3600 Family Tool List

Caterpillar Service Tools Division November 2003

PART PART TOOL CAT

NUMBER NAME FUNCTION QTY DEALER

BASIC TOOL GROUPS

4C-3502 Engine Repair Indicator Kit Used to check general engine condition 1 Recommended
9U-5105 Tool Gp. - Basic Tooling for D&A of components on diesel & gas engines 1 Required
9U-5106 Tool Gp. - Diesel Tooling for D&A of major components on diesel engines 1 Required
9U-7522 Head Repair Tool Gp. (3600) Used for general disassembly and assembly of cylinder head 1 Required

CYLINDER BLOCK & LINER

128-5113 Insert - Thread Repair Repairs damaged threads in cylinder head stud holes (1 5/8-12 thd) 1 Recommended
147-8860 Master Ring (diesel 280.025 mm) Used to calibrate dial bore gauge (280.025 I.D.) 1 Recommended
147-8862 Gauge - Dial Bore Measures cylinder liner inside diameter 1 Recommended
6V-7073 Puller Gp. - Liner Used to remove and install cylinder liners 1 Required
191-1135 Press As. - Cylinder Liner Used to install cylinder liner into engine block 2 Required

PISTON, RINGS & CONNECTING ROD

145-5190 Support Gp. - Piston Supports piston and connecting rod while servicing rod bearings 1 Recommended
1U-8692 Guide - Piston Pin Aligns piston pin during installation into piston and rod assembly 1 Recommended
4C-5719 Piston Ring Compressor Gp. Band-type piston ring compressor (280 mm diameter) 1 Required
8T-3033 Expander Gp. - Ring Used to remove and install piston rings 1 Required
4C-6357 Guide Gp. Aligns connecting rod during installation onto the crankshaft journal 2 Recommended
8T-3022 Guide Gp - Rod Aligns connecting rod during installation onto the crankshaft journal 2 Recommended
1U-9029 Gauge - Ring Groove (Oil Ring) Used to check piston ring groove wear 1 Required
1U-9030 Gauge - Ring Groove (3rd Ring) Used to check piston ring groove wear 1 Required
4C-3654 Gauge - Ring Groove (Top Ring) Used to check piston ring groove wear 1 Required
136-1452 Pliers As. - Internal Removes and installs piston retaining ring 1 Required
9U-5981 Retainer - Snap Ring Contains piston pin retainer during D&A of piston and connecting rod 1 Recommended

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Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

CRANKSHAFT, MAIN BEARINGS & FLYWHEEL

134-0932 Driver - Main Bearing Used to remove and install crankshaft main bearings 1 Required
155-8795 Gauge - Crankshaft Distortion Checks crankshaft bearing alignment or shaft deflection 1 Required
1U-9393 Pin - Damper Guide Aligns and supports single vibration damper during assembly 2 Required
4C-6506 Vibration Damper Repair Gp. Used to rebuild vibration dampers 1 Recommended
8T-0960 Tool Gp. - Handling Raises and lowers the main bearing cap and stud tensioners 1 Required
9U-5102 Cover As. - Main Brg Journal Protects crankshaft main bearing journal during engine overhaul 1 Recommended
121-7700 Block - Distorter Used to remove crankshaft seal wear sleeve 1 Required
121-7705 Stud Assembly Used to install crankshaft wear sleeve 4 Required
200-5958 Installer - Wear Sleeve Used to install crankshaft seal wear sleeve 1 Required
5P-7409 Distorter Used to remove crankshaft seal and wear sleeves 1 Required
1U-9392 Pin - Damper Guide Aligns and supports outer damper of dual vibration dampers 2 Recommended
4C-9426 Pin - Damper Guide Aligns and supports vibration damper during assembly & disassembly 2 Required
8T-0914 Pin - Flywheel Guide Aligns & supports flywheel / gear and damper during D&A 2 Required

CAMSHAFT & TIMING GEARS

4C-9451 Wrench - Idler Gear Used to remove & install and torque the rear idler gear bolts 1 Recommended
4C-9452 Wrench - Idler Gear Used to remove & install and torque the rear idler gear bolts 1 Recommended
8B-7548 Push - Puller Removes front crankshaft pulley and camshaft drive gear 1 Required
8T-0970 Tool Gp. - Camshaft Bearing Used to remove and install camshft bearings 1 Required
8T-3029 Support Gp. Supports camshaft segments during removal and installation 1 Required
9U-5932 Camshaft Torque Extension Removes and installs the camshaft segment flange bolts 1 Required

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Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

CYLINDER HEAD, VALVES & CAM FOLLOWERS

130-1449 Puller Gp. - Valve Seat Removes intake and exhaust valve seat inserts 1 Required
130-2534 Gauge - Bridge Dowel Checks straightness and projection of bridge guide dowel 1 Recommended
130-6993 Brush Cleans injector seating area in cylinder head sleeve 1 Required
147-2285 Diesel Valve Seat Gp. Measures valve seat angle after machining of seat 1 Recommended
148-2997 Tool Kit - Valve Recesssion Measures valve seat recesion 1 Required
151-8689 Seal - Template Identifies area of cylinder head that requires a smooth sealing surface 1 Recommended
1U-9570 Dowel Puller Gp. Used for pulling 5/8" and 3/4" dowels 1 Recommended
4C-6593 Valve Lash Tool - 3600 Checks and adjusts intake & exhaust valve lash clearance 1 Required
4C-6987 Socket Used to remove and install cylinder head nuts 1 Recommended
4C-8540 Driver - Dowel & Plug Used to install valve bridge dowels 1 Required
4C-8731 Rod-Pulling Used to remove valve bridge dowels 1 Required
4C-8769 Driver - Valve Seat Installs water-cooled valve seat inserts 1 Required
4C-9496 Tester - Valve Spring Tests coil springs for print conformance (545 kg max. test force) 1 Recommended
4C-9839 Retainer Gp. - Safety Safety retainer for pulling rod in case pulling rod accidentally breaks 1 Recommended
6V-2032 Adapter Used to mount brush on bench or pedestal grinder 2 Recommended
6V-2033 Brush Cleans and polishes engine valve stems 1 Recommended
8T-2660 Compressor Gp. Removes and installs valve springs & prevents valve rotator damage 1 Required
8T-2673 Sleeve - Stop Used to install valve guides 1 Required
8T-2674 Driver - Valve Seat Used to install valve seats 1 Required
8T-2676 Driver As. - Valve Guide Removes and installs valve guides 1 Required
8T-2679 Rod As. - Pulling Used to remove valve bridge dowels 1 Required
8T-2781 Pedestal Used to remove and install valve guides 1 Required
9U-6399 Gauge - Valve Guide Used to determine if new valve guide has correct inside diameter 1 Required
9U-6401 Gauge - Valve Guide Used to determine if used valve guide has correct inside diameter 1 Required
FT1741 Tester - Vacuum Checks for leaks on cylinder head between valve face and seat 1 Recommended

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Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

FUEL SYSTEM REPAIR & ADJUST

1U-8869 Digital Dial Indicator Used for fuel system and governor adjustments 1 Recommended
4C-6173 Tray As. - Fuel Drain Helps capture the fuel while draining the fuel filter housing 1 Recommended
4C-6583 Calibration Tool - Governor Holds governor shaft to fuel "on" position when synhronizing injectors 1 Required
4C-6594 Tool Gp. - Timing & Fuel Setting Tests and adjusts injector synchronization and fuel timing dimension 1 Required
8T-3268 Bolt Forcing screws to remove fuel unit injector 2 Required
5P-0328 Wrench-Crowfoot Used to remove & install 7/8" bolts holding fuel lines 1 Recommended
5P-0329 Wrench-Crowfoot Usee to remove and install 15/16" bolts holding fuel lines 1 Recommended
1U-8795 Arm - Governor Torque Holds governor to fuel "on" position while adjusting injectors 1 Required
1U-9361 Arm - Governor Torque Used to test and adjust Woodward 3161 governor 1 Required

AIR SYSTEM & MANIFOLDS

137-7024 Wash Gp - Turbocharger Removes deposits on diffuser and turbine blades 1 Recommended
148-9704 Installer Gp. - Seal Installs seals on high presure aftercoolers (HPAC) 1 Recommended
152-2067 Gauge - Differential Pressure Monitors air pressure drop across aftercooler core 1 Recommended
187-3703 Tool Gp. - NA297 (3600 Engine) Used to disassemble and assemble Naapier NA297 Turbochargers 1 Required
195-8104 Tool Kit - ABB Turbo (TPL61) Used to disassemble & assemble ABB TPL61 turbocharger 1 Required
8T-9209 Blocking Tool - Turbocharger Prevents rotation of turbo impeller for emergency engine operation 1 Required
9U-6249 Tool Gp. - Cylinder (3600 Turbo) Used to disassemble and assemble turbocharger 1 Required
9U-6250 Tool Gp - Pump (3600 Turbo) Used to disassemble and assemble turbocharger 1 Required
133-1531 Insert - Threaded Repairs stripped & damaged threads in turbo housing (M10x1.5 thd) 1 Recommended

LUBRICATION SYSTEM
132-8710 Oil Mist Detector Tool Kit Services oil mist detectors 1 Recommended
1U-9824 Tool Gp. - Oil Drain Helps capture oil while draining the oil filter housing 1 Recommended
8T-0890 Puller Gp. Removes rotor cover from centrfugal oil filter 1 Required
FT2398 Bar and Handle - Oil Pump Prevents center shaft from rotating during D & A of oil pump 1 Recommended

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Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

COOLING SYSTEM
4C-9047 Strainer - Temporary (6 inch) Filters particles from coolant lines 1 Recommended
8T-3034 Driver - Water Pump Seal Seats ceramic ring and rubber seat into water pump housing 1 Required

ELECTRICAL & IGNITION SYSTEM

9U-6461 Screwdriver - Phoenix Tightens Phoenix connectors to the correct torque 1 Required

Caterpillar: Confidential Green Page 5 of 8

Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

DIAGNOSTIC TOOLS
164-2192 Adapter Gp. - Probe Self Sealing Used with pressure gauge to check fluid-filled compartments 1 Required
237-5130 True RMS Multimeter/IR Thermometer Measures:AC/DC Volts,Amps,Frequency,Duty Cycle,Capacitance,Ohms,Type K Thermocoup Recommended
4C-6585 Indicator Gp. - Cyl. Pressure Measures cylinder pressure 1 Required
8T-5096 Dial Indicator Test Gp. Used to take many different linear service measurements 1 Required
171-4400 Communication Adapter II Gp. Allows PC to communicate with engine data link 1 Required
1U-6602 Photo-Tach Gp. Measures engine RPM 1 Recommended
1U-8860 Pickup Gp. - Blowby Checks blowby volume on large engines 1 Required
8T-1000 Electronic Position Indicator Gp. Measures dynamic and static rack position & other linear measurements 1 Required
9U-7400 Multitach II Gp. Measures engine RPM, frequency, and engine set point 1 Recommended
156-1070 Analyzer Gp. - Emission Used to set-up, service, & monitor natural gas & diesel engine emissions 1 Recommended
146-4080 Multimeter Gp. - Digital (RS-232) Measures voltage, current, resistance, duty cycle, temp, & more 1 Recommended
9U-7330 Multimeter - Fluke 87 Used to test and adjust electronic circuits 1 Recommended
163-0096 Process Calibrator Used to source and calibrate temperature and electrical signals 1 Required
6V-9130 Temp Adapter Gp. Used to measure oil, coolant or air temperatures (-50°C to 900°C) 1 Required
6V-7072 Test Lead Set Test Lead Kit for use with Digital Multimeters Recommended
7X-1710 Probe Gp. Used to measure voltages without disconnecting wiring harness 1 Required
164-3310 Infrared Thermometer Measures surface temperature without contact (battery powered) 1 Recommended
164-3320 Infrared Thermometer Measures surface temperature without contact (110 VAC or battery) 1 Recommended
166-9030 Infrared Thermometer Measures surface temperature without contact (220 VAC or battery) 1 Recommended
192-3750 Infrared Thermometer Measures surface temperature without contacting surface 1 Recommended
192-3755 Infrared Thermometer Measures surface temperatures without contacting surface 1 Recommended
213-4310 Infrared Thermometer Non-Contact Temperature Measurement Recommended
4C-6090 Multichannel Temp Selector Measures up to sixteen temperatures individually 1 Required
4C-6500 Digital Thermometer Gp. Used to measure and record temperatures 1 Recommended
8T-2844 Recorder Gp. Measures highest surface temperature of engine components 1 Required
146-1738 Borescope - Precision (12") Used to make visual inspection of internal surfaces 1 Recommended
8T-9290 Borescope - Battery Operated Used to make visual inspection of internal surfaces 1 Recommended
1U-5268 Borescope Used to make visual inspection of internal surfaces 1 Recommended

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Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER
9U-6940 Borescope - Right-angle View Used to inspect internal openings and passages 1 Recommended
186-0170 Flexible Shaft Borescope Used to make visual inspection of internal surfaces 1 Recommended
186-0180 Borescope - Rigid Tube Used to make visual inspection of internal surfaces 1 Recommended
1U-5266 Light Source (110 VAC) Provide illumination for borescopes 1 Recommended
190-8160 Light Source Provide illumination for borescopes Recommended
1U-5470 Engine Pressure Gp. Checks pressures on turbocharged diesel and natural gas engines 1 Required
5P-7277 Tester - Voltage Used to make quick checks for presence of voltage 1 Required
8T-0500 Light - Continuity Testing Used to test for non-energized or open circuits 1 Required
177-2330 Digital Battery Analyzer Used to evaluate the condition of 6 & 12 volt batteries 1 Recommended
4C-6600 Battery Voltmeter Measures battery voltage to determine state of charge 1 Recommended
1U-7297 Coolant and Battery Tester Checks coolant freezing point and battery charge condition (degrees F) 1 Required
1U-7298 Coolant and Battery Tester Checks coolant freezing point and battery charge condition (degrees C) 1 Recommended
131-5051 DataView TechStation Gp. PC based diagnostic tool that measures and records engine parameters 1 Recommended
168-7740 Fuel Flow Measurement System Measures diesel engine fuel burn rate on 3606, 3608, 3612, & 3616 1 Required
153-9630 Test Gp. - Sensor Used to test CAT ® PWM and analog sensors 1 Recommended
213-3274 Sensor - Pressure (100 psi) Pressure sensor for use with DataView 1 Recommended
213-3275 Sensor - Pressure (1000 psi) Pressure sensor for use with DataView 1 Recommended
213-3276 Sensor - Pressure (7500 psi) Pressure sensor for use with DataView 1 Recommended
134-5195 Cable As. - Adapter (40 pin) Adapts 7X-1715 Cable Assembly to a 40-pin CD-keyed connector 1 Recommended
8T-0450 Thread Identification Kit Used to determine thread sizes 1 Recommended

LIFTING, POSITIONING & HOLDING TOOLS

235-0632 Tool Gp. - Cylinder Installation Used to remove and install cylinder liner, cylinder pack or just piston. 1 Required
4C-9528 Gang Plate - Tensioners Fixture to hold cylinder head stud tensioners 1 Recommended
8T-3036 Bracket Gp. - Component Lift Eye bolts and link brackets for lifting various engine components 1 Recommended
1U-9352 Engine Stand - 1000 lb. Used for servicing small engines and large cylinder heads (1000 lb max.) 1 Recommended
126-6918 Bracket - Head Lifting Used to remove and install cylinder head 1 Recommended
126-6919 Bracket - Head Lifting Used to remove and install cylinder head 1 Recommended
126-6920 Rod - Handle Helps position head when using lifting bracket 1 Recommended

Caterpillar: Confidential Green Page 7 of 8

Last Modified: 10/24/2003
 3600 Family - Tool List
PART PART TOOL CAT
NUMBER NAME FUNCTION QTY DEALER

PUMPS, HYDRAULIC CYLINDERS & PULLERS

191-5320 Tool Gp - Stud Tensioning Used to hydraulically tension cylinder head studs and main bearing cap studs. 1 Recommended
1P-0820 Hydraulic Puller Gp. Used to push or pull bearings, gears, shafts, or other press fit parts 1 Required
207-5034 Tool Gp - Stud Tensioner Hydraulically tensions cylinder head studs and main bearing studs 1 Required
8T-3035 Lines Gp. Connects hydraulically operated tools to hydraulic pump 1 Required
3S-6224 Electric Hydraulic Pump (115V) Electric pump for hydraulically operated tools (10,000 psi) 1 Recommended
8T-0820 Gauge - Pressure Measures pressure on hydraulic pumps 1 Required
9U-6600 Hand Pump Gp. Manually operated hydraulic pump (10,000 psi) 1 Required
1P-2320 Combination Puller Combination 2 or 3 jaw puller (5 ton capacity) 1 Recommended

MISC. TOOLS & SUPPLIES

1P-0510 Driver Gp. - Bearing and Seal General purpose bearing and seal driver kit 1 Required
1P-0520 Driver Gp - Bearing and Seal Installs bearings, races, and seals 1 Required
1U-5429 Pliers - Snap Ring Removes snap rings from deep bores in engine components 1 Recommended
229-3639 Overhaul Protection Kit Plastic caps, covers and plugs protect engine when cylinder head is removed. 1 Recommended
4C-9818 Shank - Hex Used to rotate crankshaft (1/2" male square drive & 7/16" hex) 1 Recommended
4C-9819 Universal Joint Universal joint (1/2" male square drive & 1/2" female square drive) 1 Recommended

Caterpillar: Confidential Green Page 8 of 8

Last Modified: 10/24/2003