-6981 Nozzle Puller Group 9U-6278 Injector Puller Connector

SMCS Code: 1254-010, 1254-011 SMCS Code: 1254-0706, 0707
Model: 3406 Model: 3054, 3056, 3064, and 3066 Engines
• Used for removal of 8N-7006 Direct Injection Fuel Nozzles • Used to remove stuck injector nozzles due to carbon deposit build-up in bore
from 3406 Engines • Used with 1U-7600 Puller Group
• Uses several parts from earlier 6V-4061 Nozzle Puller Group • 1/2-20 thread (female) on one end and M12 x 1.5 thread (female)
on other end
1 1B-4206 Nut
2 2S-5658 Washer
3 6V-4152 Screw
4 6V-6982 Tube Assembly1
5 6V-6983 Adapter1
1 These parts are needed to make the
6V-6981 Nozzle Puller Group from the
earlier 6V-4061 Nozzle Puller Group.
ID: ph3, B51772-1T1 ID: il2, C54926T1
Tools for 3406B Engine Fuel Nozzle and Fuel Nozzle Adapter
SMCS Code: 1101-010
Model: 3406B
Warranty:
• Smaller tools required to remove and install cylinder heads on 3406B Engines, Item Part No. Description
which were redesigned with smaller diameter fuel injection nozzle adapters 1 1B-4206 Nut
2 8T-3199 Screw
3 6V-6983 Adapter
4 8T-3198 Tube
ID: ph2, B96376
4C-8175 Nozzle Puller Assembly

SMCS Code: 1254-010, 0706
Model: 3306 Engine
• Used to remove 104-9450 Direct Injection Fuel Nozzle Assembly

• Required for nozzle removal (carbon build-up around nozzle stems prevents removal by hand)
• Using specialized puller makes nozzle removal faster, easier, and helps prevent damage
• As of 6/1/94 the 104-9450 Fuel Injection Nozzle is used only in the European market
ID: ph1, C54976T1
134-2570 Nozzle Retainer Spanner Wrench

SMCS Code: 1254-010
Model: 3406B, 3406C, 3408, 3408B, and 3412 Engines with P and L Fuel Systems
• Replaces discontinued 8T-3139 Spanner Wrench and 9U-5840 Spanner Wrench Hex size 9/16 inch
• Used to remove and install 7W-2315 Fuel Injection Nozzle Retainer Overall height 20.5 mm (.81 in)
• Provides additional clearance for 3406B and 3406C Engines equipped with Jacobs Overall diameter 41.0 mm (1.61 in)
Engine Brake Distance between pins 28.5 mm (1.12 in)
• Made from SAE4140 steel and heat-treated for long tool life
ID: il2, C54981T1
2-280 TSPG 2002

1U-9725 Wrench
SMCS Code: 1106-010, 1254-010
Model: See below
Engine Serial No.

• Used on following engines to remove and replace nozzle adapters 3406B All
• Larger and stronger to eliminate breakage when removing tight adapters 3408 S/N 78Z-1277-up
• Works on both 7W-1645 (old style) and 7W-5435 (new style) Nozzle Adapters S/N 67U-11092-up (D.I.Only)
• Has 1/2 inch square drive for normal usage, and 1-1/8 inch hex so larger drive socket 3412 S/N 81Z-4579-up
S/N 38S-13223-up
can be used when removing tight adapters
S/N 60M-2477-up
ID: ph2, B83741T1
6V-4980 Torque Screwdriver Tool Group

SMCS Code: 1254-036, 1254-081, 3280-016, 4131-016, 4130-017
• Uses standard 1/4 inch hex drive bits to tighten small fasteners up to 4 N·m (3 lb.ft.).
• Very useful in many applications for applying correct torque to small fasteners;
especially needed to tighten bleed screw on some Caterpillar direct injection fuel
nozzles used in 3304 and 3306 Engines
• Makes it is easier to tighten sleeve levers on engines with sleeve metering fuel
systems; tool holder block for torque screwdriver group provides space for
6V-4141 Sleeve Metering Lever Calibration Tool Group
• Adapter provided for using 1/4 inch drive sockets in other applications within range
ID: ph2, B46662T1
of this tool
Part No. Description
NOTE: Chuck must be loosened prior to removing bits or O-ring seal will be damaged; 6V-6096 Block
O-ring seal, located inside chuck of torque screwdriver, makes gripping the bits possible; 148-5675 Case
to replace damaged O-ring seal, remove chuck from screwdriver and remove seal from 4C-9785 Block
chuck; install 1P-7363 Seal or 2D-6392 O-ring Seal in chuck and install chuck to 4C-9785 Foam Block
screwdriver
6V-6082 Bit, 5/64 inch Hex
6V-6073 Adapter, 1/4 inch Hex to 1/4 inch Square
6V-6072 Bit, 9/64 inch Ball End Hex
4C-9738 Screwdriver
6V-6075 Bit, 3/16 inch Flat
1U-5895 Line Head
148-5677 (Not shown) Block
9U-7227 Injector Height Setting Gauge

187-0482 Spacer Sleeve 4
SMCS Code: 1290-036, 0706
Model: 3406E Engines 1
9U-7227 Injector Height Setting Gauge

• Used to adjust injector Prestroke
• Leaves both hands free to make adjustments Item Part No. Description
2 1 9U-7227 Injector Height Setting Gauge
187-0482 Spacer Sleeve 3 2 187-0482 Spacer Sleeve
• Used to help prevent improper injector height settings 3 4L-5966 Setscrew
• Used with 9U-7227 Injector Height Gauge with a straight indicator pin (spacer sleeve 4 1U-9084 Flag
can be ordered separately) ID: il2, C80001T1
• Sleeve rests against injector spring to keep gauge square on spring retainer
• Earlier gauges with a support flare machined onto the indicator pin do not need Reference
this spacer SENR5580 Service Manual
• All new gauges include a spacer sleeve
SENR6421 Service Manual Module, Disassembly and Assembly 3406E Engines
TSPG 2002 2-281

9U-7227 Injector Height Gauge 1U-5895 Bit Linehead

SMCS Code: 1290-036, 0706 SMCS Code: 1254-036, 1254-081, 3280-016, 4131-016, 4130-017
Model: 3406E Engines Model: Caterpillar Engines
• Used to adjust injector Prestroke • Required to remove and install bleed screw on Caterpillar 7000 Series
• Leaves both hands free to make Nozzles, date code H7 and newer, and to tighten bleed screw to exact
adjustments torque without stripping threads — prevents leakage
ID: ph1, C55191T1 • Included in 6V-4980 Torque Screwdriver Tool Groups; also available
Reference separately to upgrade earlier 6V-4980 Torque Screwdriver Tool Group
SENR5580 Service Manual
Reference
SENR6421 Service Manual Module, Disassembly and Assembly 3406E Engines
1U-8780 Nozzle Puller Group

SMCS Code: 1000-010, 1100-017, 1254-010, 1254-011
Model: 3200, 3300
• Works to pull all 7000 Series Fuel Nozzles on 3200 and 3300 Series Engines;
short enough to use on rear cylinders on 3208 Engines in highway trucks
• Strong enough to pull stuck nozzles on 3300 Series Engines
• Replaces two nozzle pullers: 6V-6980 Nozzle Puller Group for 3300 Series Engines
and 6V-6976 Nozzle Puller Group for 3204 Engines
• Has two adapters, one with full clamp for 3300 Series Engines and one with half ID: ph2, C27145T1
clamp for 3200 Series Engines
6V-7025 Guide
SMCS Code: 1250-012
Model: 3406
• Replaces discontinued 5P-4755 Guide

• Used to properly install 5P-2060 Seal onto 4N-3761 Direct Injection Capsule Valve
Adapter on 3406 Engines
ID: ph2, A16934
9U-5127 Tool Group, 3408 PEEC, and 3412 PEEC

SMCS Code: 1251-036, 1251-025; 0766
Model: 3408 and 3412 PEEC Engine
• Replaces discontinued 4C-9579 Tool Group

• Used to test and adjust fuel pump timing on 3408 and 3412 PEEC Engines
• Increased accuracy
• On-engine field adjustments expand capability of field service mechanics
• Increases service revenue opportunities
• Durable, high quality design — convenient case protects tool investment
• 90 mm long timing pin
• Two 89 mm long rack zero pins
• Modified 3/4 inch crowsfoot with 3/8 inch drive ID: il2, C55053T1
• Slotted 1 5/16 inch socket with 1/2 inch drive Item Part No. Description
• Solenoid spanner wrench with 3/8 inch square drive 1 9U-5120 Solenoid Spanner Wrench
• 6V-2112 Pin for Haliburton Engines 2 136-3124 Socket-Sensor (rack)
3 6V-2112 Fuel Pump Timing Pin
6V-4186 Fuel Pump Timing Pin
4 4C-9581 Rack Zero Pin (2)
5 4C-9582 Crowfoot Wrench, 3/4 inch
6 6V-4186 Fuel Pump Timing Pin
Not shown 6V-3073 Case
Not shown 9U-5128 Foam
2-282 TSPG 2002

9U-5219 Tool Group 3406 PEEC Engines

SMCS Code: 1250-036, 0766
Model: 3406B PEEC Engine
• Replaces discontinued 1U-5540 Tool Group (to update former 1U-5540, order
9U-5103 Slotted Socket, 9U-5225 Foam Block, and NEEG2516 Decal
• Used to set clearance dimension between engine speed sensor and 4W-2485
Slotted Retainer (pulse wheel)
• Establish zero rack position, necessary before 8T-5282 DDT and/or 8T-8697 ECAP
can be used to calibrate rack position sensor without breaking governor seals
• Remove and install 6T-9675 Solenoid (fuel shutoff)
• Set timing position sensor, necessary before 8T-5282 DDT and/or 8T-8697 ECAP
can be used to calibrate timing position sensor
• Remove and install water temperature sensor ID: ph2, C44381T1
Reference Item Part No. Description Item Part No. Description

SEHS8746 Special Instruction 1 8T-9198 Rack Indicator Bracket Assembly 6 9U-5103 Slotted Socket
2 5P-4814 Clamp Collet 7 5P-0326 Crowfoot Wrench, 3/4 inch
3 9U-5120 Spanner Wrench 8 1U-5536 Crowfoot Wrench, 1-5/16 inch
4 6V-4186 Fuel Pump Timing Pin, 90 mm 9 1U-5425 Timing Gauge Assembly
5 1U-5426 Zero Rack Compressor Assembly Not Shown
6D-3982 Nut 6V-3072 Plastic Case
7F-2359 Spring
9S-8903 Contact Point 9U-5225 Foam Block
NEEG2516 Decal
9U-5292 Rack Preload Assembly (3400 PEEC)

9U-5295 Rack Position Group (3400 PEEC)
SMCS Code: 1250-036
Model: 3406, 3408, and 3412 Series NSFS (PEEC) Engines with Fuel Injection Pump and Governor Group
• Used to set the PEEC injection pump rack position without an electronic
control system
9U-5292 Rack Preload Assembly 9U-5295 Rack Positioning Group

• Used to hold pressure against (preload) rack in plus direction • Used to limit travel of rack and make precision rack adjustments
• Fits in place of pumps’s electronic control unit (BTM) • Fits in place of the rack shut-off solenoid
• Fluted knob provides easy adjustment • Knurled surfaces provide better grip while adjusting rack position
• Outside diameter: 82.6 mm (3.25 in) • Parts are serviced individually
• Knob: 1V-5044
Reference
NEHS0625 and NEHS0639 Tool Operating Manuals
9U-5292
9U-5295
ID: il2, C66931T1
9U-5295 Rack Positioning Group

ID: il2, C66930T1
9U-5294 Threaded Bushing
9U-5293 Rack Adjusting Screw, 1 3/16-12
3S-2713 Full Hardened Nut
TSPG 2002 2-283

8T-5160 Gas Regulator Setting Tool Group

SMCS Code: 1550-025
Model: All gas engines with Fisher Gas Regulators
(Use FT2613 for gas engines with the 7E-3407 Sprague Gas Regulator)
Item Part No. Description Quantity

• Used to adjust gas line pressure regulator on entire
current and noncurrent lines of spark ignition engines 1 6V-3072 Case
• Can service engines equipped with both smaller regulator 2 8T-5149 Fitting 3
used on 3304 and 3306, and two of the larger regulators 3 8T-5164 Tool
used on larger engines 4 8T-5163 Tool 2
• Allows adjustment of gas regulator spring with no leakage 5 8T-5165 Tool 2
at air side of regulator; air leakage during adjustment 6 8T-5159 Foam Block
causes incorrect settings
7 8T-5162 Adapter 2
6L-7141 Gasket 2
8 8T-5161 Adapter ID: ph2, B96714T1
3H-8012 Gasket
9 6V-6105 Block
3304, 3306 Positive Pressure Regulator 1 each 8T-5161 Adapter

8T-5163 Tool
8T-5149 Fitting
3H-8012 Gasket
3304, 3306 Vacuum Regulator 1 each 8T-5161 Adapter
8T-5165 Tool
8T-5149 Fitting
3H-8012 Gasket
3400, 3500 Positive Pressure Regulator 1 each 8T-5162 Adapter
8T-5163 Tool
8T-5149 Fitting
7L-7141 Gasket
ID: ph2, B96715T1
3400, 3500 Vacuum Regulator 1 each 8T-5162 Adapter
8T-5165 Tool
Application Procedure 8T-5149 Fitting
1. Select appropriate tool, adapter and gasket for regulator being set and assemble 7L-7141 Gasket
using 8T-5149 Fitting
379, 398, 399 Positive Pressure Regulator 2 each 8T-5162 Adapters
2. To install, remove gas regulator cap and thread adapter into regulator in place of 8T-5163 Tools
cap; push tool shaft down until it engages adjustment screw or nut and tighten 8T-5149 Fittings
fitting just enough to seal off any air leaks around shaft 7L-7141 Gaskets
379, 398, 399 Vacuum Regulator 2 each 8T-5162 Adapters
8T-5165 Tools
Reference 8T-5149 Fittings
Appropriate Engine Service Manual 7L-7141 Gaskets
FT2613 Gas Regulator Cap Assembly

SMCS Code: 1715-025
Model: All Models With 7E-3407 Gas Regulators
Warranty: None 3
• Used to adjust gas line pressure on 7E-3407 Gas Regulators

• Adjust regulator while engine is running
• Eliminates costly engine downtime 2
• Allows adjustment of regulator with no leakage 1
Application Procedure
1. To install, push 155-3062 through FT2613 and 8T-5149. Position hex/washer
end into regulator and tighten cap. Make sure 123-5974 O-ring is in place.
2. Tighten fitting around adjusting tool to prevent leakage, but loose enough ID: il2, C66989T1 Gas Regulator Adjusting Tool
to adjust regulator. Item Part No. Description
3. Adjust regulator and remove tools when finished. 1 155-3062 Regulator Adjusting Tool
2 8T-5149 Fitting
3 FT2613 Cap Assembly
123-5974 O-ring
2-284 TSPG 2002

FT2613 Cap Assembly made from 123-3972 Seal Cap

Item
A 1/2-14 NPTF
ID: il2, C79182T1
Fuel Injection Pump Extractors

SMCS Code: 1251-010
Model: 1100, 3100, 3200
• Use the extractor and wrenches to remove and install fuel injection pumps and retaining bushings
Item Part No. Description Use

1 8S-2244 Extractor
2 8S-2243 Wrench with 8S-2244 Extractor to remove and install fuel injection
pumps on 1100 and 3100 Series Engines and engines with
Sleeve Metering Fuel Systems
3 8T-5287 Wrench with 8S-2244 Extractor to remove and install fuel injection
pumps on engines with compact fuel systems; replaces
discontinued 8S-4613 Wrench
4 5P-1668 Wrench, 3/8 inch drive remove and install fuel pump retaining bushings where space
does not permit use of 8S-2243 Wrench on 1100, 3100 and 3200
Series Engines
ID: ph2, A69884
Buttress Taps Threads Part Pitch

• Bottoming Size Per Inch No. Diameter
• For cleaning threads on 3300 NSFS and 3400 NSFS fuel system pumps 1.375 in 12 1U-6725 33.746 ± 0.090 mm
1.750 in 12 1U-6726 43.276 ± 0.090 mm
5P-2682 Bleeder Valve Socket 8T-0833 Fuel Pump Wrench

Model: 963, 973 Model: 943, 953, 963, 973
Warranty: Lifetime
• Replaces 9F-0022 Bleeder Wrench • Used for removal and installation of fuel pump on 3408 and 3412 Engines
• Used to loosen air bleeder valve on early forged body fuel pumps (replaces 6V-0094 Universal Joint in this application)
• Fits various drive combinations when accessibility is a problem
• 1/4 inch square female and 1/2 inch hex male drive
ID: ph2, B96351T1
ID: ph2, 92237T1
TSPG 2002 2-285

6V-7050 Compressor Group

SMCS Code: 1251-023
Model: 3406
• Used for servicing fuel pump plunger and barrel assemblies Item Part No. Description
on 3406 Engines with New Scroll Fuel System 1 2N-3476 Screw
• Needed to compress heavier pump lifter springs on these engines 2 6V-7015 Clamp Assembly
when plunger and barrel assemblies are removed and installed 3 5M-7418 Nut
4 4B-1228 Screw
Reference 5 4B-2046 Nut
SMHS8278 Special Instruction
Not Shown
148-5675 Case
6V-7026 Block
148-5677 Block
ID: ph2, B58583
6V-4180 Off-Engine Lifter Setting Tool Group

SMCS Code: 1253-017, 1250-025, 1251-036
Model: All Engines with Forged Body or Compact Fuel Systems
• Replaces 5P-6600 Tool Group

• Includes lifter setting tools for all current engines, including 3400 Series Engines
• Also included are shaft assemblies which clamp positively to camshafts, eliminating
movement between camshaft and degree wheel
• Tools required for individual engines are listed in the application chart below.
• Additional tools needed, but not included, with 6V-4180 Group are also illustrated.
6V-4180 Off-Engine Lifter Setting Tool Group

1 9S-6332 Box Assembly
6V-4181 Tool Holder Block
9S-8105 Liner
ID: ph2, B39254T1
Application Charts for 6V-4180 Tool Group
Forged Body Fuel System

Item Components D311 D3400 D326 D346 D353 D379 641
of 6V-4180 D312 D4400 D337 D348 D398 650
Tool Group D315 D4600 D343 D349 D399 651
(Fig. 1) D318 D6100 619C 657
D339 D6600 824A 660
D342 D7700 1693 666
D364 D8800
D375 D11000
D386 D13000
D397 D17000
D468
2 5P-6574 Shaft 1
3 5P-6564 Shaft 1
4 5P-6566 Shaft 12 1
ID: ph2, C80294T1
Additional Tools Needed But Not 5 5P-6568 Shaft 1
Included in 6V-4180 Group 6 7F-8751 Shaft 1
Item Part No. Description 9 2S-6160 Washer 1 1 1 1 1 1
32 5P-6570 Shaft Assembly 11 0S-1594 Bolt 1 1 1 1 1 1
33 8S-2272 Shaft Assembly 12 0S-0509 Bolt 1 1 1 1 1 1
34 1B-3680 Bolt 13 0S-1617 Bolt 1
35 3F-1417 Washer 18 1P-7415 Pointer 1 1 1 1 1
36 6V-2012 Gauge Group 19 5P-6572 Shaft
37 6V-7926 Indicator Group 20 9M-4567 Wrench 1 1 1 1 1 1
38 9M-4567 Wrench 21 9M-4568 Wrench 1 1 1 1 1
39 9M-4568 Wrench 31 1P-7410 Plate 1 1 1 1 1 1
2-286 TSPG 2002

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

32 5P-6570 Shaft 1
36 6V-2012 Gauge Group 11 11 11 11 11 11
37 6V-7926 Indicator 1 1 1 1 1 1
38 9M-4567 Wrench 11 11 11
Compact Fuel System

Item Components D311H D334 D336 1140 3406 3408
of 6V-4180 D320 D343 1676 1145 3412
Tool Group D330D 1674 1150
(Fig. 1) D333 6193 1160
1670 3145
1673 3150
D8 3160
583
3204
3304
3306
7 5P-4158 1 1 1 1 1 1
8 1F-1375 Bolt 2
9 2S-6160 Washer 1 1 1 1 1
10 2S-0932 Washer 1
11 0S-1594 Bolt 1 1 1
12 0S-0509 Bolt 1 1 1 1
13 0S-1517 Bolt 1 1
14 8S-2280 Pointer 1
15 6V-6019 Pin 1
16 1J-6298 Bolt 1
17 2M-5218 Shaft 1
18 1P-7415 Pointer 1
19 5P-6572 Shaft 1
22 7S-5803 Shaft 1
23 6V-3035 Shaft 18
24 5P-1768 Pointer 1 15
25 9S-4446 Shaft 1
26 5P-3601 Adapter 1
27 1P-7420 Pointer 1 1
28 5P-1761 Shaft 1
29 6V-3066 Shaft 17
30 5P-0129 Sleeve 14
31 1P-7410 Plate 1 1 1 1 15 1
Additional Tools Needed But Not Included in 6V-4180 Tool Group

33 8S-2272 Shaft 13
34 1B-3680 Bolt 13
35 3F-1417 Washer 13
36 6V-2012 Gauge Group 11 11 11 11 11 11
37 6V-7926 Indicator 1 1 1 1 1 1
6V-2112 Pin 1 1
2A-0762 Bolt 1
1 Optional
2 619C and 824A only

3 “Max-Min” govenor only
4 3204 (45V S/N)
5 Early
pointer groups have a 5P-6219 Dowel, 15,8 mm (.622 in) diameter installed for 3408 and
3412 engines. Also the 7,14 mm (.281 in) diameter hole must be increased to 8,5 mm (.328 in)
diameter for use on later 3408 and 3412 fuel pump housings.
6A decal, Form SEHS7306, must be applied to early 1P-7410 Timing Plates to accurately time
3406 Direct Injection Truck Engines (1978 Truck Model Year)
7 3304 (9Z) and 3306 (10Z)
8 3204 (10X S/N)
TSPG 2002 2-287

6V-7870 Fixture Group

SMCS Code: 1251-010, 1251-017
• Designed with adjustable clamp and 5-position turret

• One position used for 3406B Engines with New Scroll Fuel Systems
and remaining 4 positions for other engines with fuel pumps having
reverse flow check valves
• 6V-7871 Repair Kit, consisting of turret and detent, also available
Reference ID: ph2, B79245 1 4B-6060 Setscrew (two)
SMHS8378 Special Instruction 2 4B-2046 Nut
3 6V-7015 Clamp Assembly
4 2N-3476 Screw (four)
Tools for Accessory Drive Gear

SMCS Code: 1250-010
Model: 3204 Vehicular Engines
Warranty: None
• 4 fabricated tools needed to loosen accessory drive gear from 1 FT1539 Puller
shaft without removing radiator on 3204 Vehicular Engines 2 FT1540 Puller
• FT1537 Socket and FT1539 Puller used on 45V Vehicular Engines 3 8H-8561 Adapter
• FT1537 Socket, FT1538 Puller and FT1540 Puller used on 10X 4 FT1538 Puller
Vehicular Engines 5 5P-8676 Extension
• 8H-8561 Adapter and 5P-8676 Extension also required 6 FT1823 Socket
ID: ph2, B19374-1T1
8S-2271 Timing Fixture Group

SMCS Code: 1250-025
Model: 1100, 3100
• Used to time fuel pump housings off-engine on later 1100 and 3100 Series Engines
equipped with hydra-mechanical governors
• 1P-8747 Timing Plate or 1P-7410 Timing Plate can be used

1 8S-2280 Pointer Assembly
2 9S-5446 Shaft
3 0S-1594 Bolt
ID: ph2, C05384T1
4 2S-0932 Washer
5 1J-6298 Bolt
1P-5550 Fuel Cam Locking Group

SMCS Code: 1250-025
Model: 623B, 824C, 825C, 826C
• Used to lock fuel camshaft in place when resetting pump timing on 1100,
3100 and 3406 Engines
ID: ph2, C05389T1
2-288 TSPG 2002

9S-8520 Puller Group

SMCS Code: 1250-011
Model: 1100, 3100
• Used to remove 9L-9902 Carrier from fuel injection camshaft on 1100 and 3100 Series
Engines with earlier tapered design
• Hardened 5P-3031 Thrust Washer should be procured from earlier pullers

1 9S-8527 Bolt
2 5P-3031 Thrust Washer
3 9S-8528 Bolt Assembly
ID: ph2, A13535T1
FT0887 Timing Pin 8S-4618 Timing Gauge

SMCS Code: 1250-025
Model: 1100, 3100 8S-4620 Timing Gauge
Warranty: None SMCS Code: 1250-025
Model: 920, 930, 977L
• Used to set timing dimensions on 1100 and 3100 Series Engines
• Can be used without removing fuel lines and air inlet pipe
• Used to check timing dimension on 4.75 inch bore 2-valve engines
• 8S-4618 used on 6-cylinder engines; 8S-4620 used on 4-cylinder engines
• Provide rapid method of checking timing

1 3D-7943 Ring
ID: il2, C05390T1 ID: ph2, C05393T1
Sockets for Special Applications

SMCS Code: 1250-011
Model: 3208, 1100, D379, D398, D399
ID: ph2, 92943T1

Item Part No. Description Size Uae
1 9S-5031 Deep Well Socket 5/8 inch, 3/8 inch drive Required for tachometer drive adapter shaft removal on 1100 and 3100 Series Engines equipped with
hydraulic governors; also used for removal and tightening cap on 9L-6969 Nozzle for 3208 Engines
2 8S-2357 Deep Well Socket 9/16 inch, 3/8 inch drive Required to loosen bolt which retains automatic timing advance unit to fuel injection pump camshaft
on 1100 Series Engines equipped with max-min governor
3 9S-6054 Socket Assembly 3/4 inch drive Turning injection pump camshaft when setting lifters on D379, D398 and D399 Engines
TSPG 2002 2-289

Timing Pins
SMCS Code: 1250-025
Model: 1100, 3100, 3406, 3408, 3412, 3306, 3304 D.I.
Item Part No. Description Model ID: ph2, B14959

1 6V-2112 Pin (former 8S-2291) 1100 and 3100 Series and 3406 Engines
2 6V-6019 Pin (part of 6V-4180) 3408 and 3412 Engines
3 6V-4186 Pin (part of 6V-4096 and 6V-4096; former 7N-1048) 3306 and 3304 D.I. Engines
Not shown 3P-1544 Pin 328 SMFS
Not shown 4C-9581 Pin 3408/12 PEEC
150-3992 Timing Pin Decal for 1P-7410 Degree Wheel

SMCS Code: 1250-025
150-3993 Timing Pin Model: 3406B
SMCS Code: 1251-010, 1251-025, 1000-025
• Used to time 3406 Direct Injection Truck Engines (1978 Truck Model Year)
with static fuel injection timing
• Used to install injection pumps on 3000 Series engines • Decal, SEHS7306, must be applied to early 1P-7410 Degree Wheels for
• 150-3992 pin is required to install Bosch injection pumps accurate timing
• 150-3993 pin is required to install Lucas and Stanadyne injection pumps • Decal provides timing marks in increments less than one degree
ID: ph2, A71279
9U-5692 Spring Compressor

SMCS Code: 1251-010, 0712
Model: 3406, 3408 and 3412 Engines
• Works on all three engines—3406, 3408 and 3412

• Used to compress heavier lifter springs in pump when fuel pump plunger and barrel
assemblies are removed and installed
• Clamps on side of pump housing and eliminates need to attach to adjoining pump
Reference
SENR5148 and SENR4658 Service Manuals
ID: ph2, C47940T1
2-290 TSPG 2002

9S-6326 Rack Bearing Installation Tool Group

SMCS Code: 1253-010, 1253-017
Model: D5B, D6D, D8K, 943, 953
• Used for installation of 9S-4160 Rack Bearing on 1674 and D334 Engines
and 1W-3285 Rack Bearing on 3304 and 3306 Direct Injection Engines

1 9S-6327 Plate Assembly
8H-9208 Dowel, set of three( part of 9S-6327)
2 1B-2790 Bolt (two)
3 6V-4818 Driver
ID: ph2, C80206T1
5P-1665 Alignment Plate 6V-0094 Universal Joint

SMCS Code: 1251-010
5P-1744 Alignment Plate Model: 3408, 3412
SMCS Code: 1253-010, 1253-017
Model: D3B, D4E, D5B, D6D, 215, 623B, 910, 931B, 943, 953
• Used for removal and installation of fuel pump on 3408 and 3412 Engines
as well as other applications where accessibility to fasteners is limited
• Used with 6V-4818 Driver from 9S-6326 Rack Bearing Installation Tool Group • 3/8 inch drive tool is 40 mm (1.56 in) long, which is shorter than standard
• 5P-1665 Plate used to install 9S-4160 Sleeve Bearings in fuel pump housing 3/8 inch universal joints
of 3304 and 3306 Engine
• 5P-1744 Plate (includes 8H-9208 Dowel) used to install fuel rack bearings on
3406 Engines
ID: ph1, A82269T1
ID: ph2, A09457
Special Taps
SMCS Code: 1250-023
Part No. Description Size

• Special bottoming hand taps to recondition damaged fuel pump 5P-3013 Tap 1 3/8 inch-12 NF
retainer threads in any compact or sleeve metering pump housing
5P-3012 Tap 1 1/8 inch-12 NF
5P-3011 Tap 1 inch-14 NS
ID: ph2, A10162T1
5P-6217 Fixture
5P-6218 Bearing Driver
SMCS Code: 1253-017
Model: 3408, 3412
• Used to install tanged fuel rack bearings on 3408 and 3412 Engines
ID: ph2, A30055

TSPG 2002 2-291
FT1251 Pump Housing Stand 6V-4824 Driver

SMCS Code: 1286-010, 1286-012, 1264-015, 1264-016, 1264-017
Model: Caterpillar Engines 6V-4825 Plate
Warranty: None SMCS Code: 1253-016, 1253-017
Model: 3406B
• Fuel system components conveniently serviced on this stand
• Has rails that fit holding fixture from Fuel Injection Test Bench; by using • Used to install D-shaped rack bearing in fuel injection pump housing
appropriate FITB adapter plate and holding fixture, injection pump housings on 3406B Engines
can be mounted on stand for disassembly and assembly, then easily moved • 6V-4825 Plate, bolted to pump housing, pilots bearing as it is driven
to Test Bench for final adjustment and testing into position with 6V-4824 Driver
• Assure bearing installation to correct depth and angle
Reference
3406B Service Manual
ID: ph2, B79251T1
ID: ph3, A25594-1T1
FT0960 Adapter Assembly

SMCS Code: 1251-010, 1253-017
Model: 4.75 inch Bore Engines
Warranty: None
• Used to hold fuel rack in centered position when installing fuel pumps on all 4.75 inch
bore engines with compact fuel systems except D334 and 1674 Engines
ID: illus WIDE 42p0,30p0, C05382T1
2-292 TSPG 2002

7S-7113 Rack Setting Gauge 3H-1690 Fuel Rack Setting Gauge

SMCS Code: 1251-010, 1253-017 SMCS Code: 1251-025
Model: D333, D330, D320, D311H Model: Caterpillar Engines
• Replaces 8M-0530 Gauge • Measures fuel rack setting on all Caterpillar diesel engines using forged
• Measures rack travel in both “fuel on” and “fuel off” directions body fuel injection pumps
• Readings made directly on vernier scale
ID: ph2, T97016

ID: ph2, T97425
1F-7944 Rack Setting Fixture

SMCS Code: 1251-025
Model: 5.4 inch, 5.75 inch Bore Engines
• Used with 3H-1690 Gauge to set fuel rack on some early engines
(5 1/4 inch and 5 3/4 inch bore) with flange type pumps
ID: ph2, C09465T1
1H-6471 Rack Setting Gauge

SMCS Code: 1251-025
Model: 5.12 inch Bore Engines
Warranty: Manufacturer’s
• Used to set rack on some 5 1/8 inch bore engines—may be easier to use 1H-6471
Gauge and 6V-2012 Micrometer Depth Gauge than the 3H-1690 Rack Setting Gauge

1 6V-2012 Micrometer Depth Gauge Assembly
2 1H-6471 Rack Setting Gauge
ID: ph2, C80303T1
5P-0130 Gauge, “O” Set

SMCS Code: 1251-010, 1250-025
Model: 3204
• Used to center fuel rack when adjusting racksetting on 3204 Engine in D3 Tractors,
215 and 910 Wheel Loaders, and 931 Track Loaders
1 7B-1401 Pin
2 3H-1156 Pin
ID: ph2, 77210T1
TSPG 2002 2-293

6V-7941 Overfueling Spring Compressor 6V-7942 Hook

SMCS Code: 1250-025, 1250-036, 1257-025 SMCS Code: 1251-025
Model: Caterpillar Engines Model: Caterpillar Engines
• Used to make fuel rack and fuel ratio control settings on engines with • Used to pull rack against rack centering pin on engines with negative rack
New Scroll Fuel Systems settings
• Replaces discontinued 6V-2128 Overfueling Spring Compressor • Necessary because on some of these engines, overfueling spring may not
• Plunger travel in former 6V-2128 Compressor was limited by mechanical move rack against centering pin
stops and would not permit checking full range of rack settings on above
engines; 6V-7941 Compressor does not have internal stops, and thus will
accommodate full range of rack settings
ID: ph1, B58587
ID: ph1, B58577T1
158-8665 Rack Set Tool

SMCS Code: 0706-025, 0706-082
Model: 3034 Engines
Essential Tool
• Used to adjust maximum fuel setting if timing case or fuel pump linkage
are removed or repaired
Reference
SENR5013 Disassembly and Assembly of 3034 Engine
ID: il2, C79283T1
9U-5296 Rack Positioning Assembly

SMCS Code: 1250-036
Model: 3204, 3300, and 3406 Series NSFS (Non-PEEC) Engines
• Used to set injection pump rack while pump is being tested on test bench
• Used with FITB, FIETS, and AVM test benches
Reference Overall length 171.4 mm (6.75 in)

NEHS0639 Tool Operating Manual Thread size 1/4-28
Bolt hole diameter 7.5 mm (.30 in)
Distance between holes 63.6 mm (2.50 in)
Service part 6V-8187 Nut
ID: il2, C66933T1
6V-9128 Rack Position Tool Group

SMCS Code: 1250-010, 1253-017, 1250-025, 1251-036
• Provides convenient and accurate way to set or check rack position on Caterpillar Engines
• Used to measure fuel rack position during normal operation of engine, or measure fuel rack position and make any necessary adjustments while engine is shut down
• Rack setting can be made or checked without removing injection pump
• Replaces discontinued 9S-0240 Rack Position Tool Group; both groups are identical, except new group contains metric dial indicators and low cost plastic case
Reference
2-294 TSPG 2002


1 6V-9127 Liner
2 6V-9125 Case
3 9S-0239 Adapter
0S-1616 Bolt, 25,4 mm (1/4 inch-20 x 1.00 inch)
4 5S-8090 Rod
5S-8086 Contact Point
5 9S-8521 Rod
6 8S-4627 Circuit Tester or
8T-0500 Circuit Tester
7 6V-3075 Dial Indicator
8 6V-6106 Dial Indicator
9 5S-8157 Extension
10 5S-8088 Rod Assembly
5S-8086 Contact Point
11 8T-7687 Block
12 9S-2017 Spring
13 9S-7344 Clamp Assembly
0S-1616 Bolt, 25,4 mm (1/4 inch-20 x 1.00 inch)
14 9S-7343 Bracket Assembly
2A-0762 Bolt, 16,0 mm (1/4 inch-20 x 7/8 inch)
15 9S-0227 Bracket Group (see service parts)
2H-0191 Bolt, 16,0 mm (10-24 x .625 inch)
19 5P-7276 Container
3S-3269 Contact Point, 25,4 mm (1.0 inch)
5S-8086 Contact Point, 6,35 mm O.D. (0.25 inch O.D.)
ID: ph3, B79252T1 3S-3268 Contact Point, 6,35 mm (0.25 inch)
3P-1565 Collet
5P-4814 Collet
9S-8518 Plug
9S-8519 Plug
9S-0227 Bracket Group 9S-0238 Bracket Group

9S-7350 Bracket Group
ID: ph2, C09463T1 ID: ph2, C09462T1

Service Parts
Service Parts
1 Bracket Assembly, Part of 9S-0238 Bracket Group
1 Bracket Assembly
Bracket Assembly, Part of 9S-7350 Bracket Group
2 Plug
3 Plug
3 9S-0234 Spacer
4 Rod
5 9S-0234 Spacer
5 2A-0762 Bolt
6 2A-0762 Bolt
6 5S-7348 Screw
7 5S-7348 Screw
7 3F-9190 Dowel
8 Hole Attachment
9 9S-0213 Rod
9S-0231 Ring
TSPG 2002 2-295

9S-0228 Rack Position Tool Group


2H-0191 Screw
2 9S-8883 Contact Point
3 8S-2283 Indicator
Reference
SEHS6995, rack setting procedure
ID: ph2, C09466T1
6V-6070 Tool Group

SMCS Code: 1000-010, 1250-010, 1253-017, 1250-025, 1250-036, 1272-081
• Used to check and adjust rack and fuel ratio control linkage on all engines with New Scroll Fuel Systems
(NSFS)—new procedure now used to check and adjust rack on these engines
• Replaces discontinued 6V-4095 Group and 6V-4096 Group; all tools in discontinued groups, except
6V-2128 Compressor which was discontinued, are still available for parts service
Part No. Description Part No. Description

6V-3072 Case (Plastic) 6V-2014 Bracket Assembly (see note below)
6V-6104 Block 6V-2015 Arm (Part of 6V-2014) (Qty. 2)
6V-6105 Block 217956 Bolt
6V-4186 Pin 5B-5689 Gasket
6V-2017 Tool 8H-3128 Bolt (Qty. 3)
0S-1614 Bolt (Qty. 2) 6V-3075 Indicator
6V-6106 Indicator 9S-0229 Point
6V-2030 Extention 6V-2105 Tool Group
9S-8903 Point 2P-8264 Socket
5P-4814 Collet (Qty. 2) 2P-8265 Socket
8T-9198 Bracket Assembly (Rack Indication) 6V-6151 Adapter (Overfueling Spring Compressor)
ID: ph2, B55879T1
6V-6108 Arm (Part of 6V-0109) 6V-7941 Compressor Assembly
NOTE: An FT2532 Shield is available for the
6V-2014 Bracket Assembly. Refer to the separate 2A-0762 Bolt 6V-7942 Hook
article for specifications to make the oil shield. 8H-9178 Bolt (Qty. 2) Form SEHS8024
0S-1615 Bolt Form NEEG2119 (Label)
Reference Form SEES5641 (Layout Chart)
FT2532 Oil Shield

SMCS Code: 1000-010, 1250-010, 1253-017, 1250-025, 1250-036, 1272-081
Model: 3304 and 3306 Engines equipped with New Scroll Fuel Systems
Warranty: None
• Used to create a shield to prevent oil leaking from indicator bracket when checking
fuel-to-air ratio with engine running
• Used with 6V-2014 Bracket Assembly, which is part of 6V-6070 Tool Group
• Oil shield fits over lever shaft mounting ears of indicator bracket
• Can be easily made from aluminum or steel
Item Size
• Attaches to indicator bracket with 3S-6252 RTV
Adhesive/Sealant 1 27.0 ± 1 mm (1.06 ± .04 in)
ID: il2, C66936T1
• After oil shield is installed, check for free movement 2 19.0 ± 1 mm (.75 ± .04 in)
of indicator lever 3 4.0 ± 1 mm (.16 ± .04 in)
4 0.76 mm (.03 in) maximum
5 36.0 ± 1 mm (1.40 ± .04 in)
6 R 1.0 max (4 places)
7 45 degrees
8 26.0 ± 1 mm (1.02 ± .04 in)
2-296 TSPG 2002

6V-4069 Body Group

SMCS Code: 1210-010, 1272-010, 1250-025
Model: 3208
• Used to remove fuel pump drive gear from taper on drive shaft before removing sleeve Item Part No. Description
metering fuel system on 3208 Engines 1 5L-4041 Bolt (two)
• Replaces 5P-2371 Puller Plate (provides more pulling force than 5P-2371) 2 2H-0191 Bolt
• Needed because of lack of space in vehicle 3 6V-4088 Washer
ID: ph2, B25987
5P-4203 Sleeve Metering Field Service Tool Group

SMCS Code: 1250-025, 1251-082, 1264-017
• Used for disassembly, assembly, testing and adjusting Sleeve Metering Fuel System;
used for fuel setting
• Metric tools; values for testing and adjusting given in metric pressures
As a result of changes and improvements in test and adjust procedures, the former
3P-1550 Sleeve Metering Field Service Tool Group was converted to the 5P-4203 S.M.F.S.
Tool Group. Dealers should check the list to determine what tools are required to convert
their 3P-1550 Group to the 5P-4203 Group. Some parts of the former 3P-1550 Group are
no longer needed, but a number of items should be retained in case of the need for
dynamic checking of sleeve shaft movement.
Reference
ID: ph2, A26668-3T1
Item Part No. Description Item Part No. Description Item Part No. Description
1 2P-8306 Box Assembly 11 5P-0319 Driver 22 4H-0553 Fitting
3P-1548 Block 12 5P-0318 Driver 23 5P-0299 Pin, 19,2831 mm (O.7592 in)
3P-1549 Block
13 1P-0463 Plate 24 5P-0298 Pin, 17,8587 mm (O.7028 in)
2 5P-0301 Driver
14 6L-5551 Bolt 25 5P-4209 Gauge1
3 1P-0529 Handle
15 4L-7124 Bolt 26 3J-6956 Spring
4 4B-4280 Washer
16 4B-4276 Washer (four) 27 8S-7271 Setscrew
5 1D-4538 Bolt
17 5D-9231 Connector (two)2 28 8S-2243 Wrench
6 1D-4533 Bolt 3J-7354 Seal (two) 29 3P-1565 Collet
7 3K-4910 Screw 3B-7734 Nipple
6J-3958 Coupling 30 3P-1567 Indicator includes:
8 0S-1603 Bolt 5P-6531 Contact Point, 57,2 (2.25 in)1
9 FT1632 Bolt3 18 3P-2210 Socket 5P-4228 Spring1
10 8T-0853 Gauge 19 5P-6602 Adapter1 (see note) 31 5P-0302 Bar
8B-8817 Plug (not shown) 20 5P-4205 Wrench1 32 6V-0029 Roll Pin Depth Gauge Tool2
21 3P-1544 Pin 33 6V-3071 Seal Guide2
NOTE: The 5P-4226 Adapter was replaced by the 5P-6602 Adapter, which is required for 3208 Engines with EGR systems.
1 Tools
which must be procured to convert the 3P-1550 Tool Group to the 5P-4203 Tool Group. The 3P-1567 Indicators from former 3P-1550 Tool Groups
must have the 5P-4228 Spring and 5P-6531 Contact Point installed. Some 3P-1567 Indicators had 5P-4809 Points, 50,8 (2.0 in) long.
2 Not included in early 5P-4203 Groups
3 FT1632 Bolt is made from 2H-3740 Bolt. Refer to following article.
The following parts which, were in the 3P-1550 Tool Group,

should be retained in case of the possible need for dynamic
checking of sleeve shaft movement:
3K-6896 Gasket 3P-2202 Gasket
2P-8331 Cover 7B-2742 Bolt
2P-8333 Cover Assembly 0S-1616 Bolt
3P-1543 Gasket 4F-9676 Basket
3P-1569 Point
TSPG 2002 2-297

FT1632 Bolt
SMCS Code: 1256-010
Model: D5B, D6D, D7G, 225B, 225B-3208, 229-3208, 3208, 518, 613C
Warranty: None
• Fabricated by modifying 2H-3740 Bolt in 5P-4203 Field Service Tool Group

• Used to remove 4N-2954 Sleeve modification prevents damage to threads
ID: il2, B55834T1
3P-2200 Sleeve Metering Calibration Tool Group

SMCS Code: 1250-025, 1251-082
• Used for calibrating (similar to lifter setting) sleeve metering fuel pumps in shop
• Several tools from 5P-4203 Tool Group also needed for this operation
• Metric tools; values for testing and adjusting are given in metric terms, with exception
of torque values and pressures
Reference
Additional tools from 5P-4203 Tool
Group required for pump calibration
Item Part No. Description ID: ph2, A35113-1T1
1 8S-2243 Wrench Item Part No. Description
2 5P-6602 Adapter 1 7W-8120 Bushing
3 5P-4205 Wrench 2 1P-7379 Microgauge
4 5P-4206 Wrench 3 3P-1568 Indicator
5 1D-4533 Bolt 4 6V-3186 Collet
6V-3185 Base
6 1D-4538 Bolt
5 5P-6510 Box Assembly
7 5P-4209 Gauge
6 1S-9836 Wrench
8 8S-7271 Screw
7 3P-1546 Pin 15,9410
9 2P-8264 Socket
8 3P-1545 Pin 17,3734
10 6V-0190 Clamp (two)
ID: ph2, A33381-1T1 9 3P-1540 Pump assembly
10 5P-6557 Spring (Part of 3P-1540)
5P-3516 Reaming Tool Group 6V-4164 Driver

SMCS Code: 1253-017
Model: 225B, 225B-3208, 229-3208, 3208, 613C 6V-4163 Bit
SMCS Code: 1250-010
• Used to ream 5P-4810 Camshaft Bearing when front bearing requires
replacement in sleeve metering fuel system pump housings
• Capable of applying torque required to remove and install mounting bolts
for later 8N-2663 Flyweight Carrier in sleeve metering fuel systems
ID: ph2, B11831-1T1
Item Part No. Description Item Part No. Description

ID: ph2, A15401T1 1 5P-3515 Reamer 1 6V-4164 Driver, 1/4 inch Hex, 3/8 inch square drive
Reference
2 5P-3057 Fixture Assembly 2 6V-4163 Bit, 1/4 inch and 1/8 inch hex
2-298 TSPG 2002

5P-6577 Fuel Setting Tool Group Item Part No. Description

SMCS Code: 1251-010, 1250-025, 1250-036
1 1D-4533 Bolt
2 1D-4538 Bolt
3 5P-4205 Wrench
• Contains only those tools needed for checking and adjusting 4 3P-1544 Pin
fuel setting on engines with Sleeve Metering Fuel Systems 5 3J-6956 Spring
• All tools in this group also contained in 5P-4203 Field Service 6 5P-0299 Pin
Tool Group 7 5P-0298 Pin
8 5P-6602 Adapter
3P-1565 Collet
3P-1567 Indicator
8S-7271 Setscrew
5P-6531 Point (Part of 3P-1567)
9 5P-7319 Box
ID: ph2, A40950-1T1
Calibration Tools
SMCS Code: 1250-025, 1251-082 Reference
Model: 3208 Engines with Heavy Sleeve Metering Fuel System REHS0063 Special Instructions, Sleeve Setting
• Used to set, test, and adjust heavy sleeve metering fuel pumps — these tools are
not available as a group and should be ordered to supplement existing tool groups 5
1
• Used with 3P-2200 Sleeve Metering Calibration Tool Group, 5P-4203 Sleeve Metering
Field Service Tool Group, and 5P-6577 Fuel Setting Tool Group 2
11
10
90
80
20
• The 3P-1565 Collet, 8S-7271 Setscrew, and 3J-6956 Spring are required for this
0
70 0
1
3
10 90
1
19
60 4
28
0
0
3 6 5
7
9
1 2
20 80
4
0
8
5
37
46
operation and are part of 5P-4203 Sleeve Metering Field Service Tool Group
50
30
70
60
40
or 5P-6577 Fuel Setting Tool Group
6
• A 6V-6082 Bit, 5/64 Hex, part of 6V-4980 Torque Screwdriver Tool Group, is required
3
for 8S-7271 Setscrew to adjust the injection pumps 12
4
• 146-5068 Hex Key required for on engine adjustment for aftercooled engines 10 7
• All tools can be stored in a 6V-3073 Case. 6V-4094 foam (convoluted) is used in the
lid. Two foam blocks are required in the case bottom, 6V-4873 topped with 2P-8289 8
(convoluted). All foam is cut to fit the case. 9
ID: il2, C78491T1
3208 HSMFS Service Tools
Item Part No. Description Used with Used to
1 141-6727 Calibration Pump Assembly, 3208 HSMFS 3P-2200 Calibration Tool Group for sleeve lever setting Set sleeve lever position on control shaft during injection
pump assembly
2 141-6737 Adjustable Micro-Gauge 3P-2200 Calibration Tool Group for sleeve lever setting Preset sleeve lever position before final calibration (use a
4C-9508 Wicking Sealant to lock screw in place the first
time this gauge is used)
3 145-1853 Calibration Fixture 3P-2200 Calibration Tool Group for sleeve lever setting Hold calibrating and zero pins for rack setting and
5P-4203 or 5P-6577 for fuel setting adjustments positioning control shafts for sleeve setting (required for
all 3208 HSMFS and 3208 SMFS injection pumps)
4 3P-1565 Collet
5 Original Load Stop Cover Bolts
6 8S-7271 Setscrew
7 131-3459 Sleeve Holder Position sleeve during pump disassembly and assembly —
simplifies assembly and protects sleeve from damage
8 146-5068 Hex Key-Ball End
9 5P-4809 Point-Indicator
10 3J-6956 Spring
Service parts for 141-6727 Calibration Pump Assembly
11 5P-6557 Spring
12 8T-0116 O-Ring
Recommended but not shown
6V-3073 Case
6V-4094 Foam - Convoluted
6V-4873 Foam - Block
2P-8289 Foam - Convoluted
TSPG 2002 2-299

5P-7253 Socket Assembly

SMCS Code: 1250-025, 1251-082
• 3/8 inch drive socket assembly used with torque wrench during calibration of Sleeve
Metering Fuel System to apply torque specified for the bolts holding the levers on
sleeve shaft Item Part No. Description
1 5P-7252 Bit, 9/64 inch hex
ID: ph2, A50745-1T1
FT1525 Alignment Pin

FT1526 Fixture
FT1698 Driver
SMCS Code: 1264-005
Model: 3208
Warranty: None
• Used to salvage governor housings on 3208 Engines with Sleeve Metering Fuel Systems
• Provide accurate method for maintaining proper location when reworking throttle shaft
bushing bores; FT1525 Pin and FT1526 Fixture formerly used to rework only outer bore;
with addition of FT1698 Driver and a longer drill and reamer, both bores can be reworked
Reference ID: ph2, B51764-1T1

SMHS7760-01 Special Instruction
6V-4068 Cutter Tool Group

SMCS Code: 1253-083
Model: 3208
• Used to machine counterbore and clearance face on camshaft thrust surface of sleeve
metering fuel pump housing on early 3208 Engines; 9N-5822 Thrust Washer can then
be installed
• Request drawing of FT1556 Cutter for resharpening dimensions of 6V-4064 Cutter
Reference
SMHS7897 Special Instruction ID: ph2, B23865T1

1 6V-4067 Drill Bit 7 6V-4064 Cutter
2 6V-4066 Bushing 8 1B-8710 Key
3 2H-2525 Spring Pin 9 6V-4063 Arbor
4 6V-6117 Bushing 10 3B-1142 Retainer (two)
5 1B-4331 Nut 11 9M-5350 Spring
6 4B-5276 Washer 12 2M-0849 Washer
6V-4141 Sleeve Metering Calibration Tool Group

SMCS Code: 1250-082
Model: 3208
• Makes adjustment of sleeve levers easier on Sleeve Metering Fuel Systems

• When used with 6V-4980 Torque Screwdriver Tool Group, adjustment to sleeve levers
on 3208 Engine takes about 5 minutes instead of 15 to 30 minutes
• Formerly, tolerances on sleeve lever had to be exact to 0,002 mm (0.00008 in); it was
necessary to use 3P-2220 Calibration Tool Group to make an adjustment this exact;
tolerances were changed to 0,05 mm (0.002 in) with a maximum of 0,05 mm (0.002 in) Item Part No. Description
between each lever, and 6V-4141 Tool Group can make this adjustment accurately 1 6V-4137 Fixture Group
ID: ph2, B46661-1T1
and faster
2 3P-1545 Pin, 17,3734 mm
Reference 3 8T-0888 Washer
SMHS7835 Special Instructions 4 3P-1546 Pin 15,9410 mm
2-300 TSPG 2002

Tools for Reconditioning 3208 Engine Fuel Systems

SMCS Code: 1250-020
Model: 3208
Warranty:
• Save time and make reconditioning of 3208 Engine fuel systems easier
• Increased efficiency even when rebuilding one fuel system but developed for batch
processing parts when reconditioning as many as 6 fuel systems at same time;
some of fabricated holding fixtures designed to hold 6 parts

1 6V-7039 Driver
2 6V-7045 Hydraulic Puller
Includes:
5P-5247 Puller Assembly
4F-0925 Bolt ID: ph2, B77144
2K-0337 Locknut Item Part No. Description Item Part No. Description
5K-0405 Wheel
4 6V-7044 Gauge 10 6V-7042 Driver
1K-1465 Pin (four)
Includes: 11 6V-7036 Driver
7M-0320 Screw (two)
2L-4911 Pin
3 6V-7046 Hydraulic Puller 3L-5927 Ring 12 6V-7037 Driver
Includes: 13 6V-7033 Driver
5 6V-7064 Installer
5P-5247 Puller Assembly
6V-7764 Rod 6 6V-7034 Driver 14 6V-7032 Driver
2K-0337 Locknut 7 6V-7035 Driver 15 6V-7065 Installer
5B-4507 Plater (two) Includes:
7D-2347 Pin 8 6V-7038 Driver 6N-8793 Spring
7M-0320 Screw (two) 9 6V-7041 Driver 5H-6005 Seal
Fabricated Tools for Reconditioning 3208 Engine Fuel Systems

SMCS Code: 1250-020 Item Part No. Description
Model: 3208 1 FT1693 Holding Fixture
Warranty: None
2 FT1690 Holding Fixture
3 FT1691 Parts Basket
• Used to recondition 3208 Engine fuel systems
4 FT1692 Parts Basket
6 FT1730 Gauge (Weight)
9 FT1686 Remover Installer
10 FT1687 Socket
ID: ph2, B77145
6V-4830 Fixture Group Ultrasonic Cleaner Group

• Used for disassembly and assembly of unit injectors, and to check assembled • Available under either of 2 part numbers for different electrical power supplies
injectors for free rack movement • Components: tank with heater element and timer switch, basket, cover
(basket and cover made of stainless steel)
• No parts for this group are available
Item Part No. Description through Caterpillar parts system
1 5L-1100 Bearing
2 6V-4092 Socket
3 2N-7229 Spring
4 6V-4874 Screw
5 6V-4875 Stop
ID: ph2, B60824

ID: ph2, B44413T1 6V-6050 Ultrasonic Cleaner Group, 110 V, 60 Hz
6V-6060 Ultrasonic Cleaner Group, 230 V, 50 Hz
TSPG 2002 2-301

6V-6188 Cleaning Tray 6V-4822 Tip Driver

• Holds specific parts of unit injectors in groups while they are cleaned in • Used to separate tip assembly from nut during disassembly of injector
ultrasonic cleaner tank • Can be used as alignment tool during assembly
• Plungers, bushings, tips and needles arranged in sequence so that parts
which fit together and must be kept together can be cleaned but not mixed
• Tray fits in tank of either ultrasonic cleaner group
ID: ph2, B63740 ID: ph2, B60352
6V-6056 Seal Guide

SMCS Code: 1250-012
• Used to install nut-to-body seal in injector body

• Prevents damage to seal during installation over threads on body
ID: ph2, B60361T1
149-2955 Seal Protector

149-2956 Backup Ring Installer
SMCS Code: 1290-012 SA 149-2956
Model: 3126B Engines
• Used to quickly install stiff O-ring and both backup rings in top groove of HI300 injector
• Prevents steel backup ring from deforming or damaging injector case during ring
installation

Overall length 121 mm (4.76 in)
Outside diameter (large end) 40.0 mm (1.58 in) 149-2955
Inside diameter (large end) 37.6 mm (1.48 in)
Inside diameter of taper 25.2 mm (.99 in) ID: il2, C78582T1
149-2956 Backup Ring Installer

Overall length 105 mm (4.1 in)
Inside diameter 40.75 mm (1.60 in)
Service part 5F-9657 O-ring Seal
2-302 TSPG 2002

192-5092 Removal Tool 180-0186 Removal Tool

SMCS Code: 1250-011, 0701, 0706 SMCS Code: 1250-011, 0701, 0706
Model: 3126B Engines Model: 3126B HEUI Engine
• Used to easily separate hose from fitting • Used to quickly and easily separate 175-3236 High-Pressure Hose from fitting
• Used on #10 fitting on 192-2963 Oil Supply Hose on HEUI high-pressure pump • Insert beveled edge between fitting collar and hose collar. Hose should
• Separates fitting from hose collar (insert beveled edge between hose collar release from fitting.
and fitting)
• For #6 fitting use 180-0186 Hose Tool
ID: il2, C80067T1 ID: il2, C79847T1
185-3213 Seal Positioner

187-5524 Seal Installer Group 187-5523
SMCS Code: 1290-012
Model: 3126B Engines (serial numbers 7AS0001 to 7AS75000)
Essential Tool
• 187-5523 and 187-5524 used to install 185-2161 Seal on 3126B HEUI Injectors
• 185-3213 used to slide seal into final position
• 187-5523 Seal Protector has a very thin and delicate edge that could damage a seal 187-5524
185-3213
if dented. For storage it is recommended that 187-5523 Seal Protector be stored
in the 187-5524 Seal Installer Group.
ID: il2, C80012T1
185-3213 Seal Positioner 187-5523 Seal Protector 187-5524 Seal Installer Group
Overall length 156 mm (6.1 in) Overall length 116 mm (4.6 in) Overall length 127 mm (5.0 in)
Thickness 3.2 mm (.13 in) Outside diameter (large end) 37.7 mm (1.48 in) Outside diameter 44.5 mm (1.75 in)
Width at wide end 63.5 mm (2.50 in) Inside diameter (large end) 32.5 mm (1.28 in) Inside diameter 38.1 mm (1.50 in)
Width at narrow end 25.4 mm (1.00 in) Inside diameter at taper 12.7 mm (.50 in)
Recommended but not included

Reference
REHS0184 Special Instruction, Removal and Installation
148-5675 Plastic Case Instructions for the 3126B HEUI Injector
8S-5675 Foam Block (cut to fit)
152-1057 Injector Installer

SMCS Code: 1250-012, 0700, 0701, 0703, 0706
Model: 3126B Engines, C-9
Essential Tool
1
2
• Used to push injector into bore (attaches to rocker shaft bolt)

• Used with 1/2 inch drive ratchet
• Lever action provides fast and easy installation 3
• Eliminates injector damage which can occur when using other installation methods
• Injector installers built after 9/00 will have a moveable leg allowing it to be used
on the C-9 injector.
• A 191-6077 Attachment Bracket for the injector installer is also needed for the C-9.
• Injector installers built before 9/00 can be modified per the FT2726 print available ID: il2, C80146T1
from CSTG. The 191-6077 Attachment Bracket is still needed for the C-9 injector. 1 152-1057 Injector Installer
• The 152-1057 comes with the attachment bracket used on the 3126B. 2 3126B Bracket
3 191-6077 Attachment Bracket
TSPG 2002 2-303

6V-4808 Tip Tester Adapter Group

SMCS Code: 1254-082
1 6V-4807 Nut
• Installed in tester like a complete injector 2 6V-4806 Body
• Permits tip assembly to be checked for leakage, valve opening pressure, 3 6V-1250 Seal
and spray pattern 4 6F-0722 Seal
ID: ph2, B60365
6V-4809 Rack Weight Cup

SMCS Code: 1250-084
• Used during test for free rack movement

• Weight of cup is 22,68 g (.8 oz), maximum permissible weight that can be added
to rack during test
ID: ph2, B60334T1
9U-5132 Timing Tool Group

SMCS Code: 1250-036
Model: 3500 EUI and MUI Engines
• Replaces discontinued 6V-7880 Tool Group (to upgrade 6V-7880 to 9U-5132, • 136-4587 Collet Extension and 136-4588 Collet Extension can also be used
order 6V-3072 Plastic Case, 9U-5138 Set Gauge, 9U-5233 Timing Fixture, with this tool group (use 136-4587 for 9U-6273 and 136-4588 for 122-0449)
9U-5136 Foam Insert, 129-8602 Solenoid Nut Driver, and Decal NEEG2515)
• Used to test and adjust fuel systems, including fuel timing, rack Reference
synchronization, and fuel setting NEHS0666 Tool Operating Manual
• Tool group can be used for both MUI (Mechanical
Unit Injector) and EUI (Electronic Unit Injector) engines Set gauge step Rod sleeve extension Timing fixture rod assembly
For EUI engines use 64.34 mm (2.533 in) 122-0449 122-0451 [124.0 mm (4.78 in) long]
For MUI engines use 87.00 mm (3.425 in) 9U-6273 9U-5220 [181.0 mm (7.12 in) long]
16 Item Part No. Description

12 14 4 5P-7263 Contact Point, 76.2 mm (3.00 in)
18
1 5 9S-8883 Contact Point, 12.7 mm (.50 in)
S
B
A
R
E
V
.
IN
C
.
90 0
6 4C-8753 Extended Collet
10 10
ON
/O
FF
90
in
/m
m
/A
BS
80
20 20 7 8T-2684 Rack Synchronization Gauge, 12.7 mm (.50 in)
17
/ -
ZE
RO
80
13
+
ET
ES 1 0 1
PR
70
30
30
8 6V-7918 Wrench, 5/8
0
1 0 9
9 1
28
37
28 70
37
6
60 4 5 6
4
40
5
40
50 60
9 8S-3675 Contact Point, 3 mm (.12 in)

15 10 129-8602 Solenoid Driver
2 3 7 11 9U-5138 Set Gauge
13 9U-6273 Rod Sleeve Extension2
4 14 9U-6272 Nylon Screw2
5
17 122-0449 Rod Sleeve Extension2
Optional Tooling
9 6 12 1U-8869 Digital Dial Indicator
15 5P-4814 Clamp Collet
11
16 136-4588 Collet Extension
18 136-4587 Collet Extension
8 10 Not shown
5P-4160 Contact Point, 19.0 mm (.75 in) (for digital indicator)
9S-9082 Engine Turning Tool
ID: il3, C78471T1
122-0451 Extension Rod Assembly
9U-5220 Extension Rod Assembly
1 6V-3075 Metric Dial Indicator
9U-5136 Foam Insert
2 9U-5137 Timing Fixture1
6V-3072 Plastic Case
3 5P-7276 Container 1 Part of 9U-5233 Magnetic Fixture Group
2 Additional tooling required, but not part of 9U-5132
2-304 TSPG 2002

Collet Extensions
SMCS Code: 1250-036
Model: 3500 and 3500B Engines
• Used to hold a dial indicator in 9U-5233 Fixture Group with 5P-4814 Collet Clamp
and two (2) 6V-7918 Collet Wrenches
• Released to provide an alternative to the nylon screw-type indicator mount
• Use 136-4587 Extension-Collet with 5P-4814 Collet-Clamp, instead of 9U-6273
Rod Sleeve Extension, to check and adjust fuel timing on 3500 MUI Engines
• Use 136-4588 Extension-Collet with 5P-4814 Collet-Clamp, instead of 122-0449
Rod Sleeve Extension, to check and adjust fuel timing on 3500B EUI Engines
ID: il2, C55104T1

Part No. Description Overall length Diameter Extension length External thread Internal thread
136-4587 Collet Extension 56.5 mm (2.22 in) 19 mm (.7 in) 47.0 mm (1.85 in) 7/16-20 3/8-16
136-4588 Collet Extension 23 mm (.9 in) 19 mm (.7 in) 13.5 mm (.53 in) 7/16-20 3/8-16
6V-6999 Lapping Plates

SMCS Code: 1250-070
• 3 lapping plates assembled in 6V-7011 Lapping Plate Case make a complete lapping set
• Lapping set permits distribution of lapping work between the 3 plates
• Makes it possible to lap plates against each other to make them flat after a period of use
• All parts need to be ordered separately
1 6V-7011 Lapping Plate Case
2 6V-6999 Lapping Plate
(pkg. quantity. 1 each) ID: ph2, B60375
3 6V-7151 Lapping Compound
6V-7151 Lapping Compound

SMCS Code: 1250-070
• Recommended to lap flat surfaces of parts used inside unit injectors

• Soluble (can be mixed with) in either solvent or water, and can be washed off with water
• Easier to use and to remove than 8S-2259 Compound, part of 8S-2245 Tool Group for pencil-type fuel nozzles,
which will give an acceptable surface finish and can be used if desired
• In dispenser-type container (squeeze bottle)
• Contents: 0.454 kg (16.0 oz)
1U-9395 Plate
1U-8701 Socket
SMCS Code: 1254-010
• Used with 6V-4830 Fixture Group and 6V-4822 Tip Driver to remove and install nozzle
on type 2 3500 Engine unit injector (Type 2 unit injectors are described in Jan. 1987
Engine News as those with two-piece follower.)
• Make it possible to replace nozzle assemblies that plug or fail; with 1U-9395 Plate
installed on 6V-4830 Fixture Group, injector can be held properly to remove and install
nozzle assembly ID: ph2, C23727T1
• Early nose cones on type 2 injectors have serrations on cone that are damaged during
removal; 7C-9795 Replacement Cone available with a hex to tighten it; 1U-8701 Socket Reference
required to tighten cone when replacing nozzle SEHS8993 Special Instruction
TSPG 2002 2-305

128-8822 Fuel System and Governor Tool Group, 3114-3116

SMCS Code: 1290-036, 1298-036, 0706
Model: 3114, 3116, and 3126 Engines
Warranty: One Year
• Replaces discontinued 1U-6680 Tool Group Fuel Setting

• Used to simplify the required testing and adjusting operations
9U-7271 Governor Pin Assembly
• Allows more precise fuel system adjustments in significantly less time,
at less cost, than using previous tooling • Used to properly position injector control linkage relative to governor housing
face when making static rack power setting
• Improvements to tool group are described below
• Required for 1994 and later governors where calibration pin connection is not
accessible from rear of governor (also works for earlier version governors)
Timing
9U-7308 Magnetic Base Indicator Group 9U-7265 Governor Output Clamp Assembly
• Attaches directly to tappet on top of each unit injector • Used to hold calibration pin against governor housing face when checking
or adjusting static fuel setting
• Saves time — moves from cylinder to cylinder quickly and easily
• Works on all governors except ‘94 truck (“Type V”) and later
• Use with 9U-7274 Contact Point
• Prevents setting errors that can result from improper use of holding tool
1U-8869 Digital Indicator
136-4149 Governor Connection Sleeve Pliers
• Has a programmable preset feature
• Used to move linkage cover tube between governor and head to gain access
• Allows direct reading of published timing dimensions
to governor/rack linkage connection
• Used with the 9U-7269 Timing Gauge Block
• Pliers have more gripping force than former 6V-0006 Pliers (easier to move
Synchronization stubborn cover tubes)
• Pliers have self-locking feature of “Vice-Grip” type pliers
9U-7270 Synchronization Gauge Block • Coated with vinyl material to prevent damage to sleeve (refer to “Modifications”
• Used to set #1 injector to 3.5 mm rack (gives more accurate and consistent results) section for reworking older pliers)
220-0123 Synchronization Gauge Block
• Used to Set #1 injector to 3.0 mm rack (gives more accurate and consistent results) NOTE: 1U-6681 Holding Tool (not included) is still needed for some model governors.
9U-7276 Linkage Loading Assembly and 9U-7275 Linkage Tool Support The following list of tools is broken down into essential tools, recommended
• Used to hold linkage in synchronizing position for all cylinders tools and improved tools. Many tools used in the existing 1U-6680 Tool Group
• Allows both hands to be free when making adjustments are used again in 128-8822 Tool Group. See footnotes for status of tool.
• Provides more consistent results by applying a constant spring load to the linkage If desired, an older 1U-6680 Tool Group can be updated to a new 128-8822
9U-7264 Linkage Lever Tool Group by ordering those items with footnotes 1 and 2. Unless otherwise
specified, quantity required is one of each item.
• Used to actuate linkage when zeroing rack position at each injector

1 6
5 1 128-9640 Injector Synchronization Fixture Group
128-8706 Spring Plunger (serviceable part)
2 9U-7270 Sync Gauge Block
4 8
220-0123 Sync Gauge Block
3 9U-5120 Spanner Wrench (solenoid)
4 1U-8869 Position Indicator (Digital)
5 128-8823 Locking Long Nose Pliers 238 mm (9.375 in) long
10
3 9
[Early 128-8823 were 150 mm (6.0 in)]
2 6 1U-6675 Spring Compressor
15 16 7 8T-4177 Bolt (spring compressor)

8 9U-7282 Indicator Fixture Group
11 17 9U-6272 Nylon Screw (serviceable part)
14 9 8C-4984 Bolt, (indicator stand)
10 9U-7263 Contact Point [18.5 mm (.73 in) long
13 Fuel Timing Tooling
18 11 9U-7269 Timing Gauge Block
12 12 123-4940 Magnetic Base Group2
13 128-8824 Deep Offset Wrench (16 mm and 18 mm)
21 22
19 14 128-8825 Deep Offset Wrench (17 mm and 19 mm)
15 9U-7274 Contact Point [85 mm (3.35 in) long]
24
Miscellaneous Engine Tools
23 16 5P-0302 Bar (injector removal)3

25 17 123-4941 Valve Setting Gauge (feeler gauge for adjusting valves)3
20 18 1U-8013 Hex Socket Bit Driver, 5 mm3
ID: il4, D00332T1
2-306 TSPG 2002

Fuel Setting Tooling

19 130-2711 Fuel Setting Holding Tool
20 136-4149 Governor Connecton Pliers
21 128-8827 Fuel Setting Pin Assembly
22 1U-7523 Pin Insert Pilot (use with 128-8827 Pin Assembly)3
23 1U-7299 Adjustment (FRC) Wrench (“Type V” 1994 and later Trucks)
24 1U-7300 T-handle Wrench, 3 mm hex (“Type V” 1994 and later Trucks)
25 1U-6673 Injector Sync and FRC Adjust Wrench (all models except “Type V” 1994 and later Trucks)4
Not shown
6V-7145 Case
128-8828 Foam Insert Group
NEEG2688 Decal
1 Recommended or improved tools.

2 Some of the former 9U-7305 Groups used the new 123-4940 Magnetic Base; check your specific tool group.
3 Refer to the appropriate engine Service Manual for additional information on use of these tools.
4 159-1783 Fuel Ratio Control Adjusting Wrench is 51 mm (2 in) shorter than 1U-6673. Required for 3116-3126 Engines in Challenger 35, 45 and 55.
Modifications
128-9640 Injector Synchronization Plate
Installing 180-7956 Clamp Assembly Kit may interfere with 128-9640 Injector Synchronization Fixture Group during synchronization
procedures. Modify the injector synchronization plate by machining an additional 6.5 mm (.25 in) from plate. A 128-9641 Injector
Synchronization Plate can be purchased and modified, if desired. If a complete print is required, order FT2727.
1.5 x 45˚ MAX
m
21mm 21 min)
(.8
(.8 in) ina
l
Orig mm
ID: il2, C80078T1 . 5
27 .1 in)
(1
FT2727 Injector Synchronization Plate
Remove shaded area, as shown.
ID: il2, C80079T1
136-4149 Governor Connection Pliers

The 136-4149 Governor Connection Pliers can be used for inspection procedures as outlined in Special Instruction REHS0601,
if modified. Remove 10 mm (.4 in) of rubberized coating from tips of pliers to expose metal teeth. This modification will not affect
the original function of pliers, and it will allow pliers to fit onto rivet head.
Reference
NEHS0610 Tool Operating Manual, Using the 128-8822 Tool Group
SEBR0551 Service Manual, 3116 Diesel Truck Engine
SENR3583 Service Manual, Systems Operation, Testing and Adjusting,
Basic Engine Components — 3114 and 3116 Engines
136-4149
mm
10 in)
( . 4
ID: il2, C80080T1
TSPG 2002 2-307

1U-6680 Governor and Fuel Injection Adjusting Tool Group


1U-8702 Injector Timing Block 6V-0006 Electrical Connector Pliers
1U-6678 Fixture Group 9U-5120 Spanner Wrench
8T-0267 Socket Head Bolt 1U-6675 Injector Spring Compressor, 6 each
4C-4716 Injector Timing Fixture (8T-4177 Bolt)
6V-6106 Dial Indicator 1U-6672 Rack Adjusting Wrench
1U-8815 Dial Point 1U-6673 Fuel Ratio Control Wrench (FRC) Adjusting
3S-3268 Contact Point 1U-7523 Pilot Insert Pin

ID: ph2, C26895T1
1U-6679 Indicator Group (8T-7352 Bolt) 1U-7305 Insertion Tool
1U-9563 Offset Wrench Not shown
1U-8790 Nut Driver, 6 mm 4C-5851 Insert Group
6V-7918 Wrench, 2 each 5P-0302 Bar
1U-7563 Hex Wrench, 4 mm 5P-4814 Clamp Collet
1U-7564 Hex Wrench, 5 mm 6V-7145 Case

4C-5851 Foam Insert
1U-9563 Offset Wrench 9U-5129 Seal Remover

SMCS Code: 1105-025, 1272-025 SMCS Code: 1290-010; 0706
Model: 3114, 3116 Model: 3176
• Replaces discontinued 1U-8771 Offset Wrench • Used to remove copper combustion gas seal from unit injector tip on
• Special wrench required for adjusting valve lash and injection timing on 3114 3176 Engines
and 3116 Engine • Designed for quick removal without damaging injector; stretches copper seal
• Four necessary socket sizes — 16mm, 17mm, 18mm, and 19mm so it can be removed by hand (pliers or chisels would likely damage injector)
• Offset for clearing intake manifold • Has short chisel points that indent copper seal when tool is struck with small
• Has all metric socket sizes required to adjust valve lash on any 1.1 liter hammer; chisel points are shorter than seal thickness to prevent damage
engine; discontinued 1U-8771 Offset Wrench had 2 sizes, 17mm and 19mm; to injector
world standards for metric fasteners changed and affected 1.1 liter engine;
for example, early engines have 17mm and 19mm lock nuts; later engines
have 16mm and 18mm lock nuts; interim period of engines may have
combination of sizes of lock nuts; no special serial number break exists for
different size lock nuts
ID: il2, C27003T1
5P-2413 Air Regulator Assembly

SMCS Code: 4282-010
Model: 16G
• Enables use of shop air pressure to activate air-fuel ratio controls for checking Item Part No. Description
or setting fuel rack or rack limiter
1 3B-7262 Nipple
• Applicable to both mechanical and hydraulically operated controls
2 4H-0553 Adapter
Reference
ID: ph2, A04786T1
2-308 TSPG 2002

195-0761 Pressure/Vacuum Pump Group

SMCS Code: 4282-010
Model: 3000 Series Engines With Stanadyne Fuel Injection Pumps
Warranty: 5 year (see details)
• Used to check and adjust aneroid capsule

• Includes other accessories for general diagnostic, testing, and adjusting procedures
requiring vacuum or pressure
• Compound pressure gauge
• Hand-operated, no external power required
• Includes compact carrying case
Maximum vacuum at sea level -85 kPa (23 to 25 in Hg)

Single stroke volume 16.4 cu cm (1.0 cu in)
Maximum pressure unassisted 100 kPa (15 psi)
Maximum pressure assisted 175 kPa (25 psi)
Compound pressure gauge range 100 kPa (-30 mm Hg) to 200 kPa (30 psi)
Vacuum gauge accuracy -85 kPa (15 to 30 in Hg) 3% of full range
ID: il3, C80099T1

Warranty Information Repair Information
The pump is warranted to be free of all defects in material and workmanship Prism Enterprises, Inc.
for FIVE FULL YEARS from the date of original purchase. This warranty does 6952 Fairgrounds Parkway
not apply to any defects caused by negligence of the user, use of the product San Antonio, TX 78238
in any manner other than in accordance with the instructions provided with
Phone: (800) MITYVAC (648-9822)
the product, or damage caused by accidents. It also does not apply to gauges,
(210) 520-8051
which are warranted for a period of 90 days from date of purchase.
Fax: (210) 520-8039
A 196-2965 Repair Kit is available. Website: www.mityvac.com
FT1906 Air Test Kit

SMCS Code: 4282-010
1 or 2
Model: 16G
3 13
• Used to check leakdown rate of fuel-air ratio controller with engine at low idle 4 12
• Used to read dynamic fuel-air ratio control setting 14
• Used to adjust fuel-air ratio control setting 5
11
10
Item Part No. Description 6
1 9S-8138 Gauge or 2. 6V-7775 Gauge
9
3 3B-6768 Bushing
4 5P-4459 Elbow 5
7 6
5 5P-6011 Tubing, 3.7 m (12 ft)
6 5P-4405 Connector 8
7 6N-3169 Hose Assembly
8 8L-6557 Adapter
Fuel Ratio Inlet
9 Air Pressure Bulb, BAUMA NOMETER No. 1890 or equivalent Manifold
Control
10 5P-4476 Connector Connection Connection
11 6K-5741 Drain Cock ID: ph2, C79976T1
12 6V-6757 Elbow
13 7B-0192 Cross
Reference
14 Tubing, 1.2 mm (.4 in) latex, 6.35 mm (.25 in) inside diameter SENR5594, 3306B Engine
6V-9052 Piston Seal Guide

6V-9072 Piston Seal Guide
SMCS Code: 1278-016, 1278-017
Model: D40D, D400D, 3406, 3406B
• Used to help install piston assembly in fuel ratio control body
ID: ph2, B83727T1
TSPG 2002 2-309

FT1820 Assembly Fixture 159-0271 Solenoid Spanner Wrench

SMCS Code: 1278-015, 1278-016, 1278-017 SMCS Code: 1278-016
Model: Caterpillar Engines Model: 3208 Engine with Air/Fuel Ratio Control Override Solenoids
Warranty: None Essential Tool
FT1820 (Change No. 1) • Used to install solenoid

• Redesigned (simplified) combination of former
• Used with 3/8 inch drive torque wrench
FT1820 (Change No. 0) and FT1821 Fixtures
• For installation only — DO NOT USE TO REMOVE SOLENOID
• Inexpensive device used to hold fuel ratio controls;
fuel ratio controls are ackward
to hold during disassembly and assembly
ID: ph2, B83726T1

ID: il2, C79261T1
Square drive 3/8 inch
Solenoid torque specification 20 ± 5 N·m (15 ± 4 ft lb)
Torque wrench setting 16 ± 4 N·m (12 ± 3 ft lb)
1P-0087 Adjusting Wrench FT1585 Plate

Model: Caterpillar Engines with Woodward PSG Governors Model: 3300, 973, 973LGP
Warranty: None
• Required for removal and installation of speeder spring in Woodward PSG • Used for replacing worn governor spring guides in 8N-2500 Governor Housing
governors whenever adjusting pilot valve plunger control position on 3300 Direct Injection Engines with scroll fuel systems
• Used to control spring guide depth in governor housing; spring guide installed
so its end is 1,40 ± 0,25 mm (.055 ± .010 in) below surface of housing
ID: ph2, C05408T1
ID: il2, B24893T1
6V-0022 Governor Spring Guide Tool Group

SMCS Code: 1264-010
Spring
Engine Model Guide
3400 Series Std., 6.25 in, 5.75 in, 8M-8403
• Used to replace worn governor spring guides
5.4-6 Cyl., 4.5 in, 4.75 inch Bore
• With replacement guide, governor housing can with Scroll fuel system)
be reused with considerable cost savings
3400 Series Electric Set 4N-8140
• Engines with replaceable guides listed in chart
3300 Series 4N-4572
1100 Series 9L-9870
3400 Series Marine 6N-5373
1 6V-0017 Pilot
5.4 inch-6 Cylinder (later models) 3N-1168
2 6V-0020 Pin
3 6V-0021 Pin
4 6V-0019 Adapter
5 6V-0018 Adapter
Reference
6 6V-0023 Adapter SMHS7356 Special Instruction
ID: ph2, A73809
2-310 TSPG 2002

5P-7285 Adjusting Bracket

SMCS Code: 1264-025
Model: 3412
• Used with 3P-1565 Collet and 9S-0215 Dial Indicator to adjust speed droop on engines
equipped with Woodward PSG governors
ID: ph2, A38984
8T-3226 Ring Expander

SMCS Code: 1250-012
Model: 3300, 3406
• Used for ring expanding and seal protection on all 3300 New Scroll Fuel Systems and on all 3406 New Scroll Fuel Systems
• Primary function: expander tool used with 6V-2163 Spring Compressor to install 7N-8821 Retaining Ring on weight carrier shaft; upon compression of spring
assembly, 8T-3226 Ring Expander is inserted over end of weight carrier shaft; 7N-8821 Ring is then slid down over ring expander to its proper place on shaft
• Separate but important function: tool used to protect 4N-0820 Tachometer Drive Seal
when assembling rear governor housing by placing ring expander over weight carrier
shaft prior to assembling governor housing; rear governor housing that includes
tachometer drive seal is then installed by placing it over ring expander; pre-assembled
seal is protected from damage due to its position on housing; rounded top of ring
expander guides seal into its proper position on carrier shaft
ID: ph2, C27197T1 ID: ph3, C27198T1
8T-5223 Reamer
8T-5107 Fixture Assembly
SMCS Code: 1287-012
Model: 3406B
• Used to bore 8N-9679 Governor Housing on 3406B Engine to install 8N-3945 Bushing and to salvage terminal shaft (throttle) bearing bores
• Released as supplement to existing FT drawing for dealers who do not have facilities to make FT tool

8T-5223 Reamer, Same as FT1949
8T-5107 Fixture Assembly, Same as FT1950
FT1951 Bushing-Drill (Part of FT1950)
TSPG 2002 2-311

8T-3222 Governor Adjusting Tool Group

SMCS Code: 1264-082
Model: 3406B
• Socket handle assembly along with the 5P-4205 Wrench used to adjust high idle
on 3406B Engine while in the vehicle
• Remove high idle adjusting screw cover, install 8T-3222 Governor Adjusting Tool
Group over locknut, loosen locknut, adjust high idle screw using 5P-4205 Wrench
and retighten lock nut; remove tool group and replace cover on governor

1 9S-1719 Socket Handle
2 5P-4205 Wrench
ID: ph2, C54551T1
4C-4354 Applicator
SMCS Code: 1264-012
Model: 3114, 3116
• Required to install Waldes Truarc ring (9X-2315 Retaining Ring, Series 5139-18) on servo on the 3114 and 3116 Governor
• Truarc ring requires a special applicator for installation; 4C-4354 Applicator grasps ring in a recess on underside of tool and holds
it tightly under spring tension with an arm which extends over center section; tool angled so ring can be flattened to enter groove;
when prongs have cleared shaft and ring is locked in groove, applicator can be withdrawn easily
9S-8100 Fuel Transfer Pump Tool Group

SMCS Code: 1080-017, 1256-010, 1256-016, 1256-017, 1361-017
• Contains five tools for disassembly and assembly of fuel transfer pumps
• 9S-8096 Seal Installer Sleeve for water pumps is no longer part of this group; available separately
Reference Item Part No. Description

GMGO0578 Special Instruction
1 9S-8104 Press Fixture Assembly
2 9S-8109 Screw Clamp Assembly
3 9S-8102 Seal Tamping Tool Guide
4 9S-8099 Bushing Driver ID: ph2, A92587-1T1
5 9S-8103 Seal Tamping Tool
FT1069 Driver
SMCS Code: 1256-011
Model: 621
Warranty: None
• Used to remove seal and cage assemblies from fuel transfer pump on 621 Engine
ID: il2, C09474T1
Fuel Transfer Pump Assembly Tools

SMCS Code: 1256-016
Model: 3406, 3408, 3412
• Used for assembly of fuel transfer pump on 3406, 3408 and 3412 Engines

1 5P-2391 Seal Driver
ID: ph2, 88526T1

2 5P-2392 Seal Driver
3 5P-2394 Seal Tamping Tool Guide, Discontinued
2-312 TSPG 2002

6V-6169 Check ValveInstaller

SMCS Code: 1256-012
Model: 3204, 3304B, 3306B, 3406B Series Engines with New Scroll Fuel Systems (NSFS)
• Used to install check valves in fuel transfer pumps
ID: ph1, B83735T1
5P-7345 Gauge 1P-2385 Protractor Assembly

SMCS Code: 1259-017 SMCS Code: 1264-025, 5070-016
Model: 963, 963LGP Model: D10, D6H, D7G, D8H, 224, 977L
• Required to calibrate butterfly valve to solenoid on 3208 Engines equipped • Precision tool for measuring all governor linkage angles
with EGR (Exhaust Gas Recirculation) system • Used on any linkage assemblies that are adjusted
• 5P-6602 Adapter, which replaces 5P-4226 Adapter in 5P-4203 Tool Group and by “angle” method
5P-6577 Tool Group, also required for fuel setting on EGR equipped engines
ID: ph2, C09476T1

Reference
SMHS7188 Special Instruction illustrates Woodward Governor linkages including
1 8H-3127 Bolt 2 correct linkage dimensions and angles
ID: ph2, A46365
2P-8278 Fuel Flow Tube

SMCS Code: 1000-082
Warranty: One Year
• Install this tube in engine fuel inlet line to determine amount of air entrained in fuel
Reference
GMGO0825 ID: ph1, C05409T1
9U-6872 In-line Flow Sight 185-3630 Filter Strap Wrench

SMCS Code: 1250-044, 1258-044 SMCS Code: 0602
Model: 777C, 785B, 789B, 793B, D11N, and 994 Model: Caterpillar Engines
• Used to view fuel passing through fuel line during priming

on 3500 EUI Engines • Provides quick, efficient service when removing or installing all spin-on type
fuel and oil filters
• Also used to inspect fluid clarity for other applications
• Capable of applying higher torques
required on larger filters without
denting filter can
ID: il2, C55192T1

Length 75 mm (3.0 in)
Width across flats 35.05 mm (1.380 in)
Port size 1/2-14 NPTF ID: ph2, C05388T1
Construction brass with Buna N seals Item Part No. Description
Maximum working temperature 93° C (200° F) 1 6H-7378 Retaining Ring
Maximum working pressure 345 kPa @ 21° C (50 psi @ 70° F) 2 1P-0551 Spring Pin
TSPG 2002 2-313

Special Sockets for Fast Fill Fuel System Adapters

SMCS Code: 0706
Warranty:
Fast-fill fuel system adapters require special sockets

for their removal and installation
• 3P-2230 Socket used for Wiggins Adapter
• To remove and install Buckeye Adapter, order HG-190 Socket from Apex
Machine and Tool Co, 7659 S. Western Avenue, Chicago, IL 60620
ID: ph2, C09475T1

1 3P-2230 Socket
2. HG-190 Socket
ID: ph2, 66397T1
5P-7339 Lifting Plug Assembly

SMCS Code: 1273-010
Model: 631D, 631E, 633D, 637D
• Used with 6V-2157 Bracket for lifting 9D-1750 Fuel Tanks on 631D, 633D and 637D
Tractors (Make certain threads of lifting plug are fully engaged in fuel tank boss
and that tank is empty before lifting)
ID: ph2, A49300T1
1U-8869 Digital Dial Indicator

SMCS Code: 1250-025, 1264-036
Model: 3116, 994
• Intended primarily for engine fuel system and governor adjustments but can be • Entire head, with display, can be rotated 270° for ease of readability
used in virtually any location or application that requires AGD-2 Indicator • Power is supplied by two SR 44 batteries contained in indicator
• Can be used for any rack setting that is not greater than 12 mm (.470 in.); only • Additional features, such as use with remote printer and computers, described
a few engines, such as some 5.4 bore vee engines, have rack settings that are in instructions packaged with indicator
greater than 12 mm • 1U-8869 Indicator is similar in several ways to 8T-1000 Digital Position
• Especially useful for timing adjustments on engines with unit injectors Indicator but should not be considered interchangeable; 8T-1000 Indicator has
• Has 3/8 inch stem and can be used with standard 3/8 inch collets and brackets full one-inch (25 mm) travel, remote readout and dampened transducer which
• Can directly replace both inch and metric mechanical indicators if measuring allows it to be used for running rack reading; U8869 is less tolerant of vibration
task does not require more travel than 1U-8869 is capable of; replaces 6V-3075, than 8T-1000 and is intended primarily as a versatile replacement for
6V-6106, 9M-9268, 8S-2283, and 9S215 Indicators in most applications mechanical indicators
• Digital (LED) display which reads in either inches or millimeters—readings • Service Part: 3S-3268 Point
displayed to nearest .0005 in. or .01 mm
• Total travel of 12.7 mm (.50 inches) and can be zeroed at any plunger position
which allows 1U-8869 to read either positive or negative in either direction of
plunger travel
• Can be pre-set to read a specific number at a particular plunger position
• Pre-set feature especially useful for measuring or setting timing dimension
on engines with unit injectors (1.1 liter, 3500, 3600); pre-set feature allows
indicator to be set (off engine) to set gauge dimension; when indicator and
timing fixture placed on injector, actual timing dimension is displayed
ID: ph2, C26881T1
2-314 TSPG 2002

Toolmaker’s Ink and Ink Remover

SMCS Code: 1290-012, 0645
Model: 3176
• Used to check fit of injector nose cone to injector sleeve (poor fit can be corrected
by reaming before final installation)
• Also used in general layout work RE
MOVER
• Sometimes referred to as “layout blue” INK
Part No. Description Size INK
9U-6075 Toolmaker’s ink, aerosol spray 340 g (12 oz.)
9U-6076 Toolmaker’s ink, brush-top can 222 mL (7.5 fl. oz.)
ID: il2, C66621T1
9U-6077 Toolmaker’s ink remover, aerosol spray 397 g (14 oz.)
FT2650 Vacuum Fuel Cap

SMCS Code: 0685-015, 0706
Model: 525, 527, and 545 Skidders
Warranty: None
• Used to minimize fuel loss when fuel system must be disassembled

• Special vacuum cap assembly can be installed in place of fuel filler cap
• Applying air pressure to 5P-0306 Vacuum Transducer produces a continuous
vacuum in tank
• With 3 to 5 kg/cm2 (50 PSI) air pressure applied, transducer uses 4.65 C.F.M.
of compressed air and pulls 8.75 C.F.M. of vacuum flow at 0 kg/cm2 (0 psi).
• Maximum of 406 mm (16 in) Hg is pulled at 5.6 kg/cm2 (80 PSI) or 254 mm (10 in)
Hg at 3 to 5 kg/cm2 (50 PSI).
ID: il3, C79622T1
171-1085 Bolt Remover Kit

171-1088 Torque Screw Locknut Wrench
171-1089 Idle Adjustment Locknut Wrench
SMCS Code: 1264-017, 0602-017, 0706
Model: 3054 and 3056 Engines with Stanadyne Pumps
Essential Tool
171-1085 Bolt Remover Kit NOTE: Use of these tamper resistant fastener tools is subject to Environmental
• Replaces discontinued 154-7151 Bolt Remover Kit Protection Agency (EPA) regulations. Read warning sheet included with each kit
before using these tools.
• Used to remove and install tamper resistant bolts on Stanadyne fuel injection
pump and aneroid shield
• Used with 1/4 and 3/8 inch square drive ratchets
• Used on 5YS, 7MS, 2PW, 3GW serial number engines
• Includes longer 15IPR Torx bit for adjusting torque and idle screw
171-1085
171-1088 Torque Screw Locknut Wrench
• Used to loosen and tighten the torque screw locknut
• Used with 1/2 inch open end wrench and 1-1/2 inch long 15IPR Torx bit
171-1089 Idle Adjustment Locknut Wrench

• Used to loosen and tighten the idle adjustment locknut 171-1088
• Used with open end wrench and screw driver
171-1089
ID: il2, C79387T1
TSPG 2002 2-315

173-9774 Bolt Remover

SMCS Code: 1264-017, 0602-017, 0706
Model: 3054 Engine, serial number 5HK Used in 914G and 1T14G
Essential Tool
• Used to remove and install tamper resistant fasteners used on fuel injection pump
access cover
• Hex shank bit fits standard 3/8 inch hex socket
• Use of this tool is subject to EPA regulations. The sale of this tool is intended
for internal Caterpillar Dealer use by qualified mechanics.
• Fastener torque: 22 N·m (16 lb ft)
ID: il2, C79742T1
Overhaul Tools for 144-0835 High-Pressure Pump

SMCS Code: 1304-017 A
E
Model: 3408E and 3412E HEUI Engines (7PR, 4CR) B
Essential Tool F
Warranty: None
• Used to overhaul 144-0835 High Pressure Oil Pumps C

G
Reference
REHS0192 Special Instruction
Part No. Description H

D
FT2606 Yoke Fixture
ID: il2, C66977T1
FT2607 Bearing Press Tool (2 required)
FT2606 Yoke Fixture made from SAE1018 Steel
FT2608 Rear Bearing Installation Tool
Item Size
FT2609 Valve Block Positioning Tool
A 66 mm (2.6 in) square
FT2610 Front Bearing Remover
B 33.00 ± 0.13 mm (1.299 ± .005 in)
FT2611 Front Bearing Support (HEUI)
C 33 mm (1.3 in)
FT2612 Rear Bearing Remover
D 5.00 +0.25 / -0.10 mm (.197 +.010 / -.004 in) diameter hole thru; Pilot drill hole to 25 mm (1.0 in) minimum
depth; machine 27.25 ± 0.01 mm (1.073 ± .001 in) diameter to 20.7 mm (.81 in) minimum depth
E 61.5 mm (2.42 in) minimum
F 20.5 mm (.81 in) minimum
G 50.5 ± 0.1 mm (1.99 ± .004 in) diameter
H 2.0 ± 1.0 mm (.08 ± .04 in) x 45 degrees
C FT2607 Bearing Press Tool

Item Size
Item 1 made from steel
B
A 8.20 +0.15 / -0.08 mm (.323 +.006 / -.003 in) diameter; 3/8-16-2B thread;
E 11.0 ± 0.5 mm (.43 ± .02 in) counterbore diameter; 28.00 +0.25 / -0.13 mm
D (1.102 +.010 / -.005 in) to depth shown
B 1.5 mm (.06 in) maximum radius
C 0.25 mm (.010 in) maximum radius
A
D 50.40 ± 0.13 mm (1.984 ± .005 in) diameter
1 F E 40.00 ± 0.13 mm (1.575 ± .005 in) diameter
G F 4.5 mm (.18 in)
H
A G 1.98 ± 0.01 mm (.078 ± .001 in)
I H 11.5 ± 1.0 mm (.45 ± .04 in)
2 B
I 27.00 ± 0.13 mm (1.063 ± .005 in)
Item 2 made from 1L-0509 Screw
D A 19.05 mm (.750 in)
B 14 ± 1 mm (.55 ± .04 in)
C 3/8-16 thread
D 7.0 ± 0.5 mm (.28 ± .02 in) diameter
C
ID: il3, C66978T1
2-316 TSPG 2002

F FT2608 Rear Bearing Installation Tool made from steel

Item Size
E
A 31.80 +0.25 / -0.13 mm (1.252 +.010 / -.005 in) diameter to 38.1 mm (1.50 in)
D depth; 32.50 +0.25 / -0.13 mm (1.280 +.010 / -.005 in) diameter to depth shown
B 41.27 ± 0.13 mm (1.625 ± .005 in) diameter
C 0.25 mm (.010 in) maximum radius
B C G D 7.08 ± 0.05 mm (.279 ± .002 in)

E 1.0 ± 0.5 mm (.04 ± .02 in)
F 75 mm (3.0 in) minimum
G 48.26 mm (1.900 in) diameter
A J H H 12.7 ± 1.0 mm (.50 ± .04 in)
I
I 1.0 ± 0.5 mm (.04 ± .02 in) radius
ID: il2, C66980T1
J 30 ± 1 degree
B
C FT2609 Valve Block Positioning Tool made from steel
Item Size
A 70 mm (2.8 in) minimum diameter
B 31.8 mm (1.25 in) minimum
D C 6.35 ± 1.00 mm (.250 ± .039 in)
D 44.45 ± 0.13 mm (1.750 ± .005 in) diameter
E 1.0 mm (.04 in) maximum radius
F 1.0 ± 0.5 mm (.04 ± .02 in) x 45 degrees
A F E
ID: il2, C66981T1
Item Size
FT2610 Front Bearing Remover made from -24 steel hydraulic tubing
C
A 38.1 mm (1.50 in) stock tolerance diameter
B 3.4 mm (.13 in) stock tolerance
C 230 mm (9.1 in) minimum
FT2611 Front Bearing Support made from -20 steel hydraulic tubing
A 31.8 mm (1.25 in) stock tolerance diameter
A B
B 1.6 mm (.06 in) stock tolerance
C 63.5 mm (2.50 in) minimum ID: il2, C66982T1
B
FT2612 Rear Bearing Remover made from SAE1018 Steel
Item Size
A A 31.8 mm (1.25 in) stock tolerance diameter
B 75 mm (3.0 in) minimum
ID: il1, C66983T1
TSPG 2002 2-317

Pistons, Rings and Connecting Rods
5P-3519 Piston Ring Groove Gauge

SMCS Code: 1214-020, 1214-082
• Used to check top and intermediate ring grooves (rectanglar) to determine

piston reuseability
• Includes 6 plug-type gauges that cover all widths of top and intermediate
grooves (gauges numbered 1 through 6)
• Attached tag identifies gauges and their use

1 5P-4227 Tag Holder
Form SEES5544 Instruction Card
2 6V-3190 (#1) Gauge ID: ph2, A10746T2
6V-3191 (#2) Gauge
6V-3192 (#3) Gauge
6V-3193 (#4) Gauge
6V-3194 (#5) Gauge
6V-3195 (#6) Gauge
Also available for 3500 Engines
4C-4519 Gauge Assembly (not part of 5P-3519)
Reference
SEBF8049 Guideline for Reusable Parts
1U-6431 Gauge Group

SMCS Code: 1214-020, 1214-082
Model: 3406B
• Used for checking ring groove wear on 7C-0473, 7C-3496 and 7W-3668 Pistons found
in some 3406B Truck Engines beginning with 1985 production
• Replaces discontinued 8T-3150 Gauge Group; consists of 6 gauges from 8T-3150 plus
1U-6432 Gauge and revised SEES5678-02 Instruction Card; 1U-6432 and SEES5678-02
Instruction Card can be used to upgrade existing 8T-3150 Gauge Group
ID: ph2, B96702T1

1 8T-3144 Gauge Assembly
ID: il2, C66817T1
7 1U-6432 Gauge Assembly
Description
8 5P-4227 Holder SEES5678-02 Instruction Card
SEES5678-02 Instruction Card
9 6V-3196 Chain
Reference
Service Magazine, June 1, 1987, page 15; Truck Engine News, May 1987, Page 8,
“Use Correct Pistons and Rings for 3406B Truck Engines”
2-318 TSPG 2002

9U-7360 Ring Groove Gauge Group

9U-7359 Ring Groove Gauge
SMCS Code: 1214-082, 0763
Model: 3500 Family Engines
• Accurately checks piston compression ring groove for wear to determine if piston
may be returned to service
• Significantly reduces inspection time
• Checks single piece and two piece pistons
• High precision tool — gauge dimensions held to .01 mm (.0004 in)
• Comes in protective 6V-3037 Case with 9U-7358 Foam Insert
Reference
SEBF8059-03 “Procedure to Clean and Inspect One-Piece Pistons — 3500 Family of Engines” ID: ph2, C66639T1
9U-5931 Piston Ring Groove Gauge

SMCS Code: 1214-082; 0763
• Used to measure piston ring groove

• Checks top and intermediate ring grooves to determine piston reuseability
• Used on one-piece aluminum pistons: 7C-5668, 9Y-7452, 9Y-5536, 7E-1298,
7E-3428, 7E-3578
• Dimensions: 12,7 mm x 9,52 mm x 47,62 mm (.5 in x .37 in x 1.87 in)
ID: ph2, C27044T1
Piston Ring Groove Gauge Groups

SMCS Code: 1000-040, 0701, 0767
Model: See below
Essential Tool
Warranty: Manufacturer's
• Used to quickly and accurately check top ring groove in two-piece pistons for wear
(checks top ring groove only)
• Uses a simple Go/No-Go design (if piston passes through gauge it cannot be reused)
• Improves reliability of inspection and reduces inspection time
• Manufactured to high precision tool-tolerances
• Group includes gauge, storage case, and 186-0188 Foam Insert
• Gauge repair and recalibration done only by manufacturer (damaged blades can be
replaced and adjustable design allows gauge to be easily recalibrated)
ID: il2, C80552T1 Part No. Description Model
• Protective adjustment shields are sealed by manufacturer to prevent tampering
186-0190 Ring Groove Gauge 3126/3126B
• Tolerance: 0.01 mm (.0004 in)
208-7632 Ring Groove Gauge C-12, 3196
Reference 208-7636 Ring Groove Gauge C-16
NEHS0775 Tool Operating Manual 204-8041 Ring Groove Gauge 3500/3524B
NEHS0834 Tool Operating Manual, Using the 204-8041 Gauge Group on Pistons in the 3524B
and 3500 High Displacement Engines
TSPG 2002 2-319

Piston Ring Groove Gauges

SMCS Code: 1214-082, 0763
Model: 3114, 3116, 3176, 3200, 3300, 3400, and 3406E Engines
• Accurately check piston ring grooves for wear to determine if piston may be
returned to service
• Significantly reduces inspection time and improves reliability of inspection
• High precision tool — gauge dimensions held to .010 mm (.0004 in)
• If gauge passes through ring groove, piston is not reusable
• Foam inserts are available for protection of gauges
• 6V-3073 Case provides convenient storage and additional protection for
gauges
• Decals for 6V-3073 Case are also available for each gauge
ID: ph2, C66562T1

3114 and 3116 Engine (ring grooves, all one and two piece pistons)
4C-8164 Piston Ring Groove Gauge
4C-8172 Foam Insert
NEEG2634 Decal
3176 Engine (ring groove)
4C-8173 Foam Insert
NEEG2635 Decal
3200 Engine (top ring groove)
4C-8172 Foam Insert
NEEG2636 Decal
3300 Engine (ring groove)
4C-8172 Foam Insert
NEEG2638Decal
3400 Engine (top ring groove, one piece aluminum piston)
4C-8169 Piston Ring Groove Gauge1
4C-8173 Foam Insert
NEEG2639 Decal
NEEG2693 Card
3406E Engine (top ring groove, two piece piston with steel crown)
132-4389 Piston Ring Groove Gauge2
4C-8173 Foam Insert
NEEG2640 Decal
1 4C-8169 Gauge works with these pistons: 2 132-4389 Gauge works with these pistons:
0R-2725 7E-0489 7C-2888
9Y-9889 7E-0305 7E-6262
9Y-9156 7E-0292 116-1372
9Y-7212 7C-3406 119-2111
9Y-4944 7W-3668 168-4540
9Y-4004 2W-0865 150-6223
9Y-3116 1W-9372 180-7352
7E-8929 100-7403
7E-8885 108-2716
7E-8700 112-2876
7E-8656 113-6045
7E-7310 116-8152
7E-4367 116-8154
7E-0539 116-8155
7E-0525 117-5063
2-320 TSPG 2002

FT1022 Gauge
SMCS Code: 1214-012
Model: 1100, 3100
Warranty: None
• Used to determine if correct pistons and crankshaft have been installed

in 1100 and 3100 Series Engines
ID: il2, 57062T1
1U-7616 Compressor Group

SMCS Code: 1214-010, 1225-012
Model: 3500
• Band-type piston ring compressor used for servicing 3500 Series Engines
• Similar to former band-type 6V-4021 Ring Compressor Group—improvements allow
1U-7616 to provide better seating of band assembly on cylinder liner to minimize
possibility of ring breakage
• Has lock to secure compressed piston rings in place on piston
• Two handles for easier handling of piston, rings and rod assembly

1 1U-7615 Band Assembly
2 6V-4027 Handle Assembly ID: ph2, B83923T1
6V-4020 Expander Group

SMCS Code: 1214-010, 1225-011, 1225-012
Model: 3500 Item Part No. Description
1 6V-4024 Guide Ring
2 6V-4023 Handle Assembly
• Used to remove and install piston rings on 3500 Series Engines
ID: ph2, B14946
Piston Ring Expanders

SMCS Code: 1214-010
Warranty:
• Used to easily and safely remove and install piston rings

• When removing or installing piston rings without suitable tool, rings apt to be broken
or overstressed so they no longer fit cylinder wall properly
Engine Bore mm (inch) Expander Part No. Engine Bore mm (inch) Expander Part No.
5,40 (2.125) 2H-7099 130,2 (5.125) 9F-4917
9,53 (3.75) 7B-7977 133,4 (5.25) 7B-7975
101,6 (4.00) 5F-9058 137,2 (5.4) 7M-3978 ID: ph2, T96703T1
108,0 (4.25) 7B-7976 139.7 (5.5 149-7179
114,3 (4.50) 5F-9059 146,1 (5.75) 7B-7974
120,7 (4.75) 7S-9470 158,8 (6.25) 5H-9621
TSPG 2002 2-321

Piston Ring Compressors

SMCS Code: 1214-010
Engine Bore
• Simple, but practical, one-piece piston ring compressors save time and mm (inch) Compressor Part No.
prevent damage to rings when installing pistons in older engines 108,0 (4.25) 1U-6684
• Taper on inside is ground to a smooth surface so rings slide through easily 133,4 (5.25) 1B-7822
• 2B-8184 and 6H-4140 Compressors no longer available but may be 146,1 (5.75 2B-8184 1 or FT1400
fabricated by requesting drawings for FT1400 and FT1401 Compressors 158,8 (6.25) 6H-4140 1 or FT1401
• Scissors-type piston ring compressors used on more current Caterpillar 1 Discontinued
engines; much easier and faster to use; ring breakage and injury to fingers
practially eliminated
Typical One-Piece Ring Compressor

ID: il2, C79316T1
Scissors Type Ring Compressor

Engine Bore mm (inch) Compressor Part No.
105.0 (4.13) 187-1462
114.3 (4.50) 5P-3524
120.7 (4.75) 5P-3525
125.0 (4.92) 161-4163
130.1 (5.12) 161-4164
137.2 (5.40) 5P-3526
139.7 (5.5) 149-7180
145 (5.7) 200-3914
146.1 (5.75) 5P-3527
158.8 (6.25) 5P-3528
Typical Scissor-Type Scissors Type Ring Compressor
Ring Compressor (3126 and 3126B Engines)
110.0 (4.33) 173-5529
ID: il2, C79340T1
1U-6683 Expander
4C-3601 Ring Expander
1U-6684 Compressor
SMCS Code: 1215-012
Model: 3114, 3116, 3176
• 1U-6683 Expander used to expand piston rings to install them on piston

on 3114 and 3116 Engines
• 4C-3601 Ring Expander used to remove and install piston rings on 3176 Engine
• 1U-6684 Compressor used to compress piston rings to install piston into cylinder
on 3114, 3116 and 3176
• 1U-6684 Compressor capacity: 76.2 mm (3 in) to 127.0 mm (5 in)
ID: ph2, C26884T1
Reference
SENR3582, Specification Module
SENR3583, System Operation Testing and Adjusting
SENR3611, Disassembly and Assembly Manual
SEHS8868 Special Instruction, operation
ID: ph2, C26885T1

ID: ph2, C27127T1
2-322 TSPG 2002
7F-9303 Connecting Rod Wrench

SMCS Code: 1218-011
Model: D398, D379
• Used to remove connecting rod caps
ID: ph2, T97398T1
5P-3550 Connecting Rod Boring Machine

ID: il3, A29955T1
ID: ph2, A24199
Service Parts Locating Bushing

Item Part No. Description Part No. Connecting Rod Assembly
1 5P-2705 Plunger Extension, 12,7 mm (.50 in) New (Former) Part No.
5P-2013 Plunger Extension, 19,1 mm (.75 in) 5P-3543 (2H-8234) 5B-2058, 6F-4323, 6F-4325, FH5348
5P-2014 Plunger Extension, 28,5 mm (1.12 in) 5P-3542 (2H-8235) 5B-1447, 5B-1456, 6F-1952, 6F-3276, 6F-4318,
5P-2015 Plunger Extension, 38,1 mm (1.50 in) 6F-4319, 6F-4321, 9F-2326, 9F-2330, 4H-9733,
5P-2016 Plunger Extension, 47,8 mm (1.88 in) 8H-5322, 7M-4835, 4S-6867
5P-2017 Plunger Extension, 57,2 mm (2.25 in)
5P-2018 Plunger Extension, 66,6 mm (2.62 in) 5P-3539 (2H-8236) 5B-1919, 6F-4324, 6F-4326
5P-2019 Plunger Extension, 76,2 mm (3.00 in) 5P-3541 1 (7M-6030) 8H-9354, 3K-6142, 9L-6016, 9L-8369, 9L-9326,
5P-2020 Plunger Extension, 85,9 mm (3.38 in) 1M-1079, 4N-2218, 9N-8002, 5S-6360
2 5P-2012 Plunger Assembly 5P-3544 1 (1S-7999) 8F-9411, 3H-3109, 4L-3841, 4M-7573, 4M-9218,
3 5P-2022 Spindle Assembly 7M-4923, 4N-0371, 4N-0390, 4N-4339, 1P-0009,
1S-4618, 3S-8285, 9S-8492, 8N-1728, 7N-3229
4 5P-2010 Mandrel Body, 66,6-101,6 mm (2.62 in-4.00 in)
5P-2011 Mandrel Body, 101,6-139,7 mm (4.00 in-5.50 in) 5P-3538 1 (5S-9943) 9M-3980, 5S-2793
5 6H-9691 Seal 5P-3545 (7S-3102) 4N-4261, 4N-6018, 4N-9001, 4N-9002, 2P-2671,
1S-1862, 2S-1601, 9S-5455
6 5P-3555 Spring
1 Later
bushings have the tapered portion machined so that connecting
7 5P-3553 Bushing rods with tapered pin bearings can be properly located.
8 5P-3547 Boring Bar
5B-9318 Ball (Part of 5P-3547) Reference
9 5P-2055 Flexible Drive SMHS6870 Special Instruction
5P-5251 Flexible Coupling Assembly (Part of 5P-2055)
10 5P-2021 Clamping Shaft (two)
11 5P-3552 Bushing
12 5P-4376 Rod
13 5H-4051 Tool Bit, 35,0 mm (1.375 in) Carbide Tip
5H-4052 Tool Bit, 50,8 mm (2.00 in) Carbide Tip
14 5P-2023 Tool Bit Setting Gauge Assembly
5P-2056 Contact Point (Part of 5P-2023)
5P-2058 Dial Indicator (Part of 5P-2023)
15 Use the following locating bushing to center
the connecting rod in the boring machine.
TSPG 2002 2-323

5P-4777 Torsion Bracket

5P-4778 Feed Cylinder
SMCS Code: 1218-023
Warranty: 5P-4777 Torsion Bar: G
5P-4778 Feed Cylinder: M
• Make up hydraulic feed mechanism needed for use with 5P-3550 Connecting
Rod Boring Machine
• Can also be used on former 2H-6782 Boring Machines with or without
5P-2009 Rework Group
NOTE: Later bushings have tapered portion machined so connecting rods ID: ph2, A26474
with tapered pin bearings can be properly located.
9U-5945 Rod Locating Group

9U-5948 Expanding Segment Group (1.1)
SMCS Code: 1219-024, 0672
• Aligns 3114 and 3116 connecting rods in 5P-3550 Connecting Rod Boring Machine
prior to boring rod eye bushings
• 5P-3550 Connecting Rod Boring Machine is discontinued and not available from ID: ph2, C27038T1
Caterpillar
9U-5948 Expanding Segment Group (1.1): 1 9U-5948 Expanding Segment Group
• Consists of three 50.8 mm (2 in) long segments of split collet and an O-ring (consists of 3 segments and one 7T-0507 O-Ring)
(segments sold only as a group) 9U-5945 Rod Locating Group includes:
• Sold separately — not part of 9U-5945 Rod Locating Group 2 9U-5944 Expander Nut (2)
3 9U-5943 Bushing Locating Rod
4 9U-5946 Bushing
Not shown 9U-5947 Expander Cone
9U-5949 Expander Segments Group

SMCS Code: 1218-028, 0677
Model: 3500 Family Engines
• Used when replacing bushing/bearing in connecting rod

• Insures proper alignment of rod before boring of rod eye bushing
• Used with 9U-5945 Rod Locating Group and discontinued 5P-3550 Connecting Rod Boring Machine
• Three 50.8 mm (2.0 in) long segments of a split collet and two O-rings
• Service Part: 0S-0768 O-Ring
ID: ph2, C27045T1
2-324 TSPG 2002

5P-2050 Connecting Rod Checking Fixture

SMCS Code: 1218-082
Model: Caterpillar Engines except 3600 Engines
• Provides accurate method for measuring pin bore misalignment and rod distortion
on Caterpillar connecting rods (except those on 3600 Engines)
• Connecting rods can be checked before and after rebuild
• Checking fixture and related tools serviced individually to allow dealers to purchase
only tools needed for specific engines
• Required: 5P-2050 Checking Fixture, 5P-2051 Position Arm, 5P-2052 or 5P-2053 Crank
Mandrel; and appropriate pin mandrel and plunger assembly (listed in application chart)
Reference

1 Checking Fixture
2 5P-2054 Dial Indicator (part of 5P-2050) 2
5P-2057 Contact Point (part of 5P-2050) 2
3 5P-2051 Position Arm
4 5P-2052 Crank Mandrel, 101.6-139.7 mm (4.00 in-5.50 in) or
5P-2053 Crank Mandrel, 66.6-101.6 mm (2.62 in-4.00 in)
5P-2012 Plunger Assembly (part of 5P-2052 and 5P-2053)
5 Plunger Extension Assemblies (Refer to Application Chart) 9
6 Pin Mandrels (Refer to Application Chart) 25
ID: ph4, 82256T1
Application for 5P-2050 Checking Fixture

Plunger
Connecting Rod Crank Extension Pin Mandrel Pin Mandrel
Engine Series Assembly Mandrel mm (inch) Bushing In Bushing Out
1140, 1145, 1150, 1160 9L-8369, 9L-9326, 9N-0407, 5P-2053 5P-2013 5P-2030 5P-2041
3145, 3150, 3160, 3108 9L-6016, 9N-8002, 9L-6272 19.1 (.72)
D3, 910, 931, 3204 4N-2218, 6N-8012 5P-2053 5P-2013 5P-2030 5P-2041
19,1 (.75)
D311H, D320A 8H-9354 5P-2053 5P-2705 5P-2029 5P-2042
12,7 (.50)
944 (58A) 3K-6142 5P-2053 5P-2705 5P-2029 5P-2040
12,7 (.50)
1673, D330, D330A, 1M-1079 5P-2053 5P-2014 5P-2031 5P-2041
D333, D333A 28,5 (1.12)
1670, 1673, D330B, D333B 9M-3980 5P-2053 5P-2014 5P-2033 5P-2044
28,5 (1.12)
D330C, D333C, 1673C, D334 5P-2793 5P-2053 5P-2014 5P-2033 5P-2044
1674, 3304, 3306 28,5 (1.12)
D330C, D333C, 3304, 3306 5S-6360 5P-2053 5P-2014 5P-2031 5P-2041
28,5 (1.12)
D336, 1676 1S-2862 & 4N-6018 5P-2053 5P-2015 5P-2033 5P-2044
38,1 (1.50)
D4400, D4600 5B-1919 & 6F-4325 5P-2053 5P-2013 5P-2034 5P-2049
19,1 (.75)
D3400 5B-1919 & 6F-4326 5P-2053 5P-2013 5P-2032 5P-2045
19,1 (.75)
D315, D318 6F-4323 5P-2053 5P-2014 5P-2024 5P-2046
28,5 (1.12)
D311 6F-4324 5P-2053 5P-2013 5P-2041 5P-2048
19,1 (.75)
D337F, D326F 4H-5348 5P-2053 5P-2015 5P-2034 5P-2047
38,1 (1.50)
D326, D337 8F-9411 & 3H-3109 5P-2053 5P-2015 5P-2027 5P-2037
38,1 (1.50)
D343, 1693 4M-9218 & 3S-8285 5P-2053 5P-2015 5P-2027 5P-2036
38,1 (1.50)
3406, 3408, 3412 4N-0371, 6N-1828, 6N-3911, 5P-2052 5P-2017 5P-2027 5P-2036
4N-0390, 7N-3231, 7N-3229 57,2 (2.25)
641, 650, 651, 4M-7573, 4N-4339 5P-2052 5P-2016 5P-2027 5P-2036
657, 660, 666 66,6 (2.62)
TSPG 2002 2-325

Application for 5P-2050 Checking Fixture

Plunger
Connecting Rod Crank Extension Pin Mandrel Pin Mandrel
Engine Series Assembly Mandrel mm (inch) Bushing In Bushing Out
D346, D348, D349 4N-4261, 2P-2671, 4N-9001 5P-2052 5P-2016 5P-2027 5P-2036
9S-5455, 2S-1601, 4N-9002 66,6 (2.62)
D8800, D13000 6F-1952, 6F-4319, 9F-2326 5P-2053 5P-2016 5P-2028 5P-2039
47,8 (1.88)
D6100, D6600 5B-1447, 6F-4321 5P-2053 5P-2015 5P-2028 5P-2038
D7700, D11000 38,1 (1.50)
D353 4H-9733 5P-2052 5P-2017 5P-2026 5P-2039
57,2 (2.25)
D353E 7M-4923, 9S-8492 5P-2052 5P-2017 5P-2025 5P-2035
57,2 (2.25)
D339, D32 8H-5322, 7M-4835 5P-2053 5P-2016 5P-2026 5P-2039
47,8 (1.88)
D342 (31B-3985, 32B-2269) 4S-6867 5P-2053 5P-2016 5P-2026 5P-2039
47,8 (1.88)
D17000 5B-1456, 6F-4318, 9F-2330 5P-2052 5P-2017 5P-2026 5P-2039
57,2 (2.25)
D364, D375, D386, D397 6F-3276 5P-2052 5P-2019 5P-2026 5P-2039
76,2 (3.00)
D379, D398, D399 4L-3841, 1P-0009, 1S-4618 5P-2052 5P-2020 5P-2025 5P-2035
85,9 (3.38)
3500 8N-6020, 1W-4800, 7C-8608 5P-2052 5P-2018 8T-2842 8T-2841
66,6 (2.62)
9U-5917 Pin Mandrel, Bushing Out

9U-5918 Pin Mandrel, Bushing In
SMCS Code: 1218-082, 0767
• Used to check connecting rods

• Provides accurate method for measuring bore misalignment and rod distortion
• Rod can be checked before and after rebuild with rod eye bushing in or out
• Used with 5P-2050 Connecting Rod Checking Fixture, 5P-2053 Crank Mandrel,
and 5P-2013 Plunger Extension Assembly
• Length: 140 mm (5.5 inches)
• Composition: steel
ID: ph2, C27043T1
Tools for Connecting Rod Pin Bearing Removal and Installation

SMCS Code: 1218-010
Hydraulic Service Tools for use with 5P-8639 Press Group
• Used to remove and install both tapered and standard connecting rod pin bearings Part No. Description Quantity
• Basic 5P-8639 Press Group required for all engines in addition to other tools for each family 8F-0024 Hose 1
of engines; refer to table for hydraulic service tools for use with 5P-8639 Press Group 1P-2375 Coupler Assembly 1
• 5P-8655 Tool Group required for current engines with standard rods 1P-2376 Coupler Assembly 1
Hydraulic Pump (Electric or Hand) 1
Reference
Refer to table below to select appropriate hydraulic pump and for comparison
of hydraulic pump press time.
Loading and
Hydraulic Pump Press Time1 Unloading Total Time
Part No. Seconds Time Seconds Seconds
2P-5500/2P-5550 10-15 45 55-60
(Electric)
3S-6224/8S-8033 3-5 45 48-50
(Electric)
1 Press time will vary slightly with rod and tool size
2-326 TSPG 2002

Service Parts for 5P-8639 Connecting Rod Bearing Press Group (Basic)
1 5P-8640 Clamp Bar
2 5P-8641 Clamp Bar
3 5P-8643 Post Assembly
4 5P-8642 Clamp Pin
5 5P-9725 Cylinder Group (5P-9724 Repair Kit is available)
6 5P-0159 Cap (part of 5P-9725)
7 1P-2375 Coupler Assembly (part of 5P-9725)
1P-7437 Cap (part of 5P-9725)
Ï
ID: ph2, A64865T1
Service Parts for 5P-8655 Connecting Rod Tool Group (Standard)

1 5P-8663 Adapter
2 5P-8661 Spacer
5P-8662 Spacer
5P-8654 Spacer (also in 5P-8652)
5P-8647 Spacer (also in 5P-8644)
3 5P-8656 Adapter, D320 or 3204, 3208, D330 and 3300
5P-8657 Adapter, D330 and D330
5P-8658 Adapter, 1693, 3400
5P-8659 Adapter, D342, D353
5P-8660 Adapter, D353, D398
ID: ph2, A64864T1
Tools for Removing and Installing Tapered Connecting Rod Bearings

SMCS Code: 1219-010
• Following is a complete list of tools required for bearing removal and installation.
Use the application chart to select the tools for each engine connecting rod assembly.
Reference
1 5P-8653 Adapter 8 6V-3042 Adapter
2 6V-2049 Adapter 8T-5261 Adapter
3 6V-4819 Spacer 9 6V-3043 Spacer
4 5P-8650 Adapter 10 6V-3297 Spacer
5 5P-8645 Adapter 11 5P-8647 Spacer
6 5P-8646 Adapter 12 5P-8651 Spacer
7 5P-8649 Adapter 13 6V-3029 Spacer ID: ph2, B51372
Rod
Engine Rod Push R and L Bar Part No.
Model Assembly Adapter Spacer Adapter Clamp Position
D346 4N-9001 5P-8645 5P-8647 5P-8646 5P-8641 UP
D348 4N-9002 5P-8645 5P-8647 5P-8646 5P-8641 DOWN
D349 4N-4261 5P-8645 5P-8647 5P-8646 5P-8641 UP
2P-2671 5P-8645 5P-8647 5P-8646 5P-8641 UP
9S-5455 5P-8645 5P-8647 5P-8646 5P-8641 UP
3204 6N-8012 5P-8645 6V-4819 5P-8653 5P-8641 DOWN
3208 9N-3504 5P-8645 6V-4819 5P-8653 5P-8641 UP
3300 8N-1721 5P-8645 6V-3029 6V-2049 5P-8641
3400 7N-3229-6 5P-8649 5P-8651 5P-8650 5P-8640 UP
7N-3231-6 5P-8649 5P-8651 5P-8650 5P-8640 UP
8N-1726-9 5P-8645 6V-3197 5P-8646 5P-8640
8N-2486-9 5P-8645 6V-3197 5P-8646 5P-8640 UP
3500 1W-4800 5P-8649 6V-3043 6V-3042 5P-8640 DOWN
6° 8N-9647 5P-8649 6V-3043 6V-3042 5P-8640 DOWN
3500 8N-6020 4C-8725 4C-8726 4C-8727 5P-8640 DOWN
10° 7C-8608 DOWN
1.1 L 2W-9128 4C-9749 4C-9751 4C-9750 5P-8641
12.5°
TSPG 2002 2-327

1U-6242 Pin Bushing Adapter

1U-6244 Spacer
1U-6243 Push Adapter
SMCS Code: 1219-010, 0714
Model: 3176 Engine
• Used to remove and install piston pin bearing on 9Y-1170 and 4P-2232 Connecting
Rod Assemblies
• Used with 5P-8639 Press Group
• The base plate of the 5P-8639 Press Group must be modified in order to remove
and install the piston pin bearing. Drill and tap a 5/8-11 hole, 225.00 mm (8.858 in),
from the center of the largest bore. Refer to diagram.
ID: il2, C66704T1
Reference
ID: ph2, C66695T1
1U-9032 Pin Bushing Adapter

1U-9033 Spacer
1U-9034 Push Adapter
SMCS Code: 1219-010, 0714
Model: 3406E Engine
• Used to remove and install connecting rod pin bearing (9Y-6054 Connecting Rod Assembly)
• Used with 5P-8639 Press Group
• Specifically designed for connecting rods with 12° taper
Reference
ID: ph2, C66705T1
FT1888 Slide Hammer Adapter

SMCS Code: 1214-010
Model: 3208
Warranty: None
• Used with 1P-0074 Slide Hammer to install bolts

• Used to replace bolt without removing piston/rod assembly when connecting rod bolt
is damaged ID: il2, C80302T1
2-328 TSPG 2002

Reconditioning Connecting Rod Tools

SMCS Code: 1218-020
Warranty:
• Used to produce smoother surface finish (10 MU or less required) in piston pin bearing
when new piston pin bearing is installed in connecting rod and 4W-7402 Piston is used
• Smoother surface finish required only for new piston pin bearings
• 8T-2841 and 8T-2842 Pin Mandrel used with 5P-2050 Rod Checking Fixture
ID: ph2, B99645T1
to check bend, twist, and center distance
Reference 1 8T-3103 Buffing Tool Group
8T-3105 Buffing Wheel (service part)
2 8T-3104 Polishing Compound
3 8T-2840 Bushing Compound
4 8T-3171 Tool Bit
5 8T-3170 Set Screw
Not shown 8T-2841 Pin-Mandrel (Bushing Out)
Not shown 8T-2842 Pin-Mandrel (Bushing In)
139-9039 Snap Ring Pliers

SMCS Code: 1225-010
Model: 3400 Engines
• Used to remove specially designed piston pin retaining rings without holes such as 7E-5665 and 7E-1177
• Holds ring in tight clearance against piston pin
ID: il2, C66570T1
4C-8725 Pin Bushing Adapter 4C-9749 Pushing Adapter

4C-8726 Spacer 4C-9750 Bushing Adapter
4C-8727 Push Adapter 4C-9751 Spacer
SMCS Code: 1219-010, 0705 SMCS Code: 1219-010, 0705
Model: 3500 Family Engines with 7C-8608 (10°) Connecting Rod Assemblies Model: All 1.1 Liter Engines
• Allow 5P-8639 Press Group to be used to remove and install piston pin • Used to remove and install connecting rod bearings
bearings in 3500 Family Engines with 7C-8608 Connecting Rod Assemblies • Provides economical means to rebuild connecting rods
(10° taper on piston pin end)
• Fits rods with 10° taper
ID: ph2, C27027T1

Reference Reference
SMHS7295 Special Instruction SMHS7295 Special Instructions
ID: ph2, C54931T1
TSPG 2002 2-329

FT1571 Piston Storage Cabinet and Connecting Rod Assembly

SMCS Code: 0660
Warranty: None
• After reconditioning, piston and connecting rod assemblies must be covered with oil
and placed in a clean storage area; cabinet keeps these components clean and provides
good access
• Cabinet doors made of Plexiglass front and back permitting piston and rod assemblies
to be put into cabinet on one side and removed from other side
• Doors are fastened to rollers and slide past each other
• Clear Plexiglass keeps dirt out but permits service personnel to see how many
assemblies are available
• Rear of cabinet can be made from sheet metal if it is not necessary to enter cabinet
from both sides
• Size (H x W x D): 2134 (84 in) x 2159 (85 in) x 1219 (48 in)
ID: ph2, B44682T1
8T-7748 Polishing Wheel

SMCS Code: 0674
• Replaces discontinued 6V-6147 Polishing Wheel

• Scotch-Brite polishing wheel used to easily clean and remove discoloration from
Caterpillar piston pins
• Cleaning will not damage surface finish and makes it easier to determine if pins
are reuseable
Reference
ID: ph2, B60205
Parts Baskets for Handling Pistons and Piston Pins

SMCS Code: 0661
• Durable parts baskets for handling pistons and piston pins during reconditioning of
these components
• As dealers begin to process more piston and rod assemblies for exchange programs,
efficient material handling systems need to be used to reduce repair times and prevent
handling damage.
• Baskets especially useful because handling damage is one of major reasons that
pistons and pins cannot be reused
ID: ph2, B60772T1
• Baskets formed from heavy-gauge wire and dipped in plastisol coating
• Each piston and pin held in place and prevented from contact with each other
• Baskets can be used to hold pistons and pins during cleaning operation because
coating is resistant to heat and mild chemical cleaning agents often used in
agitating-type cleaners or hot spray wash cabinets
ID: ph2, B60778T1
Tool
Tool No Name Capacity Engine Models
6V-7004 Piston 8 3200, 3300 Series
Basket
6V-7003 Piston Pin 24 3204, 3208, D330C, D333C,
Basket 1673C, 3304, 3306, 1674, D334
6V-7099 Piston Pin 12 D342, D343, 1693, D346, D348,
Basket D349, 3400 Series
ID: ph2, B60771T1
2-330 TSPG 2002

Fabricated Tools for Use in Reconditioning Piston and Connecting Rod Assemblies
SMCS Code: 1214-020, 1218-020
Warranty: None
• Used when reconditioning large numbers (batch processing) of pistons and/or

connecting rod assemblies
• Make it possible to work on several pistons and/or connecting rod assemblies
at same time decreasing amount of time needed for reconditioning
ID: ph2, B74822T1

FT1694 Piston and Rod Disassembly Fixture
ID: ph2, B74823T1

FT1716 Bolt Installation Tool
ID: ph2, B74821T1

FT1765 Connecting Rod Holding Fixture
6V-6996 Induction Bearing Heater (110V, 60 Hz)

6V-7118 Induction Bearing Heater (220V, 50 Hz)
150-7723 Ring Heater
SMCS Code: 1215-012
Model: All Models
• 150-7723 Ring Heater replaces discontinued 1U-5454 Heater Ring • Handles parts from 20 to 280 mm (.8 to 5.1 in) inside diameter and material up to
• Used to heat bearings, gears, rings and bushings where a press fit is required; also 60 mm (2.4 in) thickness [A 150-7723 Ring Heater attachment increases capacity
used to heat tapered connecting rods before a replacement bushing is installed from 70 to 330 mm (2.8 to 13.0 in) inside diameter with a maximum thickness of
• Parts are heated by inducing low voltage and high current into the part 65 mm (2.5 in)]
• Heating time normally takes 30 to 60 seconds (depending on size) and temperature • Additional temperature detectors are available in the 10°C increments between
detector will automatically shut off heater when part reaches 60°C (140°F) and 170°C (338°F)
correct temperature [up to 110°C (230°F) standard detector] • Temperature detectors and timers are available from:
• If higher temperatures are required, the temperature detector should not be
Jergens, Inc. TODA, Inc.
attached to part (use a 164-3310 Infrared Thermometer, 9U-7043 Temperature
19520 Nottingham Road 12-23, 4-CHROME, GINZA,
Recorder Group, or similar temperature measuring device to obtain desired
Cleveland, OH 44110, U.S.A. CHUO-KU
temperature of part)
Phone: (216) 486-2100 Tokyo, 104, Japan
• Heater will demagnetize a part after heating cycle Phone: (03) 541-3961-5
or
Cable: TOBAYOOKOO, Tokyo
Telex: J27796, TOBAINC
TSPG 2002 2-331

Pistons, Rings and Connecting Rods / Camshaft and Timing Gear Tools
ID: ph2, B81099T1

ID: ph2, B06770-1T1
E
B A
150-7723
Ring Heater
Item Size C
C A 60 mm
F B 95 mm
A C 35 mm
D D 35 mm
150-7723
E 55 mm ID: il2, C78594T1
6V-6996 and 6V-7118 Heaters 6V-6996 and 6V-7118 Heaters
F 180 mm with 150-7723 Ring Heater without 150-7723 Ring Heater
Minimum inside diameter (A) 20.3 mm (0.8 in) 20.3 mm (.8 in)
B Maximum outside diameter (B) 157 mm (6.2 in) 112 mm (4.4 in)
ID: il2, C78593T1 Maximum thickness (C) 81.3 mm (3.2 in) 81.3 mm (3.2 in)
Camshaft and Timing Gear Tools
FT0751 Camshaft Alignment Sleeve

SMCS Code: 1210-010
Models: D379, G379, D398, G398, D399, G399
Warranty: None
• Used when installing camshaft

• Fits over tapered end of camshaft and guides it into position, minimizing possibility
of bearing damage
ID: ph2, C05374T1
131-1525 Camshaft Alignment Pilot Assembly Length 98 mm (3.9 in)

SMCS Code: 1210-010
Outside diameter 74.74 mm (2.943 in)
Model: C-10 and C-12 Engines
Stud M10 x 1.5 thread
• Used to remove and install camshafts (threads directly onto end of camshaft)
• Made from aluminum to prevent damage to cam bearings
• Two cross-drilled holes provide means of removing pilot assemblies after
camshaft is installed
• Two required—thread one into the other to make installation between engine
and firewall easier Reference
SENR1002 and SENR1007 Service Manual Modules
ID: il2, C66925T1
2-332 TSPG 2002

Camshaft Installation Tools

SMCS Code: 1202-012
Model: 3500
• Direct replacement for discontinued 6V-4019 Pilot Group; new tooling can be used
on all earlier engines
• When installing camshaft into camshaft bearings in cylinder block, it is necessary to
provide pilot/guide for camshaft to prevent damage to bearings; because of changes
in camshafts of 3500 engines, there are new installation tools that pilot camshaft
from both ends until camshaft is in place
• Designed so camshaft can be installed from either end of engine

1 8T-3167 Guide Assembly 1 ID: ph2, C07357T1
2 8T-3168 Pilot Assembly 2

3 8T-3169 Crank Assembly 1
4 8S-3887 Bolt, 1/2 inch 13 x 11 inch 4
5 4J-7945 Bolt, 3/4 inch 10 x 1-1/2 inch 2
6 0S-1617 Bolt, 5/16 inch 18 x 3/4 inch 2
7 0S-1594 Bolt, 3/8 inch 16 x 1 inch 3
Application Procedure
1. Use three 0S-1594 Bolts, finger tight, to install 8T-3167 Guide Assembly
on flywheel housing or front cover as shown
ID: ph2, C07359T1

3. Put engine oil on all bearings and camshaft journals. Install pilot and
camshaft through guide assembly until pilot is located in first bearing.
Tighten bolts on guide assembly while turning camshaft.
4. On 3508 Engines, complete the installation of the camshaft while
rotating camshaft. Remove tooling and complete engine assembly.
On 3512 and 3516 Engines, one end of separated camshaft is rotated
and installed as far as camshaft joint. Attach other end of camshaft
and complete installation while rotating camshaft. Remove tooling
ID: ph2, C07358T1 and complete assembly of engine.
2. Install 8T-3168 Pilot Assemblies and 8T-3169 Handle Assembly on camshaft
as shown. Two-piece camshafts should be separated for installation.
125-0200 Camshaft Pilot

SMCS Code: 1202-012
Model: 3500B Engine with Large Diameter Camshaft
• Used to remove and install 106-4584 Camshaft—simply threads onto end of camshafts
and functions as a guide during installation or removal
• Used with 8T-3169 Crank Assembly to help rotate camshaft during engine assembly
and disassembly (use two 0S-1617 Bolts to attach crank assembly to camshaft)
• Length of pilot is designed to be supported by two camshaft journals at the same
time (prevents camshaft from dropping as it is installed through each bearing journal)
• Groove in end of pilot provides clearance for dowel pin in camshaft (eliminates
ID: il2, C66726T1
removal of dowel)
• Made from aluminum to prevent scratching or other damage to journal surfaces Item Part No. Description
• Diameter: 91.9 mm (3.62 in) 1 2P-1303 Taperlock Stud (part of 125-0200)
• Length: 305 mm (12.0 in) 2 0S-1617 Bolt (two required)
3 8T-3169 Crank Assembly
TSPG 2002 2-333

125-0201 Camshaft Guide Assembly

SMCS Code: 1202-012
• Used to install camshaft from either end of engine

• Reduces installation time and helps prevent camshaft bearing damage
• Used with front or rear housing in place (does not bolt to bare block face)
• Tube inside diameter: 91.98 mm (3.621 in)
ID: il2, C78578T1
Camshaft Removal and Installation Tools

SMCS Code: 1110-010, 0705
Model: 3406E Engines
• Used to remove and install camshaft in chassis

• Prevents damage to camshaft and bearings
• Provides way to lift camshaft without pinching fingers
Reference
SENR5580 Service Manual, 3406E Engines
ID: ph2, C55188T1
SENR6421 Disassembly and Assembly Manual
9U-7256 Guide Assembly (Item 1) 9U-7225 Camshaft Pilot (Item 3)

Tube (outside diameter x length) 102 x 195 mm (4.0 x 7.7 in) Material Aluminum
Plate (w x l x t) 205 x 296 x 9.5 mm (8.0 x 11.6 x .38 in) Rod (diameter x length) 84 x 85 mm (3.3 x 3.3 in)
Plate offset from end of tube 65 mm (2.5 in) Threaded stud (serviced by 3D-0490 Stud) 1/2 inch-13 x 1.0 inch
9U-7243 Alignment Sleeve (Item 2) 9U-7240 Camshaft Lifting Hook (Item 4)
Material Steel tube Handle (diameter x length) 25 x 120 mm (1.0 x 4.8 in)
Tube (diameter x length) 85 x 430 mm (3.3 x 17.0 in) Hook (diameter x length) 6.4 x 180 mm (.25 x 7.0 in)
9U-7257 Cradle Assembly (Item 5)
Rod (diameter x length) 40 x 140 mm (1.5 x 5.4 in)
Plate (w x l x t) 91 x 130 x 7.9 mm (3.5 x 5.0 x .31 in)
177-8003 Cam Tool Group

SMCS Code: 1000-010, 0700, 0701, 0703 1
Model: 3406E, 3456, C-15, C-16
3 4
• Used to remove camshaft through front or rear of cylinder head
5
• Used with three 6L-4697 Bolts to connect adapter to camshaft (not included)
2
• Used on many machines, cab over trucks, or when cylinder head is off for repair
• Saves time by allowing cam removal without removing other components
• Pilot sleeve simultaneously engages two cam bearings to guide cam without
damaging bearings — loosely assemble components to prevent tool
alignment problems
• To remove camshaft through front of cylinder head, screw only pilot sleeve into
opposite end of camshaft Item Part No. Description
• To remove cam through rear of head: 1) remove cam gear; 2) bolt adapter onto 1 177-8001 ID:Pilot
il2, Sleeve
C79803T1
camshaft; 3) screw pilot sleeve onto adapter 2 177-8002 Adapter
• Minimum pilot sleeve clearance between head and other components: 368 mm (14.5 in) 3 1F-7958 Full Nut
4 5P-8245 Hard Washer
5 3D-0472 Taperlock Stud
2-334 TSPG 2002

8S-2241 Camshaft Bearing Installation and Removal Group

SMCS Code: 1211-010
1 8S-8287 Thrust Bearing Assembly
• Used to remove and install camshaft bearings
in most Caterpillar Engines 2 8S-8288 Cone
• Each collet designed to handle bearing diameter 3 8S-8282 Collet Assembly
range listed in chart; replacement O-ring seals 4 8S-8284 Collet Assembly
used to retain collets also listed 5 8S-8285 Collet Assembly
6 8S-8289 Tube
7 8S-8293 Long Extension
Inner Diameter 8 8S-8281 Tool Box
Size Range Replacement
Collet No. mm (inch) 0-Ring Seal 9 8S-8291 Threaded Shaft
1P-0552 28,58 — 38,10 4J-0520 10 8S-8290 Nut
(1.125 — 1.500) 11 8S-8884 Backup Nut
8S-8282 43,66 — 50,80 4J-0521 12 8S-8286 Screw Expander
(1.718 — 2.000)
13 8S-8883 Backup Nut
8S-8283 48,42 — 57,15 4J-0522
14 8S-8882 Backup Nut
(1.906 — 2.250)
15 8S-8881 Backup Nut ID: ph2, C05371T1
8S-8284 54,77 — 63,50 4J-0523
(2.157 — 2.500) 16 8S-8292 Short Extension (two)
8S-8285 60,33 — 69,85 4J-0524
(2.375 — 2.750)
5P-1666 Puller Plate

5P-1667 Spacer Tube
SMCS Code: 1211-010, 1253-017, 1230-010, 3258-017
Model: D379B, D398B, D399, 657E
• Used with 8S-2241 Group for camshaft bearing removal and installation on 6.25 inch
bore V Engines (two 8S-8292 Short Extensions and one 8S-8293 Long Extension
required from 8S-2241 Group)
ID: ph2, 77662T1
1 5P-1666 Puller Plate
2 5P-1667 Spacer Tube
3 8S-8292 Short Extension (two required) (part of 8S-2241 Tool Group)
4 8S-8293 Long Extension (part of 8S-2241 Tool Group)
1P-5545 Adapter Group 6V-4869 Adapter

SMCS Code: 1211-010, 1211-012
Model: 1100, 3100, 3208 6V-6174 Plug
SMCS Code: 1211-010
Model: 3400
• Used with 8S-2241 Tool Group to install camshaft bearings on 1100 and 3100
Series and 3208 Engines • Used with 8S-2241 Tool Group to remove and install camshaft bearings
in 3400 Series Engines
• 6V-4869 Adapter used for collet assembly
• 6V-6174 Plug used for cone
ID: ph2, C05376T1

1 0S-0509 Bolt
ID: ph2, B62643T1
TSPG 2002 2-335

125-2739 Cam Bearing Pilot

125-2740 Backup Plate
125-2741 Cam Bearing Sleeve
SMCS Code: 1211-010
• Used to remove and install two sizes of camshaft bearings — makes overhaul
much simpler and reduces chance of bearing damage during installation
• Used with 6V-4077 Camshaft Bearing Tool Group and 8S-2241 Camshaft Bearing
Installation and Removal Group
• Designed to trap camshaft bearing between camshaft bearing pilot
and backup plate — can be pushed (removed) or pulled (installed)
using 6V-4077 and 8S-2241 Tool Groups ID: il2, C66892T1 Larger diameter of pilot 97.9 mm (3.85 in)
• Install thin-walled bearings by placing 125-2741 Small diameter of pilot 85.9 mm (3.38 in)
Camshaft Bearing Sleeve over the camshaft
Outside diameter of sleeve 92.1 mm (3.63 in)
bearing pilot
• Parts are plated and hardened for durability
and long life
ID: il2, C66893T1
6V-4077 Camshaft Bearing Tool Group

SMCS Code: 1211-010 Item Part No. Description
Model: D11N, 3512, 3516, 777B, 785, 789, 994
1 6V-4011 Spacer
2 6V-4015 Pulling Bar
• Used with components of 8S-2241 Tool Group for manual 3 6V-4013 Screw
removal and installation of camshaft bearings i 4 2J-3506 Nut
n 3500 Series Engines 5 5P-8248 Washer
• Otherwise 5P-5247 Hydraulic Puller can be used 6 0S-1621 Bolt
7 6V-3177 Pilot Group
8 6V-4012 Plate
9 6V-4010 Pulling Plate
10 6V-4005 Spacer (two)
ID: ph2, B14941-1T1
129-6671 Reaction Sleeve

129-6672 Puller Plate
129-6673 Bearing Pilot
129-6673 Bearing Pilot
129-6674 Backup Plate Overall outside diameter 80.92 (3.186 in)
SMCS Code: 1211-010 Outside diameter of bearing pilot 74.850 (2.9469 in)
Model: C-10 and C-12 Engines
• Used to remove and install camshaft bearings

• Used with 8S-2241 Camshaft Installation and Removal Group, 0S-1629 Bolt, and 8M-8778 Taperlock Stud
• Tools can be used to remove or install camshaft bearings (for installation, assemble parts as shown in illustration)
• Large diameter of bearing pilot guides bearing into bearing bore on engine for easier installation
• Reaction sleeve is designed with clearance for bolts on engine front housing
2-336 TSPG 2002

Camshaft Bearing Tooling

1 129-6672 Puller Plate
2 129-6671 Reaction Sleeve
3 8M-8778 Taperlock Stud
4 129-6673 Bearing Pilot
5 Camshaft Bearing
6 129-6674 Backup Plate
7 0S-1629 Bolt
ID: il2, C66740T1
Not shown 8S-2241 Camshaft Bearing Installation and Removal Group
Reference
SENR1002 Special Instruction C-10 Disassembly and Assembly
SENR1007 Special Instruction C-12 Disassembly and Assembly
Camshaft Bearing Removal and Installation Tools

SMCS Code: 1111-010, 0703
• Used to remove and install camshaft bearing with head removed

ID: ph2, C55190T1
• Used with 8M-8778 Stud, 6V-4013 Threaded Screw, 8S-8292 Short Extension,
Overall dimensions
(2 required), 8S-8293 Long Extension, (2 required), 2J-3506 Nut, 5P-8248 Washer, Item Part No. Description (diameter x thickness)
5P-5247 Hydraulic Puller Assembly and hydraulic pump
1 9U-7210 Puller Plate 95.0 mm (3.75 in) x 19.0 mm (.75 in)
• Hydraulic force easily removes bearings and prevents damage during installation
2 9U-7223 Alignment Bushing 85.0 mm (3.30 in) x 32.0 mm (1.25 in)
Reference 3 9U-7222 Cam Bearing Pilot 90.0 mm (3.50 in) x 70.0 mm (2.75 in)
SENR5580 Service Manual, 3406E Engine 4 9U-7213 Backup Plate 108.0 mm (4.25 in) x 57.0 mm (2.25 in)
5 9U-7214 Spacer Plate 90.0 mm (3.50 in) x 4.0 mm (.16 in)
SENR6421 Disassembly and Assembly Manual
132-3904 Camshaft Retainer

SMCS Code: 1100-010
• Used to hold camshaft in cylinder head during removal and installation

• Install retainer across camshaft bearing between two camshaft lobes
• Failure to use retainer can result in damaged camshafts (retainer is extremely
cost-effective when compared to price of new camshaft)
ID: il2, C66765T1
ID: il2, C66764T1
8F-3671 Gear Installation Group

SMCS Code: 1212-012
• Used with 6V-3160 Hydraulic Puller to install

camshaft gears and accessory drive gears Item Part No. Description
1 8F-3669 Spacer
2 8F-3667 Nut
3 6H-6988 Sleeve (D9 Tractor Only)
4 8F-3668 Nut
5 8F-3670 Stud; Make from 1U-7758,
1-1/8 inch-12-NF x 10.5 inch
ID: ph2, T97404-1T1
TSPG 2002 2-337

Gear Installation Tools Item Part No. Description

SMCS Code: 1207-012
1 1B-4210 Nut
Model: 933, 951, 955, 977
2 4M-3251 Adapter
3 Spacer
• Necessary only when installing accessory drive shaft with engine installed
in 933 Traxcavators and in 951, 955, and 977 Traxcavators with 4-1/2 inch
bore engines equipped with mechanical governors
ID: ph2, T97459
173-2021 Puller Group 193-9199 Socket Assembly

SMCS Code: 1000-011, 0700 SMCS Code: 1150-010, 0700, 0704
Model: 3300 Engine Model: C-15, C-16, C-17, and C-18 Engines
• Used to quickly and easily remove or install idler gear stub shaft with • T27 Torx socket fits special Torx cap screw on cam gear and idler access
a common slide hammer “peanut” cover and front gear housing
• Used with 1U-7600 Slide Hammer or similar tool with 1/2-20 threads • Square drive: 3/8 inch
• Helps eliminate damage to bore of cylinder
block and stub shaft
• Used by slipping cup over the stub shaft;
insert puller pin through side of cup
and oil feed hole in the stub shaft
• Inside bore diameter: 35 mm (1.38 in)
• Service Part: 173-2023 Pin
ID: il2, C80070T1
ID: il2, C79789T1
8F-3672 Gear Removal Plate

SMCS Code: 1206-010, 4054-010, 4262-015, 4262-017
• Removal of camshaft or accessory drive gear with hydraulic puller (2)

is simple operation combining use of plate (1) and push-puller (3)

1 8F-3672 Plate
2 6V-3160 Hydraulic Puller
3 8B-7548 Push-Puller
ID: ph2, C05379T1
167-3834 Puller Group

SMCS Code: 1000-011, 0700, 0701
Model: 3176, 3176B, 3196, C-10, and C-12
• Used to remove press fit camshaft gear without pulling camshaft or disturbing overhead components
• Used with dealer supplied 10,000 Psi 1U-5230 Single Acting Hand Pump, 3S-6224 Electric Hydraulic Pump, or equivalent
• Used with induction gear heater to install cam gear (not included)
• Saves time on front cover repairs Hydraulic ram single action
• For engines built through May 1998 Ram stroke 51 mm (2.0 in)
• Only works on cam gears with lightening holes; will not fit solid hub gears Ram capacity 25 ton
2-338 TSPG 2002


1 167-1999 Puller Leg
2 2 167-1998 Puller Plate
3 5P-8247 Hard Washer
5 3 4 6B-6683 Nut
5 167-2000 Hydraulic Cylinder
Required parts, not included
138-7575 Lifting Link
Reference
5P-2566 Bolt 1/2-13 (for lift link) NEHSO760 Tool Operating Manual
4
5P-8245 Washer (for lift link)
ID: il2, C79618T1
9U-6896 Guide Bolt

SMCS Code: 1212-010, 0714
• Used to easily align camshaft gear during installation by supporting weight of camshaft gear
• Used with 1P-7405 Eye Bolt
• Length: 127 mm (5.0 in)
• Thread: 5/8 in-11 Reference
SENR5580 Service Manual; SENR6421 Service Manual Module,
Disassembly and Assembly 3406E Engines
ID: il2, C66607T1
8S-2264 Puller Group

8S-8375 Sleeve
SMCS Code: 1162-010, 1207-010, 1207-011, 1251-010, 1286-012, 1250-025, 3100-017
Model: D330C, D333C, 3304 and 3306 Engines
Used for various pulling operations such as:

• Removing accessory drive gears on D330C, D333C, 3304 and 3306 Engines
• Removing crankshaft front pulley on 1100 and 3100 Series Engines
• Water pump disassembly and assembly on D342, D353 and 3406 Engines ID: ph2, C05378T1
• Used with an 8S-8375 Sleeve to remove the accessory drive gear on 4.75 inch 8S-2264 Puller Group
bore two valve engines Item Part No. Description
• Also used in other general purpose applications 1 8S-8375 Sleeve (not part of 8S-2264 Group)
• Available separately: 6V-7837 Screw, length 2.81 inch, 3/4 inch-16 thread 2 8S-5133 Plug
3 8S-6470 Screw
4 8S-5132 Puller Plate
4C-5613 Puller Group

SMCS Code: 1803-011
Model: 3406
• Used to remove air compressor drive gear

• Has wide puller jaws that distribute load across more surface area on gear and prevent
damage to splined teeth; conventional puller jaws will not properly grab under gear hub
due to clearance problems, so they are used to grab in spline tooth area where they
may damage gear teeth
• Can be used for general purpose pulling operations
• 3-leg, 10-ton puller with wide, flat puller jaws
1 4C-5628 Crossarm Body
2 4C-5626 Forcing Screw ID: ph2, C27247T1
3 4C-5625 Puller Jaw
4 4C-5624 Spring Clip
5 4C-5627 Tip
TSPG 2002 2-339

132-5451 Air Compressor Gear Holder

SMCS Code: 1803-017
Model: 3406E, C-10, and C-12 Engines
Inside diameter 127 mm (5.0 in)

• Used to keep air compressor shaft from turning while Height including pins 88.9 mm (3.50 in)
removing or tightening drive gear retaining nut Pin diameter 12.7 mm (.50 in)
• Holder makes removing and installing nut much simpler Retaining nut final torque 462 ± 54 N·m (340 ± 40 lb ft)
and faster — also reduces possibility of damage during
overhaul procedure
• Use shop vise to hold air compressor assembly
• Service Part: 6B-6683 Nut
.
ID: il2, C54978T1
4C-9991 Idler Shaft Retrofit Tool Group

SMCS Code: 1206-010, 1201-019,
0670 (for 9U-5033), 0671 (for 9U-5034)
Model: 3500
• Used to retrofit idler gear shaft on 3500 Vee engines

• Easily and accurately aligns drill and tap for drilling and tapping bolt holes
from 1/2-13 to 5/8-11 thread
• Eliminates replacing cylinder block
• Used with 1P-3048 Wrench Assembly and 1U-9218 1/2 inch Drill
Item Part No. Description Size

1 9U-5033 Core Drill 17/32 inch, 4-fluted
2 9U-5034 Bottoming Tap 5/8 inch-11 Thd
3 1A-5822 Bolt (not part of 4C-9991 Tool Group) 1/2 inch — 13 x 2-3/4 inch
4 9X-8883 Bolt 5/8 inch — 11 x 2-3/4 inch ID: ph2, C26994T1
5 6V-4857 Lockscrew (qty, 2)
6 4C-9993 Guide Plate
7 4C-9994 Drill Bushing .500 inch Reference
8 4C-9995 Drill Bushing .531 inch SEBF8166 Guideline for Reuseable Parts
9 4C-9996 Drill Bushing .625 inch
10 4C-9997 Drill Bushing .635 inch (pilot for .625 inch tap)
Not shown 4C-9992 Idler Shaft Retrofit Pilot
9U-7255 Adjustable Idler Assembly 9U-6148 Idler Shaft Removal Group

SMCS Code: 1206-036, 0766 SMCS Code: 1206-011, 0714
Model: 3406E Engines Model: 3064 and 3066 Engines
• Used to set backlash between camshaft gear and adjustable idler gear • Used to remove idler gear shaft
• Used with 9U-7324 Indicator Bracket, 7H-1942 Dial Indicator, 3S-3268
Contact Point, and 7H-1940 Universal Attachment (assures correct setting of Reference
backlash after SENR5553 Service Manual,
tightening mounting bolts to adjustable idler gear) 3066 Diesel Engines
• Holds adjustable idler gear in correct position while tightening mounting bolts
• Distance between centers: 204.03 mm (8.033 in)

1 9U-6147 Removal Stud
2 8T-4244 Nut (M12 x 1.75)
ID: il2, C54947T1
3 9U-6146 Sleeve Assembly
Not shown 6V-8231 Nut (M10 x 1.25)
Reference
ID: ph2, C66631T1
SENR6421 Service Manual Module, Disassembly and Assembly 3406E Engine
2-340 TSPG 2002

195-7503 Shaft Installer Group

SMCS Code: 1206-012
Model: 3034 Engine
Essential Tool 2
• Used to install front idler gear shaft

• Eliminates guesswork and measuring to determine installation depth (when installer 1
contacts block, shaft is installed to proper depth)
• Used with 159-9076 Rear Drive Handle (sold separately)

Overall size 50 mm (2.0 in) diameter x 80 mm (3.1 in) long
1 195-7503 Shaft Installer Group
Weight 2 kg (4.4 lbs)
2 159-9076 Rear Drive Handle
O-ring Seal 095-1595
ID: il2, C80119T1
Reference
SENR5013 Service Manual, Disassembly and Assembly 3034 Engines for Caterpillar-Built Machines
6V-0098 Socket, 9/16 inch Extention Hex Drive

SMCS Code: 1210-010
Model: 3204 Engines
• Used for removal and installation of 4N-5201 Tachometer Drive Stud in camshaft of D3B, IT28, 215, 910, 931B, 943
• Tightened to 14,9 ± 2,8 N·m (132 ± 24 lb in) torque when installing stud
ID: ph2, A86937-1T1
FT2781 Alignment Tool

SMCS Code: 1206-010 1.0 ± 0.2 x 45˚ 2x RO.4 MAX
Model: G3600 Engines
Warranty: None
1.5 ± 0.2 x 45˚
R1 MAX
• Used to accurately align ADEM III timing wheel with magnetic pickup
4.8 ± 0.2
• Procedure for use: Insert tool through magnetic pickup hole and lock onto
indicated timing wheel tooth. Tighten slotted wheel to correct torque.
10.0 ± 0.2
• Material: SAE1018 steel
DETAIL A
DETAIL B
Ø18.7 ± 0.1
0.3 1.5 ± 0.2 x 45˚
B
A
Ø 25.4
60 ± 1 100 ± 3
STK TOL
ID: il3, C80388T1; FT2781
9U-7324 Indicator Bracket

SMCS Code: 1206-036, 0766
• L-shaped bracket used to fasten dial indicator to front housing (allows backlash
between camshaft gear and idler gear to be measured)
• Used with 7H-1942 Dial Indicator, 3S-3268 Contact Point, and 7H-1940 Universal
Attachment
Reference
SENR5580 Service Manual: ID: il2, C66625T1
SENR6421 Service Manual Module, Disassembly and Assembly 3406E Engine Height 66 mm (2.6 in)
Threaded hole in long leg 1/4 inch-20
Clearance hole in short leg 8.20 mm (.312 in)
TSPG 2002 2-341

Starting Systems / Engine Lifting and Positioning
Starting Systems
2H-8581 Clutch Adjusting Wrench FT0201 Clutch Adjustment Tool

Warranty: None
• Used for clutch adjustment on 3 5/8 inch bore starting engine • Used to adjust clutch on 2 3/8 inch bore, 2 3/8 inch stroke starting engines
ID: il2, C79692T1 ID: ph2, C09482T1
6V-4058 Universal Extension FT0625 Starting Motor Adjusting Tool

Model: 3400 Model: Prestolite Starting Motors
Warranty: None
• Needed on 3400 Series Truck Engines to remove and install bolts that hold • Used with 8H-8568 Socket, 8H-8505 Wrench, and 7B-7640 Hollow Head
starter on engine; on some engines, truck frame rails prevent easy access Wrench to check solenoid shifting adjustment on engines equipped with
to starter Prestolite starting motors
• 1/2 inch drive tool consists of 5/8 inch double hex socket on a 6 inch
extension
ID: ph1, B31772T1
ID: il2, C09481T1
Engine Lifting and Positioning
6V-0097 Engine Rebuild Stand

SMCS Code: 1003-010, 1000-029, 1157-010, 1302-010, 3010-010, 3101-029, 3258-010, 4002-017
Model: All engine models from 3204 through D348 and 3412
• Designed to provide most efficient means for engine reconditioning NOTE: To mount D348 or 3412 Engine on earlier 6V-0097 Stands, it is
• Design permits dynamometer testing of engine on stand necessary to modify front supports to provide clearance for oil coolers. Also, to
• Normally used with 9S-9081 Sling Assembly and 9S-9060 Dual Hook Hoist to mount 3208 Engines, right rear support must be modified to provide clearance
rotate engine during disassembly and assembly for starting motor. If these modifications are required, request the following
drawings from Division Service Manager:
• Superior to former 9S-8500 Stand because of its rigid, one-piece construction
and polyurethane rather than steel wheels FT1513 — Modification for D348 or 3412 Engines
• Portable with use of 1P-0090 Dolly and channel construction allows handling FT1530 — Modification for 3208 Engines
with lift truck with two sides
Length 1854 (73 in)
Width 1016 (40 in)
Height 610 (24 in)
Weight 272 Kg (600 lb.)
2-342 TSPG 2002

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Diagnostic and Repair Tools Engine Tools

Fuel System Repair and Adjust

Fuel System Repair and Adjust

6V-2023 Flow Checking Adapter Group

4C-8180 Timing Tool Group

ID: ph2, C55111T1

TSPG 2002 2-269

1P-0540 Flow Checking Tool Group

3P-2239 Timing Plate

Timing Fixture Plates

Part No. Engine

5P-4240 D8K Engine (14° 17 inch timing)

8T-5246 Engine Timing Indicator Group

2-270 TSPG 2002

Item Part No. Description

3204 PC 2 8T-5339 3S-3264 9S-8883 6V-3075 13 9S-0239 Adapter Assembly

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

ID: ph2, 57327T1

TSPG 2002 2-271

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

ID: ph2, 79085T1

ID: ph2, T97397T1

6V-9145 Adapter Group

4C-9287 Timing Advance Holding Tool

127-1069 Timing Pin

ID: il2, C66730T1

136-4632 Timing Pin

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

208-9387 Timing Pin

9U-6188 Timing Fixture Group

Item Part No. Description

ID: il3, C55195T1

TSPG 2002 2-273

157-3719 Fuel Spanner 192-3331 Timing Gauge

ID: il2, C79246T1

ID: ph2, C78528T1

5.4 inch Bore, 6 Cylinder Vehicle Engine Lifter Setting Tools

Item Part No. Description Use

ID: ph2, 92947T1

Tools for Rotating Crankshaft

Measure dimension “X” on starter housing to determine which part to use.

9U-6943 Shaft Housing Assembly 146 mm (5.75 in)

ID: il1, C66628T1

9U-6198 Crankshaft Turning Tool

• Used to rotate crankshafts (connects directly to front of crankshafts)

ID: il2, C54937T1

208-0888 Engine Turning Tool

Square drive 3/4 inch

• Used to turn engine crankshaft by hand

ID: il2, C79845T1

5P-7306 Gear Shaft Housing Assembly

5F-2807 Cap 9S-1743 Ferrule Nut Wrench

ID: ph1, C05383T1

ID: ph1, 76011-1T1

TSPG 2002 2-275

5P-0166 Crowfoot Wrench, 3/8 inch 5P-5195 Fuel Line Wrench

ID: ph2, 77215T1

ID: ph2, A30728T1

5P-7260 Socket 5P-0144 Socket

ID: ph2, , A37348-1T1 ID: ph2, 80139T1

6V-4089 Reamer Assembly

• Removes carbon deposits from bores of pencil-type fuel nozzles

ID: ph2, B32114T1

5B-1401 Fuel Injection Valve Orifice Cleaning Tool Group