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Tools for Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Flow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Measuring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Paving Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Power Train Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Speed Measuring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Temperature Measuring Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

General Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69

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Caterpillar Inc. warrants all products sold, against defects in workmanship

or materials under normal use, for Six Months after date of purchase,
unless otherwise stated.

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Diagnostic Tools Search Electrical Tools

Electrical Tools

155-5175 AC Current Probe

SMCS Code: 1400-038, 4450-038
Model: All Generator Sets
Warranty: One Year Current range 0.1 to 1000 Amps rms
Temperature range

Compliant Operating -10 to 50°C (14 to 122°F)
Storage -20 to 70°C (-4 to 158°F)
• Used to measure AC current on Caterpillar® Generator Sets and any other
Frequency range 30 Hz to 5 kHz
application within its capability (see specifications)
Temperature coefficient <.01% per 10K
• Used with Caterpillar 6V-7070 Digital Multimeter, 9U-7330 Digital Multimeter,
or 146-4080 Digital Multimeter Accuracy
0.1 to 10A 3% ±0.1A
• Clamp-on probe replaces standard test leads (allows current measurements 10 to 50A 1.5%
without breaking circuit). 50 to 200A 0.75%
• Extends AC current measuring ability of multimeter up to 1000 Amperes rms 200 to 1200A 0.5%
by use of 1000:1 current transformer
• Measures conductors up to 54.1 mm (2.13 in) diameter
• Replaces discontinued 6V-4960 AC Current Probe
ID: C79448T1

225-8266 Clamp On Ammeter

SMCS Code: 1400-038, 1400-081, 1450-038
Model: All Service Parts
Warranty: Manufacturer’s Part No. Description AC/DC CLAMP METER

OUTPUT
mA A AC
V Hz 1200
400 ZERO
OFF
COM

1U-9533 AA Size Battery OFF

Compliant
MAX/MIN CATE 30W
CATE 40W
6V-6014 Cable

COM
HOLD
0 10 20 30 40
• Used to measure AC or DC current 225-8266

• Compact size and low cost make this unit indispensible

ID: D00363T1
• Clamp-on probe replaces standard test leads
(allows current measurements without breaking circuit) Weight 190 g (6.7 oz.) Repair Information
Overall size 183 x 61 x 36 mm Extech Instruments
• Measures current in cables up to 23 mm (0.9 in) diameter
(7.2 x 2.5 x 1.4 in) 285 Bear Hill Rd.
• User selectable 400 Ampere and 1200 Ampere scales for both AC and DC Waltham, MA 02451-1064
Resolution 1 Ampere
• Powered by two 1U-9533 AA Alkaline Batteries
Ph: (781) 890-7440
• Designed with a built-in display, push button zero control for DC operation, “display hold” Fax: (781) 890-7864
to freeze display, “max/min recording” to display highest and lowest readings, auto
power-off (unit turns off automatically after 30 minutes), and low battery indicator
• Shipped with batteries, carrying case, and user’s guide

227-4324 Clamp-On Multimeter, 2000A AC/DC

Electrical data all accuracies stated at 23°C ± 1°C (73° ± 34°F)
SMCS Code: 0769, 0785
Model: Combination Ammeter/Multimeter for EPG installations Current measurement DC, DCRMS, ACRMS
Warranty: One Year Measuring range 0 to 2000A DC or AC pk
Auto-range facility 400A / 2000A
• Provides reliable and accurate measurements Resolution 100mA in 400A range
under a wide range of operating conditions 1A in 2000A range
• Non-intrusive AC/DC current Accuracy 1 > 25A ± 1.3% reading ± 3 digits
1 < 25A ± 1.0A Frequency range
• True RMS for complex and distorted waveforms
DC and 15 Hz to 1kHz in DCRMS
• AC/DC current component analysis 15 Hz to 1 kHz in ACRMS
• Auto-ranging and auto-zeroing Frequency characteristics above 1kHz
• AC/DC Volts Signal amplitude 3dB @ 5kHz
• Ohms, continuity, and diode test 6dB @ 10kHz
• Max RMS (surge) and data hold Crest factor 6 maximum
• Analog output for recorder, logger, or oscilloscope Maximum overload 10,000A or ACRMS x frequency <400,000
DCRMS AC or DC coupling of the amps measurement
respectively
Mechanical dimensions 251 x 98 x 52 mm
Service Parts (L x W x D) (9.9 x 3.9 x 2.0 in)
Part No. Description Weight 500g (1.1 lbs)
232-3636 Analog Cable Case material Bayblend T85MN
232-3637 Carrying Case Jaw opening 55 mm (2.2 in)

ID: D00587T1

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155-5176 AC/DC Current Probe Current range 1 to 1000A AC (1400A peak) 1 to 1400A DC
SMCS Code: 1400-082, 1450-082, 1600-082, 4450-082
Frequency range DC to 10kHz at -3db
Model: All Models
Warranty: One Year Output 1mV/A
Accuracy

Compliant 1 to 100A
100 to 800A
1.5% reading ±1A
2.5% reading
• Used to measure AC/DC current 800 to 1000A 4% reading
1000 to 1400A DC only 4% reading
• Used with 6V-7070 Digital Multimeter, 9U-7330 Digital Multimeter,
or 146-4080 Digital Multimeter Working voltage 600V rms
• Replaces 9U-5795 AC/DC Current Probe Maximum conductor diameter 42 mm (1.7 in)
• Compatible with most voltmeters, multimeters, or other voltage Load impedance >100K/100pF
measuring instruments Batteries 9V alkaline (NEDA 1604A, IEC 6LR61)
• Larger jaw opening fits diameters Battery life approximately 120 hours with alkaline battery
as large as 42 mm (1.6 in) Low battery indication green LED on when battery is at 6.5V or below
• Compact size fits in tight places Influence of adjacent conductor 0.01A typical
• Extra-long cord allows positioning Influence of conductor position in opening 0.5%
of meter for easy viewing Temperature range
Operating -10 to 55°C (14 to 131°F)
Storage -40 to 80°C (-40 to 176°F)
Relative humidity 10 to 90%
Dimensions 236.5 x 97.0 x 44.0 mm (9.31 x 3.82 x 1.73 in)
Weight 480 g (1.06 lb)
Cord length 1.27 M (5 ft)

ID: C79450T1

177-2330 Digital Battery Analyzer

SMCS Code: 1401-081, 0785 Battery rating range:
Model: All Cold cranking amps (CCA) 50 to 4000
Cranking amps (CA) 65 to 5000
Warranty: One Year
Amp hours (A-Hr) 6 to 500
DC voltmeter range 1.0 to 14 Volt
• Replaces 127-8078 Battery Analyzer
Voltmeter accuracy ±0.1 Volt
• Used to quickly and accurately test condition of 6 and 12 Volt batteries (even discharged to as low as 4 Volts)
Power source 9 Volt battery or test battery
• Check for full state charge, condition of battery, and battery voltage in 20 seconds
Test time 20 seconds
• Test batteries in machine or vehicle without disconnecting battery cables
Analyzer cable length 815 mm (32 in)
• Battery does not have to be fully charged at time of testing 17
7-
23
30 Overall size 210 x 140 x 38 mm
• Saves time and money by allowing dealers to test condition of a battery while B
at
te
ry
A
(8.25 x 5.5 x 1.5 in)
n
customer is present (works great for warranty claims) al
yz
er
M C
O /F Y
E
Weight 0.68 kg (1.5 lbs)
• Eliminates need to charge and discharge a battery to test its condition
D S
E

N
O G
O
Operating temperature range 0 to 50°C (32 to 120°F)
• Compensates for cold temperatures when testing batteries in extreme conditions
Storage temperature range -20 to 70°C (0 to 160°F)
O
N

• Power-down feature prolongs battery life in analyzer

F
F

®
Over voltage protection up to 18 Volts
• Analyzer has reverse polarity and is protected to 17 Volts maximum.

Reference
NEHS0764 Tool Operating Manual, Using the 177-2330 Battery Analyzer
NEHP6014 Datasheet
ID: C79709T1

4C-4911 Battery Load Tester

SMCS Code: 1401-081, 0785
Model: All Models
Warranty: One Year

• Used to test 6, 8 and 12 Volt heavy equipment Load test 6, 8 and 12 Volt batteries
and automotive batteries Load current 0 to 1000 Amps (carbon pile)
• Has built-in LCD digital voltmeter and ammeter Duty cycle continuous, limited only
• Load adjustment knob for current drawn from by cable and clamp heating
battery to be adjusted up to maximum of 1000 amperes Operating temperature 0 - 50°C (32 - 122°F)
• Cooled by internal fan automatically activated when Voltmeter accuracy 0.1% of full scale ± 1 digit
load applied to prevent carbon pile overheating
Ammeter accuracy ±3% of reading ± 1 digit
• Large, 15 mm high display digits are easier to read
ID: B96676T1 Size 33 cm x 33 cm x 30 cm
(13 in x 13 in x 12 in)
Reference
SEHS9249 Special Instruction Weight 12.428 kg (27.375 lbs)

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4C-6600 Battery Voltmeter Range 6.0 to 60.0 VDC

SMCS Code: 1401-081 Operating temperature range -30°C to +70°C (-22°F to +158°F)
Model: All Models
Accuracy:
Warranty: One Year (4C-6600 Battery Voltmeter not repairable) 0°C to 70°C (32°F to 158°F) +.2 VDC
-30°C to 0°C (-22°F to 32°F) +.23 VDC
• Small digital voltmeter designed to quickly determine state of charge Input Voltage protection +100 VDC max.
of 6 to 60 Volt batteries on or off the machine Power powered by battery being tested
• Easier and faster than using a hydrometer to measure specific gravity Current requirement 0.18 Amp
• Works on all batteries including sealed maintenance free batteries Settling time 3 seconds
• Bright, red LED display easy to read outdoors and in low light conditions Weight .113 Kg (4 oz.)
• Chart on rear of meter shows battery approximate percent of charge Size 76mm x 84mm x 20mm (3.0 in x 3.3 in x .8 in)
based on battery voltage for 12-Volt batteries (Chart in Operating
Service part 4C-6777 Test Lead Kit (included with 4C-6600 Voltmeter)
Manual includes 6, 8, and 12-Volt Batteries)
• No internal batteries to wear out
• Small enough to carry in pocket or toolbox

Reference
NEHS0538 Operating Instruction

ID: C26911T1 ID: C26912T1

8T-0500 Continuity Testing Light

SMCS Code: 1000-017, 1000-025, 1250-025, 1250-036, 1355-081, 1400-038,
3071-017, 3100-017, 3156-010, 3156-012, 3200-038, 3224-025,
4208-010, 5050-038, 7400-036, 7451-038, 7401-045
Model: All Models
Warranty: One Year

• Replaces discontinued 8S-4627 Circuit Continuity Tester

• Used to test non-energized circuits; lamp comes on brightly when connected across Service Parts
low resistance circuit; no light appears if resistance of circuit exceeds 10 Ohms Part No. Description
ID: C33257T1
• Designed for rugged field use 4C-8363 Battery, Size N, 1.5 Volt
• Comes with light bulb and two “N” size batteries (1.5 Volts) and instruction decals 6V-3061 Bulb

Reference
NEHS0543 Special Instruction (Checking Diodes)

5P-7277 Voltage Tester

SMCS Code: 1400-038, 1400-081, 1450-081, 1700-081, 1800-081,
3168-035, 5050-081, 7300-081, 7400-081, 7451-038
Model: 215, 428, 621E, 627E, 768C, 769C, 793 All models
Warranty: One Year

• Used to make quick checks for presence of voltage

• Indispensable for checking out circuits, relays, bulbs, wires, and switches
• Designed for voltage range from 12 to 36 Volts
• Bulb lights brightly when connected to 36 Volts and gets progressively dimmer with lower voltages.
• Encased in rugged, hi-impact plastic housing which is grease and chemical resistant
• Standard 8D-1429 Bulb required for replacement

ID: A40449T1
1U-7318 Continuity Tester/Flashlight
Warranty: Manufacturer’s

• Made of high impact plastic

• Can be used as a flashlight or continuity tester
• Yellow w/black cap
• 209.6 mm (8 1/4 inch) long, uses 2 D cell batteries (1U-9532) (not included)
• Continuity wires shipped inside flashlight
• Service part: 1U-9532 D-Cell Battery

Home ID: C44286T1 Dealer Service Tools 2004 1-3

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197-7875 Lock Removal Tool Instructions for use of 197-7875

197-7876 Connector Removal Tool 1. From rear side of RTA, insert tool fingers into slots on outboard side of wires.

SMCS Code: 1800-0776 2. With tool handle parallel to wires, press down on locking tabs of terminal locks.
Model: All 3. Pull out terminal locks by hand or with a small, flat blade screw driver.

Instructions for use of 197-7876

• Used to service Caterpillar fuse 1. Remove fuse from top of RTA.
blocks using mini-fuses (GM style)
2. Locate wire terminal on outboard sides of RTA.
• 197-7875 used to remove fuse
block terminal locks 3. Place long square fingers into square holes above and below slot for fuse blade.
• 197-7876 used to remove wire 4. Press removal tool fingers completely into connector to compress terminal
and terminal from RTA, if locking tabs.
replacement is necessary
5. Remove wire and terminal.
ID: C80408T1

6V-3000 Sure Seal Repair Kit

SMCS Code: 1400-023
Model: All models with Sure Seal connectors

• Used to repair any wiring harness which has Sure Seal Connectors
• Used to make new wiring harnesses for attachments or modifications to vehicles

Reference
SMHS7531-01 Special Instruction

ID: C44363T1
Item Part No. Description Item Part No. Description Item Part No. Description
1 6V-3001 Crimping Tool 7 Receptacles: 8 Plugs:
2 9G-3695 Sealing Plug (50) 7N-7777 Receptacle, 1 pin (3) 7N-7778 Plug, 1 pin (3)
7N-9738 Receptacle, 2 pin (3) 7N-9737 Plug, 2 pin (3)
3 6V-3008 Insertion Tool (not included with early kits) 7N-7781 Receptacle, 3 pin (3) 7N-7782 Plug, 3 pin (3)
4 7N-7779 Socket (100) 7N-8204 Receptacle, 4 pin (3) 7N-8205 Plug, 4 pin (3)
9G-3678 Receptacle, 5 pin 9G-3672 Plug, 5 pin
5 7N-7780 Pin (100)
9G-3677 Receptacle, 6 pin 9G-3671 Plug, 6 pin
6 Oil sample bottle used as container 9G-3676 Receptacle, 7 pin 9G-3670 Plug, 7 pin
for alcohol lubricant 9G-3675 Receptacle, 8 pin 9G-3669 Plug, 8 pin
(not part of 6V-3000 Repair Kit) 9G-3674 Receptacle, 9 pin 9G-3668 Plug, 9 pin
9G-3673 Receptacle, 10 pin 9G-3667 Plug, 10 pin
9 6V-3007 Box Assembly
10 NEEG 2032 Insert

140-9944 Terminal Kit Terminal and Wire Splice Service Parts

SMCS Code: 1400-023, 0700 Quantity Replacement
Model: All Caterpillar Engines Shipped Part No. Description Quantity
1 9S-9150 Terminal Crimp Tool 1
10 2L-8058 Terminal (8 Ga. 1/4 in. Stud) 10
• Replaces discontinued 1P-2305 Terminal Kit
10 2L-8066 Terminal (12-10 Ga. No. 10 Stud) 10
• Used to repair wiring harness terminal ends
10 2L-8067 Terminal (12-10 Ga. 1/4 in. Stud) 10
which have become damaged or unserviceable
10 2L-8069 Terminal (12-10 Ga. 3/8 in. Stud) 10
• Hand crimping tool has built-in dies for crimping
insulated and non-insulated terminals, cutting 10 2L-8071 Terminal (12-10 Ga. 1/2 in. Stud) 10
edges for cutting wire, notches for stripping 20 2L-8075 Terminal (16-14 Ga. No. 8 Stud) 20
10 to 22 gauge wire, shears for cutting up to 20 2L-8076 Terminal (16-14 Ga. No. 10 Stud) 20
4.7 mm (.18 in) diameter bolts, two thread chasers 15 2L-8077 Terminal (16-14 Ga. 1/4 in. Stud) 15
for screws with 24 and 32 threads-per-inch screws,
15 2L-8079 Terminal (16-14 Ga. 3/8 in. Stud) 15
and a scale for measuring screw length.
ID: C80279T1 30 5P-4571 Terminal (16-14 Ga.) 20
• Splice connectors have hot-melt adhesive and shrink
ends that when heated will provide an environmental 10 4S-1988 Terminal (Blade, Crimp Type) 50
seal around wire. 15 136-4876 Wire Splice (12-10 Ga.) 1
15 136-4877 Wire Splice (16-14 Ga.) 1
15 136-4878 Wire Splice (22-18 Ga.) 1

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8T-5319 CE/VE Connector Tool Group Tool Wire Pin Socket Seal
SMCS Code: 1400-023 Item Part No Gauge Contact Contact Plug
Model: All Models with CE/VE Connectors 16,
1 4C-4074 18 8N-1538 8N-1539 7G-7917
12
• Used to service all CE/VE Connectors 2 4C-4073 14 3T-7260 3T-7261 7G-7918
• Contacts can be removed, installed 10 3T-7262 3T-7263 7G-7919
or rearranged within connector 3 4C-4072 8 3T-7264 3T-7265 7G-7919
6 8N-1546 8N-1547 7G-7920
Reference 4 4C-7071 4 8N-1548 8N-1549 7G-7920
SEHS8038 Special Instruction ID: C80203T1

6V-4148 Electrical Connector Repair Kit

SMCS Code: 1408-023
Model: Some models Part No. Description Part No. Description
with electronic controls 6V-3001 Crimping Tool 9G-6793 Terminal (9)
6V-4147 Extraction Tool 384842 Connector (6)
399862 Housing (4) 7N-6546 Terminal (32)
• Used to repair electrical connectors 6V-4145 Extraction Tool 7N-6545 Terminal (32)
made by Amp Special Industries 6V-4146 Extraction Tool 9G-6791 Pin (32)
that are used in electrical controls 301530 Terminal (8) 9G-6790 Socket (37)
and harnesses 399860 Contact (22)
9G-5859 Pin (8)
301741 Terminal (8) 368748 Connector
384841 Contact (18) 368747 Connector
384843 Plug (12) 389688 Connector (2)
309491 Housing (16) 9G-6789 Connector (2)
309492 Housing (16) 387062 Connector (2)
301782 Housing (10) ID: C78424T1
301531 Housing (4)
344953 Housing (4)
301739 Socket (8)
301740 Housing (10)
301781 Housing (10)

243-3134 Tester Group General Technical Data

SMCS Code: 4450-082, 0785 Nominal test voltage 100V, 250V, 500V, and 1000V
Model: Generator Sets
Measuring range 1.8 KΩ to 20GΩ
Warranty: One Year
Continuity range 0 to 50Ω

Compliant Resistance range 0 to 200KΩ
Voltage measurement range 0 to 600 VDC and 0 to 600 VAC TRMS
• Replaces canceled 142-5055 Insulation Tester Group
Frequency measurement 0.1 Hz resolution on 200 Hz range
• Used to measure and check insulation resistance 1 Hz resolution on 1 kHz range
for electrical power generation
Built-in timer holding “Start” button for 10 seconds starts
• Also used to perform dielectric absorption continuous measurement process
and polarization index tests
Advanced tests Dielectric Absorption available after 1 minute,
• Ammeter (low amperage capability) Polarization Index available after 10 minutes
• Measures true RMS up to 600V (time is denoted by “beep”)
• Measures frequency, resistance, and continuity Current measurement mA, RMS current measurement 20µA to
capability 199.99 mA
• 20G-ohm insulation testing with 100V, 250V,
500V, and 1000V test voltages Operating temperature -10 to -50°C (-14 to +122°F)
• Auto shut-off feature turns an unused unit off Humidity 85% or below
after 5 minutes Dimensions 220 x 98 x 52 mm (8.7 x 3.9 x 2.0 in)
• Low battery indicator Weight 800g (1 lb 12 oz)
• Operates at temperatures from -10°C to +50°C. ID: D00705T1 Power source 4 x 1.5 V (AA) batteries
Service Parts
Reference 243-3135 Lead Set
SEHS9124 Special Instruction 243-3136 Clip Set
243-3137 Fuse, 0.63 Amp

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146-4080 Digital Multimeter Group (RS-232)

SMCS Code: 0115-036
Model: All Models
Warranty: Manufacturer’s

Compliant
• Used to measure duty cycle, frequency, resistance, AC/DC voltages, AC/DC currents, temperature, continuity, diode test
and total harmonic distortion in percentage of line voltage or current at 50/60 Hz or as a percent of fundamental frequency
• Features RS-232 output which can be used to connect meter to 131-5050 DataView using a 146-8488 Cable Assembly
• Measures true RMS on AC voltage and current ranges
• Has auto/manual ranging features
• Can be programed to compare measurements to a desired reference value without an external reference source
• Has safety shutter to protect meter in the event of incorrect connections to current terminals
• 600 V fuse protected on both 10 amp and 400 milliamp range ID: C66993T1
• Ohm meter protected to 600 volts
• Automatic reading hold
General Specifications
• Digital display backlighting can be turned ON or OFF
Function Description
• Small enough to be hand held and is protected by a rubber boot
Continuity Open circuit test Voltage: 1.2V
• Battery powered THRESHOLD: Approximately <100Ω
Diode check Open circuit test Voltage: 3V
Reference MAXIMUM TEST CURRENT: 25mA
NEHS0678 Operation Tool Operating Manual Duty cycle 0.0 - 99.9%
NEHS0682 Specification, Testing, and Maintenance Tool Operating Manual (1.5Hz to 20KHz) Accuracy: within ± (0.2% per KHz + 0.1%)
THD Voltage ± (2% + 2 digits)
Measurement Current ± (2% + 2 digits)
Electrical Specifications (50/60Hz)
Function Range Resolution Accuracy Maximum Input (Total harmonic
distortion)
DC V 400mV 0.1mV 0.3% + 2d 1000V
4V 1mV 0.3% + 2d DC V Normal Mode Rejection Ratio:
40V 10mV 0.3% + 2d >20dB at 50Hz or 60Hz
400V 0.1V 0.3% + 2d Common Mode Rejection Ratio:
1000V 1V 0.75% + 3d >100dB at DC, 50Hz or 60Hz
DC A 400µA 0.1µA 0.5% + 1d µA - 400mA/600V AC V Common Mode Rejection Ratio:
4000µA 1µA 0.5% + 1d µA - 400mA/600V 85dB at dc to 60Hz
40mA 0.01mA 0.5% + 1d mA - 400mA/600V Crest factor 1:1 through 3:1. For non-sinusoidal waveforms
400mA 0.1mA 0.5% + 1d mA - 400mA/600V (45Hz to 1KHz), add ±(2% of reading) to the accuracy
4A 0.001A 1.0% + 5d A - 10A/600V
10A 0.01A 1.0% + 5d A - 10A/600V Fuse µA or mA: 1A 600V FAST fuse
protection A: 15A 600V FAST fuse
AC V 4V 1mV 0.75% + 3d 750V with >10,000A interrupt rating
40V 10mV 0.75% + 3d
400V 0.1V 0.75% + 3d
750V 1V 0.75% + 5d 3N-5612 Fuse
AC A 400µA 0.1µA 1.0% + 5d µA - 400mA/600V Voltage rating 600 Volt
4000µA 1µA (45Hz to 1KHz) µA - 400mA/600V Current rating 1 Amp
40mA 0.01mA mA - 400mA/600V
400mA 0.1mA mA - 400mA/600V Size 10.3 mm dia. X 34.9 mm (13/32 inch dia. X 1 3/8 inch)
4A 0.001A A - 10A/600V Load carrying capacity 110% load indefinitely, opens at 135% load within 1 hour
10A 0.01A A - 10A/600V
9U-6398 Fuse
Ohms 400Ω 0.1Ω 0.5% + 10d 600V
Voltage rating 600 Volt
4KΩ 1Ω 0.5% + 3d
40KΩ 10Ω 0.5% + 3d Current rating 15 Amp
400KΩ 0.1KΩ 0.5% + 3d Size 10.3 mm dia. X 38.1 mm (13/32 inch dia. X 1 1/2 inch)
4MΩ 1KΩ 0.5% + 3d
40MΩ 10KΩ 1.01% + 10d Load carrying capacity 110% load 4 hours, opens at 135% load within 1 hour

Hz 200Hz 0.01 Hz 0.05%

(1.5Hz to 2KHz 0.1 Hz +2 digits Units

200KHz) 20KHz 1 Hz (20,000 Exponents Description

200KHz 10 Hz Counts) % Percentage Annunciation in the Percentage (%) mode,
7200KHz 100Hz the THD @ 50/60Hz mode, and Duty Cycle mode.
mV Millivolts (1 x 10-3 Volts)
Temperature Specifications A Amperes (Amps)
Range Resolution Accuracy Maximum Input mA Milliamperes (1 x 10-3 Amps)
-40 to 0°C 0.1°C ±3.0°C + 1 digit 60V DC or µA Microamperes (1 x 10-6 Amps)
(-40 to 32°F) (0.1°F) (±5.4°F + 1 digit) 24V AC RMS Ω Ohms
0 to 400°C 0.1°C ±1% + 1°C 60V DC or KΩ Kilohm ( 1 x 103 Ohms)
(32 to 752°F) (0.1°F) (±1% + 1.8°F) 24V AC RMS MΩ Megohm (1 x 106 Ohms)
401 to 1,370°C (1°C) ±3.0% of reading 60V DC or Hz Hertz (1 cycle/sec)
(753 to 2,498°F) 1°F 24V AC RMS KHz Kilohertz (1 x 103 cycles/sec)

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®
NEHS0678-01
September 1997

1
®
NEHS0682-01
September 1997

4
6 TOOL
OPERATING
TOOL
OPERATING
MANUAL
MANUAL
146-4080 Digital Multimeter
Specification, Testing, and Maintenance Manual
146-4080 Digital Multimeter (Operation Manual)
SMCS Code 0785
Caterpillar 146-4080
5 SMCS Code 0785

2
RS-232 TRUE RMS MULTIMETER

HOLD
Total Harmonic Distortion
CMP EDIT RANG
E
7 8
HI/LO
TRIG
REL C
REC DC/A
ID: C78587T1
3
˚C/˚F
%

mV
v
Hz
Item Part No. Description
DUTY
10A

mA
TEMP
1 Thermocouple Adapter and Thermocouple
A

OFF
OFF

2 2 Test Leads
3 Clip Adapter
10A MAX
FUSED
400mA MAX
FUSED
MAX
AC 750V
DC 1000V
TEMP
4 NEHS0678-01 Operation Manual
MAX
600V

A mA A COM VΩ Hz
REMOVE INPUTS BEFORE SWITCHING RANGES
5 146-4080 RS-232 Digital Multimeter
6 8T-0458 Thermocouple Probe
Not Shown
ID: C78586T1 6V-7072 Deluxe Lead Kit
212-2158 Replacement Lead Set
Optional Equipment
7 146-8488 Cable Assembly (RS-232 for use with CAT 131-5050 Data View)
8 NEHS0682-01 Specification, Testing, and Maintenance Manual

6V-7070 Digital Multimeter

SMCS Code: 1000-038, 1050-038, 1400-038, 1400-081, 1450-038, 3000-038, 3168-038, 4450-038, 5700-038
Model: All Models
Warranty: One Year

• Replaces discontinued 6V-3030 Multimeter

• Made for use in Caterpillar field service environment; case has extra thick walls and O-ring seals which
keep out moisture; internal components are shock mounted; 10 Amp current range has 10 Amp 600 Volt
fuse to protect multimeter against current overloads; will measure currents up to 20 Amps
• Every function and range computer tested at factory; each meter has 100% burn-in test
• Improved reference element and voltage divider networks keep meters accurate for at least a year
without calibration
• 1U-9534 Battery, 9-Volt, will run meter for 2000 hours.

Part No. Description ID: B83924T1

6V-7070 Digital Multimeter

6V-7072 Deluxe Lead Kit for all meters
6V-3031 Carrying Case for 6V-7070 Multimeter

Service Parts
Part No. Description Use
6V-7803 Fuse, 2 Amp, 600V For all Caterpillar Multimeters
(Do not replace with 250 Volt fuse.)
6V-7802 Fuse, 10 Amp, 600V For 6V-7804 lead (6V-7070 Multimeter)
ID: B83926T1
(Buss Part No. KTK10.)
9U-6398 Fuse, 15 Amp, 600 V In newer meters
ID: B72093T1

8T-3224 Needle Tip Group

• Tips slip over standard or deluxe test lead tips to provide long, smaller
diameter tip for inserting into connectors and other tight areas
• Required when using multimeters with Caterpillar Electrical Training Aids
8T-9170, 8T-9171 and 8T-9172 (no longer available as form numbers SEKV1700,
SEKV1500, and SEKV2100, respectively)
• Insulated with teflon sleeving which may be cut back to expose more metal
or to shorten metal tip

Reference
SEHS7734-01 Special Instruction
ID: D00325T1

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212-2160 Digital Multimeter

SMCS Code: 1000-038, 1050-038, 1400-038, 1400-081, 1450-038,
3000-038, 3168-038, 4450-038, 5700-038
Model: All Models Service Parts
Warranty: Manufacturer’s Part No. Description
212-2158 Replacement Lead Set

Compliant 212-2159 Fuse, 10 Amp 250 Volt
• Used to measure AC/DC Voltage and current, resistance, capacitance, 8Q-6668 Fuse, 500 mA 250 Volt
frequency, duty cycle, and temperature (Temperature probe optional) 1U-9535 Replacement Battery AAA (2 required)
• Also has duty cycle, continuity, and diode test 8T-0458 Optional Temperature Probe
• 4000 counts on large LCD display with full function indication
• Measures temperatures up to 760°C (1400°F) (Temperature probe optional)
• Autoranging with manual range override
• Relative zero, data hold, and range hold ID: C80497T1
• 10 Amp fuse protection Function Range Resolution Accuracy
• Overload protection and indication AC Current (A AC) (40 - 400Hz) (40 - 200Hz for 400µA, 4mA ranges)
• Auto power-off shuts down after 15 minutes of inactivity—saves battery life 400µA 0.1µA ±(1.8%reading + 5 digits)
• Includes mini autoranging multimeter, protective rubber holster, 4000µA 1µA ±(1.8%reading + 5 digits)
two 1.5V AAA batteries, two test leads, and user manual 40mA 0.01mA ±(1.8%reading + 5 digits)
400mA 0.1mA ±(1.8%reading + 5 digits)
Diode test test current of 0.3 mA maximum, open circuit
voltage 1.5V DC typical 10A 0.01A ±(3.0% reading + 7 digits)
Continuity check audible signal will sound if the resistance is less Resistance
than approximately 30 Ω , test current <0.7 mA 400 Ω 0.1 Ω ±(1.2% reading + 4 digits)
Temperature sensor requires type K thermocouple 4k Ω 0.001 kΩ ±(1.2% reading + 2 digits)
Input inpedance 7.5 M ohms (VDC and VAC) 40k Ω 0.01 kΩ ±(1.2% reading + 2 digits)
Overrange indication “OL” is displayed 400k Ω 0.1 kΩ ±(1.2% reading + 2 digits)
Polarity automatic (no indication for positive polarity); 4M Ω 0.001 MΩ ±(1.2% reading + 2 digits)
minus (-) sign for negative polarity
40M Ω 0.01 MΩ ±(2.0% reading + 3 digits)
Measurement rate 2 times per second, nominal
Capacitance
Low battery indication “BAT” is displayed if battery voltage drops below
4nF 0.001nF ±(5.0% reading + 10 digits)
operating voltage
40nF 0.01nF ±(5.0% reading + 7 digits)
Fuses mA, µA ranges, 0.5A/250V fast blow 10A range,
10A/250 V fast blow 400nF 0.1nF ±(3.5% reading + 5 digits)
Operating temperature 0 to 50°C (32 to 122°F) 4µF 0.001µF ±(3.5% reading + 5 digits)
Storage temperature -20 to 60°C (-4 to 140°F) 40µF 0.01µF ±(3.5% reading + 5 digits)
Relative humidity <70% operating, <80% storage 200µF 0.1µF ±(5.0% reading + 5 digits)
Operating altitiude 2000 meters (7000 feet) maximum Frequency
Weight 260 g (9.17 oz.) 9.999 Hz 0.001 Hz ±(1.5% reading + 5 digits)
Size 121.5 x 60.6 x 40 mm (4.78 x 2.38 x 1.57 in) long 99.99 kHz 0.01 Hz ±(1.5% reading + 5 digits)
Usage For indoor use and in accordance with Overvoltage 999.9 kHz 0.1 Hz ±(1.2% reading + 2 digits)
Category II, Pollution Degree 2. Category II includes 9.999 kHz 0.001 kHz ±(1.2% reading + 2 digits)
local level, appliance, portable equipment, etc., with
transient overvoltages less than Overvoltage 99.99 kHz 0.01 kHz ±(1.2% reading + 2 digits)
Catergory III. 999.9 kHz 0.1 kHz ±(1.2% reading + 2 digits)
9.999 MHz 0.001 MHz ±(1.5% reading + 4 digits)
Function Range Resolution Accuracy Sensitivity; 0.8V rms min. @ 20% to 80% duty cycle and
<100 kHz; 5V rms min @ 20% to 80% duty cycle and >100 kHz.
DC Voltage (V DC)
400mV 0.1mV ±(0.5%reading + 2 digits)
4V 0.001V ±(1.0% reading + 2 digits) Function Range Resolution Accuracy

40V 0.01V ±(1.0% reading + 2 digits) Duty Cycle 0.1 to 99.9% 0.1% ±(1.2% reading + 2 digits)
Pulse width: 100 µs - 100 ms
400V 0.1V ±(1.0% reading + 2 digits)
Temp. °F -4 to 1400°F 1°F ±(3.0% reading + 3 digits)
600V 1V ±(1.5% reading + 2 digits) (probe % not included)
AC Voltage (V AC) (40 - 400 Hz) (40 - 200 Hz for 400mV, 4V ranges) Temp °C -20 to 760°C 1°C ±(3.0% reading + 3 digits)
400mV 0.1mV ±(2.0% reading + 30 digits) (probe % not included)
4V 0.001V ±(1.5% reading + 3 digits)
40V 0.01V ±(1.5% reading + 3 digits) Input Limits
400V 0.1V ±(1.5% reading + 3 digits) Function Maximum Input
600V 1V ±(2.0% reading + 4 digits) VDC, VAC 600V DC/AC
DC Current (A DC) Ohms, Capacitance, Diode, 250V DC/AC
400µA 0.1µA ±(1.5% reading + 3 digits) Frequency, Continuity
4000µA 1µA ±(1.5% reading + 3 digits) mA DC/AC 400mA DC/AC
40mA 0.01mA ±(1.5% reading + 3 digits) 10A DC/AC 10A DC/AC (30 second maximum)
400mA 0.1mA ±(1.5% reading + 3 digits)
Warranty Information
10A 0.01A ±(2.5% reading + 5 digits)
One year warranty: Contact Extech Instruments Corporation’s customer
service department at (781) 890-7440 or email at [email protected]
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237-5130 Multimeter with Infrared Thermometer

SMCS Code: 1000-038, 1050-038, 1400-038, 1400-081, 1450-038,
3000-038, 3168-038, 4450-038, 5700-038
Model: All Models
Warranty: Manufacturer’s

• Used to measure AC/DC voltage and current, resistance, capacitance, Specifications

frequency, duty cycle, and temperature
Temperature sensor requires type K thermocouple (included)
• Designed with a built-in infrared thermometer and laser pointer
IR spectral response 6 to 16µm
• Large, backlit LCD display makes viewing easier
IR emissivity 0.95 fixed
• 4000 count digital multimeter
IR distance ratio 8:1
• Provides a low-cost alternative to some other multimeters
Input impedance >7.5M Ohm (VDC & VAC)
AC response True rms
ACV bandwidth 50Hz to 1kHz
Service Parts ID: D00881T1
Display 4000 count backlit liquid crystal
Part No. Description
Overrange indication “OL” is displayed
237-5125 20 Amp Fuse
Auto power off 15 minutes (approximately)
8Q-6668 .5 Amp/250 Volt Fuse
Operating temperature 32°F to 122°F (0°C to 50°C)
1U-9534 Replacement Battery, 9 Volt
Storage temperature -4°F to 140°F (-20°C to 60°C)
212-2158 Replacement Lead Set
Weight 0.753lb (342g) (includes holster)
Size 7.36 in x 3.2 in x 2.0 in
(187 x 81 x 50mm) (includes holster)

Specifications
Function Range Resolution Accuracy Function Range Resolution Accuracy
DC Voltage 400mV 0.1mV ±(0.3% reading + 2 digits) Resistance 400Ω 0.1Ω ±(0.8% reading + 4 digits)
4V 0.001V ±(0.5% reading + 2 digits) 4kΩ 0.001kΩ ±(0.8% reading + 2 digits)
40V 0.01V ±(0.5% reading + 2 digits) 40kΩ 0.01kΩ ±(1.0% reading + 2 digits)
400V 0.1V ±(0.5% reading + 2 digits) 400kΩ 0.1kΩ ±(1.0% reading + 2 digits)
600V 1V ±(0.8% reading + 3 digits) 4MΩ 0.001MΩ ±(1.0% reading + 2 digits)
AC Voltage 50 to 400Hz 400Hz to 1kHz 40MΩ 0.01MΩ ±(3.0% reading + 5 digits)
400mV 0.1mV ±(1.5% reading ±(2.5% reading Capacitance 40nF 0.01nF ±(5.0% reading + 7 digits)
+ 15 digits) + 15digits) 400nF 0.1nF ±(3.0% reading + 5 digits)
4V 0.001V ±(1.5% reading ±(2.5% reading 4µF 0.001µF ±(3.5% reading + 5 digits)
+ 6 digits) + 8 digits) 40µF 0.01µF ±(3.5% reading + 5 digits)
40V 0.01V ±(1.5% reading ±(2.5% reading 100µF 0.1µF ±(5.0% reading + 5 digits)
+ 6 digits) + 8 digits)
400V 0.1V ±(1.5% reading ±(2.5% reading Frequency 5.000Hz 0.001Hz ±(1.5% reading + 5 digits)
+ 6 digits) + 8 digits) 50.00Hz 0.01Hz ±(1.5% reading + 5 digits)
600V 1V ±(1.8% reading ±(3% reading 500.0Hz 0.1Hz ±(1.2% reading + 2 digits)
+ 6 digits) + 8 digits) 5.000kHz 0.001kHz ±(1.2% reading + 2 digits)
50.00kHz 0.01kHz ±(1.2% reading + 2 digits)
DC Current 400µA 0.1µA ±(1.5% reading + 3 digits) 500.0kHz 0.1kHz ±(1.2% reading + 2 digits)
4000µA 1µA ±(1.5% reading + 3 digits) 5.000MHz 0.001MHz ±(1.5% reading + 4 digits)
40mA 0.01mA ±(1.5% reading + 3 digits) 10.00MHz 0.01MHz ±(1.5% reading + 4 digits)
400mA 0.1mA ±(1.5% reading + 3 digits) Sensitivity: 0.8V rms min. @ 20% to 80% duty cycle and <100kHz;
4A 0.001A ±(2.5% reading + 5 digits) 5Vrms min @ 20% to 80% duty cycle and > 100kHz.
20A 0.01A ±(2.5% reading + 5 digits)
Duty Cycle 0.1 to 99.9% 0.1% ±(1.2% reading + 2 digits)
AC Current 50 to 400Hz 400Hz to 1KHz Pulse width: 100µs - 100ms, Frequency: 5Hz to 150kHz
400µA 0.1µA ±(1.8% reading ±(3.0% reading
+ 8 digits) + 7 digits) Temp -4 to 1382°F 1°F ±(3.0% reading + 3 digits)
4000µA 1µA ±(1.8% reading ±(3.0% reading (type-K) -20 to 750°C 1°C (probe accuracy not included)
+ 8 digits) + 7 digits) Temp -4 to 518°F 1°F ±2.0% reading or ±2°C, ± 4 °F
40mA 0.01mA ±(1.8% reading ±(3.0% reading (IR) -20 to270°C 1°C
+ 8 digits) + 7 digits)
400mA 0.1mA ±(1.8% reading ±(3.0% reading
+ 8 digits) + 7 digits) NOTE: Accuracy is stated at 65°F to 83°F (18°C to 28°C) and less than 75% RH.
4A 0.001A ±(3.0% reading ±(3.5% reading Accuracy specifications consist of two elements:
+ 8 digits) + 10 digits)
· (% reading) - This is the accuracy of the measurement circuit.
20A 0.01A ±(3.0% reading ±(3.5% reading
+ 8 digits) + 10 digits) · (+ digits) - This is the accuracy of the analog to digital converter.

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9U-7330 Fluke 87 Multimeter

SMCS Code: 0115-036
Model: All Models
Warranty: Manufacturer’s

• Used to test and adjust electronic circuits

• Min/Max/Average recording mode with Min/Max Alert™
• Measures frequency, duty cycle, and capacitance
• Built-in protection against 1000V rms input
• Input Alert™ detects incorrect input jack connections
• Three 3/4-digit, 4000 count display, updates 4 times a second — analog display updates 40 times a second
• Four 1/2-digit mode has 1 ms peak hold, backlit display, and true rms measurements
• Touch hold and relative modes
• Case is splash and dust proof — also EMI shielded
ID: C66552T1

Size 52 x 98 x 201.0 mm (2.06 x 3.86 x 7.93 inch) 171-5209 Fuse (440 mAmp)
Weight 0.62 kg (22.0 oz) Voltage rating 1000 Volt
Battery life 500 hrs. typical using 1U-9534 Alkaline 9V Current rating 15 Amp
Display update rate 3 times/sec in Hz and 1.5/sec in duty cycle Size 10.3 mm dia. X 34.9 mm (13/32 inch dia. X 1 3/8 inch)
for inputs > 10 Hz Load carrying capacity 110% load 4 hours, opens at 135% load within 1 hour
Environmental Short circuit interruption 100,000 Amps at 600 Volts AC
Operation temperature -18 to 50°C (0 to 122°F) Ohms and Diode Test
Storage temperature -20 to 70°C (-4 to 158°F) Ohms 0 - 400.00 MΩ
Voltage Accuracy ±0.2% + 1 digit
AC and DC 0mV - 1000V Open circuit voltage < 1.3 in ohms and < 3.9V in diode test
Accuracy ±(0.1% + 1 digit) DC ±(0.7% + 2 digits) AC Short circuit current < 500µA in ohms and < 1 mA in diode test
Input impedance 10 MΩ Diode test displays voltage drop to 3.000V
Overload protection 1000V rms Accuracy ±2.0% + 1 digit
Current Continuity continuous tone 2731 Hz for resistance < 20
AC and DC 0µA - 10A Capacitance
Accuracy ±(0.2% + 2 digits) DC ±(1.0% + 2 digits) AC Range 0 nF - 5.00 µF
Input protection 3N-5612 Fuse, 1A 600V, for mAµA range Accuracy ±1.0% + 2 digits
9U-6398 Fuse, 15A 600V, for A range
Frequency and Duty Cycle
3N-5612 Fuse
Input range 0.5Hz to > 200 kHz frequency > 2 µs pulse width
Voltage rating 600 Volt
Hz range 0 - > 200 kHz
Current rating 1 Amp
Duty cycle range 0.1% to 99.9%
Size 10.3 mm dia. X 34.9 mm (13/32 inch dia. X 1 3/8 inch)
Accuracy ±(0.005% + 1 digit) frequency
Load carrying capacity 110% load indefinitely, opens at 135% load ±(0.05% per kHz +0.1%) for a 5V logic signal
within 1 hour
Sensitivity - 150 mV
171-5207 Fuse (11A)
Trigger level approx. 0V AC and 10% of range DC
Voltage rating 1000 Volt
Current rating 440 mAmp
Size 10.3 mm dia. X 38.1 mm (13/32 inch dia. X 1 1/2 inch)
Load carrying capacity 110% load 4 hours, opens at 135% load within 1 hour

244-1536 Corrosion Cable Group Probe (Red) 12 m (40 ft) long

SMCS Code: 1400-081
Alligator Probe (Black) 3 m (10 ft) long
Model: Marine Engines
Warranty: One Year

• Used to determine if metal parts exposed to sea water,

within an engine, are subject to corrosion
• Used with 237-5130, 212-2160, 146-4080, 9U-7330 Multimeters,
or any other multimeter capable of measuring millivolts
• Checks low level voltage by clipping black cable to metal part
and placing silver probe into sea water inside the component
• Determines if zinc levels are low, good, or too high—proper levels
of zinc extend service life of all parts exposed to sea water
ID: D00674T1

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152-7213 Fluke123 Scopemeter 120 VAC

SMCS Code: 0115-036
Model: All Models
Warranty: Manufacturer’s (3 years parts and labor)
Comes fully equipped with:
• For 220 VAC operation, order optional 138-1154 Battery Charger • BP 120 Rechargeable battery pack (installed)
• Used to test and adjust electronic circuits • PM 8907 line voltage adapter/charger —
• Dual channel digital scope and dual channel true-RMS DMM 120 VAC, 50/60 Hz only
• Fully integrated — always displays scope waveforms • Two STL 120 shielded test leads
and meter readings (one red, one gray; which
• Battery life of up to five hours includes two ground leads)
• AUTO key for fast, rock stable waveform display of signals • One black TL75 test lead
down to 1 Hz • Two HC 120 Hook Clips
• Save and recall feature for screen setups • Three AC 120 Alligator clips
• Integral holster stands up to rough treatment • One BB 120 Shielded Banana
• User assistance in English and Spanish to BNC adapter
• Brilliant high contrast backlit LCD • User’s Manual
• Hardened scratch-resistant lens protects LCD from damage
• Unique shielded test lead for all measurements General Specifications
ID: C66974T1
• All measurement terminals are isolated from earth ground Display
• Used to record trends and find intermittents using Cold cathode fluorescent backlit LCD. Contrast and brightness
dual-channel TrendPlot user adjustable. Wide viewing angle.
Dual Input Oscilloscope Size 72 x 72 mm (2.8 x 2.8 in)
Vertical Power
Bandwidth 20 MHz at inputs with STL120 1:1 leads: Line voltage adapter/battery charger included (120 VAC, 50/60 Hz).
12.5 MHz with PM 8918 10:1 optional For 220 VAC operation, order optional 138-1154 Battery Charger.
probes 20 MHz
Installed battery rechargeable NiCd pack
Coupling AC, DC
Operating time up to 5 hours
Sensitivity 5mV/div to 500 V/div
Charging time 4 hours
Vertical Resolution 8 bit
Environmental
Accuracey ±(2% of reading + 0.05 x range/div)
Temperature 0°C to 50°C
Horizontal
Environmental MIL-T-28800E, Type III, Class 3, Style B
Range 20 ns/div to 60 s/div
Electro-Magnetic Compatibility
Acquisition modes normal, single, roll, envelope, smooth
Emmision EN50081-1 (1992): EN55022 and EN60555-2
Max. sample rate 1.25 GS/s for repetitive signals
25 MS/s for single shot Immunity EN50082-2 (1992): IEC1000-4-2, -3, -5
Record length 512 samples per channel Enclosure protection IP51, IEC529 (dust, drip proof)
Accuracy ±(0.1% of reading + 0.04 x time/div) Mechanical Data
Glitch capture 40 ns or longer Size 50 x 115 x 232 mm (2 x 4.5 x 9.1 in)
Trigger Weight 1.2 kg (2.5 lb.)
Source A or B. External via optional ITP120 Safety
Modes auto, triggered, single Designed for measurements on 600V Overvoltage
Category III Installations, Pollution Degree 2, per:
Video NTSC, PAL, PAL+, SECAM random lines
or user selectable Line ANSI/ISA S82.01-1994, EN61010.1 (1993) (IEC1010-1),
CAN/CSA-C22.2 No. 1010.1-92, UL3111-1
Pre-trigger up to 10 division of pre-trigger view
Surge protection 6kV on input A and B
Measurements
Floating measurements600 Vrms from any terminal to ground
VDC, VAC, VAC+DC, Vpeak, Vpeak-peak, Frequency, Duty Cycle,
Pulse Width and Phase. Measurements can be scaled to Amps. Optically Isolated RS-232 Interface
Memory To printer supports HP LaserJet®, DeskJet®,
Epson FX/LQ, and Postscript
Type of memory 2 screens, 10 user setups
To PC dump and load settings and data,
compatible with FlukeView® Software
Dual Input 5000 Count Autoranging Meter SW90W/012E for Windows
DC Voltage VDC
Ranges 500 mV, 5V, 50V, 500V, 1250V 138-1154 Power Adapter, 220 Volt
Accuracy ±(0.5% + 5 counts) • Used to connect 152-7213 Fluke 123 Scopemeter to a 220 VAC utility power supply
True RMS Voltage VAC and VAC+DC Input volts 115 VAC ± 10%
Ranges 500 mV, 5V, 50V, 500V, 1250V or 230 VAC ± 15%
Accuracy ±(1% + 10 counts) Line frequency 50, 60, 400 Hz ± 10%
Additional Measurements and Functions Output voltage 15 VDC
Ohms, Continuity, Diode Test, Amps, °C or °F, Capacitance, Output current 300 milliamps maximum
dBV, dBM, Crest Factor, Touch Hold, and Zero Set. Power
(Amps, °C or °F with optional probes)
consumption 7 watt maximum
TrendPlot™
Output plug 5 mm power jack
Graphs meter readings of the MIN and MAX values per DIN 45232
from 120 seconds to 16 days. Automatic vertical scaling
Operating
and time compression. Displays the actual and MIN,
temperature 0 to 40°C (104°F)
MAX or AVG reading.
Input plug standard 110V
ID: C55085T1
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228-3175 Calibrator Group Dimensions (W x D x H) 130 x 61 x 236 (5.1 x 2.4 x 9.3 in)
SMCS Code: 7002-038, 0778-035 Service Parts Weight 1.4 kg (3 lb 1 oz)
Model: 3600 Generator Set
Part No. Description Display 240 by 200 pixel graphic LCD
Warranty: Manufacturer’s
163-0097 Battery Memory backup Lithium battery,

Compliant 5 years typical lifetime

8T-0458 Type K Thermocouple
Operating temperature -10°C to 50°C (14°F to 122°F)
• 220 VAC use only (international only) Storage temperature -20°C to 60°C (-4°F to 140°F)
• Used to source/measure temperature and electrical signals
with precise accuracy, all in one rugged, hand-held device
Electrical Specifications
• Used to calibrate 3600 Protection Systems, Marine Monitoring
Systems, 3600 Engine Management Systems, 3600 Electronic Measure Measure Source Source
Range Accuracy Range Accuracy
Unit Injection Systems, and 3600 Custom PLC Systems
(full scale) (% of reading (full scale) (% of reading
• Automatically captures calibration results + % of full scale) + % of full scale)
• Measures/simulates eleven different types RTD’s and Thermocouples 110.000 mV DC 0.025% + 0.015% 110.000 mV 0.01% + 0.005%
of thermocouples and eight different RTD’s Measure Source 1.10000V DC 0.025% + 0.005% 1.10000V 0.01% + 0.005%
• Stores up to 8,000 readings Device Accuracy Accuracy 11.0000V DC 0.025% + 0.005% 15.0000V 0.01% + 0.005%
• Unit is protected against dirt, dust, vibration, 10Ω Cu (427) 3°C 1°C 110.000V DC 0.05% + 0.005%
and moisture 100Ω Pt (3916) 0.3°C 0.1°C 300.00V DC 0.05% + 0.005%
• Operates in English, French, German, Italian, 100Ω Pt (3926) 0.3°C 0.1°C V AC, 20 TO 40 Hz 2% + 10 Counts
or Spanish
100Ω Pt (385) 0.3°C 0.1°C V AC, 40 TO 500 Hz 0.5% + 5
• Equipped with a built-in calculator
200Ω Pt (385) 0.3°C 0.1°C V AC, 500 TO 1 KHz 2% + 10
• Comes with a three-year warranty
500Ω Pt (385) 0.3°C 0.1°C V AC, 1 kHz to 5 kHz 10% + 20
• Comes with ISO9001 Calibration Certificate
1000Ω Pt (385) 0.3°C 0.1°C 30.000 mA DC 0.01% + 0.015% Source 22.000 mA 0.01% + 0.015%
• Calibrator includes: two sets of test leads,
120Ω Ni (672) 0.3°C 0.1°C 110.00mA DC 0.01% +0.15% Simulate 22.000 mA 0.02% + 0.03%
two sets of alligator clips, one set of probe
leads, one Nickel-Cadmium 7.2 V battery, E 0.3°C 0.2°C 11.000Ω 0.05% + 50Ω 11.000Ω 0.01% + 20 mΩ
one battery charger, one carrying strap, N 0.5°C 0.3°C 110.00Ω 0.05% + 50Ω 110.00Ω 0.01% + 40 mΩ
two jumper leads J 0.3°C 0.2°C 1.1000 kΩ 0.05% +0.5Ω 1.1000 kΩ 0.02% + 0.5Ω
L 0.3°C 0.2°C 11.000 kΩ 0.1% +10Ω 11.000 kΩ 0.03% + 5Ω
Repair Information K 0.3°C 0.3°C
Fluke Deutschland Gmbh 1.00 to 109.99 Hz 0.05 Hz 0.00 to 10.99 Hz 0.01 Hz
Heinrich Hertz Strasse 11 T 0.3°C 0.3°C 110.0 to 1099.9 Hz 0.5 Hz 11.00 to 109.99 Hz 0.1 Hz
Kassel, Germany, D-34123 U 0.3°C 0.3°C 1.100 to 10.999 kHz 5 Hz 110.0 to 1099.9 Hz 0.1 Hz
Phone: +49-561-959-4650 B 0.9°C 0.8°C 11.00 to 50.00 kHz 50 Hz 1.100 to 21.999kHz 2 Hz
Fax: 49-561-959-4649 R 1.0°C 0.9°C 22.000 to 50.000 kHz 5 Hz
S 0.9°C 0.9°C
C 0.6°C 0.6°C

Resolution: 0.1°C, except 1°C for 10Ω Cu.

Best case, mid-range accuracies. Sensor
inaccuracies not included. For 2-wire and
3-wire RTD measurements, add 0.4°C.
Thermocouple accuracies with external
cold junction. For internal add 0.2°C.

163-0096 Fluke 741B Process Calibrator RTD’s and Thermocouples

SMCS Code: 7002-038, 0778-035
Measure Source Measure Source
Model: 3600 Series Generator Set Device Accuracy Accuracy Device Accuracy Accuracy
Warranty: Manufacturer’s
10Ω Cu (427) 3°C 1°C E 0.3°C 0.2°C

Compliant 100Ω Pt (3916)

100Ω Pt (3926)
0.3°C
0.3°C
0.1°C
0.1°C
N
J
0.5°C
0.3°C
0.3°C
0.2°C
• Used to source/measure temperature and electrical signals
100Ω Pt (385) 0.3°C 0.1°C L 0.3°C 0.2°C
with precise accuracy, all in one rugged, hand-held device
200Ω Pt (385) 0.3°C 0.1°C K 0.3°C 0.3°C
• Automatically captures calibration results
500Ω Pt (385) 0.3°C 0.1°C T 0.3°C 0.3°C
• Measures/simulates eleven different types of thermocouples
and eight different RTD’s 1000Ω Pt (385) 0.3°C 0.1°C U 0.3°C 0.3°C
• Stores up to 8,000 readings 120Ω Ni (672) 0.3°C 0.1°C B 0.9°C 0.8°C
• Unit is protected against dirt, dust, vibration, and moisture R 1.0°C 0.9°C
• Operates in English, French, German, Italian, or Spanish S 0.9°C 0.9°C
• Equipped with a built-in calculator C 0.6°C 0.6°C
• Comes with three-year warranty
Resolution: 0.1°C, except 1°C for 10Ω Cu. Best case, mid-range accuracies. Sensor
• Comes with ISO9001 Calibration Certificate inaccuracies not included. For 2-wire and 3-wire RTD measurements, add 0.4°C.
• Used to calibrate 3600 Protection Systems, Marine Monitoring Thermocouple accuracies with external cold junction. For internal add 0.2°C.
Systems, 3600 Engine Management Systems, 3600 Electronic
Unit Injection Systems and 3600 Custom PLC Systems

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Diagnostic Tools Search Electrical Tools

Dimensions (W x D x H) 130 mm x 61 mm x 236 mm (5.1 in x 2.4 in x 9.3 in) Electrical Specifications

Weight 1.4 kg (3 lb 1 oz) Measure Measure Source Source
Display 240 by 200 pixel graphic LCD Range Accuracy Range Accuracy
(full scale) (% of reading (full scale) (% of reading
Memory Backup Lithium battery, 5 years typical lifetime + % of full scale) + % of full scale)
Operating temperature -10°C to 50°C (14°F to 122°F) 110.000 mV DC 0.025% + 0.015% 110.000 mV 0.01% + 0.005%
Storage temperature -20°C to 60°C (-4°F to 140°F) 1.10000V DC 0.025% + 0.005% 1.10000V 0.01% + 0.005%
11.0000V DC 0.025% + 0.005% 15.0000V 0.01% + 0.005%
110.000V DC 0.05% + 0.005%
300.00V DC 0.05% + 0.005%
V AC, 20 TO 40 Hz 2% + 10 Counts
V AC, 40 TO 500 Hz 0.5% + 5
V AC, 500 TO 1 KHz 2% + 10
V AC, 1 kHz to 5 kHz 10% + 20
30.000 mA DC 0.01% + 0.015% Source 22.000 mA 0.01% + 0.015%
110.00mA DC 0.01% +0.15% Simulate 22.000 mA 0.02% + 0.03%
11.000Ω 0.05% + 50Ω 11.000Ω 0.01% + 20 mΩ
110.00Ω 0.05% + 50Ω 110.00Ω 0.01% + 40 mΩ
1.1000 kΩ 0.05% +0.5Ω 1.1000 kΩ 0.02% + 0.5Ω
11.000 kΩ 0.1% +10Ω 11.000 kΩ 0.03% + 5Ω
1.00 to 109.99 Hz 0.05 Hz 0.00 to 10.99 Hz 0.01 Hz
110.0 to 1099.9 Hz 0.5 Hz 11.00 to 109.99 Hz 0.1 Hz
1.100 to 10.999 kHz 5 Hz 110.0 to 1099.9 Hz 0.1 Hz
11.00 to 50.00 kHz 50 Hz 1.100 to 21.999 kHz 2 Hz
22.000 to 50.000 kHz 5 Hz

ID: ph3, C79463T1

Item Part No. Description Quantity

1 Test leads 2 sets
2 Alligator clips 2 sets
3 Probe leads 1 sets
4 Nickel-Cadmium 7.2 V battery 1
5 Battery charger 1
6 Carrying strap 1
7 Jumper leads 2
Service Part
163-0097 Spare Battery
8T-0458 Type K Thermocouple

ID: ph2, C80310T1

1U-8115 Insulated Tip Test Lead Set

SMCS Code: 1400-081
Model: All Models
Warranty: One Year

• Optional accessory lead set for multimeters which have 9.5 mm (.375 in.) diameter input connectors;
older meters have larger diameter connectors
• Spring loaded insulators over metal probe tips to prevent tips from making accidental electrical
contact with wires and terminals during testing; accidental electrical contact can be a problem
when reaching into electrical circuitry with normal test leads which have as much as 19 mm (.75 in.)
of bare probe exposed; on 1U-8115 Test Lead probes, only very tip of probe normally exposed
• However, since insulating sleeves are spring loaded, they can be pushed back at any time to expose
more of metal tip; allows metal probe tip to enter small diameter holes when testing connectors;
insulators can be pushed back and locked in position to uncover approximately 6.3 mm (.25 in.) of bare probe ID: B83846T1
Lead length 1378 mm (54 in.)
Connectors 9.5 mm (.375 in.) diameter
shielded bannana plug
Maximum voltage rating 700 Volts AC or DC
Color 1 red and 1 black lead
Probe tip diameter 1.77 mm (.070 in.)
Probe tip length 15 mm (.6 in.) maximum

Home Dealer Service Tools 2004 1-13

Electrical Tools Search Diagnostic Tools

152-7143 Cable Assembly (GSC Data Cable)

SMCS Code: 4450-038
Model: Generator Sets
Warranty: One Year

• Used to flash-program EMCP2+ Generator Status Control (GSC) module

• Used with universal communications adapter cable (139-4166)
• Requires Caterpillar ET and communication adapter (171-4400 or discontinued 7X-1700)
• Flash-programming only used for field updates

ID: C79232T1

6V-2150 Starting/Charging Analyzer Group

SMCS Code: 1000-010, 1000-038, 1400-038, 1400-081, 1450-081
Model: All Models
Warranty: One Year

• Allows one person to quickly check 14 test points in starting and charging system on all 24-volt Caterpillar earthmoving
machines made after July 1981, that have automotive type key start and are equipped with a diagonostic connector
• Identifies deteriorated starting and charging system components before they fail.
• Checks can be made with single connection to diagnostic connector on the machine, in the field and without removal
of any sheet metal
• Works as voltmeter which gives an easy-to-read “go” or “no go” indication for all 14 test points
• 5.5 m cable permits test to be made in operator’s seat of vehicle
• Checks not only condition of components and circuits with more speed and accuracy, but can also be used as part
of Preventive Maintenance (PM) or Technical Analysis (TA) inspection; used this way, it can decrease possibility
of sudden downtime in near future ID: C33259T1
Weight 3.2 kg (7 lbs) 6V-3072 Case
Reference Size 394 mm x 311 mm x 102 mm 6V-3112 Base — Plastic housing
SENR2947 System Operation Testing and Adjusting Manual (15.5 inch x 12.25 inch x 4 inch) for test panel
SEHS8145 Special Instruction (repair) Cable Length 217 inch (5500 mm) 6V-4174 Packing Set
Power required 10 to 30 Volts at 250 mA from 6V-3178 Cable Assembly
24-Volt vehicle electrical system NEEG2036 Instruction Decal
Operating NEEG2041 Title Decal
temperature range -18°C to +60°C (0°F to 140°F)
Recommended
storage temperature -40°C to 80°C (-40°F to 176°F)

110-4645 Adapter Cable Assembly 4C-4029 Trimmer Adjustment Tool

(Starting/Charging Analyzer) SMCS Code: 0785
Model: All Models
SMCS Code: 1400-081, 1450-081, 1400-038, 1450-038 Warranty:
Model: D5M, D6M, D6R, and D7R Track-Type Tractor
Warranty: One Year
• Allows easier adjustment of small screwdriver adjustments found on VR3 and VR4
Voltage Regulators and 2301 Woodward Regulator Controls
• Used to connect machine to 6V-2150 Starting/Charging Analyzer Group
• Constructed of glass-filled, nylon body with stainless steel blades; one end has
• Used to check 24 Volt starting and charging systems recessed blade to provide captive screwdriver for adjustments that are difficult to
• Overall length: 3 m (18 ft) see; other end has exposed blade to reach adjustments that are behind panels and
have small access holes
• Gain and level controls on VR3 Voltage Regulator are inside regulator case and
difficult to adjust when generator set is in operation; inability to see the control and
vibration of regulator make fine adjustments very difficult
• Prevents broken controls on Woodward 2301 Controls
caused by improper tool usage and excessive
force required for adjustment when
ID: C44110T1
wrong tool is used

ID: C26891T1

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Diagnostic Tools Search Electrical Tools

189-1720 Analog Gauge Tester Group

SMCS Code: 0785
Model: All models
Warranty: One Year

• Used to test and troubleshoot analog temperature, pressure, fuel or articulation gauges
• Easy-to-use, hand-held unit
• Tool Operating Manual includes charts for specific gauges.

®
TO ER AL
O AT
O AN

L I
P U
M
• Decrease troubleshooting time and reduce cost by eliminating replacement of good parts

N
18
9-1

G
72
0
An
al
og
G
au
ge
• Diagnose temperature, fuel or pressure gauge problems to determine if gauge, wiring

Te
st
er
or sender is faulty
• 0-to-50, 500, 1500 and 34,000 ohm dials used in combination to simulate sender’s output
• Fuse protected from electrical overload 18
GA 9-1720
UG

®
E TE ANAL
500 600 700 ST OG
400
ER

• Not for use with the Caterpillar Quad Gauge Module

800
300 900 20 25
200 30
100 15
100 0 35
110 10
0
OH 120 40
MS 130 0
15 20 1401365 0 5
150 KOH 45
10 25 0 0
150 200 240 MS 50
30 100 250
5
33 300
35 50
OH 40 350
MS

• Resistance tolerance: ±10% at full scale

50 45 40
OH
MS 450
500

• Linearity tolerance: ±5% independent

ID: C79960T1
Reference
NEHS0786 Tool Operating Manual

4C-4693 Tester Group, VR3 and VR4 Regulator

SMCS Code: 1400-023, 0785
Model: All Models Input Voltage 110/220 VAC, 50/60 Hz
Warranty: One Year Output Voltage variable from 0 VAC to 20% over
selected Sense voltage
• Supplies voltages necessary to check all styles of VR3 Output Voltage 0 VAC to 80 VAC (PM supply only)
and VR4 regulators; serviceman selects correct sense voltage Sense Voltage 120 VAC, 240 VAC or 480 VAC
• Operates from 110/220 VAC source
• Uses 100-watt light bulb as load for field current Item Part No. Description
• Has test ports to measure sense voltage and field voltage 1 4C-4529 Line Cord
with probes supplied with Caterpillar multimeter
2 4C-4694 Cable Assembly
Reference
NEHS0535 Tool Operating Manual

ID: C27236T1

154-9740 Housing Kit

SMCS Code: 1408-023
Model: All Models
Warranty: One Year

• Used to create a solid cable-to-component connection with an easily installed thumbscrew connector
• Works on any cable using DB-9 slotted-head, screw-type connector (similar to 7X-1425 Cable)
• No need to disconnect wires from connector (requires only cutting a slit in new grommet when spanning wire)
• No extra tools required — saves time and effort
• Cable not included

ID: C79230T1

Home Dealer Service Tools 2004 1-15

Tools for Electronic Engines Search Diagnostic Tools

Tools for Electronic Engines

190-8900 Deutsch HD Style Connector Field Repair Kit

SMCS Code: 1408-023
Model: Electronic Engines

• Redesigned from the former 4C-3406 HD Style Field Repair Kit (1U-5804 Crimp Tool
in 4C-3406 has been removed from 190-8900 to avoid duplicate tool expenses at reorder.)
• Each connector in its own sealed plastic bag for cleanliness
• Quantities adjusted to better reflect most commonly used connectors
• Convenient new carrying case allows connectors to be found easily
• Easy-to-use chart for parts reordering

Part No. Description Quantity Part No. Description Quantity

151-6320 Removal Tool #14 6 8T-8737 Seal Plug 30
7X-6195 Receptacle, 9 Pin 2 9W-0847 Plug, 9 Socket 2
8T-8731 Plug, 3 Socket 10 9X-3401 Pin #16/18 30
8T-8732 Receptacle, 3 Pin 10 9X-3402 Socket #16/18 30
8T-8733 Plug, 5 Socket 5 126-1767 Pin #14 30
8T-8734 Receptacle, 5 Pin 5 126-1768 Socket #14 30 ID: C80402T1
8T-8735 Plug, 9 Socket 8 152-7997 Utility Box 1
8T-8736 Receptacle, 9 Pin 8
NOTE: 1U-5804 Crimp Tool is not included
with group. Order separately.

175-3700 DT Connector Service Kit

147-6456 Wedge Removal Tool
SMCS Code: 1408-023
Model: All Models with Electronic Controls
Warranty: One Year

• Used to maintain and repair Deutsch “DT” style connectors on electronic engine control harnesses
• 175-3700 DT Connector Service Kit — connector/contact assortment for owners of 4C-3406 Connector
Service Kits which have 1U-5804 Crimp Tool
• 147-6456 Wedge Removal Tool included in kits — also available separately

Reference Item Part No. Description

SEHS9615 Special Instruction — A black plug 1 175-3700 DT Connector Service Kit (less crimp tool)
and connector body has been released to improve 2 147-6456 Wedge Removal Tool (included in kit)
ID: C66991T1
sealing. Please refer to SEHS9615 for a more
3 152-7997 Utility Box
detailed explanation of interchangeability.

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

separately and is also part of 4C-3406 Connector Repair Kit.

121-9588 Removal Tool, 16 gauge TXL 151-6320 Removal Tool,

SMCS Code: 1408-023
Model: 3116/3126 Engines with HEUI (Hydraulic Electronic Unit Injection)
14, 16, 18 gauge SXL/GXL
SMCS Code: 1408-023
Model: All Models With Electronic Controls
• Used to remove wires from 40 pin connectors used on
ADEM II (Advanced Diesel Engine Management) controls
• Replaces discontinued 121-9587 Removal
• Tool slips over OD of wire and compresses wire
Tool (16 gauge GXL)
retaining spring inside connector allowing wire
to be removed • Used to remove pins and
sockets from Deutsch and
• If used improperly tool will break
AMP style connectors
away before causing damage to Overall length 57.5 mm (2.25 in)
connector’s pin or socket • Versatile new design
Handle size 12.7 x 25.4 mm
allows removal of 14, 16,
ID: C66809T1 (.50 x 1.00 in)
and 18 gauge pins and sockets
Overall length 56.6 mm (2.23 inch) from connectors Material plastic
Handle size 12.7 x 25.4 • Made from a more durable material
ID: C66809T1 (.50 x 1.00 inch) than former tool (reduces breakage)
Material plastic

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Diagnostic Tools Search Tools for Electronic Engines

195-1178 Extraction Tool

195-1179 Extraction Tool
SMCS Code: 1408-023
Model: 554, 574 Forwarder; 550, 570, 580 Harvester
Warranty: One Year

• Used to remove stamped and formed terminals from AMP electrical connector bodies
• Due to various wire sizes, both tools are required.

ID: C80105T1
ID: C80106T1

195-7970 Deutsch DFN Style Connector Service Tool Overall lengh 57 mm (2.24 in)
SMCS Code: 1408-023
Handle size 12.7 x 25.4 mm (.50 x 1.00 in)
Model: All Models with Electronic Engines
Material plastic

• Used to remove the wire/socket assembly from Deutsch DFN style connector plugs
• Tool slips over OD of wire and compresses socket retaining mechanism inside connector allowing wire/socket assembly to be removed.

ID: C66809T1

NEXG4508 Service Program Module, 3406 NEXG4509 Service Program Module,

B/C Truck Engine 3176/3406E Truck Engine
SMCS Code: 1900-038, 0781 SMCS Code: 1900-038, 0781
Model: 3406 PEEC Truck Engine Model: 3176/3406 Truck Engine
Warranty: One Year Warranty: One Year

• Software [in Erasable Programmable Read Only Memory (EPROM) chip] • Software [in Erasable Programmable Read Only Memory (EPROM) chip]
• Installed in 7X-6400 DDT by customer to provide all service functions for • Installed in 7X-6400 or 7X-1055 DDT by customer to provide all service
3406 B/C Truck Engine functions for 3176 and 3406 Truck Engines
• Version number printed on module and can be displayed on DDT screen under • Version number printed on module and can be displayed on DDT screen under
Mode 00 (present version number compatible with all versions of 3406 B/C Mode 00 (present version number compatible with all versions of 3176 and
Truck Engine control personality modules) 3406E Truck Engines control personality modules

Reference Reference
SEHS8743 Special Instruction SEHS8808 Special Instruction
NEEG2501 Diagnostic Code Card NEEG2501 Pocket card
NEEG2502 Driver’s Card NEEG2502 Pocket card

NEXG4519 Service Program Module, Challenger 65/75/85

SMCS Code: 1900-038, 0781
Model: Challenger 65/75/85
Warranty: One Year

• Software [in Erasable Programmable Read Only Memory (EPROM) chip]

• Installed in 7X-6400 or 7X-1690 DDT by customer to provide all service functions for 3176 Engine in Challenger 65/75/85
• Version number printed on module and can be displayed on DDT screen under Mode 00

Reference
SEHS9203 Special Instruction Home Dealer Service Tools 2004 1-17
Tools for Electronic Engines Search Diagnostic Tools

7X-1400 Digital Diagnostic Tool Group

SMCS Code: 1900-038, 0781
Model: Industrial Engine
Warranty: One Year

• Basic electronics for Industrial Engine DDTs; addition of Service Program Module (SPM) allows it to function
with Spark Ignited Engines.
• 7X-1400 DDT can display diagnostic faults and engine RPM, display and change engine timing, and display
engine detonation level on Industrial Engines; information displayed allows engine magneto to be calibrated.
• Order NEXG4511 Service Program Module (SPM) for Spark Ignited Engines through Literature System.
• 7X-1685 Cable Assembly (included in 7X-1400) needed to supply
power to DDT and allow communication to engine control.
Item Part No. Description
• Order subscription for NEXG4511 Industrial
1 7X-1685 T-Harness
Engine Service Program Module.
2 6V-3072 Carrying Case ID: C27264T1
Reference 3 Foam Insert
SEHS9122 Special Instruction 4 SEHS9122 Special Instruction
Not shown 7X-1414 Adapter, 10-Pin
Not shown 7X-1415 Adapter, 4-Pin

NEXG4511 Industrial Engines Service NEXG4526 EIS Monitor Service Program

Program Module Module
SMCS Code: 1900-038, 0781 SMCS Code: 1900-038, 0781
Model: Industrial Engines Model: Industrial Engines
Warranty: One Year Warranty: One Year

• Software [in Erasable Programmable Read Only Memory (EPROM) chip] and • Software [in Erasable Programmable Read Only Memory (EPROM) chip]
subscription for updates • Installed in 7X-1400 or 8C-9904 DDT by customer to provide most service
• Installed in 7X-1400 or 8C-9904 DDT by customer to provide most service functions for Industrial Engines
functions for Industrial Engines • Version number printed on module and can be displayed on DDT screen under
• Version number printed on module and can be displayed on DDT screen under Mode 00
Mode 00
Reference
Reference NEHS0621
SEHS8806 Special Instruction

123-6471 Diagnostic Tool Group

SMCS Code: 5450-036, 0784, 0785
Model: M312, M315, and M318 Wheeled Excavators
Warranty: One Year

• Used to set up, test, calibrate, and troubleshoot M300 Series Wheeled Excavators
• Tester will display readings from both engine control and pump control systems.
• This hand-held tool features a 4 line, 16 character liquid crystal display.
• Power for diagnostic tool is supplied through vehicle’s on-board diagnostic connectors.
ID: C78452T1
Reference Part No. Description
SEHS9825 Special Instructions Portable Diagnostic Tool (not serviced separately)
SENR6261 Testing & Adjusting M300 Family Excavators Hydraulic Systems
123-6475 Cable Assembly
SENR6265 Electronic Control System
SENR8931 Electronic Control System 6V-3072 Plastic Case
123-6473 Foam Block Group
Overall size with case 394 x 311 x 102 mm (15.5 x 12.2 x 4.0 in) NEEG2658 Decal (Outside Case)
Overall size (tester only) 205 x 106 x 31 mm (8.05 x 4.2 x 1.2 in) NEEG2659 Decal (Control Panel)
Cable length 3 m (10 ft) SEHS9825 Special Instructions

1-18 Dealer Service Tools 2004 Home

Diagnostic Tools Search Tools for Electronic Engines

9X-9647 Throttle Position Sensor

SMCS Code: 1000-081
Model: 3176, 3406B
Warranty: None

• Used for out-of-chassis testing of 3176 and 3406B PEEC Truck Engines on engine dynamometer
• Provide throttle position signal and power to ECM; allow engine to be tested on engine dynamometer like factory end-of-line test
• 9X-9647 is connected to engine’s ECM (Electronic Control Module) and 12-volt power source, as shown below; 12 VDC can be
supplied by 12-volt truck battery or by power supply of at least 10 amps.
• FT2361 Cable is 3 meters long to easily connect ECM, Throttle Position Sensor and power source; 3176 test uses both cables;
FT2360 Cable, with 3176 adapter, is just long enough to connect FT2361 Cable to 3176 ECM.
NOTE: To test an engine this way the ECM must not be programmed. If it is programmed, the customer-specified parameters must
be removed before testing. An easy way to do this is to use an discontinued 8T-8697 ECAP equipped with an NEXG4512 Configuration
Aid. Knowledge of the customer passwords is required. Access the ECM with the ECAP and, with the help of the Configuration Aid,
store the customer-specified parameters in the ECAP. Then remove the customer-specified parameters from the ECM so the ECM
is no longer programmed. After testing, the ECM can be reprogrammed to its original configuration from the data stored in the ECAP
by the Configuration Aid.

ID: B96677T1

ID: B96678T1

ID: C26917T1

ID: C26918T1

Home Dealer Service Tools 2004 1-19

Tools for Electronic Engines Search Diagnostic Tools

NETG5030 Service Technician Workbench (STW) • Hewlett Packard Laserjet V or compatible printer
SMCS Code: 1900-038, 0781 • Pointing device (mouse, trackball, touchpad, etc.)
Model: All Models
• Modem (optional); necessary only if this is a remote workstation (28.8 kbps or
Essential Tool
higher recommended)
• Service Technician Workbench (STW) is an umbrella application tying Caterpillar PC service • Emulation or LAN adapter and software suitable for the dealer host computer
tools together with a common look and feel with support, training, and delivery • Microsoft Windows 95 or 98, Service Pack 1 or higher, or Microsoft Windows NT
• Serves as a single-point, software-based tool supporting a technician’s repair process 2000 Workstation 4.0, Service Pack 4 (STW has been tested on Windows 98)
• Provides a single user interface to Service Information System (SIS), Electronic Technician • Microsoft Internet Explorer 5.x higher
(ET), Engine Performance Estimator (EPE), Dataview, and Cat Diagnostic Adviser (CDA) • TCP/IP Dialup Adapter
• Integrates tools and functions to supply point-of-service information
• Available in CD format; order NETG5030 through Caterpillar Media Logistics.
Notebook Computer
The following configuration is recommended to run STW on a notebook (laptop)
Direct Benefits to Dealer’s Service Business computer.
• Reduces time to access necessary information relevant to diagnostic and repair process • Intel Pentium II 233 MHz processor or higher
• Reduces time to correctly troubleshoot problems and identify best repair process • 128 MB RAM or higher
• Reduces purchase of printed service literature • 2.1 GB hard disk drive or higher
• Reduces time to prepare complete and accurate service reports • 3.5 inch 1.44 MB diskette drive
• Reduces processing time for complete and accurate work order information necessary • 14x speed CD-ROM (minimum) or third generation DVD drive
for prompt and accurate invoicing
• Super VGA (800x600, 256 colors) display
• Reduces processing time for complete and accurate warranty claims
• 16 bit sound card (for use with Computer Based Training and Multimedia)
Computer Recommendations • Support for two Type II PCMCIA slots
Desktop Computer • Pointing device (mouse, trackball, touchpad, etc.)
The following configuration is recommended to run Service Technician Workbench on a • Modem (internal; Hayes compatible 28.8 kbps or higher)
desktop computer. • Emulation or LAN adapter and software suitable for the dealer host computer
• Intel Pentium II 333 MHz processor or higher • Microsoft Windows 95 or 98, Service Pack 1 or higher, or Microsoft Windows NT
• 128 MB RAM or higher 2000 Workstation 4.0, Service Pack 4 (STW has been tested on Windows 98)
• 4.3 GB hard disk drive or higher • Microsoft Internet Explorer 5.x higher
• 3.5 inch 1.44 MB diskette drive • TCP/IP Dialup Adapter
• 14x speed CD-ROM (minimum) or third generation DVD drive Reference
• 15 inch or larger Super VGA (800x600, 256 colors) adapter and monitor NEHS0796 Getting Started Guide
• 16 bit sound card (for use with Computer Based Training and Multimedia) NEHS0812 Self-Paced Tutorial on CD ROM

JERD2124, Caterpillar Electronic Technician (CAT ET)

• Software subscription includes Caterpillar Flash Memory Software (used for
JERD2125, Truck Engine Only uploading new Personality Module data to ECM) and works with Caterpillar
JERD2129, All Engines and Machines Combined • Common Services modules
A 171-4400 Communications Adapter II is required, but not included, to connect a
SMCS Code: 1900-038, 0781 personal computer to ECM – comes complete with cables, manual, software CD and
Model: All Models with Electronic Controls carrying case
Warranty: One Year
Diagnostic Capabilities
Caterpillar Electronic Technician (ET) is a service tool designed to run on a personal • CAT ET software has separate pull-down menus for selecting different function
computer under Microsoft® Windows™. With ET you can display the status of a group screens and includes HELP Function Screen (very easy to use)
of parameters (temperatures, pressures, etc.) simultaneously, view and clear active and • Diagnostic software helps technicians make accurate repairs, in a short time frame,
logged diagnostics, or display the current configuration of an ECM. ET can perform on products that are increasingly complex (finds the problem quickly and analyzes
these as well as many other tasks, such as: how to correct it)
• Display parameter status • Views events where irregularities occurred and were logged by the ECM
• View and clear diagnostics • Views and changes configuration of ECM
• View events where irregularities occurred and were logged by the ECM • Retrieves engine totals for fuel used, miles traveled, etc.
• View and change configuration of the ECM • An ECM summary screen allows viewing of ECM version and identification — other
• Perform diagnostic tests screens allow diagnostic tests and calibrations to be performed
• Perform calibrations • Output data can be viewed in either English or metric units
• View Trip information through Trip Summary, Histograms and Custom reports In order to successfully run Caterpillar Electronic Technician, you will need the
following: computer hardware, communication hardware, cables, and software.
• Print reports and diagnostic results
For some subscriptions of Caterpillar Electronic Technician, additional programs have NOTE: The minimum PC Configurations should not be used as a standard when buying
been included with the ET program. new personal computers to run Caterpillar Electronic Technician. If you have existing
equipment that meets these minimum requirements it will run Caterpillar Electronic
Caterpillar Electronic Technician is designed to communicate with the ECMs through Technician.
communication data link. Caterpillar Electronic Technician allows you to obtain data,
analyze it, then diagnose existing and potential problems. Minimum PC Configuration
• IBM® PC compatible with Pentium 266 MHz processor or greater
Software Features and Requirements • 64 MB of RAM
• CAT ET is designed to run as a “stand alone” Windows program or can be called
• 400 MB of available hard disk drive
from Service Information System (SIS) using OS/2 operating system
• CD-ROM drive
• All software subscriptions include future enhancements and data updates
• 3.5 inch 1.44 MB floppy disk drive
• Software is provided with a single-use license (must purchase a copy of CAT ET for
each computer) • Super VGA monitor or display (800x600)
• Site license is available for dealers purchasing more than 50 ETs for their main store • Microsoft® Windows™ NT 4.0 (Service Pack 4), 2000, ME, XP, or Windows 9x
and branches • Microsoft® Internet Explorer 5.0 or higher
• RS232 port with 16550AF UART
• Built in pointing device or mouse
1-20 Dealer Service Tools 2004 Home
Diagnostic Tools Search Tools for Electronic Engines

Recommended PC Configuration Software

• IBM® PC compatible with Pentium 111450 MHz processor • MS or PC DOS version 5.0 or greater
• 128 MB RAM • Microsoft® Windows™ version 3.1 or greater
• 1 GB of available hard disk drive • Miscrosoft Windows 95
• 40X speed CD-ROM drive or 8X speed DVD drive Ordering Information
• 3.5 inch 1.44 MB floppy disk drive CAT ET software can be ordered through the Corporate Literature Distribution System. All orders must include
• Super VGA color monitor or display (800x600) the media numbers for the program license and the data subscription desired. (Only one data subscription
• Microsoft® Windows™ NT 4.0 (Service Pack 6), 2000, should be ordered for each CAT ET). The media numbers are as follows:
ME, XP, or Windows 98 0 RS232 port with 16550AF UART
Program Single Use Licenses:
• Built in pointing device or mouse JERD2124, Program License
• Microsoft® Internet Explorer 5.5 or higher
Annual Data Subscription (order one):
NOTE: If your Microsoft® Internet Explorer screen size JERD2125, On-Highway Truck Engine
is 640x480, press the maximize button to fill the screen. JERD2129, All Engines and Machines Combined
Other Requirements Each CAT ET software shipment includes: the CAT ET Program (single-use license) and the data
• 171-4400 Communications Adapter subscription ordered.
JEBD3003 Cat ET Software and Getting Started Guide

Caterpillar Electronic Technician (Customer Version)

SMCS Code: 1900-038, 0781 In order to successfully run Caterpillar Electronic Technician, you will need the following: computer
Model: All Models with Electronic Controls hardware, communication hardware, cables, and software.
Warranty: One Year
NOTE: The minimum PC Configurations should not be used as a standard when buying new personal
The Customer Version of ET is a very valuable PC-based computers to run Caterpillar Electronic Technician. If you have existing equipment that meets these minimum
service and electronic information tool for obtaining requirements it will run Caterpillar Electronic Technician.
information from electronic products. Order JERD3003
Getting Started Guide.
Minimum PC Configuration Recommended PC Configuration
• IBM® PC compatible with Pentium • IBM® PC compatible with Pentium
ET can perform tasks such as: 266 MHz processor or greater 111450 MHz processor
• Retrieve engine totals for fuel used, miles traveled, and hours • 64 MB of RAM • 128 MB RAM
operated • 400 MB of available hard disk drive • 1 GB of available hard disk drive
• Display status of all parameters, such as engine speed, • CD-ROM drive • 40X speed CD-ROM drive or 8X speed DVD drive
throttle position, timing advance, fuel flow, etc.
• 3.5 inch 1.44 MB floppy disk drive • 3.5 inch 1.44 MB floppy disk drive
• View active and logged diagnostic codes to identify faulty
sensors • Super VGA monitor or display (800x600) • Super VGA color monitor or display (800x600)
• Display “Logged Event Codes” to show engine overspeeds, • Microsoft® Windows™ NT 4.0 (Service Pack 4), • Microsoft® Windows™ NT 4.0 (Service Pack 6),
high temperatures, fuel consumption, etc. 2000, ME, XP, or Windows 9x 2000, ME, XP, or Windows 98 0 RS232 port with
• View ECM’s current configuration and change user settings • Microsoft® Internet Explorer 5.0 or higher 16550AF UART
• Perform diagnostic tests and calibrations, and calibrate • RS232 port with 16550AF UART • Built in pointing device or mouse
electro-mechanical and electro-hydraulic components • Built in pointing device or mouse • Microsoft® Internet Explorer 5.5 or higher
• Context sensitive help leads operator through every task Cat
ET can perform NOTE: If your Microsoft® Internet Explorer screen Ordering Information
size is 640x480, press the maximize button to fill the • Cat ET Getting Started Guide and CD-ROM
• Data Logger and Data Log Viewer allows recording of ECM
screen. for installing ET software on your PC
signals for delayed troubleshooting capability.
The functions listed below can also provide important data to Other Requirements • Full Service Cat Customer
improve operation and maintenance of equipment and increase • 171-4400 Caterpillar Communications Adapter JERD2124 — Program License
profitability. Options (select one or more): NEXG5007 — Program Subscription
• Cat “ET Trainer” is now included in ET Program. It allows • 139-4166 Data Link Unicable (Cat Data Link and • Truck Engine Parts & Service (TEPS) Customer
users to train and practice using Cat ET without a ATA Data Link Cable) JERD2124 — Program License
communications adapter or Electronic Control Module (ECM). NEXG5009 — Program Subscription
• 140-9442 Data Link T-Cable
This is a free feature of Cat ET.
• 7X-1686 In-Cab Adapter for Highway Truck Cable • Customer ET (one time only) License
• ECM Summary screen lists every control module on equipment and no subscription
being tested and gives information on these modules. • 1U-9100 Challenger 45/55 Cable
• 126-7877 M300 HEX R5232 Cable NEXG5039
• Fast hookup and real time display of systems status. Displays
readings such as rpm, boost, pressures, temperatures, etc. for
easy troubleshooting.
• Identifies faulty sensors, harness connectors, and system
parameters which are out of specification. Allows customers
to help dealer identify problems without visiting machine.
• Identifies intermittent sensors and wiring problems during
machine operation and keeps a record of each one. Shows
when problem occurred and how often it happened. Provides
added information to allow customer to assist dealer in
diagnosing and repairing problems.
• Shows all operating conditions that cause high repair costs
such as: overspeeds, high temperatures, fuel consumption,
and transmission shift counts. This can provide awareness
to change operator techniques resulting in lower machine
operating and maintenance costs.
• Tests are provided such as cylinder cutout and injector
activation pressure to make problem locating easy.
• Data Logger and Data Log Viewer allows Recording of ECM
signals for delayed troubleshooting capability.
Home Dealer Service Tools 2004 1-21
ID: C79380T1
Tools for Electronic Engines Search Diagnostic Tools

Pocket Technician™

• Includes Pocket Tec™ software, a plug-in Palm adapter and a vehicle connecting cable.
• Save trip data for a fleet of trucks, with ability to synchronize to a PC for review
• “Save to Memo” function that allows user to save configuration data for use at a later time
• View logged diagnostic codes or events
• “Read and Change” capability on 54 engine parameters allows changes instantly and routinely
• Engine operating information for up to 40 status parameters
• Driver reward-view and program targets, factors and scores
• Lifetime and trip totals
• Active diagnostic codes
• Maintenance information
• Theft deterrent
• 1 Year Limited Warranty

Pocket Tec Kits

Description Part No.
Driver Edition 1.0
Palm III - 6-pin Kit 216-2779
Palm III - 9-pin Kit 216-3923
Palm III - 9- and 6-pin Kit 216-2785
Palm III - GM ALDL Kit 216-2782
Palm m100 - 6-pin Kit 216-2788
Palm m100 - 9-pin Kit 216-2789
Palm m100 - 9- and 6-pin Kit 216-2786
Palm m100 - GM ALDL Kit 216-2787
Palm m500 - 6-pin Kit 221-1595
Palm m500 - 9-pin Kit 221-1596
Palm m500 - 9- and 6-pin Kit 221-1597
Palm m500 - GM ALDL Kit 221-1594
Fleet Edition 1.1.1:
Palm III - 6-pin Kit 221-0622
Palm III - 9-pin Kit 221-0623
Palm III - 9- and 6-pin Kit 221-0624
Palm III - GM ALDL Kit 221-0621
ID: D00714T1
Palm m100 - 6-pin Kit 221-0627
Palm m100 - 9-pin Kit 221-0628 Palm III Kits support: Palm III, IIIe, IIIxe, IIIc, VII, VIIx
HandEra TRGpro, HandEra 330, IBM Workpad, Symbol SPT-1500
Palm m100 - 9- and 6-pin Kit 221-0625 Palm V and Vx, IBM Workpad c3
Palm m100 - GM ALDL Kit 221-0626 (with Dock V Pro from www.palmdock.com)
Palm m500 - 6-pin Kit 221-1603 Palm m100 Kits support: Palm m100, m105
Palm m500 - 9-pin Kit 221-1604 Palm m500 Kits support: Palm m125, m130, m500, m505, m515, i705
Palm m500 - 9- and 6-pin Kit 221-1605
Palm UC Kits support: Palm Zire 71, Tungsten T, Tungsten C, Tungsten W
Palm m500 - GM ALDL Kit 221-1602
Palm UC - 6-pin Kit 240-9946 Available November 2003
Palm UC - 9-pin Kit 240-9947 Available November 2003
Palm is a trademark of Palm, Inc.
HandEra and TRGpro are trademarks of HandEra, Inc.
Palm UC - 9- and 6-pin Kit 240-9948 Available November 2003
Palm UC - GM ALDL Kit 240-9945 Available November 2003
Individual Parts
Fleet Edition 1.1.1 - Upgrade
from Driver Edition (Software only) 221-0619
9-pin cable (J1708-only) 204-5636
6-pin cable (J1708-only) 204-5638
GM ALDL cable (J1708-only) 206-2950
9-pin cable (Black, J1708/J1939) 240-9950
Palm III Com Adapter 204-7459
Palm m100 Com Adapter 212-8773
Palm m500 Com Adapter 221-1593
Palm UC (J1708/CDL/J1939) Adapter 228-6558 Available November 2003

1-22 Dealer Service Tools 2004 Home

Diagnostic Tools Search Tools for Electronic Engines

208-8371 Cat® Messenger

• Monitors critical performance and operating information

• Fuel monitoring—Messenger graphically displays and records fuel usage and average miles per
gallon to monitor individual performance. A maintenance monitor can be enabled to alert drivers
to preventative maintenance inspections and oil changes. Messenger also provides lifetime total,
trip totals, and driver totals.
• Theft deterrent—Messenger can allow or prevent engine starting or shutting down by requiring
a password when the engine is at idle.
• Trip data—All of the parameters can be tied to trip segments or the engine history. A Driver or
Fleet Trip Segment is available. For the Driver Trip Segment, the driver determines the start and
stop points, and for the Fleet Trip Segment the vehicle owner determines the start and stop points.
The Fleet Trip Segment can be tied to each state the vehicle operates in, as well as split between two Driver ID’s.
• Diagnostic data—Messenger provides diagnostic codes, with both a number, and a brief text explanation.
Messenger displays the codes, indicating a potentially serious engine problem automatically. ID: D00732T1
• Engine operating view—cruise control set speed, PTO engine RPM set speed, fuel temperature to the engine,
boost and oil pressure, coolant temperature, intake manifold temperature
• Vehicle trip information—fuel used (fuel economy), average vehicle speed, idle and PTO time, percent idle
time, idle fuel, PTO fuel
• Messenger is flashed and includes a harness.
• Flash software upgrades engines. Configurable for use in multiple applications
• Fully configurable graphics and menu structure for customization
• Dimmable backlight via either external dimmer input or display keypad
• 4 integral operator input buttons
• 227-4283 Gimble Mount

Specifications
• Rugged, low-cost design. 32-bit processor, 24MHz 1Mb “Flash” memory flash-able over
data link 32K EEPROM/512K RAM
ID: D00720T1
• 64(h)x240(w) fully graphic, transflective LCD allows viewing in all lighting conditions
• LED backlighting for long life and sharp contrast
• Compact and durable for adverse heavy duty off-road environments
• 8-pin integral Deutsch-DT environmentally sealed connector

Cables
SMCS Code: 1900-038, 0781
Model: All Electronic Controlled Engines Tested by ECAP
Warranty: One Year

• Used to provide power to ECAP through external power source — ECAP retains
power during engine cranking
• Used with discontinued 8T-8697 ECAP
• Cable assemblies can be connected to AC power adapter or battery — T-harness
allows cable leading to electronic control module (ECM) to remain connected
• T-harness connects between ECAP and T-cable to ECM — 7X-1854 Cable for
ECAP with metal connector, 7X-1855 Cable for older plastic connectors
• One end of 7X-1854 and 7X-1855 Cable has two-pin MS connector
(allows connection to external power supply)
• Three connections for external power sources are available — 5P-7366 Cable Assembly
(for connection to battery), 8T-9276 AC Power Supply, and 8C-9705 Converter (8C-9705
also requires 7X-1856)

ID: C66647T1
Item Part No. Description
1 7X-1854 Cable (metal connector) or
7X-1855 Cable (plastic connector)
2 7X-1856 Cable
3 8C-9705 AC Power Suppply (plastic connector)
4 8T-9276 AC Power Supply (metal connector)
5 5P-7366 Cable Assembly

Home Dealer Service Tools 2004 1-23

Tools for Electronic Engines Search Diagnostic Tools

8C-9705 Converter, 12-Volt NEXG4514 ECAP Executive/Utility Service

SMCS Code: 1900-038, 0781
Model: 3406 PEEC, 3176 Engines
Program Module
Warranty: One Year SMCS Code: 1900-038, 0781
Model: 3406 PEEC, 3176 Engines
• Provides power to Warranty: One Year
discontinued 8T-8697 ECAP
when used away from engine or vehicle • Software [in Erasable Programmable Read Only Memory (EPROM) chip]
being serviced; plugs into Port 1 on ECAP; • Included in discontinued 8T-8697 ECAP; does not have to be ordered separately except for
can be switched to provide DC power to very early ECAP’s with V1.0 installed
ECAP from either 120 or 240 Volts AC • NEXG4514 runs the ECAP; selects Metric or English display units; handles interface with
sources at either 50 or 60 Hz SPM’s in ECAP and interface with adapters connected to port 3; provides basic
communication abilities with ports 1 and 2
• Current SPM may be marked NEXG4514 V1.1, 7X-1350 V1.1, or 8C-5363 V1.1; all three are
same current software and will do same job; version number printed on SPM; also
displayed on ECAP screen during power up self test and can be displayed on screen under
SPM Version Number screen
ID: B83919T1
Reference
SEHS8741 Special Instruction

NEXG4522 Truck Service Program NEXG4516 Service Program Module,

Module, All Highway Truck Engines Marine/Industrial Engines
SMCS Code: 1900-038, 0781 SMCS Code: 1900-036, 0782
Model: All Highway Truck Engines Model: 3408, 3412 Marine/Industrial Engines
Warranty: One Year Warranty: One Year
• Software [in Erasable Programmable Read Only Memory (EPROM) chips] • All Electronically Controlled Marine and Industrial Engines
and subscription for updates • Software [in Erasable Programmable Read Only Memory (EPROM) chips] and subscription
• Installed in discontinued 8T-8697 ECAP by customer to provide all service for updates
functions for all Highway Truck Engines • Installed in discontinued 8T-8697 ECAP by customer to provide all service functions for all
• Version number printed on module and can be displayed on ECAP screen Highway Truck Engines
under SPM Version Number screen compatible with all versions of all • Version number printed on module and can be displayed on ECAP screen under SPM
Highway Truck Engine control personality modules. Version Number screen compatible with all versions of all Highway Truck Engine control
personality modules.
Reference
SEHS9349 Special Instruction Reference
NEEG2501 Diagnostic Code Card SEHS9199 Special Instruction, Using the ECAP NEXG4516 Marine/Industrial SPM (included
NEEG2502 Driver’s Card with SPM)
NEEG2490 Pocket Card

NEXG4518 Service Program Module, NEXG4512 Configuration Aid Service

Challenger 75 Program Module
SMCS Code: 1900-038, 0781 SMCS Code: 1900-038, 0781
Model: Challenger 75 Model: 3406B PEEC, 3176 Engines
Warranty: One Year Warranty: One Year
• Software [in Erasable Programmable Read Only Memory (EPROM) chip] • Software [in Erasable Programmable Read Only Memory (EPROM) chip], installed
• Installed in discontinued 8T-8697 ECAP by customer to provide all service in discontinued 8T-8697 ECAP by customer and subscription for update
functions for 3176 Engine in Challenger 65/75/85 Tractor • User friendly, menu driven interface to help determine values for Customer Specified
• Version number printed on module and can be displayed on ECAP screen Parameters; user defines configuration of truck by selecting values from lists of such items
under SPM Version Number screen as: engine rating, axle ratio, transmission, tire size and type; custom values not in the lists
can be entered by user
Reference • Once configuration defined, program steps user through each Customer Specified Parameter;
SEHS9202 Special Instruction does all necessary calculations and checks values entered for validity and conflict with other
NEEG2456 Diagnostic Code Card parameters; also displays and defaults to typical values for each parameter
• Customer Specified Parameters, including all truck configuration information, can be saved in
discontinued 8T-8697 ECAP internal memory for later use, even if power removed from ECAP;
can be reviewed and changed, if necessary; program steps user through any parameters
affected by change and provides same checking as when values were first entered
• List of configuration and parameter values can be printed using compatible serial interface
printer; Split Chart can also be plotted; chart shows shift points for each transmission gear,
along with engine RPM and vehicle speed limits
• When using NEXG4512 program, discontinued 8T-8697 ECAP can be powered by 8C-9705
12-Volt Converter or from electronic engine control using 8T-5275 T-Harness; 8C-9705
allows use of program with discontinued 8T-8697 ECAP in office or shop area; parameter
values defined can then be printed or saved to discontinued 8T-8697 ECAP memory; 8T-5275
Cable allows program to read and write Customer Specified Parameters directly to and from
electronic engine control
• Version number printed on module and can be displayed on ECAP screen under SPM Version
Number screen (present version number V1.1)
Reference
1-24 Dealer Service Tools 2004
Home SEHS88342 Special Instruction
Diagnostic Tools Search Tools for Electronic Engines

Adapter Cable Assemblies

SMCS Code: 1900-038, 0781
Model: 3406 PEEC, 3176 Engines
Warranty: One Year

• Help service 3406 PEEC and 3176 engines

• Provide test points for individual wires in wiring harness to facilitate
troubleshooting of engine control system
• “T” cables with individual tip jacks on pigtail portion of cables;
can be inserted into system wiring harness
at connector locations; individual tip jacks on pigtails labeled
same as wire to which they are connected in harness; standard
probe tips, like those on multimeter leads, can be inserted
into tip jacks

ID: ph2,Part
B89257T1
No. Description
7X-6370 Adapter Cable Assembly, 3-Pin DT Breakout
8T-8726 Adapter Cable Assembly, 3-Pin Breakout
8T-8694 Adapter Cable Assembly, 5-Pin Breakout
8T-8695 Adapter Cable Assembly, 9-Pin Breakout

ID: C44350T1

9X-0248 Transducer Breakout Adapter Cable Assembly

9X-1160 Adapter Cable Assembly, 40-Pin Breakout
SMCS Code: 1900-038, 0781
Model: 3176 Engines
Warranty: One Year

• Used in servicing 3176 Engine

• Provide test points for individual wires in wiring harness to facilitate troubleshooting
of electronic engine control system
• “T” cables with individual tip jacks on pigtail portion of cables; may be inserted into electronic
engine control system wiring harness at connector locations; individual tip jacks on pigtails
of 9X-0248 Adapter Cable Assembly labeled same as wire to which they are connected in 3176 ID: Engine
C27190T1system wiring
harness; on 9X-1160 Adapter Cable Assembly two small probes with tip jacks can be inserted into appropriate connector socket to look
at signal on any wire or between any two wires; standard probe tips, like those on multimeter leads, can be inserted into tip jacks

7X-1715 Cable Assembly, Small, 140-2266 Harness Assembly,

40 Pin Breakout 70-Pin Breakout “T”
SMCS Code: 1900-038, 0781 SMCS Code: 1900-038, 0781
Model: 3406E and 3176B Electronic Engines Model: 3176B, C-10, C-12, and 3406E Engines
Warranty: One Year Warranty: One Year

• Used to provide test points for individual wires in wiring harness • Used to provide test points for individual wires in engine wiring harness of
• Makes troubleshooting of electronic engine control systems faster, easier, electronic engine control system (harness assembly tool connects between
and more convenient engine control module and engine wiring harness)
• “T” cable has two probes attached to pigtail portion of harness — • Harness has standard probe tips (similar to multimeter leads) which allow
9X-1314 Wire Assembly, Red and 9X-1315 Wire Assembly, Black technicians to check signal on any wire or between any two wires
• Probe tips on leads of standard multimeter can be inserted into tip jacks • 9X-1314 Red Wire Assembly and 9X-1315 Black Wire Assembly comes with
of pigtail — allows serviceman to check signal on any wire or between 140-2266
any two wires
Item Part No. Description
• Connectors are A/B keyed
1 9X-1314 Red Wire Assembly
2 9X-1315 Black Wire Assembly

ID: C78422T1 Item Part No. Description

1 9X-1314 Red Wire Assembly
2 9X-1315 Black Wire Assembly

ID: C66627T1 Home Dealer Service Tools 2004 1-25

Tools for Electronic Engines Search Diagnostic Tools

167-9225 Harness Assembly

SMCS Code: 1900-038, 0781
Model: 3216, C-10, C-12, and 3406E Engines
Essential Tool
Warranty: One Year

• Used to flash ADEM 2000 ECM engines if flashing/communication through cab connector is not possible
• Used with ECAP or ET along with 139-4166 Data Link Cable and discontinued 7X-1700 Communication Adapter
• Used on 3216 ADEM 2000 ECM engines and C-10, C-12, and 3406E 1999 model year ADEM III engines
• Attaches to engine harness ECM connection
• Requires auxiliary battery power (possibly use service truck battery)
• Improves service tool's ability to maintain communication during engine cranking
• Provides voltage to ECM allowing continuous communication to service tool
• Uses an 8M-0456 Fuse to protect against voltage spikes
ID: C79358T1

217-0113 Main Harness Assembly

SMCS Code: 0781
Model: ADEM ll, ADEM lll, and ADEM lV
Warranty: One Year

• Used to communicate with ADEM ll, ADEM lll, ADEM lV, and future ECMs
• Used with 217-0114 and 224-4899 Harness Assemblies (will also work with future designs attachment harnesseses or stubs)

ID: D00249T1

217-0114 Harness Assembly (Service Tool Bypass ADEM III Stub)

SMCS Code: 0781
Model: ADEM lll and ADEM IV:E4 Electronic Control Modules
Warranty: One Year

• Used to provide communication link between Caterpillar ET and ADEM lll ECM
• Used with 217-0113 Main Harness Assembly

ID: D00255T1

224-4899 Harness Assembly (Service Tool Bypass ADEM IV:E1 Stub)

SMCS Code: 0781
Model: ADEM IV ECM
Warranty: One Year

• Used to provide communication link between Caterpillar ET and ADEM IV:E1 ECM
• Used with 217-0113 Main Harness Assembly

ID: D00261T1

239-9967 Bypass Messenger Harness

SMCS Code: 1900-038, 0781
Model: Marine, Industrial, and On-Highway Truck Engines
Essential Tool
Warranty: One Year

• Used to flash Messenger when communication through service connector is not possible
• Used with ET/Winflash
• Power is provided by service connector

ID: D00609T1

1-26 Dealer Service Tools 2004 Home

Diagnostic Tools Search Tools for Electronic Engines

134-5195 Adapter Cable Assembly, 40-pin T-harness large engine

SMCS Code: 1900-038, 0781
Model: 3500 and 3600 Engines
Warranty: One Year

• Used to adapt 7X-1715 Cable Assembly to 3500 and 3600 Engines

• Adapts a square 40-pin AB-keyed connector on 7X-1715 Cable Assembly (40-pin Breakout Small
Engine) to a square 40-pin CD-keyed connector on 3500 and 3600 Engines
• Length: 30 cm (12 in)

ID: C44107T1

208-0059 Breakout “T”

SMCS Code: 1900-038, 0781
Model: 3176B, C-10, C-12, 3406E, 3600 Natural Gas Engines and other 70-pin ECM’s
Essential Tool
Warranty: One Year

• Used to provide test point for all individual wires in engine wiring harness of 70-pin connector ECM
• Connects between ECM and main wiring harness
• Allows testing access to all 70 wires
ID: C80558T1

127-6359 Cable Assembly, Adapter HEUI Injector Test

SMCS Code: 1900-038, 0781
Model: 3116 and 3126 HEUI Engines
Warranty: Y

• Used to test injector and/or injector harness

• Allows wiring to an individual injector to be bypassed (helps to isolate problem
between injector or harness)
• Overall length: 1500 mm (5 ft)

ID: C54969T1

7X-1710 Probe Group

SMCS Code: 1408-082, 0779
Model: All Models
Warranty: One Year

• Used with 6V-7070 Digital Multimeter to measure voltages in wiring harnesses without disconnecting them
• Multimeter leads plug into probe cable jacks; probes then slide along appropriate wires into rear
of connector until they contact pin or socket of interest
• Eliminates need for new breakout “T” cable for each new connector 7X-1708 Probe, Red
• Wire: 18 gauge 7X-1709 Probe, Black
• Length: 18 inch ID: C55155T1

7X-1695 Cable, TDC

7X-1395 Adapter, SI TDC
SMCS Code: 1905-082, 0712
Model: All Engines with Electronic Controls
Warranty: One Year

7X-1695 Top Dead Center (TDC) Cable

• Used on captive engine applications
• Allows magnetic sensor to be connected to engine to input timing information to ECM
(Electronic Control Module)
• Used with ECAP/DDT
• 7X-1395 Adapter allows 7X-1695 Cable to be used on industrial and spark ignited (SI) engines

ID: C54495T1

Home Dealer Service Tools 2004 1-27

Tools for Electronic Engines Search Diagnostic Tools

ECAP and DDT Connectors

SMCS Code: 1900-036, 0779
Model: All 3176 and 3406 Electronic Engines
Warranty: One Year

• Connect 8T-5275 T-Harness cable on ECAP or DDT to connector on dash of truck cabs
ID: C27269T1
• Allow ECAP or DDT to be connected to electronic engine control from inside cab,
instead of having to open engine compartment

7X-1873 Connector
• Used to replace present six-pin Deutsch connector on older
7X-1686 Adapter Cables (present 7X-1686 Adapter Cable
manufactured with 7X-1873 Connector) Part No. Description
• Use 1U-5805 Removal Tool (green) and 1U-5804 Crimp Tool 7X-1403 Adapter Cable
• Locks onto highway truck in-cab diagnostic connector 7X-1686 Adapter Cable
7X-1686 Adapter Cable 7X-1873 Connector
• Service Part: 3E-5226 Socket 3E-5226
ID: C44357T1 Socket
ID: C66651T1

7X-1714 Engine Adapter Cable, 3116 157-4829 Adapter Cable Assembly

SMCS Code: 1900-038, 0781
Model: Electronically Controlled 3116 Engines
(SAE to CAT® CAN/ATA)
Warranty: One Year SMCS Code: 1900-036, 0779
Model: On-Highway Trucks
• Used to setup and test electronic engine controls on 3116 Engines in General Essential Tool
Motors on-highway trucks Warranty: One Year
• Connects between under dash Packard connector and 8T-5275 or 7X-1412
• Used to connect 139-4166 Diagnostic
T-Harness cable on ECAP or DDT
Cable to J1939 Under-Dash
Diagnostic Connector

ID: C66673T1 ID: C79236T1

211-4988 Adapter Cable Assembly
SMCS Code: 1900-036, 0779
Model: Marine engines
Warranty: One Year

• Used to join two Cat electronic marine engines together to record data
• Used with Cat electronic technician sea trial state and transient data recorder
• Allows simultaneous data recording from both engines using one laptop
• Reduces ET recording time by 50%
• Provides easier data reduction by having both engines’ data on same time scale

ID: C80598T1
136-7205 Extension Cable Assembly (Monitor)
SMCS Code: 0740, 0779
Model: All B-Series Excavators (Except 307) Service Parts
Warranty: One Year Part No. Description
102-7965 Female Terminal
• Used to extend monitor’s viewing position to outside of operator’s compartment
111-4815 Plug Connector
• Can be used in training of technicians by allowing monitor to be viewed by
121-1173 Male Terminal
more than one person at a time
125-4838 Plug Lock Wedge (7)
• Overall length: 6.1 m (20 ft)
128-8951 Receptacle Connector

124-5643 Three-Pin Packard Break-Out CableID: C54970T1

SMCS Code: 1900-038, 0781
Model: 3116 HEUI Engines in General Motors On-Highway Trucks
Warranty: One Year

• Used to provide test points, for individual wires in wiring harness, to help troubleshoot electronic engine control system
• Sold separately and as part of 125-2580 HEUI Tool Group
• Standard multimeter probe tips can be inserted into the break out cable tip jacks allowing service technician
to check voltage on any one wire or between two wires of a circuit.

1-28 Dealer Service Tools 2004 Home

ID: C66940T1
Diagnostic Tools Search Tools for Electronic Engines

224-9282 Breakout Harness Assembly

SMCS Code: 1900-038, 0781
Model: 3126E and C-9 Engines
Warranty: One Year

• Used to check actual current to engine-mounted hydraulic pump

• Used with a digital multimeter that has current measuring capability
• Connects digital multimeter into machine harness
• Cable has red and black banana plugs for multimeter connection
• Connects to any component with two-pin, Deutsch connectors
(designed with both plug and receptacle connectors)
• Overall length: 30.5 cm (12 in)
ID: D00303T1

125-3662 Sensor Bypass Cable

SMCS Code: 1900-038, 0781
Model: 3116 and 3126 HEUI Engines
Warranty: One Year

• Used to isolate sensors when testing for faults

• Also used to test for bad sensor wiring in wiring harness

ID: C66941T1

126-7877 M300 to PC RS-232 Cable

SMCS Code: 1901-038, 0781
Model: M300 Excavators
Warranty: One Year

• Used to setup and test electronic hydraulic controls using a personal computer
• Connects to hydraulic controls and RS-232 computer port

ID: C66939T1

Service Parts for All DDT’s and Discontinued 8T-8697 ECAP

SMCS Code: 1000-025, 1000-038, 1264-025, 1272-082
Model: 3176, 3406B
Warranty: One Year

The following are service parts for all Digital Diagnostic Tools (DDT), discontinued • 8C-4147 Connector (plastic)
8T-8697 Electronic Control Analyzer Programmer (ECAP) and their accessories. Endbell on 9-pin circular connector used on T-Harness
• 190-8900 Deutsch HD Style Connector Field Repair Kit • 3E-3423 Receptable Assembly, Connector (metal)
Provides all service parts needed for Deutsch connectors used on the cables; all 10-pin circular connector used on ECAP
parts included in 190-8900 also available separately • 8C-4148 Connector, Relief
• 4C-3501 Upgrade Kit Strain relief on 9-pin circular connector used on T-Harness
Provides all service parts needed to upgrade discontinued 1U-5803 Connector Kit • 8C-4797 Socket, Carriage
to 4C-3406 Connector Kit Socket in 9-pin Amp connector used on T-Harness
• 4C-4704 Removal Tool • 8C-5543 Case, Plastic
Insertion/removal tool used to remove contacts from 9-pin circular connectors Case for ECAP
used on ECAP, DDT’s, and T-Harness • 3E-0152 Plug Assembly, Connector
• 6V-3110 Cover, Back • 8T-5277 Cable, Probe
Back cover for DDT’s PWM cable included with DDTs
• 7T-4577 Pin, Connector • 9X-1314 Wire Assembly
Pin in 9-pin circular connector used on ECAP and DDT’s Red wire assembly used with 40-pin breakout cable
• 8C-4145 Housing, Connector (plastic) • 9X-1315 Wire Assembly
9-pin circular connector used on T-Harness Black wire assembly used with 40-pin breakout cable
• 8C-4146 Housing, Connector (plastic) • 9X-1339 Receptacle Assembly
9-pin circular connector used on ECAP and DDT’s Used on 40-pin breakout cable

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Tools for Electronic Engines Search Diagnostic Tools

Repair Tools for 9-Pin Amp Connector

SMCS Code: 1000-025
Model: 3176, 3406B Part No. Description
Warranty: One Year 4C-4704 Insertion/Removal Tool
8C-4145 T-Harness Connector
• Makes simple repairs possible on 9-pin Amp circular connector on 8T-5275 Adapter Cable Assembly 8C-4146 ECAP/DDT Connector
and on port #1 of discontinued 8T-8697 Electronic Control Analyzer Progammer (ECAP) 8C-4147 Endbell
• 4C-4704 used to insert and remove contacts from connectors when they are being replaced 8C-4148 Strain Relief
8C-4797 Socket
7T-4577 Pin

171-4400 Communication Adapter II Group

SMCS Code: 1900-038, 0781
Model: All Caterpillar models with electronic controls
Software
Essential Tool • Designed to run with Microsoft Windows 95, 98, 2000 and NT
Warranty: One Year • Ready to use, just install software program onto PC using provided CD

Compliant Communication
• Allows communication between service tools and engine controls using
• Used to monitor communication, between engine and PC, using service tool various data links such as J1939/11, DeviceNet (future release), CAT
programs such as Caterpillar Electronic Technician on J1939/11 high-speed data DataLink, and J1708 (ATA) vehicle networks
link, DeviceNet (future release), CAT DataLink, or J1708 (ATA) vehicle networks
• Flash program allows adapter firmware upgrades as additional features
• Comes complete with cables, manual, software CD, and carrying case become available
• Lightweight and portable • Uses J1939/11, high-speed data link (part of ADEM III controls), substantially
• Communication Adapter II, manual, and software can be purchased separately reducing flash times
(171-4401) • Automatically selects J1939/11 when flashing the engine (reduces the flash
• RP1210A compliant time approximately 80%, from 14 minutes to 3 minutes)

Data links J1708 American Trucking Association (ATA), CAT Data Link (CDL),
J1939-11 high-speed data link, and CAN-DeviceNet (future upgrade)
PC connection RS232 serial
Operating voltage 7-40 VDC at 1.0 amps (provided by DataLink)
Operating temperature -18 to 65°C (0 to 149°F)
Size 180 x 85 x 44.5 mm (7.1 x 3.3 x 1.75 in)
Weight 454 g (1 lb)

ID: C80103T1
Item Part No. Description
1 171-4401 Communication Adapter
Typical hookup 2 196-0055 Serial PC Cable, 7.62 m (25 ft)
3 207-6845 Data Link Cable, 51 cm (20 in)—use with ATA, CDL, and J1939-11
4 Storage Case with protective foam pad
ID: C80104T1
Not shown NEHS0758 User’s Manual and Software CD ROM

Optional Cables
Part No. Description
139-4166 Unicable; 5.48 m (18 ft) long; use with discontinued 7X-1700 or 171-4401; for ATA and CDL only
157-4829, In-Cab Adapter Cable; ATA, CDL, and J1939-11 (9 pin to 6 pin applications typically found in Freightliner)
160-0142 PC Serial Cable 3.05 m (10 ft) (ATA and CDL only)
196-0055 Serial PC Cable 7.62 m (25 ft) (provided with 171-4400)
7X-1686 In-Cab Adapter Cable (ATA only)

Reference
NEHG0758 Tool Operating Manual

1-30 Dealer Service Tools 2004 Home

Diagnostic Tools Search Tools for Electronic Engines

225-5985 Cable Assembly

SMCS Code: 1900-038, 0781
Model: All Models with Electronic Controls
Warranty: One Year

• Used to connect laptop computers without serial ports to Communication Adapter II (see note)
• Uses computer’s parallel port
• Cable is 25 pin, male-to-male, 7.6 m (25 ft) long

NOTE: Because of its length, this cable will work with Communication Adapter II only with newer PC’s
without a serial port. Older laptops will operate only with a shorter parallel cable, 2m (6ft) long maximum.

ID: D00297T1

187-8520 Wireless ET Link Group

SMCS Code: 1900-038, 0781
Model: All Machines Using Communication Adapters I and II
Warranty: One Year

• Used to provide a wireless connection between a PC and either the discontinued

7X-1700 Caterpillar communication adapter or the 171-4401 Communication Adapter II
• Enables service technician to monitor machine from service truck while machine operator
is using equipment on job sight
• Units can communicate from up to one and one-half miles apart (must stay within
line-of-sight without any obstructions between them)
• Currently certified for sale and use in USA, Canada and Japan
• A system for other countries will be available at a later date; contact CSTG for availability
• Group consists of two wireless ET link units, a service truck unit, and a machine unit
• Service truck unit is mounted on service truck and connected to a PC running Electronic
Technician software
• Machine unit is mounted on machine being tested and is connected to a communication
adapter
• Communication adapter is connected to machine’s diagnostic connector
• Magnetic feet provide easy mounting on any horizontal steel surface
NOTE: Will not work with Communication Adapter II if machine has multiple ECM’s.
Use discontinued 7X-1700 Communication Adapter I in this application.
NOTE: Will not work with VIM’s; for use with ET only

Reference
NEHS0789, Using the 187-8520 Caterpillar Wireless
ET Link Group with Caterpillar Electronic Technician
ID: C79957T1
Indoor range (normal construction) 152 to 457 m (500 to 1500 ft) Item Part No. Description
Outdoor range (line of sight, standard antenna) up to 2.4 Km (1.5 miles) 1 187-8510 Wireless ET Link Service Truck Unit
Baud rate 9600 2 187-8511 Wireless ET Link Machine Unit
Connectivity standard RS232 3 187-8507 Communication Adapter I Cable
Certifications FCC Part 15 4 187-8508 T Power Cable
Frequency band 2.4 GHz ISM band, 5 5P-7366 Power Cable
frequency hopping spread spectrum 6 4C-9031 Cigarette Lighter Power Cable
Output power 10 to 600 milliwatts 7 1U-9484 RS-232 Cable (9-pin) (replacement)
Operating temperature range -20 to 60°C (-4 to 140°F) Not shown 187-8512 Fuse, 1 Amp
Input power 11 to 32 VDC
Size (with handles and feet) 130 x 178 x 305 mm (5.1 x 7.0 x 12.0 in)
Weight 3.8 kg (8.4 lbs)

139-4166 (CAT/ATA) Universal Cable

SMCS Code: 1900-038, 0781
Model: All Models With Electronic Controls
Warranty: One Year

• Replaces discontinued 7X-1412 Adapter Cable Assembly (ATA) and 7X-1570 Adapter Cable Assembly (CAT)
• Used to connect either the ATA data-link or the Cat data-link to the discontinued 7X-1700 Communication Adapter
• Overall length: 3 m (18 ft)

Home ID: C78416T1

Dealer Service Tools 2004 1-31
Tools for Electronic Engines Search Diagnostic Tools

237-7547 USB Serial Adapter

SMCS Code: 1900-038, 0781
Model: All Caterpillar models with electronic controls
Essential Tool
Warranty: One Year

• Used to provide a communication link between PCs that have only USB ports
and 171-4401 Communication Adapter II or 131-5050 DataView
• Works with all Windows operating systems
• Comes with software CD

ID: D00755T1
129-2018 Power Cable Assembly
SMCS Code: 1900-038, 0781
Model: 3406E, 3176B, 3116HEUI, 3126HEUI, C-10, and C-12 Engines
Warranty: One Year

• Used to gain access to ECM data, in event that service tool will not communicate at OEM connector
• Also provides means of powering service tool while cranking engine
• Allows service tool to be connected directly to ECM to verify ECM operation — can also isolate
a communication problem due to OEM wiring harness
• Cable assembly has fuse protected power clips to allow direct hook up to battery
• Replacement fuses available (8M-8948 Fuse, 15 amp)
ID: C78447T1
7X-1425 RS-232 Cable
SMCS Code: 1900-038, 0781
Model: All models with electronic controls
Warranty: One Year

• Replaces discontinued 7X-1688 Cable Group

• Used to connect a discontinued 7X-1701 Communication Adapter to RS-232 computer port
(discontinued 7X-1701 Communication Adapter can now be purchased separately)
• 4C-6805 Adapter (9 to 25 pin), part of discontinued group, is sold separately for use with older computers

3E-3423 Connector Pin No. To Pin On ID: C55089T1 Pin No.

8C-4146 3E-3423 8C-4146
SMCS Code: 0785
Model: 3406 and 3176 Engines 1 A 1 Input Pre-Reg (B+)
Warranty: One Year 2 B 2 Gnd Pre-Reg (B-)
3 K 3 Gnd Pre-Reg (Gnd)
• Used to replace ECAP’s plastic Port 1 socket and mating connector 4 H 4 DL- (DL-)
with steel parts to eliminate breakage 5 (no connection) 5 (no connection)
• 3E-3423 Connector is installed into ECAP. 6 G 6 RXL (RXL)
• Rework can be done by dealer or sent to Caterpillar Service Technology. 7 J 7 DL+ (DL+)
8 C 8 Tx (Tx)
Instructions for Reworking ECAP at Dealership 9 F 9 Prog (Prog)
• Enlarge diameter of connector mounting holes by 0.41 mm (.016 inch).
No connection D and E
• Hole enlargement can be easily completed with a file.
• Move wires from plastic 8C-4146 Connector to steel 3E-3423 Connector • The other end of the wire is attached
one wire at a time. to the following locations—With
• Move wires on connector. Pre-Regulator Board or (Without)

7X-1713 EIS Loopback Cable Service Parts

SMCS Code: 1900-038, 0781 Part No. Description
Model: All Engines with EIS (Electronic Ignition System) 9W-0844 Socket
Warranty: One Year 8T-8730 Socket
8T-8735 Plug
• Used to allow EIS (Electronic Ignition System) control to test itself
8T-8729 Pin
8T-8737 Plug
7X-6222 Plug

1-32 Dealer Service Tools 2004 Home ID: C66682T1

Diagnostic Tools Search Engine Tools

Engine Tools

142-5865 Remote Calibrator

142-5866 Extension Cable 142-5865
SMCS Code: 1356-036, 0787
Warranty: Manufacturer’s
SE
TU
P 142-5866
EX TE
T ST
• Used to calibrate Flexxaire Mark III fan controller (manual comes with controller) NT
L
T1
TE
M
CA P E
L XT

• Allows technician to set pitch of fan blades, set turn-on and turn-off temperatures RE
T
AC
SE TU
of fan drive, and set “purges-per-hour” of fan to control engine temperature T2 T AT
OR
UP

• As many as four extension cables can be connected, in series, for remote testing RE
T
TE
MP

and calibration. DO
W
N
• Length of cable: 6.1 m (20 ft)

Reference ID: C78415T1

01503-0 Flexxaire Fan Installation and Maintenance Manual

219-2368 Diagnostic Plug

SMCS Code: 1000-038, 0706
Model: 3126 HEUI Engines

• Used to troubleshoot HEUI pumps

• Used with 9X-1484 Seal Kit

References
REHS1281 Service Manual

ID: D00296T1

125-2580 HEUI Engine Tool Group

SMCS Code: 0770, 0774, 0775, 0781, 0782, 0784
Model: 3116 HEUI and 3126 HEUI Engines
Warranty: One Year

• HEUI diagnostic tooling — includes all necessary cables, harnesses, and electrical Parts List
pin removal tools to troubleshoot the electrical system, conveniently packaged
in a separate plastic box within the group Part No. Description Part No. Description

• Hydraulic diagnostic tooling — includes all necessary fittings, pressure gauge 1U-7587 Pry Bar, 6 inch Long 123-4941 Feeler Dealer Tool
3J-7352 Connector Gauge Assembly
and hose, and a special breakout tee to troubleshoot the hydraulic system—including
the injection actuation pressure sensor and control valve/pump combination 3J-7354 O-Ring Seal 125-2581 Electronic Tool Group
• Injector and IAPC valve removal and installation tools 5P-0144 Fuel Line Socket 125-2583 Clamp Assembly
• Modified injector clamp to aid in proper assembly and tightening of the jumper tube 5P-0333 Crowfoot Wrench 125-2584 Hex Ball Driver
• Necessary bit drivers and socket to work on hard-to-reach components 5P-5008 Flared Reducer 125-2588 Hex Wrench, 7/64 inch
• Double-ended offset feeler gauge for setting valves 6V-8397 O-Ring Seal 125-2589 Diagnostic Fitting

6V-9508 Face Seal Plug 125-5902 Foam Insert GP

7J-0204 O-Ring Seal 6V-7145 Case

8C-7310 Adapter 1U-5757 Hose Assembly

9S-5518 Plug 3B-6768 Reducing Bushing

9S-8007 O-Ring Plug 8S-7169 Pipe Coupling

8T-0852 Pressure Gauge Group

Home Dealer Service Tools 2004 1-33

Engine Tools Search Diagnostic Tools

1U-5470 Engine Pressure Group

SMCS Code: 1000-038, 1000-081, 1000-082, 1050-038, 1050-081, 1058-082, 1250-025, 1270-036, 1250-081, 1300-038
Model: All Models
Warranty: One Year

• Used to check performance of turbocharged diesel and natural gas engines and, • Chart in case lid used to convert kPa or PSI to inches of mercury as shown in Fuel
with optional 1U-5554 Panel and 8T-0840 Pressure Gauge, to make operating Setting and Related Information microfiche
adjustments to naturally aspirated gas engines • 6V-6045 Accessories Case contains fittings that can be installed in all 1/8 inch
• Replaces discontinued 6V-3150 Engine Pressure Groups and 4S-6553 Engine NPT ports on Caterpillar Engines for setting up pressure taps for 1U-5470;
Evaluation Test Group; contents of 6V-3150 still serviced, but contents of 4S-6553 8T-0821 Tubing is easily connected to and disconnected from 1U-5470 panel and
no longer serviced; 6V-3150 can be upgraded to essentially same functional engine port fittings; internal O-ring seals tubing outer diameter and internal collet
specifications of 1U-5470 by installing optional 1U-5554 Panel with either 0-200 mechanism locks tubing into fitting
kPa [0-60 inch mercury (Hg)] 1U-5469 Pressure Gauge (0-60 inch Hg) or 100-0-100 • Optional 8T-0840 Pressure Gauge used to measure intake manifold pressure on
kPa (30-0-30 inch Hg) 8T-0840 Pressure Gauge natural gas and gasoline engines and to power balance natural gas engines in
• Equipped with 4 different pressure gauges that indicate pressure relative to multiple engine applications; mounts on optional 1U-5554 Panel Assembly which
ambient atmospheric pressure; require no measurement corrections due to can be permanently installed in 1U-5470 Engine Pressure Group; 6V-4045 cannot
atmospheric pressure changes be stored in 1U-5470 with optional gauge installed
• 8T-0848 Pressure Gauges used to measure fuel pressure, intake manifold • Optional slack tube 8T-0452 Water Manometer available for use with 1U-5470;
pressure on turbocharged diesel engines, cooling system pressure and to power measures static, vacuum, or differential pressure over range of 500 mm to 500
balance diesel engines in multiple engine applications (0-58 PSI) mm H2O for total range of 1000 mm H2O; stored in optional 8T-3153 Foam Block
• 8T-0846 Pressure Gauge used to measure oil pressure and air compressor cut-in placed in lid of 8T-0841; optional 8T-3117 Foam Block can be used to store
and cut-out pressures (0-145 PSI) 8T-0452 in case lid of 6V-9450 Engine Pressure Group

8T-0848 Pressure Gauge range 400 kPa (58 PSI)

8T-0846 Pressure Gauge range 1000 kPa (145 PSI)
1U-5469 Pressure Gauge range of engine boost
or positive intake manifold pressure 0 to 200 kPa (0 to 60 inches Hg)
8T-0839 Differential Pressure Gauge range up to 12 kPa [50 inches water (H2O)], as well aseither
12 kPa (1.74 PSI) pressure or vacuum
All other gauges in group read directly in kPa and PSI
8T-0840 Pressure Gauge range 0 to 100 kPa (0 to 30 inches Hg)
Vacuum range 0 to -100 kPa (0 to -30 inches Hg)
Operating temperature range -1°C to 60°C (30°F to 140°F) for differential pressure gauges.
-18°C to 71°C (0°F to 160°F) for all other gauges
Gauge accuracy ±2 percent of full scale for differential pressure gauge.
SAE Grade A (±1.5 to 1 percent of full scale for all other gauges).
Operating position Position has no effect on differential pressure gauge, if gauge has been
mechanically adjusted to ZERO in the test position. On all other gauges,
position has no effect on accuracy. ID: B83902T1
Optional 8T-0452 Water Manometer
Pressure media Differential pressure gauge — clean air and gases only (no liquids). (SEHS8907, pg. 7)
All other gauges —air, gases and liquids (oil, water, antifreeze, fuel, etc.).
Item Part No. Description
Size 390 mm x 310 mm x 190 mm (15.4 in X 12.2 in x 7.5 in)
1 8T-0452 Water Manometer
Weight 6.8 kg (15 lb)
2 8T-3153 Foam Block

NOTE: DO NOT use any acids or other highly corrosive liquids in the gauges.

Item Part No. Description

1 8T-0841 Case
2 8T-0839 Differential Pressure Gauge
3 8T-0846 Pressure Gauge
4 1U-5469 Pressure Gauge
5 8T-0848 Pressure Gauge (3)
6 4C-3974 Bulkhead Fitting (8)
7 8T-0821 Tubing, 16 m (52.5 ft)
8 4C-3973 Straight Connector (6)
9 4C-3972 Elbow Fitting (6)
10 C-3971 Union (2)
ID: B83908T1
11 6V-6132 Cable Tie (4) Optional 8T-0840 Pressure Gauge
12 6V-6045 Accessories Case Item Part No. Description
ID: B83903T1 Form SEES5575 Accessories Label 1 8T-0840 Pressure Gauge
13 6V-6115 Packing Set Base 2 1U-5554 Panel Assembly
Not shown Form SEES5677 Conversion Chart
Not shown Form NEEG2187 Title Decal

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198-4240 Digital Pressure Indicator Group Operating temperature 0 to 38°C (32 to 100°F)
SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038, 0788 Storage temperature -40 to 66°C (-40 to 150°F)
Model: All Battery 9 Volt alkaline battery
Warranty: Manufacturer’s
Battery life (approx.) 1 transducer 108 hours, 2 transducers 77 hours,
3 transducers 51 hours, 4 transducers 43 hours
• Used to measure vacuum, pressure, differential pressure, and temperature Group weight 2.36 kg (5.2 lbs)
• Self-contained, microprocessor based digital meter Carrying case 394 x 311 x 102 mm (15.5 x 12.3 x 4.0 in)
• Uses sensors and cables to remotely measure systems under pressure Pressure pickup sensors 500, 5,000, and 10,000 PSI (3,500, 35,000 and 70,000 kPa)
• Indicator has four input connectors: (198-4240 Group does not include 5,000 PSI pressure pickup)
- Connector 1 measures pressure or vacuum
NOTE: The Digital Pressure Indicator Group pressure sensors cannot be used
- Connectors 1 and 2 measure differential pressure
with Data View at the present time.
- Connectors 2, 3, and 4 measure pressure
• Includes Type-K thermocouple for measuring temperature

Part No. Description Range Accuracy/Specification

198-4237 Pressure Pickup Sensor, 500 PSI ±0 to 30 in. Hg 0.5% ±0.33 in. Hg
±0 to 100 PSI 0.5% ±1 PSI
±0 to 500 PSI 0.5% ±5 PSI
±0 to 35 Bar 0.5% ±0.35 Bar
±0 to 3,500 kPa 0.5% ±34 kPa
198-4238 Pressure Pickup Sensor, 5,000 PSI 0 to 5,000 PSI 0.5% ±50 PSI
0 to 350 Bar 0.5% ±3.5 Bar
0 to 35,000 kPa 0.5% ±340 kPa
198-4239 Pressure Pickup Sensor, 10,000 PSI 0 to 10,000 PSI 0.5% ±100 PSI
0 to 700 Bar 0.5% ±7.0 Bar
0 to 70,000 kPa 0.5% ±700 kPa
8T-0458 K-Type Thermocouple Sensor -40 to 2500°F 0.5% ±2 of reading
-40 to 1350°C 0.5% ±2 of reading
ID: C80153T1

Item Part No. Description

1 6V-3072 Case (case decal NEEG2931)
2 198-4235 Foam Insert
3 198-4234 Indicator (face decal NEEG2932)
4 8T-0458 Thermocouple Temperature Sensor
5 198-4236 Extension Cable (two, 20 foot)
6 198-4237 Pressure Pickup, 500 PSI (3,500 kPa), blue connector
7 198-4239 Pressure Pickup 10,000 PSI (70,000 kPa), orange connector
8 NEHS0818 Tool Operating Manual
Optional Items
Part No. Description
198-4238 Pressure Pickup, 5,000 PSI, red connector
6V-4144 Valved Replacement Coupler, 1/4 inch NPT, internal thread
6V-3965 Valved External Nipple, 9/16 inch SAE
6V-3966 Valved External Nipple, 1/4 inch NPT
8T-3613 Valved External Nipple, 1/8 inch NPT
6V-0852 Protective Dust Cap

ID: C80154T1

198-4229 Digital Pressure Indicator Cable

SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038, 0788
Model: All 23
6
8-4

Warranty: One Year 19

• Used to increase distance between pressure pickup

and hand-held, digital pressure indicator
Warranty Information
• Used with 198-4240 Digital Pressure Indicator (DPI) SPX Service Solutions
• Allows technician greater freedom to move around during
testing, especially when working on large equipment Service Repair:
2300 Park Drive
• Overall length: 12 m (40 ft) Owatonna, MN 55060
Reference (800) 533-0570
NEHS0818, Using the 198-4240 Digital Pressure Indicator Group After Market Technical Services:
ID: D00327T1
Electronic Product Repair
(800) 344-4013 (Lynn extension 4369)

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Engine Tools Search Diagnostic Tools

8T-5300 Timing Indicator Group Magnetic Transducers

SMCS Code: 1000-025, 1000-036, 1000-038, 1250-025, 1251-082, 1272-038, 1552-036 SMCS Code: 1162-082
Model: See Below Model: 3208
Warranty: One Year

• Replaces discontinued 6V-3100 Timing Indicator Group Can be used with 8T-5300 Engine Timing Indicator Group to indicate No. 1
• 6V-9060 Spark Timing Adapter Group required for 3304, 3306, 3516 Engines Cylinder Top Dead Center to measure RPM
• 8T-5301 Diesel Timing Adapter Group required for 300, 1100, 3200, 3300
and 3400 Series Engines 8T-5184 Transducer
• Used to measure fuel injection timing for a diesel • Has 89 mm (3.5 in) long steel shank which is 12,7 mm (.5 in) shorter than
engine using 8T-5301 Diesel Timing Adapter Group existing 6V-2197 Transducer included in 8T-5300 Engine Timing Indicator
• Checks operation of automatic timing advance Group
unit on engines that are so equipped, by • Can be used in applications where 6V-2197 Transducer is too long, such as
using appropriate adapter group on some 3208 Engines where access to top center hole in front cover is
• Cannot perform any function alone; needs limited by fan belts and fan guard
either 8T-5301 Diesel Timing Adapter
or 6V-9060 Spark Timing Adapter 8T-5185 Transducer
• Powered from vehicle electrical system • Has 178 mm (7.0 in) long steel shank which is 63,5 mm (2.5 in) longer than
or from two 6-volt lantern-type batteries 6V-2197 Transducer
(not included) • Can be used in applications where 6V-2197 Transducer is too short, such as
on D7G SA Tractor
Reference
SEHS8580 Special Instruction Part No. Description
8T-5184 Magnetic Transducer, 1/4 inch Dia., 3.5 inch long
ID: C10302T1
Item Part No. Description 8T-5185 Magnetic Transducer, 1/4 inch Dia., 7.0 inch long

1 6V-7145 Case
2 8T-5250 Indicator
3 8T-3253 Packing Set
4 5P-7366 Cable Assembly
5 8K-4644 Fuse (5)
6 6V-3093 Transducer Adapter, 1/4 inch NPTF (1U-5795 Ferrule Set)
7 6V-2199 Transducer Adapter, 1/8 inch NPTF (1U-5795 Ferrule Set)
8 6V-2197 Magnetic Transducer (TDC)
9 5P-7362 Cable (TDC)
Not shown 6V-6045 Accessories Case
Additional accessories available separately
Part No. Description Size
8T-5184 Transducer 8.9 cm (3.5 in) long
8T-5185 Transducer 17.8 cm (7 in) long

4C-6710 Governor Test Unit Group

4C-6711 Frequency Measurement Cable
4C-6712 Governor Test Cable
SMCS Code: 1908-036
Model: 3600 Family Engines with Heinzmann Governors
Warranty: One Year

• Used to test and adjust Heinzmann Electronic Governors without running engine
• Simplifies installation and service of governor
• Measures governor frequency when engine is running and feedback voltage when engine is stopped
• Simulates engine for following tests:
- Check governor frequency at different fuel levels
ID: B96667T1
- Adjust and check minimum and maximum governor frequency levels
Frequency range 100 - 10,000 Hz (± 5 Hz)
- Adjust speed droop during droop operation
- Check effect of gain, stability and derivative value settings on operation of engine Voltage range 1 - 6 Volts (± 50 mV)
Simulator frequency 150 - 8,000 Hz
Reference Output voltage 8V peak-peak maximum
SEHS9222 Special Instruction
Current consumption 8 mA maximum
SENR4661 Heinzmann Governor Service Manual
Battery 1U-9534 Battery, 9 Volt
Temperature range 0-45°C (32-104°F)

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8T-5301 Diesel Timing Adapter Group

SMCS Code: 1000-025, 1000-036, 1000-038, 1250-025, 1251-082, 1272-081, 1552-036
Model: 300, 1100, 3200, 3300 and 3400 Series Engines
Warranty: One Year Item Part No. Description
1 6V-2198 Cable
• Used to check timing on diesel engines using 8T-5250 Timing Indicator 2 6V-7910 Transducer
(part of 8T-5300 Timing Indicator Group) 3 5P-7436 Adapter
• Allows 8T-5250 Timing Indicator to measure engine/fuel system timing 4 5P-7437 Adapter
and mechanical advance
5 5P-7435 Adapter
• 6V-7910 Transducer installed in No. 1 fuel line to provide RPM signal
to 8T-5250 Timing Indicator 6 6V-3016 Washer

ID: C10300T1

6V-9060 Spark Timing Adapter Group

SMCS Code: 1272-038, 1552-036
Model: 3304, 3306, 3516
Warranty: One Year

• Used to check timing on spark ignited engines using 8T-5250 Timing Indicator
(part of 8T-5300 Timing Indicator Group)
• Fiber optic link that allows 8T-5250 Indicator to check dynamic timing on
engines that have individual coils for each cylinder
• Connected to port labeled injection or spark transducer input; can also be
used with discontinued 6V-3100 Timing Indicator Group and connected to
port abeled Diesel Injection Transducer; transmitter portion of adapter is then
Item Part No. Description
connected to primary (low voltage) coil terminals of No. 1 cylinder on engine
(NOTE: 6V-9060 Spark Timing Adapter Group will be destroyed if it is connected ID: C10301T1 1 8T-5259 Transmitter, Discontinued
to the secondary (high voltage) side of the coil.) 2 8T-5260 Cable, Discontinued
3 8T-5257 Receiver, Discontinued
1U-5524 Adapter Cable
• Part of the 6V-9060 Spark Timing Adapter Group 4 8T-5258 Coil Adapter Cable

• Allows dynamic timing of engines equipped with integral shielded ignition coils and Altronic magnetos Not Shown
to be checked; engines with Altronic magnetos have integral shielded ignition coils with 3-pin connectors 1U-5524 Cable, Ignition Coil Adapter
for which 1U-5524 Adapter Cable is designed 1U-5524 Adapter Cable
• Connected at primary (low voltage) coil terminals of No. 1 cylinder; cable from magneto disconnected at
primary coil connector and two 1U-5524 Adapter Cable 3-pin connectors are coupled in between the coil Reference
and cable; remaining 2-pin connector of adapter is coupled to 6V-9060 Spark Timing Adapter Group; when SEHS8580 Special Instruction
6V-9060 and TDC Magnetic Transducer are connected to 8T-5250 Indicator, engine RPM and timing displayed

163-5443 Detonation Sensor Harness

SMCS Code: 1559-038
Model: 3400, 3500, and 3600 Gas Engines
Warranty: One Year

• Used to determine condition of detonation sensor on 3400, 3500 and 3600 gas engines

Reference
Page 13, May 1999, Engine News, “Testing Detonation Sensor for Proper Use”
ID: C79780T1

1U-5524 Adapter Cable

SMCS Code: 1272-038, 1552-036
Model: 3304, 3306, 3516
Warranty: One Year

• Part of the 6V-9060 Spark Timing Adapter Group

• Allows dynamic timing of engines equipped with integral shielded ignition coils and Altronic magnetos to be checked; engines
with Altronic magnetos have integral shielded ignition coils with 3-pin connectors for which 1U-5524 Adapter Cable is designed
• Connected at primary (low voltage) coil terminals of No. 1 cylinder; cable from magneto disconnected at primary coil connector
and two 1U-5524 Adapter Cable 3-pin connectors are coupled in between the coil and cable; remaining 2-pin connector of adapter
is coupled to 6V-9060 Spark Timing Adapter Group; when 6V-9060 and TDC Magnetic Transducer are connected to 8T-5250 Indicator,
engine RPM and timing displayed

Reference
SEHS8580 Special Instruction, use and service of 8T-5300 Timing Indicator Group and 6V-9060 Spark Timing Adapter Group

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Engine Tools Search Diagnostic Tools

Timing Cables
SMCS Code: 0779, 1550
Model: G3408C and G3412C Gas Engines (EIS, Electronic Ignition System)
Warranty: One Year

• Used to check ignition timing using a timing light and flywheel markings
Part No. Description Use
• Used to determine if a primary signal is going to each transformer
143-4508 Timing Cable G3408C
• Cable installs between ignition wiring harness and valve cover connector
143-4509 Timing Cable G3412C
• Makes timing less difficult because ignition wiring is encased in ridge/flexible
conduit or in a braided wire bundle

ID: C79425T1

Block Heater Power Cables

Model: D9R, D10R, D11R Track-Type Tractor 218-7221 125 Volt AC, 30 Amp
218-7223 250 Volt AC, 30 Amp

• Used to supply power to the block heater on large track-type tractor

• Length: 15.25 m (50 ft)
• Provides watertight seal
• Used with Marinco Engine Block Heater connectors
• Requires customer-supplied NEMA standard locking receptacle
125 or 250 Volt outlet for 30 Amp electrical circuit
ID: D00266T1

6V-3072 Carrying Case

Item Part No. Description
SMCS Code: 1000-025, 1000-038, 1250-025, 5050-038
Model: 6V-4060 Indicator Group, Engine Set Point 1 6V-3072 Case
Warranty: One Year 2 Form SEHS7920 Label
for 6V-3072 Case,
“6V-4060 Engine
• Depending on use, 6V-4060 Set Point Indicator Set Point Indicator”
can be stored with Engine Pressure Group
3 6V-4863 Foam Insert
or as individual unit in 6V-3072 Carrying Case.
4 6V-6045 Case
5 Form SEHS8009 Label
for 6V-6045 Accessories
Case

ID: B64235T1

9U-6695 Electronic Spark Plug Firing Indicator

SMCS Code: 1550-036
Model: Spark Ignited Engines
Warranty: One Year

• Greatly improved tool providing reliable way to diagnose ignition problems

• Adjustable sensitivity—user can set firing indicator to flash when placed near
primary wire on exposed coils of 6.25 inch bore engines
• Flashing LED on top of indicator easily seen in daylight
• Indicator can be carried easily in shirt pocket
• Once user sets sensitivity, instrument is activated when spring clip is depressed
• Rugged plastic housing and electronic circuit board combine durability features
for a dependable, durable instrument.

Diameter 15.0 mm (.57 in)

Length 133.4 mm (5.25 in)
Indicator bright red LED
Battery 3 required (147-6202 Battery)

ID: C80358T1

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9U-5358 Timing Light

SMCS Code: 0701, 0712, 0781
Model: All spark ignited engines
Warranty: Manufacturer’s

• Replaces canceled 5P-6584 Timing Light

• Inductive clamp provides fast and easy hookups Repair Information
KalEquip
• Super bright Xenon flash tube for easier reading of timing marks
15825 Industrial Parkway
• Built with dependable, solid-state circuitry for years of trouble-free service Cleveland OH 44135
• Detachable lead set
Phone: 800-228-7667
• Works on all 12 Volt systems Fax: 216-898-1636
• Light-weight and easy to handle [1.1 kg (2.4 lbs)] Email: [email protected]
ID: D00579T1

8T-5100 Smoke Meter Group

Discontinued — Service Parts Available

Item Part No. Description

1 6V-9449 Case
SEES 5696 Decal (8T-5100 Group)
8T-5312 Block Group (foam insert with case)
2 8T-5309 Pump Group
3 8T-5307 Evaluator
4 8T-5310 Clamp Assembly
5 8T-5311 Mounting Group
6 8T-5304 Probe
7 8T-5305 Probe
8 8T-5323 Filter Paper

ID: C14638T1
Reference
SEHS8731 Special Instruction

9U-6958 Magneto Peak Detect Module

SMCS Code: 1552-082
Model: 3500 and 3600 Engines
Warranty: One Year with CSTG Tool Repair Service

• Used to check magneto performance during actual operating conditions (problem could be spark plug or magneto related)
• When used with 6V-7070 or 9U-7330 Digital Multimeter or an equivalent, serviceman can measure magneto output DC Voltage
• Provides interface to magneto ignition system (9U-6959 T-Cable is included with the 9U-6958)
• Provides a separate voltage output for oscilloscope viewing of firing pulse train
• Does not require power to operate

Reference
NEHS0588 Tool Operating Manual

Input 0-200 VDC

DC voltmeter connections 0-200 VDC
Scope connections 0-200 VDC
Operating temperature -40 to 60° C (-40 to 140° F)
Dimensions 168 x 190 x 41 mm (6.6 x 7.5 x 1.6 in)
Weight 0.5 kg (1 lb.)
ID: C55193T1

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Flow Tools Search Diagnostic Tools

Flow Tools

8T-2700 Blowby/Air Flow Indicator Group

SMCS Code: 1000-038, 1350-038, 1350-081, 1350-082, 1400-038
Model: 3204, 3208, 3304, 3306, 3406, 3408, 3412, 3512
Warranty: One Year

• Replaces discontinued 9S-7373 Air Meter Group

• Contains hand-held digital indicator, remote mounted pickup, 915 mm (3 ft) of cable, blowby hose
and necessary connections
• Measures volume of blowby gases coming out of crankcase breather or air velocity through radiator
(9S-7373 measures only radiator air velocity)
• Battery-powered digital indicator; can also be powered with external 11 to 40 Volts DC from machine battery,
or AC powered with optional converter
• Volume of blowby gases coming out of engine breather(s) very helpful in planning engine repairs
(shown in either liters/min or cubic feet per hr)
• Air velocity through radiator core helpful to quickly find plugged or partially restricted areas
(shown in either meters/min or ft/min)
• Digital value appears when instrument is used.
Reference
SEHS8712 Special Instruction

ID: B89198T1
Item Part No. Description
ID: B89199T1 1 6V-7145 Case
Optional items that can be ordered to use with the blowby/air flow instrument
2 8T-2685 Pickup
Item Part No. Description Use
3 8T-2701 Indicator
1 5P-7366 Power Cable Connects machine batteries (11 to 40 Volts DC) to
hand-held indicator Service Parts
2 8T-5268 Converter Converts 110/220 Volts AC, 50/60 Hz, power supply Part No. Description
to 11 top 20 Volts DC at .3 Amp maximum for 8T-0899 Membrane Switch
powering indicator
8T-0844 Front Cover
3 6V-2198 Extension Cable, 5500 mm (18 ft) long Operates indicator more than 914.4 mm (3 ft) from
8T-0887 Connector Assembly
the pickup
8T-1005 Liquid Crystal Display

1U-8860 Large Engine Blowby Pickup Group • Large blowby meter has no moving parts because an ultrasonic sound vortex
SMCS Code: 1000-038, 1350-038, 1350-081 shedding principle measures the air flow. This makes the pickup reliable and
Model: 3500, 3600 Family Engines, Larger 300 Family Engines virtually maintenance free.
Warranty: One Year • Large blowby pickup connected to output of crankcase breather or vent tube on
engine; cable connects pickup to 8T-2701 Indicator which will give digital reading
of blowby value or air flow value
• Optional pickup for use with the 8T-2701 Blowby/Air Flow Indicator
• Before using 8T-2701 Indicator with large pickup, install 1U-8863 Blowby
• Replaces 8T-2685 Small Pickup for measurement of 3500 Engine blowby; use
Conversion Group in indicator; makes indicator accurate for both large pickup and
8T-2685 small pickup on these engines for short duration test only because of
small pickup
reduction of engine breather tube during test; use 8T-2701 Blowby/Air Flow
Indicator with large probe • Pickup meter is sensitive to high frequency engine noise; to avoid incorrect
readouts, keep pickup as far from engine as possible when making blowby
• Large 38mm (1.5 inch) I.D. pickup used on large engines without increasing
measurements; do not put pickup near turbocharger or fan blades because this can
crankcase pressure
cause reading error.
• Checks blowby volume on Caterpillar 3500 and 3600 Engines and larger 300 Series Item Part No. Description
Engines, as well as competitive large engines 1 6V-7145 Case
• All-metal construction and large size makes tool suitable for permanent installation 2 SEHS8984 Special Instruction
on engines; permanent installation allows continuous monitoring of blowby,
3 Large Engine Pickup
making group useful for dynamometer rooms, marine or generator set applications. (Not Serviced)
• When used with 8T-2701 Indicator, measures blowby on any engine within 4 9M-0164 Hose Clamps
blowby range of 94 to 1888 liters per min. (200 to 4000 cubic feet per hour)
(includes Caterpillar D397, D398, and D399 Engines, 3500 and 3600 Family 5 1U-8863 Conversion Group
Engines); smaller D300 and 3500 Engines may not have enough blowby at idle 6 1U-8868 Hose (Pickup)
or partial load to give reading when they are in good condition; indicator display
will read zero until engine is under load.
• Can also measure air velocity such as radiator cooling air flow
• Connected directly to 8T-2701 Blowby/Air Flow Indicator, provides digital display
of air flow or blowby value (volume of exhaust gas escaping to crankcase); blowby
value helps determine engine condition; should not be used as stand-alone
good/bad indicator for engine overhaul; other engine condition indicators, such as
oil consumption, low power, hard starting, and excessive fuel consumption, need
to be looked at also.
ID: B83857T1
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When used with 8T-2701 Indicator

Blowby measuring range
Liters/minute 94 to 1888
Cubic feet/hour 200 to 4000
Air flow measuring range
(with BLOWBY V1.20 PROM installed in 8T-2700 Indicator)
Meters/minute 83 to 1656
Feet/minute 272 to 5436
Accuracy ±10% of reading
Resolution
Blowby 1 liter per minute (1 cubic foot per minute)
Air flow 1 meter per minute (one foot per minute)
Operating temperature
ID: B83860T1
Pickup -18° to +121°C (0° to +250°F) Optional items for use with large engine pickup group
Storage temperature (Items 3, 4, and 5 are also optional items for use with 8T-2700 Indicator
Group for small engines, and may already be in your shop.)
Pickup -40° to +232°C (-40° to 450°F)
Item Part No. Description
Probe Size
1 8T-2701 Blowby/Air Flow Indicator (part of 8T-2700 Indicator Group).
Length 382 mm (15 in)
2 8T-5297 Blowby Pickup Cable, 914.4 mm (3 ft)
Outside diameter 50.8 mm (2.0 in)
3 6V-2198 Blowby Pickup Cable, 5500 mm (18 ft)
Inside diameter 38.1 mm (1.5 in)
4 5P-7366 Indicator Power Cable, 5500 mm (18 ft)
Width 113 mm (4.5 in)
5 8T-5268 Converter; converts 110/220 Volts AC, 50/60 Hz power supply
Height 130 mm (5.2 in)
to 11 to 20 Volts DC at .3 Amp maximum for powering the indicator
1U-8860 Group
Case size 432 mm W x 330 mm D x 114mm H Reference
(17 in W x 13 in D x 4.5 in H)
SEHS8984 Special Instruction (Large Engine Blowby Pickup Group)
Weight of 1U-8860 Group 6.1 kg (13.5 lb) SEHS8712 Special Instruction (Blowby Indicator)
Weight of 1U-8861 Pickup only 3.0 kg (6.5 lb)
Power provided by Pickup connector
on 8T-2701 Blowby/Air Flow Indicator

Medium Engine Fuel Flowmeter Groups Single Flowmeter

SMCS Code: 1250-036, 0782 Calibration range 189 to 1895 Lph (50 to 500 gph)
Model: 3408 and 3412 Electronic Engines or D300 and 3500 Engines Accuracy ±0.5% of reading
Warranty: Manufacturer’s
Two flowmeter system burn rate range 0 to 1895 Lph (0 to 500 gph)
• Versatile fuel flow measurement system used to help evaluate engine performance Operating Specifications
• Meter groups are fully field tested for accuracy Ambient air temperature 0 to 105°C (32 to 221°F)
Fuel temperature -20 to 85°C (-4 to 185°F)
154-8101 Medium Engine Fuel Flowmeter Group Storage temperature -40 to 100°C (-40 to 212°F)
• Used with existing 8T-9300 Fuel Flow Monitor Hand-Held Display
Maximum pressure 862 kPa (125 PSI)
154-8100 Medium Engine Fuel Flowmeter Group Weights
• Includes newer style 154-8106 Hand-Held Display. 154-8103 or 154-8104 Flowmeter 8.1 kg (6.75 lbs)
• Consists of 2 groups: 1U-5306 Hose/Adapter Group (Large) and 154-8102 Fuel Flow 154-8101 Flowmeter Group 14.5 kg (32 lbs)
Measurement System Group (each group must be ordered separately). 154-8102 Fuel Flow Measurement System Group 17.3 kg (38 lbs)
Flowmeters 1U-5306 Hose/Adapter Group (Large) 5.5 kg (12 lbs)
• State-of-art loose geometry, gear-type flowmeters
• Fail-safe design prevents engine fuel starvation even if flowmeter
becomes disabled by debris
• Flowmeter can be serviced in line
• Flow straighteners designed into inlet fitting
• Accuracy of ±0.5% of reading per flowmeter
• Durable construction
• Non-intrusive sensor/transmitter (screws into flowmeter body)
• Transmitter contains a microprocessor that 1) linearizes output signal and 2)
temperature corrects flow rates to provide accurate fuel flow and fuel temperature data.
Reference
NEHS0697 Tool Operating Manual
NEHS0698 Tool Operating Manual

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Flow Tools Search Diagnostic Tools

154-8101 Medium Engine Fuel Flowmeter Group

Item Part No. Description
1 154-8103 Fuel Flowmeter
2 156-1824 Sight Glass
3 154-8092 6.1 m (20 ft) Flowmeter Cable to 8T-9300 Monitor
4 4C-9660 King Pelican Case with NEEG2803 Decal
5 154-8098 Component Foam Insert
6 154-8099 Lid Foam Insert
7 NEHS0697 Tool Operating Manual
8 NIST Traceable Flowmeter Calibration Certificates

ID: C79325T1

ID: C79327T1
ID: C79326T1 Additional Components to make 154-8101 a complete test system
154-8102 Fuel Flow Measurement System Group
Item Part No. Description
Item Part No. Description
1 1U-5306 Hose/Adapter Group (Large)
1 154-8104 Fuel Flowmeters
2 8T-9300 Fuel Flow Monitor
2 156-1824 Sight Glasses
3 8T-9280 Power Supply
3 154-8107 Junction Box
4 5P-7366 Power Cable Assembly
4 8T-9280 Power Supply
5 1U-5297 Cable Assembly, 8T-9280 Power Supply to 8T-9300 Monitor
5 5P-7366 Power Cable Assembly
6 4C-9660 King Pelican Case
(Decal NEEG2802, 154-8098 Component Foam Insert, Optional Items (available separately)
and 154-8099 Lid Foam Insert) Part No. Description
7 154-8106 Hand-Held Display 154-8093 6.1 m (20 ft) Extension Cable, connects 154-8103 Flowmeter to
8 154-8097 6.1 m (20 ft) Cable, 8T-9280 Power Supply 154-8092 Cable; 154-8104 Flowmeter or 154-8107 Junction Box
to 154-8107 Junction Box to 154-8095 Cable
9 154-8095 6.1 m (20 ft) Meter/Display Cable 1P-7438 Beaker for taking fuel density tests
Not Shown 1P-7408 Thermo-Hydrometer (range 29 to 41° API)

NEHS0697 Tool Operating Manual 5P-2712 Thermo-Hydrometer (range 39 to 51° API)

NIST Traceable Flowmeter Calibration Certificates Cable Assembly connects 154-8103 or 154-8104 Flowmeter
to DataView (contact CSTG)
1U-5306 Hose/Adapter Group (Large)
(this group must be ordered separately) For 154-8102 only
154-8096 AC Power Supply Group (90 to 264 VAC, 47 to 63 Hz),
connects directly to the 154-8107 Junction Box
131-5047 AC Power Plug Cable (USA plug), connects
to 154-8096 AC Power Supply Group
137-0171 European Power Plug Adapter, connects to 131-5047 AC Power Plug
133-6975 AC Power Cable, 220 VAC (European Plug), connects
to 154-8096 AC Power Supply Group
For 154-8101 only
8T-9276 AC Power Supply, 110/220 VAC, 50/60 Hz switchable
6V-2198 Extension Cable, 5.5 m (18 ft), 8T-9300 Monitor to 154-8092 Cable
8T-9295 Magnetic Holding Base (for 8T-9300 Monitor)

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3600 Engine Fuel Flowmeter Group

SMCS Code: 1250-036, 0782
Model: 3606, 3608, 3612, and 3616 Engines
Warranty: One Year

• Used to evaluate engine performance

• State-of-the-art, gear-type flowmeters are fully tested for field accuracy
• Flowmeter available in separate group: 168-7735 Flowmeter communicates with 154-8106 and 8T-9300 Fuel Flow Monitor (see 168-7730 Flowmeter Group)
• Powered by 11 to 40 Volts DC at 1.2 Amps from machine battery or other source
• Fail-safe design prevents engine fuel starvation, even if flowmeter becomes disabled by debris
• Used as dual-meter system on engines with both supply and return-to-tank fuel lines or as ingle-meter system for engines without return line;
uses 2 fuel flowmeters and handheld monitor to measure fuel flow and fuel temperature of both supply and return lines, and calculate burn
rate of engine; handheld monitor displays average and total fuel burned during given period of time; monitor instantly indicates out-of-range
conditions such as underflow or overflow; information displayed in English or Metric units
• Non-intrusive sensor/transmitter (screws into flowmeter)
• Transmitter contains a microprocessor that linearizes output signal and temperature-corrects flow rates to provide accurate fuel flow and fuel
temperature data
• Microprocessors in state-of-the-art “smart” turbine flowmeters linearize output signals of both flow and temperature to give meter accuracy
of ±0.5% of reading; automatically compensates for fuel expansion as it changes temperature
• Meter groups fully field-tested to ensure accuracy
• Includes pulse dampeners, flow straighteners and sight glasses Single Flowmeter
Calibration range 569 to 4740 Lph
168-7740 Fuel Flowmeter Group, 3600 Engine (150 to 1250 gph)
(includes the 154-8106 Fuel Flow Display) Accuracy ±0.5% of reading
Two Flowmeter System
Burn rate range1 0 to 4740 Lph
(0 to 1250 gph)
Flowmeter Operating Specifications
Ambient air temperature 0 to 105°C (32 to 221°F)
Fuel temperature -16 to 85°C (-3 to 185°F)
Storage temperature -40 to 100°C (-40 to 212°F)
Maximum pressure 1700 kPa (250 PSI)
Weights
168-7745 Flowmeter 5.5 kg (12.2 lbs)
168-7750 Hose/Adapter Group 7.7 kg (17 lbs)
1 Return flowmeter fuel flow must not be less than 569 Lph (150 gph)
ID: C79630T1
Item Part No. Description
1 168-7745 Fuel Flowmeter
Additional Items Necessary for Testing
3612 and 3616 Engines (168-7740)
2 168-7739 Sight Glass
3 154-8107 Junction Box
4 8T-9280 Power Supply
5 5P-7366 Power Cable Assembly
6 4C-9660 King Pelican Case
NEEG2839 Decal
168-7742 Component Foam Insert
154-8099 Lid Foam Insert
7 154-8106 Hand Held Display
8 154-8097 Cable, 6.1 m (20 ft) (8T-9280 to 154-8107)
9 154-8095 Meter/Display Cables, 6.1 m (20 ft)
Not shown NEHSO74O Tool Operating Manual
Not shown NIST Traceable Flowmeter Calibration Certificates
Optional Items (sold separately)
Part No. Description
154-8096 AC Power Supply Group, 90 to 264 VAC, 47 to 63 Hz, ID: C79632T1
(connects to junction box)
Item Part No. Description Quantity
131-5047 AC Power Plug Cable (USA plug), (connects to 154-8096)
1 1U-5295 Accumulator 2
137-0171 Power Plug Adapter 220 VAC (connects to 131-5047)
2 168-7736 Swivel Tee 2
133-6975 Power Cable 220 VAC, (connects to 154-8096)
3 NEEG2180 Decal 2
Not shown 3K-0360 O-Ring Seal (package of 20)
Optional Items for 168-7730 or 168-7740 (sold separately) Not shown 5P-2963 Charging Adapter for 1U-5295
168-7755 Cable, (168-7735 to DataView)
168-7750 Hose/Adapter Group
168-7733 Hose Assembly, size 20, 1 m (3 ft) Reference
154-8093 Extension Cable, 6.1 m (20 ft), (168-7735 to 154-8092 NEHSO74O Tool Operating Manual, Using the 168-7740 Caterpillar
or 154-8107 to 154-8095) FuelCom Fuel Flow Measurement System for 3600 Engines
1P-7438 Beaker (for taking fuel density tests)
1P-7408 Thermo-Hydrometer (range 29 to 41° API)
5P-2712 Thermo-Hydrometer (range 39 to 51° API) Home Dealer Service Tools 2004 1-43
Flow Tools Search Diagnostic Tools

Small to Medium Engine Burn Rate Meter Systems, with Hand Held Display or No Display
SMCS Code: 1250-036, 0782
Model: 3116, 3126, 3176, 3208, 3304, 3406, and 3408 Engines
Warranty: One Year

• Used to evaluate engine performance

• Provides extremely accurate (±1% of reading) measurement of burn rate

Burn Rate Meter

• Uses a positive-displacement, rotary piston burn rate meter to measure
burn rate and a built-in heat exchanger to cool return fuel
• Air bubbles in return flow do not affect burn rate readings.

Burn Rate Computer

• 179-0701 Burn Rate Computer provides automatic temperature compensation and output scaling.
• Burn rate computer’s microprocessor linearizes output signal and temperature to provide burn rate
measurement accurate to ±1% of actual value.

Output Signals
• Includes frequency output signal to allow 131-5050 Dataview or 9U-7401 Multitach II to
display burn rate
• Provides RS485 Communications for 154-8106 Fuel Flow Hand-Held Display
• 154-8106 Display flashes “UNDERFLOW” or “OVERFLOW” when fuel flow is out of the
ID: C80273T1
allowable range.

Power Supply
• Uses 11-32 volt DC engine battery with an optional 100-240 VAC power supply available
• The power switch on 179-0701 Burn Rate Computer must be in “OFF” position when
connecting an AC power supply or the system will not power up.
• Not recommended for engines with supply fuel lines larger than a #10 JIC because of fuel
flow restriction

Burn Rate Meter

Burn rate 4 to 260 Lph (1.1 to 69.0 gph)
Accuracy ± 1% of reading, ± 0.4 Lph (.10 gph)
Frequency output scaling 10 Hz = 1 gph
Fuel Temperature
Fuel temperature range -17.7 to 85°C (0 to 185°F)
ID: C80351T1
Fuel temperature accuracy 0.5°C (1°F) providing fuel has been
flowing through burn rate meter long
enough to stabilize the reading NOTICE
Power Supply
Do not use the Burn Rate Meter System for 3500 Engines.
Restriction created by burn rate meter will cause return fuel
DC 11 to 32 Volts DC at 10 amp maximum to overheat, resulting in engine damage.
Horsepower Range
Horsepower 11.3 Kw (15.2 hp) — 735 Kw (1000 hp)
Optional Alternating Current
179-0713 AC Power Supply 100 to 240 Volts AC, 47 to 63 Hz NOTICE
at 1.6 Amps input Provides The meter should be upright, with the carrying handle on top
24 Volts DC, 3.0 Amps output when being operated. The meter can be tipped 30 degrees
Low Filter Response Times from an upright position and still work properly.
Flow change from 11.4 Lph (3 gph) to 121.3 Lph (32 gph) 6 seconds
Flow change from 121.3 Lph (32 gph) to 11.4 Lph (3 gph) 21 seconds
High Filter Response Times
Flow change from 11.4 Lph (3 gph) to 121.3 Lph (32 gph) 4 seconds
Flow change from 121.3 Lph (32 gph) to 11.4 Lph (3 gph) 6 seconds
Weight and Overall Size
179-0700 17.7 kg (39 lbs)—320 x 298 x 130 mm
(12.6 x 11.8 x 5.1 in) includes filter
179-0701 3.2 kg (7 lbs)—260 x 160 x 90 mm
(10.3 x 6.3 x 3.5 in)
179-0705 9.5 kg (21 lbs)—660 x 394 x 109 mm
(26.0 x 15.5 x 4.3 in)

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179-0710 Small to Medium Engine Burn Rate Meter

System with Hand Held Display
Item Part No. Description
1 179-0700 Burn Rate Meter
2 179-0701 Burn Rate Computer
3 179-0702 Cable
4 179-0705 Hose Group
5 4C-9660 Carrying Case
6 179-0706 Foam Insert
7 154-8106 Fuel Flow Hand Held Display
8 154-8095 Display Cable
9 5P-7366 Power Cable
10 6V-2198 Extension Cable

ID: C79884T1

Service Parts
Item Part No. Description
1 179-0703 Metric to JIC Adapter
2 179-0704 Electronic Connector (Fuel Meter)
3 179-0708 Temperature Sensor
4 081-4662 Fuel Filter
Optional Parts
Part No. Description
154-8093 Extension Cable
131-5047 AC Power Cable
1P-7408 Thermo-Hydrometer
5P-2712 Thermo-Hydrometer
ID: C79886T1 1P-7438 Beaker
179-0713 AC Power Supply
137-0171 European Power Plug Adapter
133-6975 AC Power Cable, 220 VAC (European Plug)
179-0715 Y Cable

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Measuring Tools

8T-1000 Electronic Position Indicator Group

SMCS Code: 0760
Model: All Models
Warranty: One Year

• Replaces mechanical dial indicators and allows readings to be taken in • Dynamic reading — such as rack position on an operating engine can be taken
applications where mechanical dial indicators cannot be accurately used such as well as static measurements; filtering included in indicator to help stabilize
as rack position on an operating engine (rapidly changing dynamic readings) rapidly changing readings
• Digital readout precision linear measuring gauge capable of dynamic and static • Floating zero — ZERO touch switch resets display to zero at any probe position;
measurement display will then show distance probe shaft moves from this zero position and
• Displays either millimeter or inch displacement indicate which direction it had moved with a # indicator
• Digital readout — 4-1/2 inch digit custom LCD (liquid crystal display) for digital • Storage memory — 3 separate storage memories record minimum, maximum,
display of measurement value with arrows to indicate functions being used; and difference values of measurement being taken; values can be displayed at
optional backlighting for use in dark locations and display heater for use in cold any time, allowing total travel of probe measuring shaft to be measured and
climates recorded
• Touch switch — front panel touch switch controls functions of indicator; has • Hold feature — value on display can be held constant for any length of time
tactile feel to allow operator to know when switch has been pressed hard with press of front panel touch switch
enough to enter a function • Power — 8T-1001 Indicator powered with internal 9-Volt battery; 11 to 40 Volts
• Remote readout — position probe which has same mounting stem as DC external power can be used for permanent installations or when battery is
mechanical dial indicators is connected to indicator with a cable; allows low; AC power adapter available; power-saving feature turns display off if
readings to be taken from remote location such as dynamometer control room, probe not used in 10 minutes, but retains all functions and information in
or from operator's compartment on machine; extension cables may be used to memories; if probe not used in 20 minutes, indicator turns itself completely off,
locate probe further from indicator clearing memories and zero; auto turnoff feature may be disabled if desired

When using 25.4 mm (1.0 inch) probe:

Measuring range 0-25.4 mm (0-1.0 inch)
Resolution .01 mm (.001 inch)
Accuracy ±.025 mm (.001 inch) accuracy in band from 5.08 mm (.200 inch) to 20.32 mm (.800 inch) starting with prove
shaft in 5.08 mm (.200 inch) from fully extended position; a ±.050 mm (.002 inch) outside band of 5.08 mm
(.200 inch) to 20.32 mm (.800 inch) for 25.4 mm (1.0 inch) travel starting with probe fully extended
Power internal, standard 9-Volt Battery, NEDA 1604, or 6F22 or 006P, or external 11 to 40 Volts DC at .007 Ampere
Battery life alkaline battery — 100 continuous hours, nominal or up to 300 hours intermittent
Polarity indicator can be changed to indicate either + or - as probe moves in either direction from zero point
8T-1000 Group size 394 mm x 311 mm x 101 mm (15.5 in x 12.3 in x 4 in)
8T-1001 Indicator size 190 mm x 112 mm x 40 mm (7.5 in x 4.4 in x 1.6 in)
8T-1002 Probe Size
Length (not including probe shaft) 89 mm (3.5 in)
Body diameter 19 mm (.75 in)
Mounting stem diameter 9.5 mm (.375 in)
Mounting stem length 21 mm (.85 in)
Probe shaft diameter 4.75 mm (.187 in)
Cable length 914 mm (36 in)

Item Part No. Description

1 6V-3072 Case
2 6V-6045 Accessory Case
3 8T-5295 Foam Insert
4 8T-1001 Electronic Position Indicator
5 6V-2198 Cable
6 8T-1002 Probe, 25.4 mm (1.0 inch)

Reference
SEHS8623 Special Instruction

ID: C80428T1

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4C-8753 Extended Collet

SMCS Code: 1250-036
Model: 3500 Family Engines
Warranty: Six Months (Not repairable)

• Improves accuracy of fuel setting measurement and adjustment on the 3500 Engine
• Used with 8T-1002 Electronic Position Indicator Probe or dial indicator
• Prevents side loading of probe shaft by fuel stop lever in governor; side loading can
cause setting errors and breakage of contact point on indicator
• Attaches to indicator probe or dial indicator; is correct length for 5P-7263 Contact Point
specified in 3500 fuel testing and adjusting instructions
• Has been added to 6V-7880 Timing and Fuel Setting Tool Group
• Fits all dial indicators with 9.5 mm (.375 in) mounting boss
• 82.6 mm long; 3/8-16 THD for mounting on engine
• Allows 25.4 mm (1 in) probe travel when used with 76.2 mm (3 in) shaft extension ID: C26949T1

Reference
SEHS9278 Special Instruction

8T-5096 Dial Indicator Test Group Item Part No. Description

Warranty: Manufacturer’s 1 6V-3072 Box
2P-8311 Block
• Provides tooling used in taking many different service measurements 2 7H-1946 Arm
such as gear backlash, end clearance, side clearance, valve movement 3 7H-1941 Base
or rack position. 4 7H-1942 Indicator
• Contains all components of the 7H-1949 Dial Indicator Group, along 5 8S-2329 Base
with an 8S-2329 Base and 8S-2327 Post.
6 7H-1940 Universal Attachment
• Magnetic base provides easier and quicker mounting of the dial
7 7H-1947 Holder
indicator. The former 7H-1949 Dial Indicator Test Group can be
updated by adding the 8S-2329 Base and the 8S-2327 Post. 8 8S-2327 Post
9 7H-1945 Holding Rod
10 7H-1645 Holding Rod
11 7H-1944 Post
ID: 92953-1T1 12 7H-1943 Clamp
13 7H-1948 Snug

6V-7926 Dial Indicator Group

Warranty: Manufacturer’s

• Used primarily for measuring off-engine timing dimensions when setting fuel pump lifters
• Measurements made with a 25.4 mm (1.00 inch) travel indicator and 5 contact points
• Can also be used in other applications for accurate depth measurements up to 127 mm (5.00 inch)

Item Part No. Description

1 6V-3073 Box Assembly
6V-7029 Liner Block
6V-7924 Holder Block
2 8S-3158 Indicator
3 3P-1565 Collet Clamp
4 5P-4156 Base
5 5P-4163 Contact Point, 120.65 mm (4.75 in) long
6 5P-4162 Contact Point, 95.25 mm (3.75 in) long
7 5P-4161 Contact Point, 69.85 mm (2.75 in) long
8 3S-3270 Contact Point, 44.45 mm (1.75 in) long
9 5P-4160 Contact Point, 19.05 mm (.75 in) long
10 5P-4159 Gauge Stand
ID: A16821-1T1 11 5P-4158 Gauge, 50.8 mm (2 in)
12 5P-4157 Gauge, 101.6 mm (4 in)

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165-8958 Indicator Base

SMCS Code: 7561-012
Model: All Models Containing Duo-Cone Seals
Essential Tool

90
• Used to measure installation height of Duo-Cone seals

20
10

80
0
2

70 0
3
• Used with 6V-3075 Dial Indicator, 6V-6167 Contact Point, and 3P-1565 Indicator Collet

10 90

60 40
• Made of plastic to prevent damage to sealing surface of seal ring 1 0 1

9
0
1 0 9
1

20 0
28 28

8
37 37

• Extra long base provides stability when measuring installation height.

50
6 4
4 5 6
5

300
Item Part No. Description

40
7

60
Overall length 127 mm (5.0 in) 1 165-8958 Indicator Base
3
Length from centerline of indicator to outer edge 122 mm (4.8 in) Additional tooling required
Width 15 mm (.6 in) 1 2 6V-3075 Dial Indicator
Threaded hole 3/8-32 thread 3 3P-1565 Collet Clamp
Material plastic Not shown 6V-6167 Contact Point

ID: C79357T1

9U-6175 Soft Tool Case

SMCS Code: 0787
Model: All Models (1U-9800)
Warranty: One Year

• Low-cost protection for 1U-9800 Ultrasonic Wear Indicator

• Resistant to oil, fuel, and coolant
• Adjustable neck strap for hands-free operation
• Clear vinyl front allows use of encased keyboard and display
• Quick-close top uses Velcro to permit quick removal of instrument.
• Dimensions: 195 x 195 x 40 mm (7.25 x 7.25 x 1.75 in)
• Weight: 227 g (.5 lb.)

ID: C55122T1

168-7720 Ultrasonic Wear Indicator III Group

• Automatically recalls and shows last machine location display screen when
168-7721 Ultrasonic Wear Indicator III turned on
SMCS Code: 4150, 0787 • Measurements stored in non-volatile memory
Model: All • Can select where machine data is stored in Indicator III when transferring from a
Warranty: One Year PC that is using CTS
• Less time cleaning parts — eliminates measurement errors due to dirt packing or

Compliant (168-7721) differences in measurement techniques between inspectors
• Replaces 9U-6700 Ultrasonic Wear Indicator II—includes many improvements • Accurate to within ± 0.1 mm (.010 in) in Low Resolution Mode and ±0.076 mm
• Used to measure track bushings (before and after turning), idler center flange (.003 in) in High Resolution Mode
wear on fabricated idlers, bulldozer blades, bucket base edges, scraper bowls, • Capable of storing 64 CTS inspections and uses direct alphanumeric entry
truck beds, components protected by guards, or any other thickness — works
quickly and easily
NOTICE
• Uses state-of-the-art surface mount electronics for high reliability If alkaline batteries are installed, do not use a 4C-3024 Battery Charger or
• Easy battery access — loosen two battery cover screws on Indicator III’s back 168-7734 Battery Charger or damage to the Indicator Ill may result. Place
side tape over the charge connector to prevent charging when alkaline batteries
• Uses five Alkaline or NiCad AA batteries (no battery pack) are installed.
• Liquid crystal display backlight can be turned on or off
• Power level monitor shows percent of estimated remaining battery power Operating Temperature
• Mono-earphone connector accepts earphone to hear beeper while in a noisy Ambient air -18 to +60°C (0 to +140°F)
environment Storage Temperature
• Built-in multiple language capability (English, Portuguese, French, Spanish, and Without batteries -40 to +60°C (-40 to +140°F)
German) — no program modules needed to switch language
With NiCad batteries less than 6 months -20 to +46°C (-4 to +113°F)
• Group includes a new probe with longer, more durable cable. This probe can also
With alkaline batteries less than 6 months -40 to +60°C (-40 to +140°F)
be used with the former 9U-6700 Indicator II.
Weights
• Used with Custom Track Service (CTS) inspections, which can be downloaded
directly to a computer for viewing or printing 168-7720 3.5 Kg (7.60 lbs)
168-7721 0.82 Kg (1.81 lbs)
168-7722 0.1 Kg (0.22 lbs)

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Item Part No. Description

1 168-7721 Ultrasonic Wear Indicator Ill
2 168-7722 Ultrasonic Probe (includes Certificate of Conformity)
3 6V-7145 Case
4 4C-3024 Battery Charger
5 9U-6000 Paper Towels (Qty 16, from 9U-6000 Paper Towel Case)
6 9U-7981 Couplant
7 NEEG2835 Group Label
Not shown 4C-4772 Foam Insert
Not shown Four RS232 Protective Caps (1 9/16 in)
Not shown NEHSO73O Tool Operating Manual

ID: C79635T1
Item Part No. Description
1 9U-7981 Couplant
Not shown One RS232 Protective Cap (1 9/16 in) Installed
Not shown One Calibration Certificate
Service Parts
Part No. Description
4C-5490 Couplant Holder
1U-7445 Nicad Battery, rechargeable, package qty 1 (5 required to power Indicator III)
1U-9533 Alkaline Battery, non-rechargeable, package qty 96 (5 required to power Indicator III)

ID: C79636T1
NOTICE Optional Items
Do not use battery charger if original rechargeable batteries in the Part No. Description
Ultrasonic Wear Indicator III are replaced with non-rechargeable 9U-6175 Soft Protective Case
batteries. Damage to instrument may result. Place a piece of tape over
4C-5488 Cable Assembly RS232 - to transfer thickness values
the charge connector to prevent charging. to the CTS program in a PC AT version
4C-5489 Cable Assembly RS232 - to transfer thickness values
to the CTS program in a PC XT version
Reference 4C-5897 Modem Cable
NEHSO73O Tool Operating Manual

135-3156 Battery Pack Installation Procedure

SMCS Code: 4150-0787 1. Remove back cover.
Model: 9U-6700 and 1U-9800 Ultrasonic Wear Indicators 2. Disconnect the 2 pin connector (on battery holder wires).
Warranty: One Year
3. Remove 4 screws on battery holder.
4. Install new battery pack using original screws.
• Used to provide nickel cadmium (NiCad) battery power to wear indicators (can be
easily installed with a Phillips screw driver, in place of 4C-9417 Battery Holder) 5. Connect the two-pin connector
• Used with 9U-6700 Ultrasonic Wear Indicator II Group or 1U-9800 Ultrasonic Wear 6. Replace back cover.
Indicator Group and a 4C-3024 Battery Charger (135-3156 Battery Pack is now
standard with all new wear indicators and can be retrofitted to all existing units)
• More resistant to corrosion, and provides better contact with battery holder terminals
• Rechargeable batteries should be replaced when not holding an adequate charge or
once each year (replace all former battery holders at this time).
• Charge all new battery packs for at least 14 hours before using the wear indicator.
• 4C-9417 Battery Holders are no longer available.

Instructions for Replacement Battery Holder

Former battery holder should be replaced with new battery pack if experiencing ID: C78402T1
any problems such as lost data, turns off by itself, displayed information locks-up,
not measuring properly, and/or display shows “memory failed.”
If wear indicators are experiencing any of these problems then check the serial number
(found on back cover).
If units have a serial numbers from 962 to 2095, fax a photocopy of back side of unit
and return mailing instructions to the Caterpillar Service Technology Group and a new
battery pack will be sent free of charge.
If units have a serial number below 962, a battery pack may be ordered through the
Caterpillar Parts Department. If problems persist even with the new battery pack,
contact the Caterpillar Service Technology Group. Reference
Voltage requirement 6 VDC
NEHS0606 Tool Operating Manual, 9U-6700 Ultrasonic
Wear Indicator II and SEHS9089 Special Instruction,
Life of charge 12 hours 1U-9800 Ultrasonic Wear Indicator Operating Instructions
ID: C78401T1
Battery pack five, shrink-wrapped batteries
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9U-7370 Belt Tension Tester

SMCS Code: 4197-036
Model: All “C” Series Challengers
Warranty: One Year, CSTG Tool Repair

• Used to check pressure in belt tension cylinder — checked from wiring harness or pressure transducer
• Used with 6V-7070 Multimeter or 9U-7330 Multimeter (tester can be easily and quickly interfaced)
• Built-in voltage, temperature, and pressure chart on back of tester
• Power to transducer supplied directly from tester — no need for external power supply
• Battery saver automatically turns tester OFF after one minute.

Reference
NEHS0600 Tool Operating Manual

ID: C55196T1
Item Part No. Description
Input 0 to 5 VDC (supplied by pressure transducer) 1 9U-7370 Belt Tension Tester
Output 0 to 5 VDC (measured at tip jacks on tester) Includes Service Parts
Power internal 9 VDC battery 2 9U-7368 Cable Assembly
Battery 1U-9534 Battery, Alkaline 3 9U-7369 T-Cable Harness
Battery saver time limit one minute Not shown 6V-3110 Back Cover
Battery life approximately eight hours (continuous use) Not shown 8T-0844 Front Cover
Not shown NEEG2562 Decal
Not shown NEEG2563 Decal

6V-7059 Multiple Anvil Micrometer

6V-2034 Adapter
Warranty: Manufacturer’s

• Micrometer used for measuring top flange thickness on cylinder liners, and also with the
6V-2034 Adapter to measure Caterpillar engine valve lip thickness. (5P-6518 Fixture Group
can also be used to measure lip thickness on engine valves.)
• Furnished with two anvils — one anvil is for measuring parts which can not be measured
with a standard micrometer; the other anvil permits the micrometer to be used as a general
purpose 0-25 mm measuring instrument.
• When measuring engine valve lips with the 6V-2034 Adapter, refer to the
valve dimensions given in the Guideline for Reusable Parts, Form SEBF8034.

ID: B62608-1T1

ID: B03107T1

6V-2012 Gauge Group, Micrometer Depth (in)

6V-7030 Gauge Group, Micrometer Depth (mm)
Warranty: Manufacturer’s

• Contains a complete set of measuring rods from 0-9 inch (0-228.6 mm) which are all stored in the wooden case
• Base: 76.2 mm (3.00 inch) wide; uses 3.96 mm (5/32 inch) rods

Item Part No. Description

1 6V-2013 Case
2 6V-0088 Rod, 177.8-203.2 mm (7-8 in)
3 6V-0091 Rod, 203.2-228.6 mm (8-9 in)

ID: A68774T1

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6V-6042 Point Group

Warranty: Manufacturer’s

• Has more contact points for the dial indicators

• Has straight contact points from 2.18 mm (.09 inch) long to 120.5 mm (4.74 inch) long,
three flat points, and a 12.7 mm (.50 inch) extension
• Has a plastic box with a divided tool holder and space to cut more slots for storage
of special points. Part numbers and sizes are shown on a chart inside the lid of the box.
• These contact points will fit all dial indicators with 4-48 threads but will not fit the
1P-2103 Dial Indicator.
• Comes with 6V-2030 Indicator Extension
ID: C34470T1

Additional Contact Points Available Item Part No. Description

Part No. mm inch Part No. mm inch 1 5P-2057 Contact Point
5S-8086 1 2.4 .094 5P-7261 31.8 1.25 2 1P-5512 Contact Point
9S-8903 2 2.4 .094 5P-2393 38.1 1.50 3 6V-6167 Contact Point1
8S-3675 3.1 .12 3S-3270 44.5 1.75 4 5P-4160 Contact Point
6V-2057 3 3.17 .125 5P-4809 50.8 2.00 5 1P-5513 Contact Point
3S-3268 6.4 .25 5P-6531 57.2 2.25 6 5P-2056 Contact Point
9S-0229 9.7 .38 5P-7262 63.5 2.50 Not shown 6V-6045 Case (included)
9S-8883 12.7 .50 5P-4161 69.9 2.75 Service Parts
5P-4160 19.1 .75 5P-7263 76.2 3.00 Not shown 6V-6043 Block Holder
1 30.0 mm (1.18 inch) long, AGD 4-48 Thd.
3S-3269 25.4 1.00 5P-4162 95.3 3.75
1 6.4 mm (.25 inch) diameter flat face.
2 12.7 mm (.5 inch) diameter flat face with a bevel to 9.7 mm (.38 inch) diameter.
3 9.52 mm (.375 inch) diameter flat face.

5P-2170 Dial Bore Gauge Group

Warranty: Manufacturer’s

• Gauge and related masters provide accuracy to .0025 mm (.0001 inch) for measuring all bores
in the size range 19.05-38.10 mm (.750 inch to 1.500 inch).
• Particularly useful for measuring the relief valve spool bores in pressure control bodies
on 631, 633, 637, 641, 650, 651, 657, 660, and 666 Tractors with eight speed transmissions

Item Part No. Description

1 5P-2170 Dial Bore Gauge Group
2 Master Gauges (available separately)
5P-2043 Gauge, 19.050 mm ( .7500 in)
5P-2059 Gauge, 22.225 mm ( .8750 in)
5P-2169 Gauge, 25.400 mm (1.0000 in)
5P-2171 Gauge, 27.051 mm (1.0625 in) ID: A04955T1
5P-2172 Gauge, 28.575 mm (1.1250 in)
5P-2173 Gauge, 31.750 mm (1.2500 in)
5P-2174 Gauge, 38.100 mm (1.5000 in)

1P-3537 Dial Bore Gauge Group for Inch Measurements

Warranty: Manufacturer’s

• Useful for making any critical bore measurement from 50.8 mm (2.00 inch)
to 203.2 mm (8.00 inch)
• Specifically, they should be used when reconditioning the cylinder bores on 1100 and
3100 Series Engines and when refinishing connecting rods in 137.16 mm (5.4 inch) bore
V8 and V12 Engines.
Reference
GMGO0981 Special Instruction ID: B19516T1
Item Part No. Description
1 9U-6615 Size Setting Fixture Group
2 1P-3535 Dial Bore Gauge
3 5P-6580 Nest Kit (Early gauges require
5P-6580 Nest Kit if used on later
size setting fixtures.)

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6V-7898 Dial Bore Gauge, Metric

6V-7899 Size Setting Fixture, Metric
6V-7897 Dial Indicator for Converting 1P-3535 Dial Bore Gauge to Metric
Warranty: Manufacturer’s

• Used for precision metric measurements

• Measure all internal diameters from 1.97 inch to 7.87 inch (50 to 200 mm) and depths from 0.51 inch to 11.81 inch (13 to 300 mm)
in increments of 0.00008 inch (0.002 mm)
• The increased accuracy is needed for applications such as connecting rods where the tolerances are very small.
• Use of the gauge is simplified because all current specifications are given in metric dimensions.
• 6V-7897 Dial Indicator is available to convert the current 1P-3535 Dial Bore Gauge to the 6V-7898 Dial Bore Gauge.
(All 1P-3535 Gauges can be converted except earlier gauges marked “MADE IN ENGLAND.”)

Reference
SMHS8253 Special Instruction, instructions for use of the 6V-7898 Dial Bore Gauge and also information for converting the 1P-3535 Gauge to the 6V-7898 Gauge
SMHS8254 Special Instruction, instructions for use of the 6V-7899 Size Setting Fixture.

ID: B76597-1T1

ID: B76599T1

Dial Bore Gauge and Master Rings

Model: 3600 Engines, Gas and Diesel

147-8862 Dial Bore Gauge

10
90
80
20

0
70 0

10 9
1
3

0
1

0
19
28
60 4

0
0

• Used to measure 3600 Engine cylinder liners

3 6 5
7

20 80
1 28
4
0

37
46
50

30
70
60
40

• Dial graduated to 0.002 mm

• Tool can reach up to 457 mm (18.0 in)

147-8860 Master Ring (diesel 280.025 mm) 147-8862

• Used to calibrate dial bore gauge to 280.025 mm (11.0246 in)
• Calibrates gauge for use on diesel engines

147-8861 Master Ring (gas 300.00 mm)

• Used to calibrate dial bore gauge to 300.000 mm (11.811 in)
• Calibrates gauge for use on gas engines

Reference
ID: C78577T1
SEBF8109 Guideline for Reusable Parts

Typical Dial Bore Gauge

Calibration Rings
ID: C78511T1

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6V-6000 Dial Bore Gauge for Metric Measurements

6V-6030 Size Setting Fixture
Warranty: Manufacturer’s

6V-6030
• Precision measuring instrument with a diameter range of 30.0 to 50.8 mm (1.2 inch to 2 inch)
graduated in 0.002 mm (.00008 inch) increments
• Depth range: 8.5 to 150 mm (.335 inch to 5.91 inch)
• Gauge is especially useful for measuring piston pin bores for 3300 Series Engines.
• Will set or check the dial bore gauge in 0.002 mm (.00008 inch) increments within its range
of 0 to 50 mm (0 to 1.97 inch)
• Fixture has a magnifying glass for easier reading.

Reference ID: B51220T1

SMHS8037 Special Instruction for 6V-6000
SMHS8036 Special Instruction for 6V-6030

8T-0450 Thread Identification Kit

Warranty: Manufacturer’s

• Used to meausre the size of internal port threads, external adapter threads, and bolt threads
• Good for Metric, BSP and US Standard Threads

Components of the 8T-0450 Thread Identification Kit

8T-0447 Dial Caliper
• 0-152 mm (0-6 inch) capacity
• Dial reads in .254 mm (.010 inch) and 1.58 mm (1/16 inch) graduations.
• Vernier scale reads in 1 mm and 1 inch graduations.
• 4-way measurement: inside, outside, depth, and height or step
• Made of strong super polyamid

8T-0448 Pitch Gauge

• U.S. Standard — 6, 7, 8, 9, 10, 11, 11 1/2, 12, 13, 14, 16, 18, 20, 24, 27, 88
• Metric — 0.70, 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 3.00, 3.50, 4.00
• British Standard Pipe — 10, 11, 14, 19, 28

8T-0449 Seat Angle Gauge

• 45° and 37° angles ID: C34467T1

8T-0451 Seat Angle Gauge

• 30° and 12° angles

Reference
SEHS8429 Special Instruction

7B-0337 Surface Plate

Warranty: Manufacturer’s

• Use for checking small shafts and bars for straightness; checking flat surfaces for warp;
and trimming rings, bearing caps, etc., using fine emery cloth
• Plate measurements: 304.8 mm (12.00 inch) x 330.2 mm (13.00 inch) x 38.1 mm (1.5 inch)

NOTE: As this plate is meant for general shop use, its surface is ground but not spot-scraped.

ID: C09439T1

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Paving Products

4C-5558 Auto Vibration Bypass Control 178-3832 Tank Valve

SMCS Code: 6606-036 SMCS Code: 4200
Model: CB434, CB534 Vibratory Compactors Essential Tool
Warranty: One Year Model: PS-150B, PS-200B, PS-360B Pneumatic Compactors

• Allows vibration mode to operate while machine is standing still for testing
and adjusting • Used to check and set high and low pressure
• Without this tool machine has to be in motion for vibration mode to operate regulator settings for air-on-the-run systems
• Consists of ON/OFF switch attached to 10-foot long cable • Used with 3B-7764 Reducing Bushing
• Must be used to set high/low pressures after
Reference replacing pressure regulator switch
KENR1305 Service Manual • Easily connects to air-on-the-run tank
• Equipped with standard valve core and sealing cap

Thread 1/4 NPT

Maximum pressure rating 1378 kPa (200 PSI)
Overall length 38 mm (1.5 in)
Material brass
ID: C79627T1

Reference
KENR2721 Service Manual; Supplement for
PS-150B, PS-200B, PS-360B Pneumatic
Compactors Air-on-the-Run System

Test Harnesses
SMCS Code: 0740, 0779
Model: E(L)200B, E(L)240B, and E(L)300B Excavators
Warranty: One Year (4C-8758, 990049 and 990050)

• Allows access to electrical control signals to be checked for correct operation and measurement
of voltages, current, resistance and continuity

Reference
SENR4527, Testing and Adjusting module for E(L)200B
SENR4843, Electronic Power Unit module for E(L)240B
SENR4871, Electronic Power Unit module for E(L)300B
NEHS0546 Tool Operating Manual adjustment to electronic
power unit control system

ID: C27222T1
Item Part No. Description Use
1 990048 Extension Harness In electronic control circuit
2 990049 Test Harness To check governor control potentiometer
3 990050 Test Harness To check the Proportional Reducing Valve
(PRV) on E(L)200B Excavator
Not shown 4C-8758 Test Harness To check the PRV on E(L)240B and E(L)300B

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Power Train Tools

9U-7500 Transmission Analyzer II Group

Various Cables and Adapters
SMCS Code: 3000, 3150, 3418, and 4800-038
Model: Machines with Electrical Transmission Controls
Warranty: One Year

• Replaces discontinued 1U-7446 Transmission Shift Analyzer Group • Analyzer can determine if shift lever is functioning correctly on transmissions
• Used to test and adjust proportional valves which control transmission not controlled by autoshift electronic control feature
(connects directly to solenoids of transmission) • Software updated annually to accommodate New Product Introduction
• Analyzer works on Powershift planetary, Powershift countershaft, Individual Software Subscription NETG5021.
Clutch Modulation (ICM), Challenger transmissions, H-Series Motor Grader
transmissions, and Electronic Clutch Pressure Control (ECPC) transmissions H-Series Motor Graders
• Designed and built with an Intel microprocessor with flash memory (provides • Analyzer can turn on solenoids in a timeline sequence
dealers with capability of updating analyzer for new types of transmissions, • Modulates current to one or all of initialized solenoids at any point in time
without purchasing a new analyzer)
• Easy to read menus provide step-by-step sequence for analyzer operation Challenger and ECPC Transmissions
• Lighted LCD makes it easy to see readings on display screen • Analyzer outputs pulse width modulated (PWM) current (required for this type
of transmission)
• Performs three basic functions: checks solenoid condition, shifts
transmission, and checks shift lever operation Reference
• Analyzer performs automatic or manual testing for shorted or open solenoid NEHS0644 Tool Operating Manual
coils on one or all solenoids (can also alert mechanic to intermittent
problems with solenoid coils)

Size 393 x 311 x 171 mm (15.5 x 12.3 x 6.7 in)

Weight
Group 6.2 kg (13.8 lbs)
Tester 4.04 kg (8.9 lbs)
Operating voltage (DC power) 11 to 40 VDC
Minimum current requirements
(DC power) (Challenger 35, 45, and 55) 20 amps
Minimum current requirements (all other units) 10 amps
AC power 110 or 240 VAC
Memory one megabyte CMOS flash memory
Microprocessor Intel 80C51FA
LCD display size 43 x 124 mm (1.7 x 4.88 in); four line x 20
characters
Operating temperature range -18 to 60°C (0 to 140°F)
Storage temperature range -40 to 60°C (-40 to 140°F)
Overcurrent protection protected with a current limiting
electronic circuit and against
a short circuit fault by a 40 amp quick-trip
circuit breaker
ID: C66959T1

Part No. Description

9U-7499 Transmission Analyzer II
Not shown
1U-9485 AC Power Cable
1U-9486 DC Power Cable
9U-7497 Test Cable
9U-7496 Test Cable
Optional Tools
1U-9479 Gear Shift Test Adapter Cable
1U-9480 Gear Shift Test Adapter Cable
9U-7498 Extension Cable,
9U-7495 Test Cable (Wheel Loaders)
1U-9483 Test Cable (Challenger)
1U-9484 Programming Cable
1U-9482 Test Cable (ICM)
223-2217 Test Cable (D6M)
Service Parts
1U-6141 Connector (Service Repair)
1U-9458 Connector (Service Repair) Home Dealer Service Tools 2004 1-55
Power Train Tools Search Diagnostic Tools

223-2217 Dozer Speed Sensor Cable

SMCS Code: 3030
Model: D6M and D6R Track-Type Tractors
Warranty: One Year

• Used to shift transmission and measure speed sensor signals during a bench test
• Used with 9U-7500 Transmission Analyzer II Group
• One end plugs directly into transmission control connector
• Speed sensor connectors plug directly into multimeter
ID: D00177T1

1U-9100 Adapter Cable (Challenger to PC) 4C-4068 Extension Cable

SMCS Code: 7490-035 SMCS Code: 3000-035
Model: Challenger 35, 45, and 55 Model: 621E, 623E, 627E, 631E, 637E, 651E, 657E
Warranty: One Year Warranty: One Year

• Used to connect a personal computer into the • 14-foot long extension cable that enables serviceman
Challenger’s on-board electronic system to position ICM control box in cab while
• Used with personal computer troubleshooting transmissions
• Cable connects RS232 port on computer to Diagnostic and • Make troubleshooting safer and easier
Maintenance (D.A.M.) connector on Challenger
• Cable allows Electronic Technician (ET) software to read fault
codes, delete fault codes (where allowed), and change vehicle
parameters
• Cable comes complete with communication adapter which
allows computer to communicate with Challenger’s electronic system
ID: C66845T1
• Cable length: 2.1 m (7.00 ft)
• Computer connection: 9 pin serial

139-5210 Extension Cable Assembly (ARC/EPTC II)

SMCS Code: 0740, 0779
Model: See List Below
Warranty: One Year

• Extension cable for Automatic Retarder Control (ARC) used on 769D, 771D, 773D, 775D, 776D, 777D, 785B, 789B, 793B, and
793C Off-Highway Trucks; and Electronically Programmable Transmission Control (EPTC II) used on 769D, 771D, 773D, 775D,
776D, 777D, 785B, 789B, 793B, and 793C Off-Highway Trucks; D250E, D300E, D350E, and D400E Articulated Trucks; and 621F,
623F, 627F, 631E, 633E, 637E, and 657E Wheel Tractor Scrapers
• Connects to 10-pin sure seal connector on ARC or EPTC II
• Two additional connectors allow 4C-8195 Control Service Tool and 7X-1700 Communication Adapter to be connected
• Allows serviceman to position ARC and EPTC II in cab while troubleshooting ID: C66569T1
• Overall length: 4.3 m (14 ft)

198-1758 Calibration Group Service Parts Reference

SMCS Code: 5084-524 Part No. Description RENR1528, RENR1534, and RENR1593 Service Manual Modules
Model: 621G, 623G, 627G, 631G, and 637G Scaper
3J-7354 Seal 198-6593 Calibration Instructions
Essential Tool
3K-0360 Seal
8C-7325 Adapter
• Used to calibrate electro-hydraulic implement control system 9X-4455 Switch Assembly
• Used with Caterpillar Electronic Technician (ET) software 202-4995 Harness Assembly
• Ensures efficient operation of implement system 142-2763 Coupler Assembly
• Overall length: 650 mm (25.6 in)

4C-5974 Adapter Cable 232-1065 Cable Adapter

SMCS Code: 0785 SMCS Code: 0785
Model: Machines with military-type connectors Model: 740 Articulated Truck
Warranty: One Year Essential Tool
Warranty: One Year
• Used to adapt military-type connector, previously used on majority of
Caterpillar machines, to Sure Seal connector • Used to connect transmission ICM solenoid to harness from 9U-7500
• Standard harness with military-type connectors can now be used with the Transmission Analyzer II
serviceable replacements that use • Adapts two-pin, military-type connector to two-pin Duestch DT connector
Sure Seal connectors without any modification of wiring harness.
• Allows 9U-7500 Transmission Analyzer II to be used on newer articulated
• Testing and analysis equipment can be used on hardware with new Sure
truck transmissions
Seal connectors.
• Overall length: 300 mm (11.8 in)

ID: C27266T1
ID: D00537T1
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Diagnostic Tools Search Speed Measuring Tools

Speed Measuring Tools

9U-7400 Multitach II Group

9U-7401 Multitach II
9U-7402 Multitach II Photo Group
SMCS Code: 1250-025
Model: All Caterpillar Products
Warranty: One Year

Compliant
• Used to measure rpm, frequency, and engine set point — combines three instruments into one
• Engine set point indicator captures and displays set point rpm
• Hz frequency meter measures gen set or other signal frequency
ID: C66677T1
• Easy to use photo pickup for fast RPM measurement
• Two digital displays show Input 1 and Input 2 values simultaneously — eliminates RPM measurement range 1-9999 rpm
switching screens Measurement accuracy ±1 rpm
• Displays minimum, maximum, and difference values of inputs Pulses per revolution 0.1 to 256 PPR (selectable)
• Displays difference between Input 1 and Input 2 Frequency measurement range 0-9999 Hz
• Backlit display for operation in low light conditions Frequency measurement
accuracy:
• Optional RS232 output available for sending data directly to printer
0-999.9 Hz ±0.5 Hz
• Adjustable pulses per revolution 1000-9999 Hz ±1.0 Hz
• Operated by rechargeable battery — designed with low battery indicator and internal Set point measurement set point — 20 rpm = full load rpm
battery voltmeter Overrun indicator 0 to 10% rack contact
• Accepts many different types of pickups (including most pickups used with former Multitach II) Set point rpm 11% rack contact (RPM held on display)
• Program each input separately with different PPR (Pulses Per Revolution) values for Overrun and lug off 11 to 74% rack contact
each — different pickups can be used simultaneously
Lug indicator 75 to 100% rack contact
• Stays pre-programmed to values last used — displays values when turned on

Item Part No. Description

1 9U-7505 High Voltage (600 Volt Max.) Input Adapter
2 4C-3024 Battery Charger
3 Storage for three spare AA size batteries
4 9U-5140 LED Photo Pickup (also storage for additional photo pickup)
5 9U-7401 Multitach II
6 6V-6045 Accessories Case
NEEG2061 Accessories Case Decal
7 1U-6605 Retro-Reflective Tape 12 mm x 1.5 m (.5 in x 5.0 ft) roll
8 6V-3138 Extension Rod for Magnetic Base
9 9U-7506 Magnetic Adapter Cable
10 8T-5111 Rack Adapter Cable
11 5P-7360 Tachometer Generator
12 Storage for additional Tachometer Generator
13 Storage for additional Tachometer Drive Group
14 5P-1759 Tachometer Drive Group (additional parts in accessory
case)
15 9U-7508 Foam Insert
16 6V-2198 Extension Cable 5.5 m (18.0 ft)
17 6V-7145 Carrying Case
NEEG2573 Group Label on lid of 9U-7400 Group
ID: C66650T1
18 6V-7072 Test Lead Set (for use with high Voltage adapter)
19 1P-7446 Rack Cable 5.5 m (18.0 ft)
20 Storage for additional photo pickup magnetic base
21 6V-3137 Photo Pickup Magnetic Base
22 Storage for two spare AA size batteries
23 NEEG2593 Inside Lid Decal
24 NEHS0605 Operating Instructions

Home Dealer Service Tools 2004 1-57

Speed Measuring Tools Search Diagnostic Tools

Item Part No. Description

1 Storage for five spare AA size batteries
2 9U-5140 LED Photo Pickup
3 9U-7401 Multitach II
4 6V-6045 Accessories Case
NEEG2061 Accessories Case Decal
5 1U-6605 Retro-Reflective Tape 12.5 mm x 1.5 m (.5 in x 5.0 ft)
6 6V-3138 Extension Rod for Magnetic Base
7 6V-3072 Carrying Case
NEEG2574 Group Decal on lid (9U-7402 Group)
8 6V-2198 Extension Cable 5.5 m (18.0 ft)
9 9U-7507 Foam Insert
10 6V-3137 Magnetic Base for Photo Pickup
11 4C-3024 Battery Charger
12 NEEG2594 Inside Lid Decal
13 NEHS0605 Operating Instructions

ID: C66664T1

ID: C66638T1
Optional accessories for 9U-7401
Item Part No. Description
1 4C-9499 RS232 Output Adapter
2 155-5175 AC Clamp-on Probe (use with 9U-7505 High Voltage Adapter or 9U-5265 Banana Plug Adapter to measure Hz)
3 155-5176 AC/DC Clamp-on Current Probe (use with 9U-7505 High Voltage Adapter or 9U-5265 Banana Plug Adapter to measure Hz)
4 9U-5215 Diagnostic Tool Soft Case (not as shown)
5 8T-5297 Extension Cable 0.9 m (3.0 ft)
6 9U-5265 Adapter (connects two banana plugs to 9U-7506 magnetic adapter cable)
7 6V-0093 Retro Reflective Tape, 12 mm (.5 in) wide x 15 m (50.0 ft) long roll
8 4C-6919 Retro Reflective Tape, 25 mm (1.0 in) wide x 2.5 m (100.0 in) long roll, with honeycomb pattern design
9 and 10. 4C-6821 Injection Line Speed Pickup Group (for Multitach or Data Logger)
10 and 11 6V-4950 Injection Line Speed Pickup Group (for Multitach only)
12 1U-7445 NiCad (Nickel Cadmium) Rechargeable Battery, AA (packaged singly)1
13 1U-9533 Alkaline Non-Rechargeable Battery, AA (package of 96)1
14 8L-4171 Magnetic Pickup (general purpose)
15 8T-5184 Magnetic Pickup, 88.9 mm (3.50 in) long x 6.35 mm (1/4 inch)
16 6V-2197 Magnetic Pickup, 114.3 mm (4.50 in) long x 6.35 mm (1/4 inch)
17 8T-5185 Magnetic Pickup, 177.8 mm (7.00 in) long x 6.35 mm (1/4 inch)
18 6V-2199 Pickup Adapter, 6.35 mm (.250 in) dia. x 1/8 inch NPT
19 6V-3093 Pickup Adapter, 6.35 mm (.250 in) dia. x 1/4 inch NPT
Not shown 1U-6605 12.2 mm (1/2 in) Retro Reflective Tape, 1 - 1524 mm (5 ft) long roll.
1 Five batteries are required to power Multitach II.

Reference
NEHS0605 Operating Manual

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Diagnostic Tools Search Speed Measuring Tools

5P-1759 Tachometer Drive Group

SMCS Code: 1250-25
Model: All Models

• Used on engines with ENM Service Meters including engines with Sleeve Metering Fuel Systems
• Replaced 9S-5609 Drive Group
• To use 5P-1759 Drive Group, service meter is removed and drive group installed.
• On 5.4 inch bore engines not equipped with tachometer drive group, 5P-1758 Shaft Assembly must be used.

Item Part No. Description Use

1 1W-2316 Adapter Assembly (former 9N-3018) For all engines with ENM Service Meters
4M-8308 Seal (outside) ID: A69888-2T1

2 5P-1758 Shaft Assembly With 1W-2316 or former 9N-3018 for 5.4 inch bore V—
engines
3 4N-0538 Coupling With 1W-2316 or former 9N-3018 and 5P-0537 for
engines with Sleeve Metering Fuel Systems
4 5P-0537 Washer (discontinued) Between former 9N-3018 and 4N-0538 (5P-0537
Washer, discontinued, is not needed with later
1W-2316 Adapter Assembly)
5 9S-3032 Clamp (two)
6 9S-0211 Clamp (two)

168-7727 Battery Cover Group

SMCS Code: 1250-25
Warranty: One Year
3 4 Item Description
• Replacement battery cover kit for the following hand held 1 Battery Screw Cover
diagnostic tools which have external battery access: 2 O-Ring Seal
9U-7401 Multitach II 3 Battery Cover
168-7721 Ultrasonic Wear Indicator III 2
4 Gasket
Not Shown
1
Battery Clip, Single (2)
Battery Clip, Dual (4)

ID: D00248T1

211-1773 Drive Motor Speed Pickup Breakout-T

211-1774 Engine Speed Sensor Breakout-T
Model: D3G, D4G, D5G Track-Type Tractor
Warranty: One Year

• Used to monitor drive motor speed pickup and engine speed sensor
• Used with DataView
• 211-1773 connects between machine harness and engine speed sensor (magnetic pickup)
• 211-1774 connects between machine harness and drive motor speed pickup (Hall-effect sensor)

ID: C80493T1

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7M-6001 Drive Adapter Group

SMCS Code: 1000-025
Model: All Models

• Some engines are equipped with service meters that have no means of attaching a tachometer drive.
Installation of the 7M-6001 Adapter Group is accomplished by removing the Service Meter and installing
the drive assembly with the 7M-6010 Bushing using two 1B-2713 Bolts through the swivel mounting plate.
Two 1B-7182 Bolts are used to secure the drive assembly to the service meter cover mounting boss and
the swivel mounting plate is not used.
D2 Tractors, early 933 Traxcavators, and D311 Engines (prior to series H) require a 4F-4246 Shaft and
a 7B-1075 Spacer in addition to the 7M-6001 Tachometer Drive Adapter Group.
• On engines equipped with the ENM Service Meter (manufactured in England) either the 7M-6001
or the 5P-1759 Drive Group may be used. On engines with Sleeve Metering Fuel Systems, the 4N-0538 Coupling
must be used. If the 7M-6001 Adapter Group is used, the Service Meter must also be removed.

ID: D00942T1
1 6B-3127 Cable Service Parts for Tachometer Drive Group
2 7M-6003 Adapter Item Part No. Description
3 Tachometer Drive Group includes one Bushing: 1 9B-2232 Cap
7M-6010 2 1F-3257 Shaft
4 7M-6004 Fitting 3 7M-6007 Housing Assembly
5 1B-2713 Bolt (two) 4 2B-4602 Plug
3B-4504 Washer (two)
5 7M-6010 Bushing
6 1B-7182 Bolt (two)
3B-4505 Washer (two) 6 7B-9002 Washer
7 1F-3275 Screw Assembly

ID: C05359T1

5P-0935 Tachometer Drive Adapter Group

SMCS Code: 1000-025
Model: 910. 931, D3, 3204
Warranty: One Year

• Used with Tachometer Drive Group for checking engine speed on 3204 Engine
in D3 Tractors, 910 Wheel Loaders, and 931 Track Loaders (7M-6006 Group
must be modified by removing plate and machining housing to dimension shown)

Item Part No. Description

1 5P-0933 Adapter (Part of 5P-0935)
2 5P-0934 ShaftID:(Part
74071T1
of 5P-0935)
3 7M-6006 Drive Group

8N-5945 Adapter Assembly

SMCS Code: 1250-025, 3224-025, 5050-038, 7106-011
Model: 943, 953, 3204

• Used for measuring engine speed on 3204 Engines, 10X1-2935, in 943 and 953 Loaders
• 90° drive adapter assembly installed on engine timing gear cover
• Used with 5P-7360 Tachometer Generator; 4M-8303 Seal and two 9S-3032 Clamps
also required for installation of adapter assembly

ID: B11770-1T1
5P-6560 Tachometer Adapter
SMCS Code: 1000-025
Model: 627B
Warranty: One Year

• Used to connect tachometer drive cables (with SAE No. 12 heavy duty input fitting and SAE No. 10 Marine output fitting)
to 9S-3047 Generator Assembly
• Desirable arrangement on machines, such as 627B Tractors, where engine tachometer drive is not accessible
• 5P-7360 Generator Assembly included with 5P-3600 Flowmeter, 5P-2160 Engine Horsepower Meter and 1P-5500 Phototach Group

ID: A36336-1T1

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Diagnostic Tools Search Speed Measuring Tools

6N-1345 Tachometer Drive Adapter

SMCS Code: 1000-025
Model: 943, 953, 215, 3204

• Used for measuring engine speed on later 3204 Engines, 10X-2396-Up, in 943 and 953 Loaders and 215 Excavators
(different adapter needed for later engines because of change to camshaft)
• Also required for adapter installation: 4M-8303 Seal, 5P-1758 Shaft Assembly, two 9S-3032 Clamps,
two 0S-1617 Bolts and two 9M-1974 Washers
ID: B39042T1

7N-8929 Cable Connector

SMCS Code: 1000-025
Model: All Models

• Used to connect tachometer drive cable to 9S-3047 Tachometer Generator (included in 1P-5500 Phototach Group) on engine
applications where access to tachometer drive is difficult; disconnect tachometer drive cable at tachometer and use this fitting
ID: A24450T1

1U-5550 Oil Pressure Adapter Group

SMCS Code: 1300-036
Model: XNIP Peugeot Engines

• Used to measure oil pressure on XNIP Peugeot Engines. These engines are found on several models of Caterpillar lift trucks.
The 1U-5550 is installed in place of the oil pressure solenoid in the oil filter base. The 1U-5550 provides a 9/16 inch 18-2B
(SAE No. 6) port for pressure measurement purposes.

4C-6821 Pickup Group, Injection Line Speed for Data Logger

Discontinued — Service Parts Available

Service Parts
Item Part No. Description
1 1U-9139 Pickup
2 4C-6812 Amplifier

Reference
SMHS7504-01 Special Instruction
SEHS7807 Special Instruction
SEHS8224 Special Instruction

ID: C44356T1

1U-9139 Universal Fuel Line Pickup

SMCS Code: 1000-025
Model: All non-unit-injected Caterpillar diesel engines
Warranty: One Year

• Used with 6V-2100 Multitach (as accessory part for 6V-4950 Pickup Group) to measure diesel engine speed
• Works on Perkins fuel lines as well as on those with remote unit pump group, on all precombustion chamber
fuel systems and on some smaller direct injection fuel systems
• Not applicable to unit injected 3500 and 3600 Engines
• Adaptable to different fuel line sizes from 5.5mm Perkins to 7.0mm size range

Reference Item Part No, Description

SEHS8029 Special Instruction 1 1U-9139 Universal Fuel Line Pickup
SEHS7807-03 Special Instruction 2 6V-6113 Amplifier
ID: B83852T1

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Speed Measuring Tools Search Diagnostic Tools

1U-9710 Adapter Cable

SMCS Code: 1250-025
Model: Most Caterpillar Spark-Ignited Engines
Warranty: One Year

• Used with 6V-2100 Multitach to measure RPM on most Caterpillar spark-ignited engines
• Used with 6V-9060 Spark Timing Adapter Group and 6V-2100 Multitach or 6V-3121 Multitach Group
• Multitach owners have method of measuring RPM of spark-ignited engines.
• 6V-2100 Multitach has digital LCD display.

ID: C27156T1

1U-6602 Photo-Tach Group

SMCS Code: 1000-025
Model: All Models
Warranty: One Year

• Measures RPM by directing laser light beam onto piece of reflective tape and counting reflected light pulses; reflective tape can be affixed to any rotating component
• RPM can be measured to and is accurate within 1 RPM
• LCD viewed simultaneously while aiming the instrument
• Provides low cost tachometer for general use; does not replace 6V-3121 Multitach Group. The 1U-6602 is a phototach only and reads only the basic input frequency (1
pulse per revolution per piece of reflective tape). The more versatile 6V-3121 accommodates multiple RPM pickup devices (e.g., photo, magnetic, fuel lines) and can be
programmed to divide by any number up to 256. This allows the RPM to be displayed directly.

Measurement range 5 to 100,000 RPM

Accuracy ±1 RPM
LCD size 6 digit 12.7 mm (.50 in) high
Range 0 to 3 m (0 to 10 ft) from reflective tape
Angle up to 45° from perpendicular to target (Best results at angles from 5° to 20°)
Last measurement memory displays last measurement approximately 1 min. after trigger release
Power-on switch pistol grip trigger; may be locked on with latching push-button for longer duration measurements
Optical system linear reflective laser - 3mW
Recommended size of reflective tape 13 mm (1/2 in) square
Size 83 mm x 45 mm x 156 mm (3.25 in x 1.75 in x 6.13 in)
Weight approx. 0.57 kg (1.25 lbs.)
Power 1U-9533 “AA” size batteries (4) (Can operate instrument for 8 continuous hours)
or optional, rechargeable 1U-7445 Nickel Cadium Batteries

Item Part No. Description

1 6V-3073 Case
2 1U-7771 Tachometer
3 1U-9533 Battery (4)
4 1U-6605 Reflective Tape
5 4C-3024 or 161-8384 Recharger, 110/220 VAC. 4C-3024 (older
units) photo-tach has 2.54 mm (.10 in) hole
for charger connection.
161-8384 (newer units) photo-tach has
6.35 mm (0.25 in) hole with center pin for
charging connection.
Optional
Not shown 1U-7445 Nickel Cadmium Batteries (4)
Not shown 1U-7772 Foam Block

Reference
ID: B96709T1 SEHS8854 Special Instruction

161-8384 Battery Charger Charger connector barrel type

SMCS Code: 1900-038, 0781 Connector OD 5.6 mm (.22 in)
Model: All Models Connector ID 2.5 mm (.10 in)
Warranty: One Year
Center pin (ID) polarity negative

• Used to recharge nickel cadmium batteries on newer hand-held Photo-Tach

Reference
• Used with 1U-7771 Photo-Tach, part of 1U-6602 Photo-Tach Group SEHS8854 Special Instruction, Using the 1U-6602 Photo-Tach Group

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Diagnostic Tools Search Temperature Measuring Tools

Temperature Measuring Tools

4C-6500 Digital Thermometer Group

SMCS Code: 1000-082, 3000-082, 4000-082, 5000-082, 7000-082, 0776
Model: All Models
Warranty: One Year

Compliant • Records minimum and maximum temperatures for each channel

• Fast and accurate method of measuring temperature • Has battery saver features
• Backlit, digital LCD display for use in low light conditions • Compatibility with probes for 131-5050 Data View offers greater flexibility in solving
• Larger liquid crystal display for easier viewing temperature problems. Probes designed to be used with Cat’s probe seal adapters
• Does not need to be calibrated every time it is used • Temperature readings can be sent to serial printer (requires optional, user-installed
• Provides user with differential temperature calculated from 4C-9499 RS-232 Output Adapter Group
any 2 of the 5 channels
Reference
Operating Manual NEHS0554
4C-6800 Datalogger Tool Operating Manual NEHS0549

Inputs 5, 4-wire PRTD (Platinum Resistance Temperature Detector)

Output Optional, RS-232 level 300 or 1200 Baud rate
Power Internal rechargeable batteries or 110/220 VAC, 50/60 Hz line power using 4C-3024 Battery Charger
Range -50°C to 850°C (-58°F to 1582°F)
Resolution ± 0.1°C or F
Accuracy -50°C to 260°C, ± 0.5°C (-58°F to 500°F, ± 1°F); 261°C to 850°C, ± 1.1°C (501°F to 1562°F, ± 2°F)
Operating temperature -18°C to 60°C (0°F to 140°F)
Weight 4.95 kg (11 lbs.)

Item Part No. Description

1 4C-3024 Battery Charger
2 4C-4545 Probe Seal Adapter, 3/4 inch O-ring
4C-4547 Probe Seal Adapter, 1/2 inch O-ring
5P-2720 Probe Seal Adapter, 1/8 inch NPT
5P-2725 Probe Seal Adapter, 1/4 inch NPT
5P-3591 Probe Seal Adapter, 9/16 inch O-ring
3 4C-6264 Probe, 1 inch RTD
4C-6265 Probe, 1.5 inch RTD
4C-6266 Probe, 2.5 inch RTD
4C-6268 Exhaust Probe RTD
4 6V-2198 Extension Cable, 20 ft
5 4C-6501 Digital Thermometer
8T-0844 Front Cover
4C-6355 Back Cover
4C-6499 Front Panel Switch
4C-6356 Transflective Display
6 6V-6045 Accessory Case
7 6V-7145 Carrying Case
4C-6498 Foam Insert
Not shown
4C-6267 Probe, 3.5 inch RTD
4C-6496 Immersion Probe, Handheld
ID: C26990T1 4C-6497 Surface Probe, Handheld
4C-9499 Adapter, RS-232

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Temperature Measuring Tools Search Diagnostic Tools

Infrared Thermometers Part No. Description

SMCS Code: 0776-082 164-3310 Infrared Thermometer (Standard, Battery Power Only)
Model: All
164-3320 Infrared Thermometer (Enhanced, 110 VAC) or Battery
Warranty: One Year
166-9030 Infrared Thermometer (Enhanced, 220 VAC) or Battery

• Has 16-point laser circle spot (know exactly what area is covered) not available on former 123-6700
• Used to measure temperature (without contact) in hard to reach places, around moving machinery, or without stopping production
• Measures component temperatures on engine, transmission, power train, hydraulic, electrical, and mechanical systems, axles, and bearings
• Measure equipment, electrical panel, circuit breaker, generator, and gearbox temperatures in production plants; piece part temperatures in manufacturing facilities; or
component and system temperatures in field applications
• Monitor temperatures in commercial applications such as supply and return registers, air stratification, and duct leakage; monitor temperatures of gasoline and diesel
engine cylinders; check food preparation and storage temperatures
• Small light-weight units—extremely portable

164-3310
• Replaces discontinued 123-6700 Thermometer II
• Unit is lower priced
• Designed with adjustable emissivity, audible/visible high alarm,
maximum/minimum temperature, and bar graph display
• Battery powered only (x 2 AA Cells)

164-3320
• Designed with easily adjustable emissivity, on-board emissivity table, 16-point
laser circle spot (know exactly what area is covered), audible/visible high alarm,
audible/visible low alarm, maximum/minimum temperature, DIF and AVG
temperature, bar graph display, RS232 data output port, 100 point data logging,
Windows-compatible Data Graphing Software, and 110 VAC power supply ID: C79623T1
• Hand held thermistor probe included Target Specifications
• Can be powered by battery or AC power access Temperature measurements can be taken at any distance as long as the target
size is larger than the target spot. The chart measures target distance in meters
166-9030 (feet) and spot size in millimeters (inches). If the target distance is greater than 3
• Can be powered by battery or AC power access meters (10 ft), divide the target distance by 24 to figure the spot size.
• This unit is 220 VAC version of the 164-3320.
Former 50:1 New 60:1
Graphic Display Target Distance Spot Size Spot Size
• Allows more information to be displayed at a glance mm (ft) mm (in) mm(in)
• Automatically creates a graphic display of last 10 temperature points 0.3 (1) 20 (.8) 20 (.8)
measured using maximum and minimum temperature values to establish range 0.6 (2) 20 (.8) 20 (.8)
0.9 (3) 23 (.9) 20 (.8)
1.2 (4) 25 (1.0) 20 (.8)
1.5 (5) 30 (1.2) 25 (1.0)
1.8 (6) 38 (1.5) 30 (1.2)
2.1 (7) 43 (1.7) 36 (1.4)
2.4 (8) 51 (2.0) 41 (1.6)
2.7 (9) 58 (2.3) 46 (1.8)
3.0 (10) 69 (2.7) 51 (2.0)
ID: C79621T1

Temperature reading range -30 to 900°C (-25 to 1600°F)

Accuracy ±1% of reading or ±1°C (±2°F), whichever is greater
Repeatability ±0.5% of reading or ±1°C (±2°F), whichever is greater
Response time (95%) 250 mSec
ID: C79624T1 Spectral response 8 to 14 um, thermopile detector
Display resolution tenth degree reading up to 900°C (.2 to 999.8°F)
Laser Targeting Feature
Ambient operating range 0 to 50°C (32 to 120°F)
• Laser targeting accuracy is greatly increased (60:1 ratio of distance versus
spot size as compared to former 50:1 ratio). Relative humidity 10 to 95% RH noncondensing @ up to 30°C (86°F)
• Increased accuracy when several heat sources are present (16 percent Storage temperature -20 to 50°C (-4 to 120°F) without battery
smaller target spot over former spot size at same distance) Power source two 1.5 volt alkaline batteries
• Factory aligned laser circle accurately pinpoints target, even when viewed at Power direct current
different angles. Operating time without laser 25 hours
• Compact, solid-state laser is mounted inside thermometer and is Operating time with laser 10 hours
manufactured for rugged use. Tripod mount 1/4-20 UNC
• Laser targeting can be turned off when not required. Dimensions 200 mm x 170 mm x 50 mm (7.9 in x 6.7 in x 2 in)
Weight 480 g (1 lb. 6 oz)

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192-3750 Infrared Temperature Tool (single point)

192-3755 Infrared Temperature Tool (circular point)
SMCS Code: 1800-082, 0776
Warranty: One Year

• Used to measure surface temperatures without having to contact surface

• Used to find restrictions in hydraulic lines or radiators, perform cooling checks,
measure cylinder temperatures, measure air stratification, etc.
• Backlit LCD display
• Laser target marker can be turned on or off.
192-3750
192-3750 (single point)
• Single point laser shows user where target area temperature is being measured.

THERMOMETER WITH LASER

192-3750 COMPACT IR
• Economically priced for general temperature measurement
• Measures temperatures from -32 to 400°C (-25 to 750°F)

LASER CIRCLE
®

192-3755 COMPACT IR
THERMOMETER WITH
192-3755 (circular point)
• Provides circular laser pattern on surface area being measured
192-3755
• Much better definition of the target area eliminates guesswork of single point
laser (only objects inside circular pattern are measured). ID: C79997T1
• Measures temperature of any engine or machine component up to 600°C (1100°F)
[in some cases turbocharger temperatures can exceed 600°C (1100°F)] Accuracy 1%, ±1°C (2°F) which ever is greater
at 18 to 28°C (64 to 82°F ambient temperature
• Measures temperatures from -32 to 600°C (-25 to 1100°F); for applications up to
900°C (1600°F), use 164-3310 Infrared Thermometer or 164-3320 Infrared Thermometer Response time 500 milliseconds
• Adjustable high and low temperature alarms (works well when taking repetitive Spectral response 7 to 18 microns nominal
temperature measurements; alarm(s) is activated if temperature is outside of alarm settings) Display resolution 1°C or 1°F
• Calculates maximum, minimum, and average temperatures Ambient operating range 0 to 50°C (32 to 120°F)
Relative humidity 10 to 95% non-condensing, at up to 30°C (86°F)
Repair Information
Storage temperature -25 to 70°C (-13 to 158°F) without battery installed
United States Repair Center European Repair Center Battery 1U-9534 Battery, 9 volt alkaline
Raytek UPS and Normal Post: Dimensions 260 x 200 x 75 mm (10 x 8 x 3 in)
1201 Shaffer Road Raytek Sensorik GmbH
Santa Cruz, CA 95061 Borkumstrasse 2 Weight 270 g (9.5 oz)
Attn: Instrument Repair 1 - 1100 Berlin, Germany
Phone: (800) 227-8074 Air Freight:
(408) 458-1110 Airport Berlin Tegel (BLN TXL)
Fax: (408) 458-1239 Raytek Sensorik GmbH
Telex: 171890 Borkumstrasse 2
Phone: 37-2-4725126
49-30-4632070
Fax: 37-2-4710251

213-4310 Infrared Thermometer Temperature

SMCS Code: 1800-082, 0776 measurement range -20 to 260°C (0 to 500°F)
Model: All Models Accuracy 1 percent or 1°C (2°F) which ever is greater at
Warranty: Manufacturer’s 18 to 28°C (64 to 82°F) ambient temperature
Response time 500 milliseconds

Compliant Spectral response 7 to 18 microns nominal
• Used to measure surface temperatures without surface contact Displace resolution 1°C to 1°F
• Single point laser shows user where target area temperature is being measured Ambient operating range 0 to 50°C (32 to 120°F)
• Economically priced for general temperature measurement Relative humidity 10 to 95 percent non-condensing at up to 30°C (86°F)
• Applications include testing engine cooling systems, checking brakes and Storage temperature -25 to 70°C (-13 to 158°F)
bearings, inspecting undercarriage components, verifying heating and air Battery 1U-9534 Battery, 9 volt alkaline
conditioning systems and inspecting defroster grids
Dimensions 190 x 45 x 45 mm (7.5 x 1.75 x 1.75 in)
Weight 160 g (5.6 oz)
Warranty
One year from purchase date
Raytek Corporation Raytek GMBH
1201 Shaffer Road Arkonastrasse 45-49
Santa Cruz, CA 95060, USA D-13189 Berlin, Germany
Phone: (800) 866-5478 Phone: 49 30 478 0080
Raytek China Company Raytek Japan Inc.
Beijing, China Tokyo, Japan
Phone: 86 10 6437 0284 Phone: 81 3 5976 1531
Web site: http://www.rayteck.com

Home Dealer Service Tools 2004 1-65

ID: C80581T1
Temperature Measuring Tools Search Diagnostic Tools

1U-6236 Non-Contact Temperature Probe

SMCS Code: 0776
Model: All Models
Warranty: One Year

• Measures surface temperatures without touching object

• Same measurement method as 1U-8865 and 9U-5828 Infrared Thermometers
• Used with 6V-7070 Digital Multimeter or 9U-7330 Digital Multimeter
• Easy to use — provides fast, accurate, and reliable measurements
• Enhances use of technician’s digital multimeter — provides low cost optional attachment for measuring temperature
• Uses 1U-9534 Battery, 9 Volt
Output 1mV DC per C or F
Reference Temperature range -18 to 260 °C (0 to 500 °F)
NEHS0618 Tool Operating Manual Ambient operating temperature 0 to 65 °C (32 to 150 °F) ID: C66687T1

Output accuracy (the greater of the two) ±2% of reading or ±2 °C (±3 °F) at 23 °C (73 °F)
ambient operating temperature
Repeatability ±1% of reading or ±1 °C (±2 °F)
Typical response time 1 second
Spectral response 8 to 14 microns nominal
Emissivity 0.95 preset
Relative humidity 10 to 95% relative humidity at up to 30 °C (86 °F)
under noncondensing conditions
Storage temperature (without battery) -25 to 70 °C (-13 to 158 °F)
Power 9 volt battery (1U-9534)
Battery life 50 hours at 23 °C (73 °F)
Low battery indication display flashes -60 °C (-76 °F)
Dimensions (LxWxH) 180 x 30 x 50 mm (7.1 x 1.2 x 2.0 in)
Weight 80 grams (6.4 oz)

4C-6090 Multichannel Temperature Selector

SMCS Code: 0785
Model: 3500 Captive Engines
Warranty: One Year

• Saves time and money by allowing serviceman to read individual

cylinder exhaust temperatures to quickly locate faulty fuel injector
• Measures 16 exhaust temperatures individually
• Supplied with 8-channel cable pack stored in lid; optional 4C-6097 Cable Pack,
8-Channel, available to provide 16 channel capability
• Uses 6V-7070 and 6V-9129 Temperature Adapter to digitally display temperatures
• Connected to thermocouples installed in engine at assembly, starting
with the following engine serial number and product designation:
99W-2034 — D11N and 777
96Z552 — 785 ID: C27261T1
54Z404 — 789 Item Part No. Description
• Input: 16 channels, type K thermocouple, miniature connector 1 4C-6096 Adapter Cable
• Output: switch selectable, one of 16 inputs, miniature connector 2 4C-6089 Foam Insert
3 4C-6093 Cable Pack, Ch. 1 - 8
Reference
NEHS0537 Special Instruction

4C-9030 Mini TC-K Jack

SMCS Code: 0702-038, 0707-038, 0708-038, 0776-038
Model: All Models

• Used with 7X-7481 Cable and 4C-6095 Mini Plug to make extension cables
• More uses for 4C-6090 Multichannel Temperature Selector, with extension cables
and 8T-0933, 8T-0934, 8T-0935, 8T-0936, 8T-0458 and 6V-9055 Thermocouple Probes
• Industry standard, miniature yellow type K thermocouple jack

Reference
Temperature rating 204° C (400° F) Item Part No. Description
NEHS0537-02 Operating Manual
NEHS0544 Installation Instructions Connector 27 x 16 x 8 mm 1 4C-9030 Mini TC-K Jack
dimensions (1.06 x 0.624 x 0.312 in) 2 ID: C26983T1
7X-7481 Cable
Thermocouple 3 4C-6095 Mini Plug
connections “-” red wire, “+” yellow wire

1-66 Dealer Service Tools 2004

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Diagnostic Tools Search Temperature Measuring Tools

6V-9130 Temperature Adapter Group

SMCS Code: 1000-038, 1050-038, 5050-038
Model: 0785
Warranty: One Year

Compliant
• Used with any Caterpillar high impedance digital multimeter to measure oil, coolant or air temperatures
from -50°C to 900°C (-58°F to 1652°F)
• 6V-9129 Temperature Adapter converts input from a K-type thermocouple to 1mV/°C or 1mV/°F output,
for use with Caterpillar 6V-3030 or 6V-7070; if adapter (with the 6V-9131 K-type Thermocouple attached)
is plugged into VOLT and COMMON inputs of a multimeter, temperature will be displayed on multimeter
• 8T-0458 Thermocouple Wire can be used to take temperature measurements in areas where probe is not necessary.
Because thermocouple wire has less mass, response time is faster than with 6V-9131 Thermocouple Probe
• 6V-3073 Carrying Case, SEES5666 Decal, 8T-0485 Foam Block, and 6V-4094 Foam Top available to store
6V-9129 Temperature Adapter, 6V-9131 Thermocouple Probe, 8T-0458 Thermocouple Wire, and 6V-3030,
6V-7070 or 6V-7800 Digital Multimeter and Probes ID: C80337T1
• 6V-9129 Power source: 1U-9534 Battery, 9V Probes Item Part No. Description
Part No. Length Diameter Application 1 6V-9129 Temperature Adapter
NOTE: Use with 5P-2720, 5P-2725, 5P-3591, 4C-4545 and 8T-0936 3.5 in 1/8 in Probe seals 2 6V-9131 Thermocouple Probe, Type K
4C-4547 Self-Sealing Probe Adapter Groups (Diagnostic
Tools Section of Tool Guide, Speed Measuring Tools) 8T-0935 2.5 in 1/8 in Probe seals
8T-0934 1.5 in 1/8 in Probe seals

Reference 8T-0933 1.0 in 1/8 in Probe seals

SEHS8382 Special Instruction 6V-9055 1 6 in 1/4 in Exhaust (bent)
6V-9131 6 in 1/8 in Hand held
8T-5334 Surface Hand held
1 For 6V-9055 Probe replaceable fitting

238-5636 Exhaust Thermocouple

SMCS Code: 1000-038, 1050-038, 5050-038
Model: All models
Warranty: Manufacturer’s

• Used to measure exhaust temperature

• Used with 237-5130, 212-2160, 146-4080, or 9U-7330 Digital Multimeters; can also be used with 6V-3030
or 6V-7070 Multimeters with a 6V-9130 Temperature Adapter Group. 9U-7330, 6V-3030, and
6V-7070 Multimeters require optional 6V-9129 Temperature Adapter.
• Probe is attached to exhaust housing with an adjustable threaded ferrule

Thermocouple Probe Type K

Temperature range 0 to 850°C (1560°F)
Probe length 127 mm (5.0 in) ID: D00549T1
Probe diameter 6.4 mm (.25 in)
Probe threads (male) 1/4 inch NPT with adjustable ferrule
Probe cord length 182 cm (72.0 in)

8T-2844 Temperature Recorder Group

SMCS Code: 1000-082
Temperature Recorder (Range)
Model: All Models
°C °C °C °C °C °C
Part No. (°F) (°F) (°F) (°F) (°F) (°F)
8T-2820 60 66 71 77 82 88
• Used for checking operating temperatures of the cooling (140) (150) (160) (170) (180) (190)
system, engine oil system, hydraulic system and brake
8T-2821 82 88 93 99 104 110
system
(180) (190) (200) (210) (220) (230)
• Quick, easy, inexpensive method to determine
8T-2822 104 110 116 121 127 132
component’s surface temperature (220) (230) (240) (250) (260) (270)
• 6 silver-colored temperature sensitive indicator windows 8T-2823 127 132 138 143 149 154
on each recorder; each window turns permanently black (260) (270) (280) (290) (300) (310)
when temperature for that window is reached or exceeded.
8T-2824 149 154 160 166 171 177
• 5 different temperature recorders for 5 different ranges (300) (310) (320) (330) (340) (350)
• Adhesive back — attach to any clean dry surface; remove
and keep as permanent record.
• Withstands repeated temperature changes, solvents, andID:water
B97626T1

• Consist: 3 each of temperature recorders listed in chart

• Response time: approximately 1 sec.

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Thermometers
Warranty: One Year

• Used to check:
- General temperature measuring applications.
- Coolant temperature.
- Heat indicator accuracy.
• 9U-5324 measures in Centigrade, 9U-5323 in Fahrenheit (both include a 1.5V silver oxide battery).

ID: C80306T1
Item Part No. Temperature Length Type Readout Accuracy
1 2F-7112 -1.11°C to 116°C (30° to 240°F) 226.1 mm (8.9 in) Mercury with 6.4 mm (1/4 in) pipe connect Linear ±1%
2 6H-3050 10°C to 204°C (50° to 400°F) 171.45 mm (6.75 in) Mercury Linear ±1%
3 9U-5324 40° to 110°C 177.8 mm (7 in) Electronic Digital ±1%
4 9U-5323 40° to 230°F 177.8 mm (7 in) Electronic Digital ±1%

Self-Sealing Probe Adapter Groups

SMCS Code: 5050-038
Model: All Models
Warranty: One Year

• Provide method for checking pressure or temperature in fluid-filled

compartments without cooling down machine and draining fluid
• Can be installed in any prime product
• Seal permits probe insertion through center and seals automatically
when the probe is removed ID: A92067T1
• All temperature probes included with thermistor thermometer and Item Part No. Descrption
164-2192 Pressure Probe can be used in these probe adapters. 1 5P-2720 Self-Sealing Probe Adapter Group (1/8 inch pipe thread)
• 9F-2247 Plug (1/8 in) installed in adapter groups to serve as protective 2 5P-2725 Self-Sealing Probe Adapter Group (1/4 inch pipe thread)
cover when tests are concluded 3 5P-3591 Self-Sealing Probe Adapter Group (9/16 inch standard thread)
• Oil can be checked at temperatures less than 132°C (270°F) and pressures 4 9F-2247 Plug (Part of 5P-2720, 5P-2725 and 5P-3591)
less than 3100 kPa (450 PSI).
• Coolant and fuel can be checked at temperatures less than 121°C (250°F)
and pressures less than 690 kPa (100 PSI).

Self-Sealing Probe Adapter Groups

SMCS Code: 0785
Model: 1.1 Liter Engine
Warranty: One Year

• Used with 6V-9130 Temperature Adapter Group, 4C-6500 Digital Thermometer Group, 3
and 131-5050 Data View Temperature Sensors
3
WARNING 4 1

Using the probe seal at pressures and temperatures higher than those
indicated can result in injury to personnel or damage to the machine.

Maximum oil temperature 132°C (270°F) at 3100 kPa (450 PSI)

5
Maximum fuel/coolant temperature 120°C (250°F) at 690 kPa (100 PSI) 2
ID: C79669T1
Item Part No. Description
1 4C-4545 Self-Sealing Probe Adapter Group, #8 (3/4 inch x 16 Thd)
2 3K-0360 Seal O-Ring
3 9F-2247 Plug
4 4C-4547 Self-Sealing Probe Adapter Group, #5 (1/2 inch x 20 Thd)
5 1J-9671 Seal O-Ring

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General Diagnostic Tools

4C-8195 Control Service Tool, CMS II

Size 190 x 120 x 40 mm
SMCS Code: 7490-038, 0785
(7.5 x 4.7 x 1.5 in)
Model: All Models with CMS Panels
Warranty: One Year Weight 0.2 kg (.44 lbs)
Cable length 2.4 m (8 ft)
• Replaces discontinued 9U-6665 CMS Service Tool
• Used to access diagnostic modes on CMS panels (allows service technician to easily
enter diagnostic modes)
• Used with available adapter cables to diagnose Wheel Loader transmission controls;
also used on countershaft transmission controls
• Allows technician to scroll through active and logged faults
ID: C66938T1
• Allows logged faults to be cleared Item Part No. Description
• 138-7795 replaces discontinued 134-2576 Countershaft Transmission Cable Assembly 1 4C-8196 Cable, CMS II
2 4C-8197 Wheel Loader Transmission Control Cable
Reference
NEHS0586 Tool Operating Manual 3 138-7795 Countershaft Transmission Control Cable
(for H-Series Motor Grader)
NEEG2741 Switch Positions for H-Series Motor Grader

217-7202 Interface Kit (Standard 520)

217-7203 Interface Kit (Premium 550)
SMCS Code: 0734, 0779, 0785
Model: 3054 and 3056 Marine Generator Sets
Warranty: One Year 217-7203

Compliant
• Used to access configuration stored within control module on 3054 and 3056 Marine
Generator Sets: CHN1-UP, TCN1-UP, SNX1-UP
• Allows user to view diagnostic display from control module
• Kit contains one 25 to 9 pin Adapter Cable, one FCC-68 Interconnecting Cable, and one Windows-based CD
ID: D00158T1
PC Requirements
Processor 486, 66 Mhz minimum
Operating system Windows 95, 98, 2000 or NT
217-7202 Ram 16 Mb
Display resolution 640 x 480
Fixed disk 10 Mb free, 80 Mb minimum
Disk drive CD Rom
Communication port RS-232
Operating Environment
Temperature -15 to 55° (5 to 131°F)
Power Requirements
Power DC (powered from control module)

ID: D00164T1

237-9074 Calibration Group Service Parts

SMCS Code: 0734, 0779, 0785 Part No. Description
Model: C2.2 Marine Generator Set 146-8488 9-pin, RS-232 Cable
Warranty: One Year
237-9075 Interface Box

• Used to configure and adjust speed controller parameters CALI

B
SA-4RATION
475 TOO
• Allows interactive, real-time display of engine speed using a personal computer REV.
A L 7.0

• Comes with 9-pin RS-232 cable, interface box, and NETG5038 CD-ROM software
(Windows-based)
Hardware Requirements
PA IAL
RT #
SE . #

#
R
RE
V

IBM compatible, personal computer equipped with a CD-ROM drive and

a serial port with DB-9 connector, capable of 9600 baud communication
Windows software: 95/98/Me/2000/XP
64 MB of available RAM memory and a hard disk with at least 2.0 megabyte
of free disk space
SGVA capable video card and monitor, capable of 256 colors and 800 x 600 display ID: D00554T1

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218-2944 Data Transfer Cable 146-8488 RS-232 Cable

Model: Power Module Models PM3512, PM3516, and PMG3516 Model: Power Module Models PS003, PS004, PS005, and PS010
Warranty: One Year Warranty: One Year

• Used to connect a computer to touchscreen display for downloading • Used to connect a computer to power module protective relays for download
configuration files of configuration files
• Requires a RS-232 (DB-9) port • Used to connect 146-4080 Cat Digital Multimeter to 131-5050 DataView
• Standard 9 pin DB9 RS232 cable and socket to pin adapter included

ID: D00302T1
ID: D00308T1

148-9610 PC Cart, 110-125 VAC, 60 Hz Power Management Features

SMCS Code: 7600-052 • Master on/off switch (lighted) that will turn on all components at one time
Model: All Models
• 381 mm (15 ft) power cord
Warranty: Manufacturer’s
• NEMA power block with two outlets
Used to hold PC, monitor, printer and data view hardware • “Quick release” power cord wrap system
in one portable workstation
Printer and Monitor Features
• Accommodates most dot matrix or laser printers
• Universal printer securement strap (maximum printer weight 12.2 kg, 27 lbs)
• Universal monitor mounting system will hold diagonal screen size monitors
up to 431 mm (17 in)

Overall dimensions (H x W x D) 1263.7 x 958.9 x 749.3 mm (49.75 x 37.75 x 29.50 in)

Internal equipment area 546.1 x 781 x 565.2 mm (21.5 x 30.7 x 22.25 in)
Two internal storage compartments 235 x 381 x 546.1 mm (9.25 x 15 x 21.5 in)
Cart weight, empty 84 kg (185 lb)
Shipping weight 104.4 kg (230 lb)
Casters (four swivel) 127 x 50.8 mm (5 x 2 in) two with brake
Color base is dark grey; top platform is medium grey
Capacities and Other Dimensions
Largest monitor screen (diagonal measure) 431 mm (17 in)
Largest monitor base (W x D) 317.5 x 285.7 mm (12.5 x 11.25 in)
Maximum monitor column width 184.1 mm (7.25 in)
Maximum printer dimensions (W x D) 438.2 x 400.1 mm (17.25 x 15.75 in)
Maximum printer weight 12.2 kg (27 lbs)
CD storage capacity (in door) 90 disks
ID: C66969T1 Largest keyboard (W x D) 609.6 x 216.9 mm (24.0 x 8.50 in)
General Features
Mouse pad (largest recommended): (W x D) 279.4 x 215.9 mm (11.0 x 8.50 in)
• Durable corrosion resistant baked on powder coat finish on steel body
Power 148-9610
• Protective bumper wraps around top of PC cart
Rated voltage 125 VAC
• Large 127 x 50.8 mm (5 x 2 in) casters which are customer installed
Rated amperage 15 Amps
• Two lower compartments for paper and supplies
Rated frequency 60 Hz
• CD storage with self closing door holds up to 30 CD’s
Power cord 4572 mm (15 ft)
• Retractable cup holder
Power Strip
• Four position communication and data port blank panel
Outlets 4
• Five cable hangers
Surge Suppressor
• Care and use maintenance guide
Electrical rating 125 VAC, 15 Amps
• One year limited manufacturer’s warranty
Maximum surge voltage 6 KV
Protection Features Maximum surge dissipation 75 Joules
• Fan and filter system provides added protection for computer Maximum spike current 4500 Amps, at 25°C (77°F)
components Maximum clamping ratio 1.2:1
• Locking cabinet door protects computer components Clamping volts 330 Volts
• CPU securement system Clamping response time < 1 Nanosecond
Temperature range -40 to +80°C (-40 to +176°F)
Outlets 6

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Borescopes 1U-5268, 9U-6940 and 186-0180 Rigid Tube Borescopes

SMCS Code: 0777-000 • 1U-5268 Borescope provides straight viewing of internal surfaces.
Model: All Models • 1U-5269 Mirror Tube Adapter slides over shaft of 1U-5268 Borescope for right
Warranty: One Year angle viewing.
• 9U-6940 Fixed Right-Angle Borescope provides a more durable right-angle
• Caterpillar’s line of borescopes are used to make visual inspections of internal viewing borescope.
surfaces where normal viewing is not possible. • 186-0180 Borescope with Adjustable Angle of View is typically used for larger
• In most cases, inspection and analysis can be done without disassembling a (3500 and 3600) engine applications to check cylinders, etc.
product, significantly reducing inspection time. • Used with either a 1U-5266 and 1U-5267 Light Source or a 1U-5265 Battery Light
• Use a borescope as a first means of component inspection. Source
• An adjustable focus under the eyepiece allows clear viewing of internal surfaces • A 6V-9459 Fiber Optic Light Cable can be used with 1U-5268, 9U-6940, and
and objects. 186-0180 Borescopes.
• Borescopes can be used to inspect internal engine surfaces through fuel nozzle • A 6V-9461 Right Angle (90 degree) Viewing Adapter allows operator to view into
holes on engines using “pencil style” injectors. borescope from a 90 degree direction (use with 1U-5268 Borescope).
• Other applications include checking turbochargers for cracked or missing blades,
checking valve bodies for internal damage or blockage, and checking cylinder
walls for scratching or scouring.

Probe Working Direction Total adjustable

Part No. Description diameter length of view Field of view Focus range view coverage Magnification Resolution Used with
1U-5268 Borescope 6.50 mm 580 mm 0 degrees 60 degrees 4.8 mm (.19 in) — — — —
(.256 in) (23.0 in) to infinity
1U-5269 Mirror Tube Adapter 7.24 mm 580 mm 90 degrees 60 degrees 4.8 mm (.19 in) — — — 1U-5268
(.285 in) (23.0 in) to infinity Borescope
9U-6940 Fixed Right-Angle 6.50 mm 570 mm 90 degrees 60 degrees 4.8 mm (.19 in) — — — —
Borescope (.256 in) (22.5 in) to infinity
186-0180 Borescope with 14.00 mm 940 mm 95 degrees 45 degrees 6.35 mm (.25 in) 140 degrees 1:1 at 76.2 mm 4 LPMM —
Adjustable Angle (.551 in) (37.0 in) to infinity viewing distance (3.00 in) minimum
of View

Basic Borescope Inspection System

(items shown in photo must be ordered separately)
Item Part No. Description
1 1U-5268 Direct View Borescope
2 1U-5269 Mirror Tube, 90 degree direction of view)
3 6V-9459 Fiber Optic Light Cable 1830 mm (72.0 in)
4 6V-9461 Right Angle (90 degree) Viewing Adapter
5 1U-6345 Instrument Case, 355 x 832 x 115 mm (14.0 x 32.8 x 4.5 in)
6 1U-5265 Battery Light Source
Not shown 6V-9465 Replacement Rubber Eye Piece (1U-5268 and 9U-6940)
Not shown 1U-6346 Foam Packing for use with 1U-6345
Not shown 9U-5118 Lamp, 6 Volt, for use with 1U-5265

ID: C80075T1

ID: C80087T1

ID: C80077T1

ID: C80088T1 Item Part No Description

1 6V-9459 Fiber Optic Light Cable
2 4C-9664 Heavy-Duty Case

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8T-9290 and 146-1738 Battery-Operated Borescopes

• Provides a compact, battery-powered borescope
• 8T-9290 battery handle can be attached directly or using an extension cable.
• 146-1738 battery handle attaches directly to viewing tube.
• 146-1738 provides 90 degree viewing.

Part No. Description Probe diameter Length Direction of view Field of view Focus range
8T-9290 Battery-Powered Borescope 8.0 mm (.32 in) 240 mm (9.5 in) 90 degrees 60 degrees 6.4 mm (.25 in) to infinity
146-1738 Borescope 6.4 mm (.25 in) 305 mm (12.0 in) 0 degrees 40 degrees 10 to 317 mm (.4 to 12.5 in)
Borescope Mirror Tube 8.0 mm (.32 in) 305 mm (12.0 in) 1.0 (.03 in) to infinity 90 degrees 40 degrees

Service Parts
Part No. Description
1U-6862 Bulb
4C-6493 Bulb

See NEHS0504 for correct

replacement bulb.

ID: C80084T1

1
146-1738
Item Description
1 Borescope Case
2 2 Precision Borescope
3 90 Degree Viewing Adapter
4 Flashlight (light source)
3

4
ID: C80085T1

186-0170 Flexible Shaft Borescope

• Allows viewing in areas where rigid-shaft borescopes cannot reach
• Articulated tip can be steered around or through obstructions.
• Provides 0 degree and 90 degree directional view

Diameter 6.00 mm (.236 in)

Length 600 mm (24.0 in)
Direction of view 0 degrees
Field of view 50 degrees
Focus range 5.0 to 304.8 mm (.20 to 12.0 in)
Light cable built-in
Mirror head (90 degree side view)
Direction of view 90 degrees
Field of view 50 degrees ID: C80086T1

Item Part No. Description

1 186-0185 Mirror Head (90 Degree Side View)
2 4C-9662 Heavy-Duty Case

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Optional Parts/Equipment
110 VAC (1U-5266) and 220 VAC (190-8160) Light Sources

Compliant (190-8160)
• Compact, lightweight units provide illumination with a 150 watt bulb
• Can be used with 1U-5268, 9U-6940, 186-0170, and 186-0180 Borescopes
• Light intensity is adjustable and is controlled by varying Voltage output of solid state dimmer
• Light cable plugs into a 12.7 mm (.25 in) receptacle
• A cooling fan keeps units from overheating
• Bulb circuit is protected with a 2 Amp fuse
or circuit breaker which is replaceable (resetable)
ID: C80083T1

ID: C80082T1
Replacement
Part No Descriptiion Voltage Hertz Output lamp (21 V) Unit weight Dimensions Warranty
1U-5266 Light Source 120 V 50 to 60 Hz 150 Watts 1U-5792 — — —
(110 VAC)
190-8160 1 Light Source 220 to 230 V 50 to 60 Hz 150 watts 1U-5792 4 kg (8 lbs) 222.3 mm (8.75 in) x Manufacturer’s
(220 VAC) 120.7 mm (4.75 in) x
158.8 mm (6.25 in)
1 Contact CSTG for more information on this light source.

1U-5265 Battery Light Source 207-8837 Light Source Adapter

• Rechargeable from 110 VAC power source • Used to connect 1U-5268, 9U-6940, and 186-0170 Borescopes
• Used with 1U-5268, 9U-6940 and 186-0180 Borescopes to 1U-5265 Battery Light Source
• Makes borescopes more portable
• Allows use in areas where a 110 VAC
or 220 VAC power source is not available

ID: C80116T1

ID: C80089T1
Camera Adapters
A variety of camera adapters are available for 1U-5868 and 9U-6940 Borescopes. Refer to NEHSO5O4 for a complete listing.

Repair Information
All borescope systems are warranted to be free from defects in material and workmanship for a period of 12 months from original
purchase date from Caterpillar Inc. If repair is necessary, contact Lenox Instrument Company Inc., for information on obtaining required
service. Borescopes less than one year old will be repaired under warranty (EXCEPT FOR ABUSE). Cost of out-of-warranty repairs will
be charged to the owner.
Lenox Instrument Company Inc.
265 Andrews Road
Scottsville Industrial Park
Trevose, Pa. 19053-3427
Phone: (215) 322-9990 or (800) 356-1104
Fax: (215) 322-6126

Reference
NEHSO838 Tool Operating Manual, Using the 8T-9290, 1U-5268, 9U-6940, 146-1738, 186-0170, and 186-0180 Inspection Borescopes

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131-5050 DataView Group

131-5051 DataView Portable TechStation Group
SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038, 0788
Model: All Models
Warranty: One Year

Compliant
• PC-based diagnostic tool that accepts up to nine standard Caterpillar sensors • Calculated channels for displaying sum, difference, and hydraulic horsepower
for measurements on any engine or machine—data is displayed on a personal • Automatic sensor identification of “Analog” sensors for automatic set-up using
computer (PC) Auto ID cables (optional)
• Includes Data Logger using 2 Mbyte PC Memory Card for storage. Data Logger • RS232 input connector for 146-4080 Digital Multimeter (DMM)
has Auto Triggering and Pre-Trigger information settings. • Portable TechStation carrying case holds DataView and a portable PC.
• Measures pressure, temperature, blowby, position, RPM, Hz, duty cycle (PWM), • Internal battery operates for up to eight hours.
hydraulic flow, and fuel flow
• Operates and charges on 110/220 VAC, 11 to 40 VDC, or 12V Automotive
• DataView hardware unit connects to standard PC parallel (printer) port. Cigarette Lighter
DataView software program runs on PC using Microsoft Windows™.
• Allows many current hand-held diagnostic tools to be replaced with a single
diagnostic unit.
• Includes digital and analog measurements, bar graphs, charts, and histograms
in real time or Data Logged data
• Can provide test/diagnostic data for test facilities such as dynamometer rooms,
transmission test centers, or any other application where diagnostic
measurements are required.
• Future versions of DataView software will interface with other programs such
as SIS and ET via Service Technician Workbench (STW).
• Six “Analog” inputs for measuring any combination of pressure, temperature,
blowby, and position
• Three “Frequency” inputs for measuring RPM, Hz, duty cycle (PWM), hydraulic
flow, and fuel flow
• Two “Engine Set Point” inputs
ID: C78428T1
Minimum PC Requirements
Connection to PC standard parallel (printer) port
Computer IBM PC compatible with 486, 33 Mhz SL or SXL processor or greater
RAM 8 Mb
Available hard disc space 10 Mb
Diskette drive (internal or external add-on) 3.5 Inch, 1.44 Mb
Monitor VGA
DOS version 5.0 or greater
Operating system Microsoft Windows™ version 3.1 or Windows 95, OS2 version 2.11, or Warp 3.0
Printer port parallel
General Hardware Specifications
Internal power source rechargeable internal nickel metal hydride battery (Varta C526F, 7.2 Volt 2400 mAh)
AC external power 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz
External power connector 11 to 40 VDC machine power or cigarette lighter adapter
Power consumption 2 amp max at 15 VDC
Low battery indicator flashing ON light
Battery life 10 hours nominal (dependent upon sensors being used)
Battery charge time 6 hours
Battery charge indicator light off - not charging, light on solid - fast charge, light flashing - trickle charge
Operating temperature -17 to +60°C (0 to 140°F)
Storage temperature -40 to +100°C (-40 to +212°F)
Size 297 x 229 x 45.7 mm (1.7 x 9.0 x 1.8 in)
Weight DataView hardware (enclosure only) 1.8 kg (4 lbs)
Data Logger Specifications
Channels data can be logged from all nine input channels
Memory 2 Mbyte PC PCMCIA flash memory card is standard
Sample rate adjustable up to 1000 samples per second
Recording time varies depending on sample rate and number of channels in use
Maximum log size At first release of software, logs will be limited to 8000 samples.
A later software version will provide larger size logs.
Pre-trigger allows logging of events which happen before the log trigger point
Auto trigger logging can be triggered from an event or change in any channel
Manual trigger logging can be manually started from the PC or from the hardware

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Analog Channel Specifications

Connector type 5 pin DIN connectors (female)
Analog channel sensor types analog inputs are automatically reconfigured with relays to accept voltage, milliamp,
RTD, or resistance-type output sensors.
Analog channel input ranges 0 to 5 VDC; Milliamp: 4 to 20 mA; RTD: 100 Ohm, PRTD; Resistance: 15K Ohm nominal
Sensor power supply ranges 5, 8, 12, or 15 VDC available, firmware selectable
Input impedance 500K Ohms minimum
A/D resolution 12 bit
A/D Access time 10 microseconds
Channel scan rate 50 microseconds per channel (10 channels scanned in 500 microseconds)
Frequency response DC to 300 Hz (2000 samples per second)
A/D input voltage range 0 to 5 VDC
Max input voltage protected to 40V RMS or peak
Frequency Channel Input Specifications
Frequency sensor types waveform or pulse inputs
Input voltage range 0.1 to 40 VAC or VDC peak
Allowable signal offset +0.040 VDC
Input impedance 50K Ohms minimum
Frequency response 3 Hz to 15K Hz
Frequency accuracy ±1 Hz
RPM measurement range 1 to 9999 RPM
RPM accuracy ±1 RPM in selected RPM/PPR ranges
Pulses per revolution 0.1 to 256 pulses per revolution;
Hz fixed at 60 pulses per revolution
Pulse width measurement 1 to 100% duty cycle for 40 Hz to 15K Hz
Cat PWM sensor measurement special adapter cable required because of DC offset on output signal
Pulse width accuracy ±1% for signals above 1V peak
Photo pickup power provided for 9U-5140 Photo Pickup
Photo pickup range 3 to 30 inches from retro-reflective tape target
Engine Set Point Specifications
Set point inputs 2 inputs provided for use with 2 frequency channels
Rack contact voltage 12 VDC
Rack contact current 5.5 mA
Overrun indication 0 to 10% rack contact closure
Set point indication 11% rack contact stores engine rpm
Lug indication 75 to 100% rack contact closure

131-5050 Basic Cat DataView Group

• Very basic group which includes only DataView hardware unit and accessories
necessary to power it and connect it to the PC
• No sensor or adapter cables are included.
• The memory card for data logging is not supplied but can be purchased separately.

Item Part No. Description

1 JERD2163 DataView Software
2 131-5050 DataView Hardware
3 137-0172 DataView Mounting Kit
4 137-0169 DataView Front Flash Programming Cable
5 131-5059 DataView Rear Flash Programming Cable
6 131-5053 DataView to PC Parallel port cable (short)
7 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz
8 131-5047 AC Power Cable, 110 VAC (USA Plug)
9 137-0171 European Power Adapter
10 NEHS0662 Tool Operating Manual
ID: C78297T1

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131-5051 DataView Portable TechStation Group Item Part No. Description

• Contains all accessories, excluding sensors, needed to operate DataView on a PC. 1 JERD2163 DataView Software
• Includes carrying case which holds DataView unit and PC (not included). 2 133-6976 Memory Card for DataView (2 MB Capacity)
3 131-5050 DataView Hardware
4 137-0173 DataView Carrying Case
5 131-5058 Foam Insert for Universal PC
6 137-0172 DataView Mounting Kit
7 6V-2198 Extension Cable 5.5 m (18 ft), (4 provided)
8 8T-5111 Rack Adapter Cable
9 1P-7446 Rack Cable
10 131-5054 Adapter Cable for Caterpillar Pressure Sensors
11 131-5055 Adapter Cable for Blowby/Airflow Pickups
12 9U-7506 Magnetic Adapter Cable
13 131-5056 Adapter Cable for Caterpillar Hydraulic Flowmeters
14 131-5065 Auto ID Cable for Caterpillar Electronic Position Probe
15 NEHS0662 Hardware Operating Instructions
16 JEBD3004 Software Program Operating Instructions
ID: C78298T1
17 9U-7505 High Voltage Adapter
18 6V-7072 Test Lead Set
19 131-5053 DataView to PC Parallel port cable (short)
20 137-0169 Flash Programming Cable, DataView Front
21 131-5047 AC Power Cable, 110 VAC (USA Plug)
22 131-5052 AC Power Adapter, 90 to 264 VAC, 47 to 63 Hz
(NEEG2740 label)
23 137-0171 European Power Plug Adapter
24 131-5059 DataView Rear Flash Programming Cable
Not shown NEEG2723 Group Label on lid of 131-5051 DataView Group

Optional Equipment

ID: D00539T1
Item Part No. Description
1 131-5058 Generic Foam Insert Fits in 137-0173 Case and has locations for DataView and a square hole for almost
any laptop PC, plus a location for Caterpillar communications adapter
2 137-0173 DataView Carrying Case Has access door in front to allow DataView to be used without removing it from
case. Foam inserts must be ordered separately, depending on configuration
3 138-8779 Top Foam Insert Replaces generic PC foam in DataView case to allow Cat Portable PC (Itronix) with
CD ROM drive and Cat Communications adapter to be used with 131-5051 DataView
Portable TechStation
4 137-0168 External Power Cable, 11 to 40 VDC, 5 m (18 ft) long
5 133-6975 European DataView Power Cable (220 VAC) European-style connector to fit 131-5052 AC Power Adapter
6 137-0170 Cigarette Lighter Power Cable (12 VDC)
Not shown 229-9392 DataView Replacement Battery

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Optional Cables and Sensors to Use with DataView

Analog Channel Sensors Frequency Channel Sensors
Part No Description Part No Description
Pressure Sensors for Analog Channels Photo Pickup Speed Sensor
A 131-5054 Adapter Cable or Auto ID Cable is always required to use the following sensors: 9U-5140 LED Photo Pickup
213-3274 Auto-ID Pressure Sensor (0 to 100 PSI) 6V-3137 Magnetic Mounting Base for 9U-5140
213-3275 Auto-ID Pressure Sensor (0 to 1000 PSI) 6V-3138 Extension Rod for 6V-3137
213-3276 Auto-ID Pressure Sensor (0 to 7500 PSI) 1U-6605 Retro-Reflective Tape, 12 mm (.5 in) x 15 m (5.0 ft) long
4C-6816 Pressure Sensor (0 to 60 PSI) 6V-0093 Retro-Reflective Tape, 12 mm (.5 in) x 47.5 m (50 ft) long
131-5060 Auto ID Cable (for 4C-6816 Sensor) 4C-6919 Retro-Reflective Tape, 25 mm (1.0 in) x 2.5 m (100 in) long
4C-6817 Pressure Sensor (0 to 100 PSI) Injection Line Speed Sensor
131-5061 Auto ID Cable (for 4C-6817 Sensor) 6V-4950 Injection Line Pickup Group (from Multitach Group)
4C-6818 Pressure Sensor (0 to 500 PSI) 4C-6821 Injection Line Pickup Group (from Data Logger Group)
131-5062 Auto ID Cable (for 4C-6818 Sensor) Tach Generator Speed Sensor
4C-6819 Pressure Sensor (0 to 1000 PSI) 9U-7506 Magnetic Adapter Cable
131-5063 Auto ID Cable (for 4C-6819 Sensor) 5P-7360 Tach Generator (20 tooth internal gear)
4C-6820 Pressure Sensor (0 to 7500 PSI) 5P-1759 Tachometer Drive Group
131-5064 Auto ID Cable (for 4C-6820 Sensor) Flywheel TDC Magnetic Speed Sensors
Probe Type RTD Temperature Sensors 9U-7506 Magnetic Adapter Cable
4C-6264 RTD Temperature Sensor, 25.4 mm (1.0 in) long, 3.2 mm (.125 in) diameter 8T-5184 Magnetic TDC Pickup 89 mm (3.5 in) long
4C-6265 RTD Temperature Sensor, 38.1 mm (1.5 in) long, 3.2 mm (.125 in) diameter 6V-2197 Magnetic TDC Pickup 114 mm (4.5 in) long
4C-6266 RTD Temperature Sensor, 63.5 mm (2.5 in) long, 3.2 mm (.125 in) diameter 8T-5185 Magnetic TDC Pickup 178 mm (7.0 in) long
4C-6267 RTD Temperature Sensor, 88.9 mm (3.5 in) long, 3.2 mm (.125 in) diameter 9U-7506 Magnetic Adapter Cable (required for TDC Sensors)
Exhaust RTD Temperature Sensor 6V-2199 Sensor Mounting Adapter, 1/8 in NPTF
4C-6268 Exhaust RTD Temperature Sensor 6V-3093 Sensor Mounting Adapter, 1/4 in NPTF
Hand Held RTD Temperature Probes 7X-1171 Sensor Mounting Adapter, 7/16-20 Straight Thread
4C-6496 Immersion Hand Held RTD Temperature Probe, 3.18 mm (.125 in) diameter Magnetic Pickup Speed Sensors
4C-6497 Surface Hand Held RTD Temperature Probe, 6.35 mm (.25 in) diameter 8L-4171 General Purpose Magnetic Speed Sensor,
Blowby Sensors for Analog Channels 91 mm (3.5 in) long, 5/8-18 Thread
8T-2685 Small Blowby/Air Flow Pickup (Part of 8T-2700 Blowby Group) 9G-6724 Magnetic Speed Sensor, 76 mm (3.0 in) long, 3/4-16 Thread
131-5066 Auto ID Cable for Small Blowby Pickup 6V-4156 Adapter Cable (required for above sensors),
Amphenol to Phono Jack
1U-8860 Large Engine Blowby/Air Flow Pickup Group (For 3500 and 3600 Engines)
9U-7506 Magnetic Adapter Cable (required for above sensors)
131-5067 Auto ID Cable for Small Blowby Pickup Phono Jack to Data View
Position Sensor for Analog Channels Fuel Flowmeters and Fuel Flow Communicator
8T-1002 Position Sensor 0 to 25 mm (0 to 1.0 in) range 1U-9500 Fuel Flow Communicator
131-5065 Auto ID Cable for 8T-1002 Position Sensor 1U-5450 Complete Engine Fuel Flow Monitor Arrangement
6V-6042 Contact Point Group 4C-9764 Fuel Flow Monitor Group
5P-4814 Fuel Setting Collet 4C-9758 Supply Fuel Flowmeter Group, Small
9U-6909 Extended Fuel Setting Collet (for 3500 engines) 4C-9760 Supply Fuel Flowmeter Group, Large
4C-9761 Return Fuel Flowmeter Group, Large
1U-5305 Hose Adapter Group, Small
1U-5306 Hose Adapter Group, Large
1U-5420 Hose Adapter Group, 3600 Engine
1U-5299 Case Assembly
1U-5430 Small to Medium Engine Fuel Flow Monitor Arrangement
1U-5440 Medium to Large Engine Fuel Flow Monitor Arrangement
Hydraulic Flowmeters for Frequency Channels
The 131-5056 Adapter Cable is required to use the following flowmeters:
4C-9911 Hydraulic Flowmeter, 8 to 50 lpm (2 to 12 gpm)
4C-9436 Hydraulic Flowmeter, 12 to 120 lpm (3 to 25 gpm)
4C-9912 Hydraulic Flowmeter, 20 to 220 lpm (5 to 50 gpm)
4C-9913 Hydraulic Flowmeter, 30 to 300 lpm (8 to 80 gpm)
4C-8687 Hydraulic Flowmeter, 45 to 450 lpm (10 to 100 gpm)
4C-9914 Hydraulic Flowmeter, 50 to 550 lpm (12 to 150 gpm)
4C-8686 Hydraulic Flowmeter, 60 to 700 lpm (15 to 180 gpm)
Hydraulic Flowmeters with Load Valves for Frequency Channels
160-2513 Tester Flowmeter, 5-50 gpm
160-2514 Tester Flowmeter, 4-125 gpm
160-2515 Tester Flowmeter, 15-180 gpm

Reference
NEHS0662 Tool Operating Manual, Using the Caterpillar Data View
NEHP5622 Data View Marketing Brochure

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153-9630 Sensor Test Group

SMCS Code: 1000-038, 3000-038, 4000-038, 5000-038, 6000-038
Model: Electronically Controlled Cat® Equipment
Warranty: One Year

Compliant
• Recommended for testing CAT PWM and analog sensors on or off the
machine
• Used with 131-5050 DataView and DataView 2.0 software
• DataView 2.0 software lists common sensors for easy setup
• Internal power supply powers active sensors while removed from equipment

Reference
NEHS0711 Tool Operating Manual
ID: C79438T1
Item Part No. Description
Input impedance 120 kΩ
1 153-9629 Insert Foam
Input voltage 5 VDC (from DataView) 148-5675 Case
Output voltage 9.4 VDC (sensor power) 6V-6096 Foam
Maximum sensor current 40 mA maximum at 9.4 VDC NEEG2813 Decal
Operating temperature -17 to 60°C (0 to 140°F) 2 153-9625 PWM Sensor Adapter
Size 85 x 56 x 35 mm (3.3 x 2.2 x 1.4 in) 3 153-9627 Cable Assembly, DT
Weight (153-9625) 0.23 kg (.5 lb) 4 153-9626 Cable Assembly, HD

DataView Auto ID Pressure Sensors Part No. Description

SMCS Code: 1000-038, 4000-038, 5000-038, 6000-038, 0788 213-3274 DataView Auto ID Pressure Sensor, 689 kPa (100 PSI)
Warranty: One Year 213-3275 DataView Auto ID Pressure Sensor, 6890 kPa (1000 PSI)

Compliant 213-3276 DataView Auto ID Pressure Sensor, 51675 kPa (7500 PSI)

• Low cost pressure sensors

• Used with 131-5050 DataView (sensors are not designed for use with
4C-6800 Data Logger and will not give correct readings if used)
• Built-in auto ID
• Plugs directly into DataView Analog Channels
• Accuracy of ±1%
Pressure ranges 0 to 689 kPa (0 to 100 PSI)
• Replaces discontinued 143-4062, 143-4065 , 0 to 6890 kPa (0 to 1000 PSI)
and 143-4066 Pressure Sensors 0 to 51675 kPa (0 to 7500 PSI)
Accuracy ID: C80595T1 ±1% of full scale or ±1% of reading typical

Proof pressure two times rated range

Burst pressure five times rated range
Connection male, 1/4 inch NPT thread
Connector male, 5-pin DIN
Operating temperature range -40 to 100°C (-40 to 212°F)
Maximum diameter 26.0 mm (1.02 inches)
Sensor length 84 mm (3.3 inches)
Cable length 305 mm (12 inches)
Weight 0.13 kg (.28 lbs)
DataView Auto ID resistor built-in

177-8910 Power Link Group

SMCS Code: 7100-038, 0759, 0769, 0599
Model: Challenger 35, 45, 55, 65, 75, 85, and 95
Warranty: One Year

• Used to measure actual drawbar horsepower of Ag Tractors

• Allows side-by-side comparison between Caterpillar Challenger and competitive equipment or any tractor equipped with a traditional drawbar
• Complete portable system ideal for field use
• Quick and easy installation and set-up
• Measures true ground speed and draft load
• All measurements are shown on power link display screen.
• Designed to accommodate a wide range of tractors and implements, complete with drawbar pins for row crop and tillage machines
• Measures tractors with up to 18,160 kg (40,000 lbs) drawbar pull and 36,320 kg (80,000 lbs) maximum rating

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177-8910 Power Link Group

Storage case 560 x 480 x 230 mm (22.0 x 19.0 x 9.0 in), 2 required
Weight (power link case) 27.7 kg (61 lbs)
Weight (accessory case) 17.7 kg (39 lbs)
Operating temperature range 0 to 40°C (32 to 104°F)
Storage temperature range -40 to 85°C (-40 to 185°F)
Accuracy ±5%
177-8905 Power Link Display
Provides readout device for user
Size 290 x 178 x 92 mm (12.0 x 7.0 x 4.0 in)
Weight 2.25 kg (5 lbs)
Power requirements 0.5 to 2 Amps
Output (data) RS232
Operating voltage 10.5 to 29 Volts DC ID: C80350T1
Fuse 3 Amp slow blow, 2 required
Operating temperature range -40 to 85°C (-40 to 185°F)
Storage temperature range -40 to 85°C (-40 to 185°F)
177-8902 Power Link - provides drawbar pull information
Size 380 x 150 x 100 mm (15.0 x 6.0 x 4.0 in)
Weight 14.5 kg (32 lbs)
Nominal impedance 350 Ohms
Operating voltage 5 Volts DC
Pull capacity (continuous) 16,160 kg (40,000 lbs)
Pull capacity (maximum) 36,320 kg (80,000 lbs)
Vertical load capacity 2,725 kg (6,000 lbs)
Power requirements 15 mA
Output DC milli-volt
ID: C80477T1
Operating temperature range -40 to 60°C (-40 to 140°F)
Storage temperature range -40 to 85°C (-40 to 185°F)
177-8906 Radar - provides ground speed information
Size 220 x 110 x 115 mm (8.5 x 4.3 x 4.5 in)
Weight 1.6 kg (3.5 lbs)
Power requirements 150 mA
Velocity range 0.161 to 48 km/h (0.1 to 30 mph)
Beam width 7 degrees
Mounting height 460 to 1070 mm (18 to 42 in)
Input voltage 11 to 26 Volts DC
Output (data) RS232 ID: C80475T1
Operating temperature range 0 to 40°C (32 to 104°F)
Storage temperature range -40 to 85°C (-40 to 185°F)
Accuracy 0.161 kmp (0.1 mph)

Item Part No. Description Repair Information

1 4C-9660 Equipment Case, 2 required 177-8906 Radar Sensor
2 177-8904 Radar Foam Insert O’Conner Engineering
3 177-8906 Radar Sensor 1060 Grant Street 1B
4 177-8908 Radar Sensor Bracket Benicia, California 94510
5 9U-5061 Velcro Strap Phone: 270-838-1000
6 162-7120 Hitch Lock Pin Fax: 707-745-3191
7 177-8919 Angle Indicator A Return Material Authorization
8 177-9455 Radar Mount Tie Down Number is required
9 NEEG2868 Decal
177-8902 Power Link
10 177-8907 Power Link Power Cable
177-8905 Power Link Display
11 177-8905 Power Link Display
Stress-Tek, Inc.
12 NEHS0768 Tool Operating Manual 5920 South 194th Street
13 177-8920 Radar Cable Kent, Washington 98032
14 113-5518 Hitch Pin (1 3/8 inch) Phone: 253-872-1910
15 FT2686 Extension Hoses (not included) Fax: 253-872-9626
16 NEEG2867 Decal A Return Material Authorization
17 177-8909 Power Link Cable Number is required
ID: C79890T1 18 135-4730 Hitch Pin (2 inch)
19 177-8902 Power Link Reference
20 177-8903 Foam Insert, Power Link NEHS0768 Tool Operating Manual

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4C-9024 Battery Pack Group

4C-9031 Battery Cable
SMCS Code: 0785
Model: All Models
Warranty: One Year

• Portable, rechargeable power supply for use with all Caterpillar diagnostic tools that require
12-Volt DC power, e.g., 4C-9021 Torsional Vibration Signal Conditioner Group
• Recharged from self-storing 4C-9026 Charger from standard 110 Volt wall outlet
• Provides quick power for short diagnostic tests — no need to open vehicle battery compartment
• 4C-9031 Cable required to connect to diagnostic tools
Part No. Description
4C-9024 Battery Pack Group 4C-9025 Rechargeable Battery
Volts 12 VDC ID: C26988T1 4C-9026 Battery Charger
Capacity 6 amp hrs. at 20 hr. rating (25° C, 77° F)
Internal resistance 25 milliohms
Self discharge 2-3% per month
Size 210 mm L x 73 mm W x 165 mm H
(8.25 in L x 2.875 in W x 6.5 in H)
Weight 7 lbs.(3.18 kg)
Charge/discharge cycles up to 500 typical
Operating temperature -60 to +60 ° C (-76 to +140° F)
Charging temperature -16 to +50 ° C (+4 to +122° F)
Recharge time 16-20 hrs.

Typical operating times

ID: C26989T1
Current drain (amps) 0.25 0.5 1.0 2 4C-9031 Cable, Battery to Tool
Power drain (watts) 3 6 12 24 Length 182 cm (6 ft.)
Operating time (hours) 20 11 5 2 Weight .113 kg (.25 lbs)
Connectors:
Plug standard cigarette lighter plug with integral 1 Amp fuse
Receptable standard MS, 2-pin connector used on diagnostic tools

Reference
NEHS0562 Operating Manual, 4C-9021 Torsional Vibration Measuring Group

9U-7560 Field Soldering Iron Group

9U-7561 Field Soldering Iron
SMCS Code: 0709
Model: All Models
Warranty: One Year

• Used to solder electrical connections in the field — light-weight and easy to use
• Used with 4C-9024 Battery Pack Group
• Tip is temperature regulated (provides better control for outdoor usage).
• In-line fuse prevents damage and/or overload.
• Plugs into any 12V vehicle cigarette lighter plug
• The optional 4C-9024 Portable Battery Pack will power 9U-7561 for three hours continuously.
ID: C66644T1
Reference Item Part No. Description
NEHS0601 Tool Operating Manual 1 9U-7561 Soldering Iron
Voltage requirement 12 VDC
2 9U-7562 Solder, 0.5 kg (1 lb.) Spool
Wattage 42 Watts
3 6V-3073 Case
Tip temperature 370°C (700°F)
Service Parts
Length 190 mm (7.5 in)
Part No. Description
Cord length 3.5 m (11.50 ft.)
9U-7563 Tip, Soldering Iron Replacement
6V-4094 Foam Block
2S-6024 Fuse or 333672 Fuse, 5 Amp
NEEG2588 Soldering Iron Label
NEEG2587 Case Label\

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4C-5607 Combustible Gas Detector

SMCS Code: 1250-034
Model: Spark Ignited Engines
Warranty: One Year

• Portable, battery operated, solid-state Power supply 2 (2.4V) Ni-Cad batteries

• Approved for use in Class-1 Hazardous Atmospheres Battery life 4 hours
• Provides “geiger-counter” ticking signal which increases in frequency as source of combustion Sensitivity 50 - 1000 PPM
gas or vapor is approached Warm-up time automatic, approx. 15 sec.
• Excellent for instantly pin-pointing gas leaks in Class-1 Atmospheres, as minute as 50 PPM Response time instantaneous
• Includes flexible probe, sturdy carrying case, rechargeable batteries, and recharger adapter Weight 439 grams (15.5 oz.)
Dimensions 20.32 cm x 7.62 cm x 4.57 cm (8 in x 3 in x 1.8 in)
Materials the 4C-5607 will respond to:
Hydrocarbons Duty cycle continuous, no limitations
• Methane (Natural Gas) • N-Butane Operating temp. range 0°C to 38°C (33°F to 100°F)
• Ethane • Isobutane Probe length 38.1 cm (15 in.)
• Propane • Pentane
• Benzene • Hexane
Service Part
• Acetylene • Gasoline
• Butane • Diesel Fuel Part No. Description
Halogenated Hydrocarbons 4C-5611 Sensing Tip
• Methyl Chloride • Trichloroethane
• Methylene Chloride • Vinyl Chloride

ID: C33391T1

4C-5608 Vacuum Leak Detector/Transmitter

SMCS Code: 7300-034
Model: All Models
Warranty: One Year

• Designed to detect high pressure and/or vacuum leaks through use of ultrasonics (All pneumatic
and vacuum leaks emit high-frequency sound in range far above that audible to human ear.)
• Transmitter (included in 4C-5608) to be used with Vacuum Leak Detector when checking system
that does not generate a high frequency tone
• Excellent for finding door seal leaks in cabs.

Service Part
Part No. Description
4C-5609 Replacement Transmitter for 4C-5608

Power supply 1U-9534 Battery, 9V

Battery life 40 hrs for carbon-zinc, 80 hrs for alkaline
Sensitivity automatic
Response time instantaneous
Reset time 1/4 second
Set time 1 second ID: C33390T1
Warm-up time instantaneous
Weight 14.5 oz. with battery
Dimensions 20.32 cm x 7.62 cm x 4.57 cm (8 in x 3 in x 1.8 in)
Probe length 31.75 cm (12.5 in.)

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8T-9295 Diagnostic Tool Holder

SMCS Code: 0785
Model: All Models
Warranty: One Year

• Frees serviceman’s hands while performing critical diagnostic tests

• Magnetized, adjustable device holds multimeter, multitach, electronic position indicator or any diagnostic tool.
• Especially helpful while checking or adjusting fuel systems

ID: C44352T1

9U-5215 Tool Case, Soft

SMCS Code: 0785
Model: All Models

• Universal soft case for most Caterpillar hand-held “green box” diagnostic tools
• Foam insert used to hold standard-size tool; without foam, will hold 4C-6500 Digital Thermometer
• Resistant to coolant, diesel fuel, and oil
• Adjustable/removable strap
• Clear vinyl front for excellent instrument visiblity; provides extra protection
• Opening in top for easy access to all connections of instrument

ID: C27065T1

156-1060 Emission Analyzer Group (Gas Engines Only)

156-1070 Emission Analyzer Group (Gas and Diesel Engines)
SMCS Code: 1088-036, 0781
Model: All Models of Gas and Diesel Engines
Warranty: Manufacturer’s

NOTE: Manufacturer’s one year warranty from date of purchase on all parts Input exhaust from engine under test
except the 156-1061 Oxygen Sensor which has a two year warranty.
156-1067 length 305 mm (12.0 in)
156-1068 length 4572 cm (15 ft)
156-1060 Power cord length 4572 cm (15 ft)
• Replaces discontinued 4C-8710 Emissions Analyzer
Power
• Used for fast, easy set-up and servicing of lean burn and stoichometric
Internal sealed lead acid battery, 12VDC, 2.2 AH rechargeable
engines
External selected 110/220 VAC, 50/60 Hz
• Measures exhaust concentrations of oxygen (O2), carbon monozide (CO), low
nitricoxide (NO), and nitric oxide (NO2) External converter 12VDC, battery cables and cigarette lighter plug
(available separately)
156-1070 Operating Temperatures
• Used for fast, easy set-up and servicing of lean burn, stoichometric, and Analyzer 6.7 to 50.0°C (20 to 122°F)
diesel engines Probe -17.8 to 982.2°C (0 to 1800°F)
• Measures exhaust concentrations of oxygen (O2), carbon monoxide (CO), nitric Storage temperature -40.0 to 60.0°C (-40 to 140°F)
oxide (NO), nitric dioxide (NO2), and combustibles (CxHx) Measurements
External dimensions 48.3 x 40.6 x 16.5 cm (19 x 16 x 6.50 in)
156-1060 and 156-1070
Weight 12.71 kg (28 lbs)
• Measures exhaust and ambient temperatures, stack draft, and smoke test
• Calculates carbon dioxide, excess air, efficiency, and losses
• Display shows all parameters at once and has two levels of zoom
• Housed in a durable aluminum reinforced case
• Durable pistol grip probe (one foot in length)
• Built-in thermal printer
• Automatic water dump

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Measurement Measurement Measurement

Range Resolution Accuracy Sensor Life
Oxygen (O2) 0 to 21% 0.1% ±2% of reading 2 years
Carbon monoxide (CO) low 0 to 4000 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Carbon monoxide (CO) high 0 to 40,000 ppm 5 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Nitric oxide (NO) 0 to 4000 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Nitrogen dioxide (NO2) 0 to 500 ppm 1 ppm ±2% of reading 3 years (Depends on usage and gas concentration)
Combustibles (CxHx) 0 to 6% 0.01% ±2% of reading 3 years
Ambient temperature -17.8 to 121.1°C (0 to 250°F) 0.6°C (1°F) -16.1°C (3°F) 10 years
Exhaust temperature -17.8 to 982.2°C (0 to 1800°F) 1.7°C (1°F) -16.1°C (3°F) 10 years
Stack draft 0 to 40.00 inches H20 0.01 inch H20 2% of reading 10 years
Smoke test 0 to 9 spot method — — —

Components included with 156-1060 or 156-1070 Emission Analyzer Group

Item Part No. Description
1 156-1067 Probe
2 156-1068 Sample Line
3 Two rolls of printer paper
4 Package of smoke test paper and comparison chart
5 Single water trap assembly
6 Ambient thermocouple with magnet
7 Shoulder strap
8 Calibration certificate and magnet
9 AC power cord
10 NEHS0713 Tool Operating Manual
11 Package of water trap filters
12 Drain hose
13 Emission Analyzer
ID: C79262T1
14 NEHS0714 Tool Operating Tips Pocket Card
Not shown Two keys for case latches

Part No. Description Replacement Parts (available separately)

Sensors provided with 156-1060 Analyzer Group (installed in analyzer) 156-1069 Inlet O-Ring (draft)
156-1061 Sensor, Oxygen 156-1076 Inlet O-Ring (gas)
156-1062 Sensor, Carbon Monoxide (CO) Low 156-1071 Printer Head
156-1064 Sensor, Nitric Oxide (NO) 156-1067 Probe
156-1065 Sensor, Nitric Dioxide (NO2) 156-1068 Sample Line
Sensors provided with 156-1070 Analyzer Group (installed in analyzer) 156-1061 Sensor, Oxygen
156-1061 Sensor, Oxygen 156-1062 Sensor, Carbon Monoxide (CO) Low
156-1062 Sensor, Carbon Monoxide (CO) Low 156-1063 Sensor, Carbon Monoxide (CO) High
156-1063 Sensor, Carbon Monoxide (CO) High 156-1064 Sensor, Nitric Oxide (NO)
156-1064 Sensor, Nitric Oxide (NO) 156-1065 Sensor, Nitric Dioxide (NO2)
156-1065 Sensor, Nitric Dioxide (NO2) 156-1066 Sensor, Combustibles (CxHx)
156-1066 Sensor, Combustibles (CxHx) Optional (available separately)
Service Parts (available separately) 156-1077 Power Inverter - 12VDC, includes battery cables and cigarette lighter adapter
156-1078 Printer Paper 156-1075 Remote Display - includes a cable 76.2 cm (30 ft) in length
156-1074 Smoke Test Paper Data Acquisition Software (contact CSTG)
156-1073 Filter Media (purple beads)
156-1072 Water Trap Filter
Reference
NEHS0713 Tool Operating Manual
NEHS0714 Tool Operating Tips Pocket Card

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209-5545 Oxygen Analyzer Temperature

SMCS Code:0781,1088 Measurement range -40 to 600°C (-40 to +1112°F)
Warranty:Manufacturer’s Accuracy ±0.5°C (0 to +99.9°C)
±0.5% (from +100°C)

Compliant Resolution 0.1°C
• Battery operated—will operate more than 4 hours on Sensor Thermocouple Type K
4 AA-size alkaline batteries (NiCr-Ni) to DIN IEC 584 Part 2, Class 1
• Can be operated from AC power with optional power supply Draft/Pressure Measurement
• Measures oxygen content and temperature of exhaust gases Measurement range ±40 mbar (±0.6 PSI)
of natural gas, diesel, oil, and propane powered engines Resolution 0.01 mbar
• Updates quickly to easily track adjustments Accuracy 0.03 mbar
• Magnet-backed case provides ease of mounting Maximum overload 1000 mbar (14.5 PSI)
Gross/ Net Efficiency
Part No. Description ID: C80590T1
Measurement range 0 to 100 %
Oxygen Analyzer Resolution 0.1 %
1U-7538 AA Non-rechargeable Alkaline Batteries Oxygen Measurement
209-5551 Protective Rubber Boot with magnetic back Measurement range 0 to 21 volume %
209-5552 Gas Probe/Hose Assembly Accuracy ±0.2 volume %
Reference Guide Resolution 0.01 volume %
Calibration Information Carbon Dioxide Measurement
Instruction Manual Display range 0 to CO2 maximum
6V-7145 Carrying Case Accuracy ±0.2 volume %
209-5574 Foam Insert Resolution 0.01 volume percent
Service Parts Measurement Digital calculation from O2
209-5554 Particle Filter (10 per pack) General Technical Data
209-5555 Oxygen Sensor Power supply AA-size batteries (4), rechargeable
AA-size batteries (4), or power supply
Optional Parts (order separately)
209-5556 Environmental Case (for instrument)
209-5558 Power Supply (120 VAC)
209-5560 Power Supply (240 VAC)
209-5561 In-line Water/Particulate Trap (for high water content)
209-5563 Replacement Filter for 209-5561 Water/Particulate Trap

206-2933 ProLink Printer (220 VAC / 12 VDC)

SMCS Code: 1900-036, 0779 Power source input 220 VAC
Model: On-Highway Trucks
Power output to printer 12 VDC
Warranty: Manufacturer's

• Used to print active diagnostic codes, logged fault event codes,

data lists, trip recorder, customer specified parameters, engine Repair Information
rating specifications, snap shot data, and maintenance data NEXIQ Technologies
6839 Caminito Sueno
• Provides printed copy for permanent history folder
Carlsbad, CA 92009
• Helps troubleshoot intermittent engine problems
(allows comparison between properly running Phone: 800-639-6774
engine and an engine with problems) Fax: 810-731-3348

Reference
STG00-15 Manual
ID: C80409T1

205-8335 Monitor Extension Cable

SMCS Code: 1901-038, 0781
Model: 320C Excavator
Warranty: One Year

• Used to connect in-cab system monitor to a remote monitor

• Provides ground-level system monitoring to instructors and training students

ID: C80406T1

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22 Wiring Harnesses for 320 SCM Excavators 192-8735 Harness Group (320 C)
SMCS Code: 1901-038, 0781 • Used to check operation of engine/pump attachment controller by measuring a
Model: 320 B and C SCM Hydraulic Excavators voltage signal across different connections of controller
Warranty: One Year • 197-3834 Test Harness used for CONNECTOR 3
• 197-3835 Test Harness used for CONNECTOR 4
• Used to check a variety of electrical connections including: continuity between terminals,
terminals and ground, or terminals and battery; measuring voltage between terminals; and 190-0150 190-0159
checking reducing valve, governor actuator, engine/pump controller signal, engine/pump
controller, and engine/pump attachment controller
192-8731 Harness Group (320 B and C) 190-0152
190-0160
• Used to check continuity between terminals, terminals and ground, or terminals and
battery
• 190-0150 Harness Type 1 used on clip-type terminal 190-0154
190-0162
• 190-0152 Harness Type 2 used on terminals of Yazaki female type
• 190-0154 Harness Type 3 used to connect between Yazaki male and female type
• 190-0155 Harness Type 4 used on terminals of Yazaki female
190-0155
190-0163
• 190-0156 Harness Type 5 used to connect between Deutsch female and clip-type terminal
• 190-0157 Harness Type 6 used on Deutsch female terminals 190-0156
• 190-0158 Harness Type 7 used on Deutsch 2-pin type plug
192-8732 Harness Group (320 B) 190-0165
190-0157
• Used to check continuity between terminals, or measure voltage between terminals,
terminals and ground, or terminals and battery
• 190-0159 Harness Type 8 used on AMP female terminals 190-0158 190-0166
• 190-0160 Harness Type 9 used on AMP female terminals
• 190-0162 Harness Type 10 used to connect AMP female and clip-type terminal
• 190-0163 Harness Type 11 used on Deutsch 2-pin type receptacle
190-0167
192-8733 Harness Group (320 C)
• Used to check continuity between terminals, or measure voltage between terminals,
terminals and ground, or terminals and battery 188-8588
• 190-0165 Harness Type 12 used on AMP female terminals
• 190-0166 Harness Type 13 used on AMP female and clip-type terminal
• 190-0167 Harness Type 14 used to connect Deutsch 2-pin type receptacle and clip-type
terminal
188-8588 Valve Test Harness (320 B and C)
• Used to check operation of reducing valve by measuring a current signal (Sweep Test) 197-3837
197-3836
188-8589 Governor Test Harness (320 C)
• Used to check operation of governor actuator by measuring a voltage signal across 188-8589
different connections (Sweep Test)
190-0169 Harness Group (320 B)
• Used to check operation of engine/pump controller signal by measuring a voltage signal
across different connections of controller
• 197-3836 Test Harness used for CONNECTOR 1
• 197-3837 Test Harness used for CONNECTOR 2
197-3832
192-8734 Harness Group (320 C) 197-3833
• Used to check operation of engine/pump controller by measuring a voltage signal across 197-3834
different connections of controller 197-3835
• 197-3832 Test Harness used for CONNECTOR 1 ID: C80505T1
• 197-3833 Test Harness used for CONNECTOR 2

8T-5200 Signal Generator/Counter Group Item Part No. Description

SMCS Code: 0785 1 6V-3072 Carrying Case
Model: All Models
2 8T-5267 Foam Block
Warranty: One Year
3 8T-5201 Signal Generator/Counter
4 6V-2198 Extension Cable
• Small handheld square-wave generator
5 8T-5198 Transmission Adapter Cable
• Used mainly to simulate speed in place of magnetic
speed pickup for troubleshooting transmission 6 8T-5197 Calibrator Cable and Adapters
electronic control units; 8-Volt (Peak to Peak) square 7 8T-5112 Signal Input Cable
wave OUT PUT provided 8 6V-6045 Accessories Case
Other functions:
• Electronic diagnostic tool calibration in number of
applications that currently use 5P-9698 Calibrator;
Reference
3-Volt (Peak to Peak) square wave CAL OUT SEHS8579 Special Instruction
provided; frequency (Hz) range approximately 3 Hz ID: C06286T1 4C-6534 Harness in Tool Guide
(cycles per second) to 7000 Hz, infinitely variable by (setting electronic speed switches)
turning Hz adjustment knob, and displayed by 4-1/2 digit LCD
• Frequency (Hz) counter when input is pulsating DC or AC signal within following parameters: 10 cycles
per second (Hz) to 19,999 cycles per second (Hz) then signal level must be 0.1 to 50 Volts peak
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196-1900 MAC14 Frequency Input Adapter

SMCS Code: 0785
®

Model: Off-Highway Trucks and Wheel Tractor Scrapers

196-1900
Warranty: One Year MAC14
FREQUENCY ADAPTER

• Used to simulate a transmission output speed WARNING

(TOS) to allow service technician to observe
transmission shifting through all gears Using the signal generator to simulate
transmission output speed could cause the
• Used with 8T-5201 Signal Generator Counter Group
machine to move. To prevent possible injury, refer
• Enables signal generator to input a frequency signal into to the procedure in the Service Manual for the
a MAC14 control (multiple application control 14 outputs) correct installation and operating instructions.

ID: C79993T1

4C-6534 Harness
SMCS Code: 7427-036
Model: All Models
Warranty: One Year

• Replaces discontinued 9W-6370 Harness

• Used with 8T-5201 Signal Generator/Counter to test and adjust all engine
Reference
SEHS8657 Special Instruction
electronic speed switches, whether 2-, 3- or 4-element (9W-6370 checks
only 2- and 3-element speed switches; 4C-6534 Harness provides higher
voltage signal which will operate 4-element speed switches.)
• Length: 1524 mm (60 in)
ID: C26937T1

Hook and Loop Fastener

Warranty: Manufacturer’s

• Fast — lets you secure and release cables

Part No. Description Size (W x L)
quickly and easily with the combinations
of Velcro strap and nylon tie 9U-5061 Closed Loop 25.4 mm x 177.8 mm (1 in x 7 in)
• Easy — mounts to cables permanently; 9U-5062 Open loop 25.4 mm x 177.8 mm (1 in x 7 in)
installs in seconds 9U-5063 Open loop 38.1 mm x 457 mm (1 1/2 in x 18 in)
• Reuseable
• Tidy — keeps cables neat and safe
• A great way to coil them for storage — a better
way to keep harnessed cables organized
ID: C44268T1

6V-2196 Microscope
6V-7894
6V-7894 Microlite • Provides a light source for the 6V-2196
Warranty: Manufacturer’s Inspection Microscope; clip included to attach
the light to the microscope
• Uses a standard 222 bulb with a screw-type
6V-2196 base and focus lens (can also use 6V-3061 as
• This 20X microscope is a general usage replacement bulb);
instrument, but is specifically recommended two standard 1.5 Volt “AAA” size batteries are
for checking crankshaft bearing surfaces after required, but not included with the microlite.
magnetic inspection. • For longer service life 1U-9535 Alkaline
• Accurate measurement is provided by a scale Batteries are recommended.
ID: B62607-1T1
reading in 0.1 mm increments.

Dual Scale Pressure Gauges

Connection Range Range Connection Range Range
Part No. Location (PSI) (kPa) Part No. Location (PSI) (kPa)
• Dual scale, liquid-filled pressure gauge
8T-0846 1 Back 0 to 145 0 to 1000 8T-0855 Stem 0 to 580 0 to 4000
in a brass case
8T-0847 Back -15 to 0 to 72 -100 to 0 to +500 8T-0856 Stem 0 to 870 0 to 6000
• Inside scale is kilopascals (kPa) identified
by a yellow band. 8T-0848 1 Back 0 to 58 0 to 400 8T-0857 Stem 0 to 1450 0 to 10 000
• Outside scale is pounds per square inch (PSI) 8T-0849 1 Back 0 to 290 0 to 2000 8T-0858 Stem 0 to 2300 0 to 16 000
8T-0850 1 Back 0 to 580 0 to 4000 8T-0859 Stem 0 to 3600 0 to 25 000
8T-0851 1 Back 0 to 2300 0 to 16 000 8T-0860 Stem 0 to 5800 0 to 40 000
Gauge diameter 2.50 in (63.5 mm) 8T-0852 1 Back 0 to 5800 0 to 40 000 8T-0861 Stem 0 to 8700 0 to 60 000
Accuracy 1.6% 8T-0853 Stem 0 to 58 0 to 400 8T-0862 Stem -15 to 0 to 72 -100 to 0 to +500
Connector 1/4-18 NPTF 8T-0854 Stem 0 to 145 0 to 1000 8T-0863 Stem 0 to 36 0 to 250
1 Can be used in 1U-5481 Transmission Test Group

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Standard and Certified Pressure Gauges Dual Scale Pressure Gauges (Stem Connector) 2.50 in
Certified Standard Range
Part No Part No kPa (PSI)
Accuracy 1.6%
• Dual scale, liquid-filled pressure gauge in a brass case 186-2601 8T-0853 0 to 400 (0 to 58)
Connector 1/4-18 NPTF
• Inside scale is kilopascals (kPa) identified by a yellow band. 186-2602 8T-0854 0 to 1,000 (0 to 145)
Gauge diameter 63.5 mm (2.50 in)
• Outside scale is pounds per square inch (PSI) 186-2604 8T-0855 0 to 4,000 (0 to 580)
Gauge diameter
• Certified gauge has a serial number and — 212-7043 0 to 700 (0 to 100)
of 186-2613 101.6 mm (4.0 in)
certificate of accuracy from the manufacturer. 186-2605 8T-0856 0 to 6,000 (0 to 870)
186-2606 8T-0857 0 to 10,000 (0 to 1,450)
Dual Scale Pressure Gauges (Back Connector) 2.50 in 186-2607 8T-0858 0 to 16,000 (0 to 2,300)
Certified Standard Range 186-2608 8T-0859 0 to 25,000 (0 to 3,600)
Part No Part No kPa (PSI) 186-2609 8T-0860 0 to 40,000 (0 to 5,800)
186-2592 8T-0846 1 0 to 1,000 (0 to 145) 186-2610 8T-0861 0 to 60,000 (0 to 8,700)
186-2593 8T-0847 -100 to 0 to 50 (-15 to 0 to 72) 186-2611 8T-0862 -100 to 0 to 500 (-15 to 0 to 72)
186-2594 8T-0848 1 0 to 400 (0 to 58) 186-2612 8T-0863 0 to 250 (0 to 36)
186-2595 8T-0849 1 0 to 2,000 (0 to 290)
186-2596 8T-0850 1 0 to 4,000 (0 to 580) Dual Scale Pressure Gauges (Stem Connector) 4.00 in
186-2597 8T-0851 1 0 to 16,000 (0 to 2,300) Certified Standard Range
186-2598 8T-0852 1 0 to 40,000 (0 to 5,800) Part No Part No kPa (PSI)
1 Can be used in 1U-5481 Transmission Test Group 186-2613 8T-0820 0 to 70,000 (0 to 10,000)

ID: C80258T1

8T-0820 Standard Pressure Gauge 218-8445 Differential Pressure Gauge

Model: 201-8131 Heavy Duty Filter Cart
186-2613 Certified Pressure Gauge
• Used to monitor pressure drop across filter element
• Grade “A” liquid-filled dual scale (kPa range • Used with 201-8131 Heavy-Duty Filter Cart
0-70,000, PSI range 0-10,000), 101.6 mm (4.0 in) • Easily mounts anywhere (can be panel mounted)
diameter with 1/4 inch NPT thread and stem
mounted • 1/4 inch NPT hose connections
• General purpose gauge; can be used with
all Caterpillar electric hydraulic pumps
• Certified gauge has serial number and certificate 40
60
of accuracy from the manufacturer. 80
20
PSID

0
dp
ID: C80258T1

8T-5342 and 8T-5343 Pressure Gauge

• Liquid-filled pressure gauges designed for use with the most popular series of
hydraulic pullers and rams ID: C80596T1
• 8T-5343 Gauge is a bottom mount pressure gauge having 1/4 inch NPT threads. Maximum temperature 93°C (200°F)

• 8T-5342 Gauge is a lower back-mounted pressure gauge. Maximum pressure 400 bar (6000 PSI)

• Both gauges have a 101,6 mm (4.00 in) liquid filled housing Full range scale 0 to 100 PSI

• Provide Grade A accuracy with a pressure range of 0-70,000 kPa (0-10,000 PSI) Accuracy FSD ± 2%

• Tonnage scales are provided for 30, 50, 70, 100 and 150 ton cylinders (27T, 45T, Dial size 63.5 mm (2.50 inches)
63.5T, 91T and 136T). Hose connections 1/4 FNTP
Line connections back mount
Lens plastic
210-6990 Digital Pressure Gauge (0-500 PSI) Body material aluminum
Units of measure pounds per square inch (PSI)
Seals Viton
• 2 3/4 inch gauge has 1% of full Red zone from 60 PSI and higher
scale accuracy 21
0-
69
• Gauge reads in PSI only 90
• Operates in 0-50°C (32-122°F)
• NIST certified
• 1/4 inch NPT stem style connection
PS
• Requires a 9-Volt alkaline battery MAD
IN
USA
E
IG

• Weight: 0.198 kg (7 oz)

ID: D00965T1
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9U-6986 Service Indicator 1U-5809 Grommet

Warranty: Manufacturer’s

• Used to monitor filter condition • Provides protection to gauges during field operations
• Has a 2-inch diameter face with green • Fits stem or back-mounted gauges with 63 mm (2 1/2 in) face diameters and
background to 20 PSI, yellow background thicknesses of 28 mm (1 1/8 in)
to 24 PSI, and red background to 60 PSI
• Has 1/8 inch NPT port out on middle
of back

ID: D00821T1 ID: B96658T1

5P-8558 Calibrating Group Pressure Gauge

Warranty: Manufacturer’s

• 3 gauges of 1/2% accuracy with pressure ranges of 1100 kPa (160 PSI), 4150 kPa (600 PSI), and 34 500 kPa (5000 PSI)
• Two lower pressure gauges protected from excessive pressure by two sensor valves which shut off the pressure signal
to the gauges at a preset value
• A separate source of pressure such as the 1U-5230 Hand Pump is required to actuate the calibrating group.

Components Used for Testing with the

5P-8558 Calibrating Group
Item Part No. Description
1 1U-5230 Pump Group
2 1P-2375 Coupler Assembly
3 1P-2376 Coupler (two)
4 8F-0024 Hose Assembly ID: A66421-1T1
Item Part No. Description
5 1S-8937 Valve
1 5P-0946 Box
6 5P-8998 Nipple
2 1P-2375 Coupler Assembly
3 8S-4600 Nipple (two)1
4 8S-4599 Coupling Assembly
1 Othernipples available for gauge attachment
are: 2S-5244, 1/4 inch NPT External Thread
ID: A66422-1T1

204-7393 Gauge Comparator Range 0 to 68900 kPa

(0 to 10000 PSI)
Pressure medium water, animal/
vegetable oil, or alcohol
• Used to compare accuracy of analog and/or digital gauges
Mounting 4 holes
(compares gauge in question to a precise master gauge)
Dimensions (w x h x d) 275 x 200 x 270 mm
• Used with 204-7394 7000 kPa Precision Gauge, 204-7395 35000 kPa Precision (10.8 x 7.9 x 10.6 in)
Gauge, and 198-9257 70000 kPa Precision Gauge (not part of 204-7393)
Weight 5.9 kg (13 lbs)
• Can also be used to check accuracy of 198-4240 Digital
Pressure Indicator Group Connections 1/4-18 NPTF female

• Quick-sealing, threaded gauge adapters allow quick and easy Accuracy ±0.25% of span
gauge changes
• Works in stationary or portable applications (can be bench mounted
or mounted to a rolling cart)
ID: C80576T1
• Hand wheel allows minute pressure changes to be made
• Large diameter master gauges for easy pressure reading
• Master gauges have dual scale pressure readings [inside (kPa) and outside (PSI)]

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8T-5135 Gauge Mounting Group

Warranty: Manufacturer’s

• Used to mount fluid-filled, 63.5 mm (2.50 in) diameter gauges, both kPa and PSI back-mounted, in the discontinued
6V-4160 Transmission Test Case. Some U-shaped mounting panels may need to be modified by brazing a piece of
sheet metal to the U-shaped mounting panel to make it 4.8 mm (.188 in) deeper.
• Use for transmission test cases without a U-shaped mounting panel.

ID: C44063T1

6V-7830 Tetragauge

• Functions as a general purpose pressure measuring device

• Capable of measuring hydraulic or air pressure from -100 kPa (-14.5 PSI) to 40 000 kPa (+5800 PSI)
• The two lower pressure gauges are protected from over-pressurization by two sensor valves which shift and prevent
pressure from increasing past a pre-set value which is less than the full-scale range of the gauges. The highest
pressure gauge is not protected by a shutoff valve.
• Background of the kPa scale is highlighted
in yellow to indicate metric units.
• Repair Kit: 8T-5324 Repair Kit
Item Part No. Description
1 6V-3081 Hose Assembly
2 8T-0862 Gauge, -100 kPa (-14.5 PSI) to +500 kPa (+72.5 PSI)
3 8T-0860 Gauge, 40 000 kPa (0 kPa to 5800 PSI)
4 8T-0855 Gauge, 4000 kPa (0 kPa to 580 PSI)
5 6V-4144 Coupler Assembly
ID: B97290T1
6 4S-6399 Connector

4C-5623 Smoke Candle Ordering Information

SMCS Code: 7301-034, 7325-034 U.S. and Canadian dealers — This product is a direct shipped item from
Model: All Models our supplier to anywhere in the U.S. and Canada. Order this part number
on the DTS (Dealer Terminal System) as a class 3A order.(There is no
emergency charge for this product.)
• Easy, inexpensive way to find air leaks in vehicle cabs by pressurizing Do not order this product on a stock order. The system will not accept it.
cab and watching for leaks identified by escaping white smoke This direct shipped product is not stocked in Caterpillar Parts
• Does not leave residue Departments. The stock check procedure always shows “no stock” and
• Contains no explosive materials therefore will reject the order.
• Blends readily with air; stays in suspension for 10-15 minutes All dealers outside the U.S. and Canada — Order as a class 3A order with
• Smoke is generated as a mist that contains a large amount of atmospheric moisture your subsidiary parts department. (There is no emergency charge for this
as opposed to solids being generated as a by-product of burning. These smoke product.) After placement of your order you should notify your subsidiary
candles have a rating of 2100 total obscuring power (T.O.P.), compared to 200 T.O.P. parts department that this is a direct shipped item from the U.S. (Do not
for crude oil. T.O.P. is the scientific method of determining the quantity of smoke order this product on a stock order. The system will not accept it.) Your
generated by a given unit of smoke composition. order will be direct shipped from the supplier through a freight forwarder
in the U.S. to your subsidiary parts department.

Reference
Material Safety Data Sheets (MSDS) for all chemical products are
required by law. All of Caterpillar Material Safety Data Sheets are on file
at the Rocky Mountain Poison Center in Denver, Colorado. In addition,
Caterpillar now has a dedicated “Safety Hotline” to the Center. This toll
Smoke duration 30 seconds free number (1-800-458-5924) is staffed by trauma specialists 24 hours
Smoke color white to gray depending per day all year round and is available to U.S. and Canadian dealers.
upon density and lighting
ID: C27233T1
Volume generated 4000 cubic feet
Quantity 12 candles per box

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9X-3075 Cable Assembly

SMCS Code: 0781
Model: Off-Highway Trucks
Warranty: One Year

• Used to download information from TPMS (Truck Payload Measurement System) to a user’s laptop computer
• Setup functions, diagnostics, and productivity reports are available using TPMS, this cable, and TPM software
package (available separately).
• Truck cab connector: 5 pin MS
• Computer connector: 9 pin serial port

ID: C79231T1

127-9797 Cable, TPMS, VIMS, WLP to PC

SMCS Code: 7494-038, 0779
Model: All Off-Highway Trucks Service Parts
Warranty: One Year Part No. Description
8C-6313 Connector
• Replaces discontinued 9X-3393 Cable Group 8C-4797 Socket
• Used to download data from off-highway trucks
• Used with Truck Payload Measurement System (TPMS) software package and IBM compatible personal computer
• Cable connects to 5-pin circular connector on TMPS and 9-pin “D” connector on computer.
• New cable allows data to be downloaded from ground level (eliminates need to turn keyswitch inside cab).

ID: C66799T1

9U-6386 Extension Cable

SMCS Code: 5050-082, 5050-036
Model: 320, 330, and 325 Hydraulic Excavators
Warranty: One Year

• Used to extend reach of 7Y-5500 Control Group into cab — allows technician Service Parts
to adjust hydraulic system from inside cab Part No. Description
• Efficient and cost effective way to diagnose hydraulic system problems 7N-8204 Housing Plug
• Length: 6 meter (20 feet) ID: C66601T1
7N-8205 Receptacle Housing
7N-7779 Connector Socket
7N-7780 Connector Pin

218-3363 Breakout T-Adapter 209-1969 Training Harness

Model: Lexion Combine SMCS Code: 0115
Warranty: One Year Model: C-15 Engines
Warranty: One Year
• Used to check voltage at solenoid while it is in use (verifies
if solenoid is not working or there is no power to solenoid) • Used to connect between C-15 Electronic Training Aid and 70 pin ECM
• Fits all standard DIN 43650 type connectors connector
• Connects between machine harness and solenoid • Simulates six-cylinder industrial engine

ID: D00128T1

ID: D00228T1

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114-0905 Electronic Engine Training Aid

118-3381 Electronic Transmission Training Aid
129-3906 VIMS Training Aid
SMCS Code: 0315
Model: D11 and Off-Highway Trucks with 3500 Electronic Engines, 3176 Marine Engines, 3500B Engines, EPTC II Transmission Control
Warranty: One Year

• Used to train personnel in diagnosing problems with electronic control systems Service Parts
• Reduces or replaces the need for a machine to be present during the training course Part No. Description
• Facilitates electronic unit injector (EUI) training in classroom environment 109-9842 Electronic Control System Simulator
• Allows ECAP screen projection without an engine or machine 109-9843 Parallel Expansion Board
• Provides realistic pre-programmed diagnostic 109-9844 Analog to Digital Module
training with faults 109-9845 Digital to Analog Module
• 114-0905 includes engine 109-9846 Timer/Counter Module
component panel, simulation
110-0313 Harness, EPTC II Panel to Simulator
computer, and reusable
shipping crate. 110-0314 Engine Component Panel
110-0315 Harness, Engine Panel to Simulator
110-4541 Harness, Engine Panel to 9X-9972 ECM
110-4542 Engine Care Simulation Software
110-4543 TTT Application Software
111-7842 Shipping Crate
112-6225 Parallel Expansion Board
124-2451 Harness (allows simulation of D11N Track-Type Tractor)
128-1171 Harness (allows simulation of 3500B Engines)
ID: C66654T1

169-0720 Vibration Analyzer Group

Discontinued—Service Parts Available

ID: C80464T1 ID: C80465T1

Part No. Description Part No. Description Field Balance Attachment for 169-0720
169-0717 Vibration Analyzer, discontinued 217-6422 Software Group (Virtual Printer)1 Item Part No. Description
169-0716 Leather Case 169-0735 Balance Group1 1 169-0734 Software Group
169-0718 Clear Plastic Sheath 4C-3036 Sensor Extension Cable 2 4C-6918 Photohead
169-0719 Break Away Strap 169-0721 Communication Cable Assembly 3 4C-6921 Adapter Cable Assembly
169-0733 Isolator 4C-3039 Accelerometer / Velometer Adapter 4 6V-2198 Cable Assembly
4C-3032 Accelerometer Pickup 4C-5629 Velometer Pickup 5 4C-6919 Reflective Tape
169-0711 Battery Charger 9U-5087 Velometer Cable Assembly
169-0712 Battery Pack 4C-3042 Magnetic Base
9U-6955 Current Adapter (Trickle) 9T-5505 Plate (Magnet Keeper)
169-0725 Software Kit1 9U-5933 Probe
169-0726 Routes Disk1 — NEHS0850 Manual
1 Contact CSTG Hotline for ordering instructions.

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Harnesses
SMCS Code: 0315
Model: 3500B EPG and Marine Engines
Warranty: One Year

• Used to connect engines’ ECM to front panel connectors on Electronic Control System Simulator
(wire colors and wire codes match production machines)
• Engine wire harness colors are identical to the training aid wire harness colors
• Used with 114-0905 Electronic Engine Training Aid
• 189-2231 Harness used for 3500B EPG Engine applications
• 203-0202 Harness used for 3500B Marine Engine applications
ID: C80420T1

ID: C80410T1

4C-3030 Vibration Analyzer Group Item Part No. Description

Discontinued — Service Parts Available 1 4C-3026 Plastic Sheath
2 4C-3027 Barrel Connector
3 4C-3031 Vibration Analyzer (not available)
4 4C-3035 Cloth Carry Case
5 4C-3036 Extension Cable
6 4C-3037 Communication Cable
7 4C-3039 Adapter, Acc./Vel.
8 4C-3042 Magnetic Base
9 4C-3040 Printer Adapter
10 4C-4085 Slide Rule
11 4C-5629 Velometer
12 9T-5505 Plate
13 9U-5087 Velometer Cable
14 9U-5605 Battery Charger
15 9U-5834 Linear Routes Loader Software Disk
ID: C44351T1 16 9U-5835 Analyzer Functions Loader Software Disk
Reference 17 9U-5933 Probe
NEEG2536, 4C-3030 Quick Reference Guide 18 NEHS0568 Operating Manual, 4C-3030 Vibration Analyzer
19 NEHS0569 Operating Manual, Route Documentation
20 NEHS0570 Operating Manual, Balancing, Application Guide
Not shown Battery
Not shown 4C-3038 Adapter Cable
Not shown 4C-9658 Case
Not shown 9U-5090 Foam Block

9U-6745 Board Group

SMCS Code: 0781
Model: All Models
Warranty: One Year

• Used for upgrading previous analyzers to current standards

• Used with 4C-3030 Vibration Analyzer Group
• Over three times more memory for data storage
• Upgrades storage memory for routes and programs from 128k to 320k
• 9U-6699 Memory Board: 256 KB of DRAM
• Vibration Analyzer: 320K Part No. Description
9U-6699 Memory Board
Reference 6V-6045 Case
NEHS0568 Tool Operating Manual ID: C54917T1 NEHS0583 Tool Operating Manual

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4C-6920 Field Balance Group Item Part No. Description

Discontinued — Service Parts Available 1 4C-3021 Balance Software Disks (2) (not serviced)
2 4C-6918 Photo Head
NEEG2455 Decal
3 4C-6921 Adapter Cable Assembly
4 6V-2198 Cable Assembly
5 4C-6916 Magnetic Base Group
8D-6894 Washer
6V-3137 Magnetic Base
4C-6917 Adapter Assembly, Photo Head
2S-6251 Machine Screw
6 4C-6919 Reflective Tape
7 NEHS0539 Operating Manual
Not Shown 6V-3072 Plastic Case
Not Shown NEEG2381 Decal
Not Shown 4C-6915 Foam Insert

ID: C27001T1
Reference
NEHS0539 Operating Manual, 4C-6920 Field Balance Group
NEHS0570 Operating Manual, 4C-3030 Vibration Analyzer Group, Application Guide

Vibration Analyzer Replacement Batteries

SMCS Code: 0781, 0783
Model: All Models
Warranty: Manufacturer's

Part No. Description Voltage Dimensions Weight Use

4C-6729 1 Battery Pack ±12/24 Volts, 600 mAh 32 x 146 x 51 mm (1.3 x 5.8 x 2.0 in) 0.5 kg (1 lb) Used to replace battery in 4C-4031 Vibration Analyzer
169-0712 Battery Pack 7.2 Volts, 3.0 AH 26 x 153 x 51 mm (1.0 x 6.0 x 2.0 in) Used to replace battery in 2117 Vibration Analyzer
206-2689 Battery Pack ±12 Volts, 1200 mAh 35 x 172 x 51 mm (1.4 x 6.8 x 2.0 in) Used to replace battery in 2115 SX and 2115 SU Vibration Analyzer
1 Reference: NEHS0568 Tool Operating Manual

4C-9021 Torsional Vibration Measure. Group Item Part No. Description

SMCS Code: 0781, 0783 1 4C-9022 Torsional Vibration Signal Conditioner
Model: 3600 Family Engines
2 4C-9024 Battery Group
Warranty: One Year
4C-9025 Charger
4C-9026 Battery
• Used with 4C-3030 Vibration Analyzer Group to measure torsional vibration 8D-8113 Fuse
at front and rear of crankshaft of 3600 Family Engines
3 4C-9023 Volts Adapter
• Permits torsional vibration audits of new installation, evaluation of engine
4 4C-6918 Photo Head Pickup
damper condition and diagnosis of torsional vibration problems
NEEG2455 Decal (Not Shown)
• Case has space for 4C-3030 Vibration Analyzer Group.
5 4C-6916 Magnetic Base Group
• Includes photo head pickup for monitoring RPM 8D-6894 Washer
• With proper gear and magnetic pickup, can measure torsional vibration 4C-6917 Adapter Assembly, Photo Head
of other engines and driven equipment 2S-6251 Machine Screw
6 4C-6919 Reflective Tape
4C-9022 Torsional Vibration Signal Conditioner 7 6V-2198 Cable Assembly (photo head ext.)
Weight 15.5 oz. 8 4C-6921 Adapter Cable Assembly (photo head to analyzer)
Dimensions 1.6 x 4.4 x 8.0 in. 9 4C-9028 Adapter Cable Assembly (sure seal-BNC)
Input ±30 MV to ±100 V magnetic pickup 10 5N-9292 Magnetic Pickup
Torsional amplitude range 0.1-10° 11 4C-3023 Cable Assembly (4 ft. BNC-BNC)
Power requirement 12 VDC (4C-9024 battery gp. included) 12 4C-3036 Cable Assembly (10 ft. BNC-BNC)
Temperature 32-140°F 13 NEHS0562 Tool Operating Manual
14 4C-9027 Cable Assembly (Power)
7T-0037 Fuse (Not Shown)
15 9U-5091 Torsional Vibration Software Diskettes
NETG5006 Decal (5.25 in.)
NETG5007 Decal (3.50 in.)
Not shown 9U-5090 Foam Group
Not shown 4C-9658 Case
Not shown NEEG2471 Decal
Not shown NEEG2503 Decal

Reference
NEHS0562 Tool Operating Manual, 4C-9021 Torsional Vibration Measurement Group
NEHS0558 Special Instruction, 4C-9024 Battery Group
Home Dealer Service Tools 2004 1-93
ID: C27067T1
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Accessories for 4C-3030 Vibration Analyzer Group

SMCS Code: 0781, 0783
Model: All Models
Warranty: One Year

4C-3032 Accelerometer 4C-9023 Volts Adapter

• Useful for higher frequency measurements where acceleration units are needed • Used with 4C-3031 Vibration Analyzer to perform frequency analysis of any
• Response is flat between 6 and 6000 Hz (±5%, 3-10000 Hz). voltage signal (±10 Volts)
• Used to calibrate 4C-3031 Analyzer (signal generator required for calibration)
Model Wilcoxon Research Model 762S
9U-5616 Adapter Cable
Weight 80 grams
• Permits charging spare
Dimensions 43.2 x 21.6 dia. (1.7 x .85 in.)
4C-6729 Battery Pack
Sensitivity 10 mV/G outside of 4C-3031 Analyzer
Frequency response ±5% 3.0-10000 Hz, ±10% 2.0-12000 Hz, ±3 dB 1.0-15000 Hz
Temperature range -50 - 120°C
Attachment 1/4-28 thread

9U-6955 Adapter, Charger to Analyzer

• Used with 4C-3030 Vibration Analyzer Group to prevent damage to 4C-3031
Analyzer batteries caused by overcharging
• Connects standard 4C-3033, 9U-5606 and 9U-5605 Battery Chargers and
4C-3031 Vibration Analyzer ID: C54531T1
9U-5836 Adapter Cable
9U-5606 Battery Charger • Permits connecting
• Same as 9U-5605 except 4C-3031 Analyzer to battery
it is for 220-240 VAC charger while using speed pickup
• Has U.S. 110-120 VAC
household-type plug

ID: C54532T1

ID: C54530T1
163-0097 Spare Battery
SMCS Code: 0785

• For discontinued 163-0096 Process Calibrator

210-5530 S·O·S Quick Disconnect Coupler Assembly

SMCS Code: 5050-036
Model: All
Warranty: One Year

• Used only with 183-7264 and 183-8652 Dual Purpose S·O·S Sampling Valves
• Used to quickly take samples for testing
• 210-5530 valve is specifically designed for use with portable particle analyzers
• Easily snaps onto S·O·S sampling valves for continuous oil flow sampling

NOTICE
Using discontinued 170-8505 Quick Disconnect Coupler will cause damage
to 183-7264 and 183-8652 S·O·S Sampling Valves. Only use new 210-5530
ID: C80543T1
Quick Disconnect Coupler on these valves. Using the 210-5530 with the Operating pressure 41397 kPa (6000 PSI)
following valves will cause leakage: 8C-3446, 8C-3345, and 7X-3387.
Burst pressure 165517 kPa (24000 PSI)
Maximum operating temperature 104°C (220°F)
Seal material nitrile/buna

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243-3133 S·O·S Coupler Assembly

SMCS Code: 5050-036
Model: All
Warranty: One Year

• Used to quickly take oil samples for testing (easily connects to S·O·S sampling valve for continuous oil flow)
• Used with 7X-3387, 8C-3445, and 8C-3346 S·O·S Sampling Valves
• Cannot be used on 183-7264 and 183-8652 Dual-purpose Valves because valves can be damaged, resulting in fluid leakage
• Designed specifically for portable particle analyzers
• Black oxide finish

Operating pressure 3500 kPa (500 PSI)

Burst pressure 1400 kPa (2000 PSI)
Maximum operating temperature 34 to 107°C (93 to 225°F)
Seal material buna-N
ID: D00656T1

170-8500 S40 Particle Analyzer Group

SMCS Code: 0784, 5050-082
Warranty: Manufacturer's

Compliant
• Used to analyze particle contamination on pressurized and non-pressurized hydraulic systems
• Portable self-contained system uses red laser sensor technology to count and size particles in fluids
(same sensor technology as particle analyzers used in S·O·S lab and other Caterpillar factory applications)
• Performs fluid analysis in 90 seconds
• Internal battery pack capable of performing 60 tests per charge
• Self-contained digital display and printer shows test results
• Equipped with keypad and graphical, back-lit LCD (Liquid Crystal Display) with resistive touch screen

Operating voltages Service Parts

Internal battery 100-240 VAC 50/60 Hz Part No. Description
External battery 12-24 VDC
184-7679 Paper Roll
Weight 9 kg (20 lbs)
131-5047 Power Cable
Measurements 300 x 140 x 300 mm
(11.8 x 5.5 x 11.8 in) 6V-4144 Coupler Assembly
Ambient temperature 5 to 40°C (40 to 104°F) 9U-6794 Adapter ID: D00379T1

Relative humidity maximum 70% 170-8506 Hose Assembly Repair Information

Size range 4-30 mm 188-0639 Hose Assembly The unit is warranted by the manufacturer for 1 year from date of receipt. If the unit
(certified ISO-11171) needs servicing, contact one of the following manufacturer's repair facilities:
Maximum viscosity 300 cSt C & J International Inc. Sintech Scientific (SEA) Pet Ltd. PAMAS GmbH
6721 E. 106th St. No. 196 Pandan Loop # 02-18 Dieselstrabe 10
Tulsa, OK 74133, USA Pantech Industrial Complex D-71277 Rutesheim
Singapore 128384 Postfach 162
Tel: 0 01 91 82 99 40 19
Germany
Fax: 0 01 91 82 99 74 10 Tel: 0 06 57 79 00 07
Fax: 0 06 58 72 23 92 Tel: + 49 7152 9 96 30
Fax: + 49 7152 5 48 62
Reference
NEHS0799 Tool Operating Manual

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243-3130 Contamination Monitor Group

SMCS Code: 0784, 5050-82
Warranty: One Year

Compliant
• Used for on-line monitoring of ISO cleanliness of hydraulic fluid or lubrication oil in systems with
a maximum pressure of 689 kPa (100 PSI)
• Used with 6V-4144 Coupler Assembly, 210-5530 S·O·S Coupler Assembly, and/or 243-3133 S·O·S Coupler Assembly
• Provides limited capability (ISO code only) but offers less expensive alternative to particle analyzers
• Applications include using monitor with filter carts or as a quick check of a S·O·S bottle samples
• Monitor will suction oil from a zero pressure system or bottled test sample
• User configurations can be changed with included software and computer cable
• Group includes: monitor assembly, DC battery supply cable, AC adapter power supply, communication
cable, software disk, manual, and carrying case
ID: D00753T1
Maximum pressure 689 kPa (100 PSI) Service Parts Repair Information
Display 3-digit ISO cleanliness class for quick check Part No. Description The unit is warranted by the manufacturer for
measured liquid (ie 18/15, 16/13, etc) 243-3131 Battery Supply Power Cable 1 year from date of receipt. If the unit needs
Monitoring 3 channel with integrated piston pump for with Alligator Clips servicing, contact the manufacturer's repair facility:
use on low or no pressure systems 243-3132 AC Adapter Power Supply PAMAS-USA
Power requires 12 to 30 VDC 243-3144 RS232 Communications Cable 6721 E. 106th St.
AC adapter input: 110 to 250 VAC, 50 to 60 Hz, 1.9 amp, Tulsa, OK 74133, USA
188-0639 Low-Pressure Hose Assembly
output: 24 VDC output, 80W
Phone: 918-299-4019
Communications requires DB9 connector Fax: 918-299-7410
Calibration ISO-11171
Overall size 299 x 203 x 172 mm (11.75 x 8.0 x 6.75 in)

Fitting Groups
SMCS Code: 0783, 0784
Warranty: One Year
220-8602

220-8607 Fitting Group

• Used to connect a particle analyzer to a low 220-8607 Fitting Group
pressure source, quick disconnect fitting, or Part No. Description
210-5530 S·O·S quick disconnect fitting 220-8602 Tube Fitting
• Used with 6 mm plastic tubing 220-8604 Brass Tube Insert
• 1/4 inch NPT threaded end
• Comes with 220-8604 Brass Tube Insert for plastic tubing
220-8604

ID: D00195T1
220-8608 Fitting Group
• Replaces high pressure input/low pressure output fittings 220-8608 Fitting Group
on 170-8500 Particle Analyzer with low pressure fittings Part No. Description
220-8603
• Used with 6 mm plastic tubing 220-8603 Tube Fitting
• Used for pressures between 0 and 689 kPa (0 and 100 PSI) 220-8604 Brass Tube Insert
• Eliminates flow restriction for SAE50 and SAE60 high viscosity
fluids during low pressure sampling
• Connects low pressure tubing to 170-8500 Particle Analyzer
for direct fluid flow into a catch can or bottle
• 1/4 inch BSPP threaded end
• Comes with 220-8604 Brass Tube Insert for plastic tubing
220-8604

ID: D00189T1

Service Kits
Item Part No. Description Qty
1 220-8609 Tube Insert Kit 10
2 220-8610 Tube Nut Kit 10
3 220-8611 Tube Ring Kit 10
1 2
3
ID: D00183T1

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202-2301 Portable Contamination Instructional Kit

• Used to estimate amount and type of solid contamination in hydraulic fluid or lubrication oil
(cannot determine exact particle counts)
• Conduct on-the-spot visual field evaluations of system fluid contamination
• Can be used by trained technicians to compare actual patches (25 ml fluid volume) to examples
shown in NEHS0729 to generally classify amount and type of contamination in a fluid sample

Reference
NEHS0729 Portable Contamination Instructional Kit Item Part No. Description
(The examples shown in this brochure are typical of 1 202-2267 Dish Kit
the type of contamination found using the portable 2 — 500 ml/16 oz LDPE Wash
contamination instructional kit. The examples are Bottle with 28 mm Cap
shown for reference only. Instructions on obtaining,
3 6V-9449 Carrying Case 1
preparing and viewing samples are also provided in
this brochure.) 4 202-2266 Funnel
5 1U-5718 Vacuum Pump
6 4C-6605 Tweezers
7 231-9405 Patch Group
8 169-7372 Sample Bottle (4)
9 — Grease Pencil
10 — Spray Stem for Bottle
11 1U-9533 AA Batteries for Light (2)
12 — Microscope
13 — Penlight 2 ID: D00869T1

Not shown 1U-5719 Vacuum Pump Seal Kit

1 Replacement case without foam
2 Included with microscope

8C-8456 Sealed Cap

Warranty: Manufacturer’s

• Used to seal the valved and non-valved nipples listed below. The nipples are used on machines, tool groups, and dealer shop equipment.
• A heavy-duty, pressure-tight cap that provides both positive sealing and added protection for the nipples

Adaptable to these Pressure Diagnostic Quick Disconnect Nipples

Dust Cap Ref.
Part No. Description Color
6V-3965 Nipple, 9/16 inch-18 thd. SAE external (for #6 Port) Buna-N® Seal zinc chromate
6V-3966 Nipple, 1/4 inch-NPTF external thd. Buna-N® Seal zinc chromate
8C-8456
Sealed Cap
6V-3989 Nipple, 1/4 inch-NPTF internal thd. non-valved zinc chromate
6V-4142 Nipple, 1/8 inch-NPTF internal thd. non-valved zinc chromate
6V-4433 Nipple, 9/16 inch-18 thd. external (for #6 Port) Viton Seal green chromate
6V-7691 Nipple, 1/4 inch-NPTF external thd. Ethylene Propylene Seal red chromate
8T-3613 Nipple, 1/8 inch-NPTF external thd. Buna-N® Seal zinc chromate
8T-3614 Nipple, 1/8 inch-NPTF external thd. Ethylene Propylene Seal red chromate

Mating Valve Ref.

Operating pressure 42,000 kPa (6100 PSI)
ID: C26876T1
Minimum burst pressure 168,000 kPa (24,000 PSI)
Operating temperature -34° - 107°C (-29° - 225°F)
Seal material High Temp. (Buna-N®)

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9U-5155 O-Ring Measuring Cone Cross Section Diameter or Width

Warranty: Manufacturer’s Dash Series -0 1.78 mm (0.070 in)
Dash Series -1 2.62 mm (0.103 in)
Find the correct O-ring replacement faster and easier. Dash Series -2 3.53 mm (0.139 in)
• An O-Ring Measuring Cone designed to measure SAE industry standard O-ring Dash Series -3 5.33 mm (0.210 in)
dimensions (cross section and dash size). These dimensions are published by the
Dash Series -4 6.99 mm (0.275 in)
Society of Automotive Engineers (SAE).
• 457.2 mm (18 in) tall, cone shaped, made of high-impact, yellow plastic
• Round base with five industry standard O-ring cross section diameters (widths) The second two digits of the dash size give an indication of the size of
cut into the edge the O-ring’s inside diameter, but do not give the exact dimensions. As
the inside diameter of the O-ring becomes larger, so do these two digits.
• Cone has 65 steps indicating varying inside diameters.
To determine the cross section diameter (width) of an O-ring:
The dash size consists of a three-digit number in Insert the O-ring into the slots located around the base of the cone.
which the first digit indicates the dash series. These The O-ring will fit snugly into one of the five slots, and its dash series
SAE industry standard O-ring dash series are: -0, -1, can be identified by looking at the first digit of the numbers imprinted
-2, -3 and -4. Every O-ring in a dash series has on the cone directly above the slot in which the O-ring fits.
the same cross section diameter (width).

ID: C54426T1

ID: C54425T1
ID: C54427T1 ID: C54428T1
Drop the O-ring over the peak of the cone, Determine the dash size by: Determine the Cat O-ring part number by:
ensuring that it sits level on one of the cone’s Reading the dash size column located above the slot identifying the Refer to the Special Instruction NEHS0571
steps. The O-ring should not overlap any part O-ring’s cross section dia. or width. The number imprinted on the Cross-Reference List. This list will identify the
of the step’s edge; a snug fit is required. face of the step on which the O-ring rests identifies the three-digit proper Caterpillar O-ring part number.
dash size (you may have to move the O-ring to read the number).

Fluid Sampling Supplies

We offer a complete assortment of fluid extraction tools to service pressurized vehicle compartments such as engine, transmission, and hydraulic systems, as well as
non-pressurized vehicle compartments such as final drives, differential, transfer case, and axle housings. Get extra protection and maximum performance by using Cat fluids,
filters, and regular oil analysis through scheduled oil sampling (S·O·S).

Fluid Sampling Extraction Tools for Pressurized Compartments

Warranty: Manufacturer’s

• Valve locations provide oil sample confidence and continuity — Comparative data of pressurized oil samples is more reliable because the sample is taken from a
continuous flow of oil at a known location.
• A probe is provided that allows the valve to be quickly flushed prior to taking the oil sample.
• The sample bottle group is packaged, and sealed in a plastic bag to insure cleanliness.
• Pressurized oil sampling is a fast, economical and clean method of obtaining oil samples from pressurized systems.
• Better represents oil condition because the oil is continually mixed and circulated
• 10 to 20 times faster than sampling oil from non-pressurized systems
• Mailing container is available so the oil sample can be conveniently mailed to the testing laboratory.

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8T-9208 Probe Assembly (Package Qty. — 1)

The 8T-9208 Probe Assembly can be attached to a 6.35 mm (1/4 in) I.D. rubber hose
(6K-0713 Hose — 228.6 mm (9 in) long or any desired length cut from bulk 5P-6442
Hose or equivalent 100R6 type high temperature — low pressure hose). The
8T-9208 Probe and hose connected to a locally obtained waste container provide a
method to purge or flush the 8C-3446, 8C-3345, or 7X-3387 sample valves prior to
obtaining the desired oil sample using either the 169-8373 Bottle Group or
177-9343 Probe and Cap Group with the desired bottle. Approximately 14.8 cm3 to
29.6 cm3 (1/2 to 1 ounce) of expelled fluid purges the valves.
Pressurized systems on many Caterpillar products are factory equipped with
sampling valves to quickly extract oil samples with the above tools. Special
Instruction SEHS9043 details retrofitting some earlier models with oil sampling
valves, as well as pointing out the respective valve locations on models currently
factory equipped with the oil sample valves
ID: C80305T1
Item Part No. Description The following valves, fittings and adapters are required or are commonly used for
1 169-8373 Bottle Group, 300 per box retrofitting the sampling valves to pressurized systems:
2 162-8873 Probe, Holder
3 177-9343 Cap and Probe Group, 500 per box Oil Sampling Valves and O-Ring Seals
4 4C-4600 Mailer Container — reusable Part No. Description
Tube — 30.5 m rolls (100 ft)
8C-3446 Oil Sampling Valve (7/16 inch-20 ext. thread)
5 1U-8757 6.35 mm O.D. x 30.5 m rolls
(1/4 in x 100 ft) (5 rolls per box) 3J-7354 O-Ring Seal for 8C-3446

6 4C-4056 7.9 mm O.D. x 30.5 m rolls (5/16 in x 100 ft) 8C-3345 Oil Dampling Valve (Mid X1 ext. thread)
(5 rolls per box) (not pictured) 8T-7876 O-Ring Seal Form 8C-3345
7 169-7373 Clear Bottle, 71g (2 1/2oz), 200 per box 7X-3387 Oil Sampling Valve (1/4 inch-18 NPTF ext. thread)
8 169-7372 Clear Bottle, 114g (4 oz), 200 per box Protective Dust Caps for Oil Sampling Valves
9 1U-5718 Vacuum Pump (These are rubber caps with embossed symbols to indicate
1U-5719 Seal Kit for 1U-5718 Pump (not pictured) system being sampled.)
10 8T-9208 Probe, purging 8C-3445 Dust Cap (Engine)
11 1U-7648 Tube Cutter 8C-3447 Dust Cap (Transmission)
1U-8589 Replacement Blades (not pictured) 8C-3451 Dust Cap (Hydraulic)
12 8C-8456 Sealed Cap 6V-0852 Dust Cap (Blank)
13 8C-3446 Oil Sampling Valve (7/16 inch-20 — ext. thread) 8C-8456 Sealed Cap
3J-7354 O-Ring Seal for 8C-3446 (not pictured)
14 7X-3387 Oil Sampling Valve (1/4 inch-18 NPTF— ext. thread)
The 8C-8456 Sealed Cap can be applied to the valves with the valve dust cap
15 8C-3345 Oil Sampling Valve (M10 x 1 — ext thread)
8T-7876 O-Ring Seal for 8C-3345 (not pictured) retention ring left in place. This cap enables the user to quickly seal a leaking valve
and prevents the need to immediately deadline (or stop) the machine or
16 8C-3445 Dust Cap (Engine)
compartment. The leaking valve can then be repaired (flushed) or replaced during
8C-3447 Dust Cap (Transmission) (not pictured)
8C-3451 Dust Cap (not pictured) the scheduled maintenance period.
6V-0852 Dust Cap (Blank) (not pictured) Some retrofit applications of the various valves may require the 8C-8456 Sealed
Not shown Tube, 2.1 m (7 ft) pieces Cap to provide maximum protection for both sealing and environmental
Not shown 4C-4055 6.35 mm O.D. x 2.1 m (1/4 in x 7 ft), 250 pieces per box contamination, such a brake and hydraulic system exposed to severe elements. This
Not shown 4C-4057 7.9 mm O.D. X 2.1 m (5/16 in x 7 ft), 240 pieces per box
cap serves ONLY as a temporary solution to a leaking sampling valve.
Not shown 4C-3602 Frosted Bottle, 57g (2 oz), 700 per box
Miscellaneous fittings and adapters commonly used
169-8373 Bottle Group (Package Qty. — 300) for oil sampling valve retrofit installations
This bottle group is sealed in a plastic bag with sampling instructions included. Part No. Description
The bottle group is ready to use when it is removed from the bag after the valve 3B-7722 Reducer 3/8 inch-18 NPTF to 1/4 inch-18 NPTF
has been purged and the sample is ready to be taken. The bottle included in this 8C-6427 Adapter 1/4 inch-18 NPTF external to 7/16 inch-20 SAE internal
group (169-7372) has the capacity to provide a 114 g (4 oz) sample. The 169-7372
6V-7529 Adapter 1/8 inch-27 NPTF external to 7/16 inch-20 SAE internal
can also be ordered by itself, 200 per case.
7J-8611 Adapter 90° street elbow 1/4 inch-18 NPTF
After the sample is obtained, the probe and tube are removed from the bottle cap
5P-9617 Adapter Reducer 9/16 inch-18 SAE external to 7/16 inch-20 SAE internal
and holder, and discarded, and the cap-cover seals the bottle. Labels for
identifying the sample (obtained locally) can then be attached to the bottle for 3J-1907 O-Ring Seal for 5P-9617 Adapter
identification purposes. The 4C-4600 mail tube is available to send the oil sample 3J-5390 Adapter Reducer 3/8 inch-18 NPTF external to 1/8 inch-27 NPTFinternal
to the laboratory. The laboratory also provides the mailing label. 9T-6865 Adapter Plug 5/8 inch-12 SAE external to 7/16 inch-20 SAE internal
177-9343 Probe and Cap Group (Package Qty. — 500) 2S-4078 O-Ring Seal for 9T-6865 Adapter Plug
The probe and cap group provides the same probe and cap that are used in the 5P-3501 Adapter 9/16 inch-18 SAE external to 1/4 inch-18 NPTF internal
169-8373 Bottle Group, however, without the bottle. This group is also sealed in a 3J-1907 O-Ring Seal for 5P-3501 Adapter
plastic bag with sampling instructions included. This group allows the dealer the 3L-6521 Adapter Tee 1/4 inch-18 NPT(two internal and one external)
flexibility to use other bottles such as the smaller 71 g (2 1/2oz) 169-7373 bottle
1P-9369 Adapter Tee 1/8 inch-27 NPT (two internal and one external)
assembly (which must be ordered separately). (The cap requires that the bottles
have a 38 M thread.) 6V-3966 Pressure Test Valve 1/4 inch-18 NPTF external
7M-8489 Adapter 90° elbow 9/16 inch-18 SAE external to 1/4 inch-18 internal
169-7373 Bottle Assembly (Package Qty. — 200)
5P-3413 Pipe Sealant 12/3 oz (85 g) tube.
This smaller bottle assembly (169-7373) can be used with the 177-9343 Probe and
Cap Group and reduces mailing expense by approximately one-half for dealers
whose oil sample labs can provide effective full service analysis with 71 g (2 1/2
oz) or less of oil. These bottles can be used for engine samples since particle count
is not used for engine samples. This bottle can also be used with the 1U-5718
Vacuum Pump used for non-pressurized oil sampling. Dealer Service Tools 2004 1-99
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Fluid Sampling Extraction Tools for Non-Pressurized Compartments

Warranty: Manufacturer’s

Fluid sampling extraction tools are used to obtain fluid samples from The following summarizes various sampling tools available through the Caterpillar
non-pressurized vehicle compartments such as final drives, differential Parts Distribution System:
compartments, transfer cases, axle housings, etc.
Part No. Description
The 1U-5718 Vacuum Pump is capable of pulling 25 inch (7.62 mm) Mercury
4C-4056 Tube, 7.9 mm (5/16 inch) O.D. by 30.5 m (100 ft) lengths (5 rolls per box)
(vacuum). The pump is compact and accepts the 169-7372, 114 g (4 oz), and
169-7373 Bottle Assembly, 71 g (2 1/2 oz), bottles, or any 38 M threaded plastic 4C-4057 Tube, 7.9 mm (5/16 inch) O.D. by 2.1 m (7 ft) length (250 per box)
bottle, and 6.35 mm (1/4 inch) O.D. and/or 7.9 mm (5/16 inch) O.D. plastic tube. 4C-4055 Tube, 6.35 mm (1/4 inch) O.D. by 2.1 m (7 ft) length (250 per box)
The 1U-5719 Kit provides replacement seals for the vacuum pump. 177-9343 Probe and Cap Group
8C-3345 Oil Sampling Valve
The 169-7372 Bottle has 4 oz (114 g) capacity. The bottle is marked showing
fluid fill range at 3/4 capacity. The fill range provides a reminder to not overfill 8C-3446 Oil Sampling Valve
the bottle. Partially filling the bottle satisfies both mailing and lab requirements. 8C-3445 Dust Cap (Engine)
Full bottles expand because of temperature changes that can possibly rupture 8C-3447 Dust Cap (Transmission)
within the mailing container. The partially filled bottle also allows the lab to 8C-3451 Dust Cap (Hydraulic)
shake the fluid sample prior to extracting fluid for testing. Labels identifying the
8C-8456 Sealed Cap
fluid are obtained locally. The label is processed locally and attached to the
sample bottle. 3J-7354 O-Ring Seal for 8C-3446 Valve
8T-7876 O-Ring Seal for 8C-3345 Valve
The 169-7373 Bottle is the same as the 169-7372 bottle except the capacity is 71
g (2 1/2 oz) rather than 114 g (4 oz). Both are clear high performance plastic 169-8373 Bottle Group
rated at 91°C (195°F). 8T-9208 Purging Probe, brass
The 1U-8757 Tubing consists of five 30.5 m (100 ft) rolls of 6.35 mm (1/4 inch) 1U-5718 Vacuum Pump
O.D. plastic tubing. Random lengths of tubing can be easily dispensed from the 1U-5719 Seal Kit for 1U-5718 Vacuum Pump
tubing package. The tubing connects the vacuum pump to the fluid in the 169-7372 Bottle, 114 g (4 oz)
compartment. The tubing is discarded after each sample extracted.
169-7373 Bottle, 71 g (2 1/2 oz)
The 4C-4056 Tubing consists of five 30.5 m (100 ft) rolls of 7.9 mm (5/16 inch) 4C-4600 Mail Tube
O.D. plastic tubing. Again, random lengths of tubing can be easily dispensed
1U-7648 Tube Cutter
from the tubing package. This tubing permits extraction of heavier oils when
using the vacuum pump. 1U-8589 Replacement Blades
1U-8757 Tube, 6.35 mm (1/4 inch) O.D. by 30.5 m (100 ft) length (5 rolls per box)
Both tubing sizes are also available in pre-cut 2.1 m (7 ft) lengths that are
packaged 250 pieces per box. This eliminates cutting the tube for each sample. 6V-0852 Dust Cap (Blank)
7X-3387 Oil Sampling Valve
The 4C-4055 Tubing contains 250 pieces of 6.35 mm (1/4 inch) O.D. tubing each
2.1 m (7 ft) long.
The 1U-7648 Tube cutter is a convenient tool that easily cuts the desirable
length of either 6.35 mm (1/4 inch) or 7.9 mm (5/16 inch) plastic tubing. The
cutter can cut the tubing at 90° or at a bias. The 1U-8589 blades are available as
replacement blades for the cutter.

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