g3500_tools list.pdf

8/18/2019 G3500_tools list.pdf

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PARTNUMBER

PARTNAME

G3500 Gas Engine Tool List

QTY

Caterpillar Service Technology Group

DEALERCAT

FUNCTIONTOOL

March 2006

BASIC TOOL GROUPS4C-3502 Engine Repair Indicator Kit 1Used to check general engine condition Recommended

CYLINDER BLOCK & LINER

8T-0455 Tool Gp. - Liner Projection 1Measures cylinder liner projection and counterbore depth Essential

2P-8260 Installer Gp. - Cylinder Liner 1Pushes cylinder liner into cylinder block Essential

FT1543 Plate 1Used to install cylinder liners into cylinder block Essential

1U-6319 Socket 1Used with cylinder pack puller to allow use of impact gun Essential

5P-8665 Puller - Cylinder Liner 1Removes cylinder liner from cylinder block Essential

8T-2686 Puller - Cylinder Liner 1Used to remove & install cylinder pack (rubber plug type, 170 mm bore) Essential

FT1970 Bridge 1Used to remove cylinder liner Essential

PISTON, RINGS & CONNECTING ROD

1U-7616 Compressor Gp. - Ring 1Compresses piston rings for installation into cylinder bore Essential

6V-4020 Expander Gp. - Ring 1Removes and installs piston rings Essential

5P2050 Checking Fixture - Con Rod 1Used to measure pin bore misalignment and rod distortion Recommended

4C-8725 Adapter 1Used to remove and install connecting rod pin bearing Essential

4C-8726 Spacer 1Used to remove and install connecting rod pin bearing Essential

4C-8727 Adapter 1Used to remove and install connecting rod pin bearing Essential

5P-8639 Press Gp. 1Used to remove and install connecting rod pin bearings Essential

5P-8649 Adapter - Pin Bushing 1Used to remove and install connecting rod pin bearings Essential

6V-3042 Adapter - Push 1Used to remove and install connecting rod pin bearing Essential

6V-3043 Spacer 1Used to remove and install connecting rod pin bearings Essential

136-1452 Pliers As. - Internal 1Removes and installs piston retaining ring Essential

4C-4519 Gauge As. 1Checks top and intermediate ring grooves to determine piston reusability Essential

Pa e 1 of 6Caterpillar: Confidential GreenLast Modified: 02/17/2006


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G3500 Gas Engine - Tool List

PART

NUMBER

PART

NAME QTY DEALER

CAT

FUNCTION

TOOL

CRANKSHAFT MAIN BEARINGS & FLYWHEEL

155-8795 Gauge - Crankshaft Distortion 1Checks crankshaft bearing alignment or shaft deflection Essential

238-9586 Engine Turning Tool 1Used to manually rotate the engine Essential

5P-7409 Distorter 1Used to remove crankshaft seal and wear sleeves Essential

6V-3143 Distorter Adapter 1Used to remove crankshaft seal and wear sleeve Essential

6V-4001 Forcing Ring 1Used to install crankshaft seal and wear sleeve Essential

6V-4002 Forcing Bracket 2Used to install crankshaft seal and wear sleeve Essential

6V-4003 Locator 1Used to install crankshaft seal and wear sleeve Essential

6V-4977 Installer 1Installs crankshaft seal and wear sleeve Essential

8T-3099 Installer 1Installs crankshaft seals and wear sleeves Essential

9S-8858 Nut As. 1Used to install crankshaft seal and wear sleeve Essential

1P-4000 Tool Gp - Line Boring 1Used to bore semi-finished bearing caps Recommended

2P-5517 Bearing R&I Tool 1Used to remove and install main bearing upper halves Essential

9U-5023 Wrench - Main Bearing 1Used to remove and install crankshaft main bearing Essential

203-6597 Repair Kit - Thread 1Used to repair main bearing cap bolt holes Essential

203-6598 Repair Kit - Thread 1Used to repair main bearing cap bolt holes Essential

CAMSHAFT & TIMING GEARS

8B-7548 Push - Puller 1Removes front crankshaft pulley and camshaft drive gear Essential

8T-3167 Guide As. 1Used to install camshaft Essential

8T-3168 Pilot As. 1Used to install camshaft Essential

8T-3169 Crank As. 1Used to install camshaft Essential

6V-4077 Tool Gp. - Camshaft Bearing 1Removes and installs camshaft bearings Essential

8S-2241 I & R Gp. - Camshaft Bearing 1Removes and installs camshaft bearings Essential



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PART

NUMBER

PART

NAME QTY DEALER

CAT

FUNCTION

TOOL

CYLINDER HEAD VALVES & CAM FOLLOWERS

124-0662 Socket 1Removes and installs cylinder head bolts (3/4"-12 point socket) Recommended

155-1536 Tool Kit - Valve Recession 1Measures valve seat wear and valve projection Essential

166-7441 Tool Gp. - Valve Seat Extractor 1Used to remove valve seat inserts Essential

194-2062 Tool Gp. 1Used to set valve lash Essential

4C-9496 Tester - Valve Spring 1Tests coil springs for print conformance (545 kg max. test force) Recommended

4C-9576 Compressor - Valve Spring 1Compresses all four valve springs on or off engine Essential

5P-3536 Gauge Gp - Valve Guide 1Measures valve guides for size, taper, and roundness Recommended

6V-0087 Gauge - Valve Stem 1Measures valve stem wear Essential

6V-2032 Adapter 2Used to mount brush on bench or pedestal grinder Recommended

6V-4009 Driver - Dowel 1Used to install valve train bridge dowels to correct height Essential

9U-7511 Spark Plug Seat Cleaner 1Cleans spark plug hole (18mm) threads and gasket seat Recommended

147-2056 Indicator - Dial (inch) 1Used to set engine valve lash Recommended

147-2059 Wrench - Torque 1Used to torque rocker arm nuts (preset to 70 N-m) Recommended

147-2060 Wrench - Socket 1Used to torque rocker arm nuts Recommended

147-5482 Gauge Gp - Valve Lash 1Set engine valve lash using factory setting methods Recommended

147-5537 Indicator - Dial (metric) 1Used to set engine valve lash Recommended

5P-0942 Extractor 1Used to remove bridge dowels from cylinder head 11,13 mm (.438 inch) Essential

5P-0944 Puller Gp. - Dowel 1Used to pull 0.375" diameter dowels Essential

5S-1330 Compressor - Valve Spring 1Used to remove and install valve springs (off engine) Essential

5P-1729 Installer Bushing 1Used to install valve guides Essential

7M-3975 Driver 1Removes and installs valve guides Essential

FUEL SYSTEM REPAIR & ADJUST

157-5225 Cap As. 1 Adjust gas line pressure on 7E-3407 Gas Regulators Recommended

1U-8869 Digital Dial Indicator 1Used for fuel system and governor adjustments Recommended

8T-5160 Tool Gp. - Gas Regulator Setting 1 Adjusts gas line p ressure regula tor Recommended



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PART

NUMBER

PART

NAME QTY DEALER

CAT

FUNCTION

TOOL

AIR SYSTEM & MANIFOLDS

152-2067 Gauge - Differential Pressure 1Monitors air pressure drop across aftercooler core Recommended

194-2061 Wrench As. 1Used to set valve lash and adjust wastegate bypass valve Recommended

5P-6518 Fixture Gp - Parts Reusability 1Measures turbo shaft straightness and engine valve lip thickness Recommended

9S-6343 Fixture As. 1Used for disassembly and assembly of turbo rotating assembly Recommended

9S-6363 Fixture Gp. - Turbocharger 1Used for disasembly and assembly of turbocharger Recommended

LUBRICATION SYSTEM

185-3630 Strap Wrench - Filter 1Used to remove and install spin-on oil & fuel filters Essential

COOLING SYSTEM

4C-9046 Strainer - Temporary (5 inch) 1Filters particles from coolant lines Recommended

ELECTRICAL & IGNITION SYSTEM

132-8263 Wrench - Spanner 1Installs and removes 127-8893 Terminal Assembly Recommended

216-1685 Spark Plug Socket 1Used to remove and install 199-9012 spark p lug w/13 /16" hex ( th in wall design) Essential

4C-4601 Socket - Spark Plug 1Used to remove and install 7/8" hex, 194-8518 spark plug (thin wall design) Essential

9U-7516 Spark Plug Gauge 1Checks spark plug gap Essential



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PART

NUMBER

PART

NAME QTY DEALER

CAT

FUNCTION

TOOL

DIAGNOSTIC TOOLS

193-5859 Tool Kit - Cylinder Pressure 1Measures cylinder compression pressure Recommended

8T-5096 Dial Indicator Test Gp. 1Used to take many different linear service measurements Essential

1U-6602 Photo-Tach Gp. 1Measures engine RPM Recommended

1U-8860 Pickup Gp. - Blowby 1Checks blowby volume on large engines Essential

7X-1400 Digital Diagnostic Tool Gp. 1Used for monitoring engine functions and diagnostic fault codes Essential

9U-6958 Module - Magneto Peak Detect 1Checks magneto performance during actual operating conditions Essential

9U-7400 Multitach II Gp. 1Measures engine RPM, frequency, and engine set point Recommended

156-1060 Analyzer Gp. - Emission 1Used to setup, service, and monitor natural gas engine emissions Recommended

146-4080 Multimeter Gp. - Digital (RS-232) 1Measures voltage, current, resistance, duty cycle, temp, & more Recommended

6V-9130 Temp Adapter Gp. 1Used to measure oil, coolant or air temperatures (-50°C to 900°C) Essential

164-3310 Infrared Thermometer 1Measures surface temperature without contact (battery powered) Recommended

4C-6500 Digital Thermometer Gp. 1Used to measure and record temperatures Recommended

8T-2844 Recorder Gp. 1Measures highest surface temperature of engine components Essential

146-1738 Borescope - Precision (12") 1Used to make visual inspection of internal surfaces Recommended

1U-5266 Light Source (110 VAC) 1Provide illumination for borescopes Recommended

1U-5470 Engine Pressure Gp. 1Checks pressures on turbocharged diesel and natural gas engines Essential

5P-7277 Tester - Voltage 1Used to make quick checks for presence of voltage Essential

8T-0500 Light - Continuity Testing 1Used to test for non-energized or open circuits Essential

177-2330 Digital Battery Analyzer 1Used to evaluate the condition of 6 & 12 volt batteries Recommended

4C-6600 Battery Voltmeter 1Measures battery voltage to determine state of charge Recommended

131-5051 DataView TechStation Gp. 1PC based diagnostic tool that measures and records engine parameters Recommended

134-5195 Cable As. - Adapter (40 pin) 1 Adapts 7X-1715 Cable Assembly to a 40-p in CD-keyed connector Recommended

163-5443 Harness - Detonation Sensor 1Used to measure condition of detonation sensor Recommended

8T-0450 Thread Identification Kit 1Used to determine thread sizes Recommended

6V-9060 Adapter Gp. - Spark Timing 1Checks dynamic timing on gas engines Recommended

6V-7898 Dial Bore Gauge - Metric 1Measures internal diameters (50 to 200 mm) & depths (13 to 300 mm) Recommended

9U-6695 Indicator - Spark Plug Firing 1Indicates spark plug firing Recommended



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PART

NUMBER

PART

NAME QTY DEALER

CAT

FUNCTION

TOOL

LIFTING POSITIONING & HOLDING TOOLS

8S-6691 Stand Group - Cylinder Head 2Supports cylinder head on work bench during repair process Recommended

4C-9832 Roll-Over Stand - Large Engine 1Used for disassembly and assembly of engine Recommended

HAND TOOLS1P-1861 Retaining Ring Pliers 1Used to remove and install retaining rings (No. 25) Essential

PUMPS, HYDRAULIC CYLINDERS & PULLERS

1P-0820 Hydraulic Puller Gp. 1Used to push or pull bearings, gears, shafts, or other press fit parts Essential

9U-6600 Hand Pump Gp. 1Manually operated hydraulic pump (10,000 psi) Essential

1P-2320 Combination Puller 1Combination 2 or 3 jaw puller (5 ton capacity) Recommended

MISC. TOOLS

176-7129 Tool As. - Terminal R&I 1Used to remove and install 169-4290 Terminal without removing extension Recommended

1P-0510 Driver Gp. - Bearing and Seal 1General purpose bearing and seal driver kit Essential

1P-0520 Driver Gp - Bearing and Seal 1Installs bearings, races, and seals Essential

5F-7465 Puller 1Used to remove gears, pulleys, and flanges Recommended

9S-9082 Turning Tool 1Used to manually rotate engine crankshaft Essential


g3500_tools list.pdf

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