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Major Equipment
Hydraulic Cylinder Service 8-1 Gas Cutting/Welding Equipment 8-18

Chain Wrench 1U-7608 8-5 Check Valves — 8-20
Cylinder Tester 188-3926 8-4 Circle Cutting Attachment 1U-6573 8-20
Cylinder Tester 9U-6803 8-4 Heating and Flame Cleaning Equipment — 8-21
Cylinder Washer Tank Group 250-6597 8-3 Heavy-Duty Oxy-Acetylene Deluxe Kit Vac Pac 1U-6470 8-19
Flange Adapters — 8-4 Heavy-Duty Oxy-Acetylene Deluxe Kit 1U-6469 8-18
Hydraulic Cylinder Repair Stands - Heavy-Duty Oxy-Propane Deluxe Kit Vac Pac 4C-4113 8-19
30,000 and 40,000 ft lb (40.8 and 54.4 kN·m) torque — 8-1 MIG/TIG Flowgauge Regulators — 8-20
Hydraulic Cylinder Repair Stands - MIG/TIG Flowmeter Regulators — 8-20
60,000 ft lb (81.6 kN·m) torque — 8-2 Mini Cutting Torch 8T-7792 8-21
Manual Hone Components — 8-5 Plasma Arc Cutting — 8-22
Welding Hose — 8-20
Hydraulic Test Centers 8-6
Adapter Plates and Stand Assembly — 8-9 Weld Protection 8-22
Bench Testing Hydraulic Components Fittings Bib 185-0150 8-25
and Drive Connections — 8-10 Cape (Extra Large) 185-0144 8-25
Drive Shaft Adapter 4C-4336 8-10 Cape (Large) 185-0143 8-25
Drive Shaft 1U-9832 8-10 Eye Cup Welding Goggles 1U-8105 8-24
Flow Straightener Block 9U-5902 8-11 Half Mask Respirator 235-6479 8-23
Heat Exchanger 9U-5893 8-11 Leather Welding Gloves 185-0153 8-25
Hose Assemblies and Quick Disconnects — 8-12 Replacement Parts for Ultrashade Welding Helmets — 8-23
Load Sensing Valve 4C-3582 8-11 Welding Blanket — 8-25
Motor Stall Adapters — 8-10 Welding Coat (Extra Large) 185-0152 8-24
Mounting and Drive Hardware for Hydraulic Pump Welding Coat (Large) 185-0151 8-24
and Motor Testing — 8-9 Welding Goggles with Lift Front Lens 1U-8104 8-24
Pressure Reducing Valve 1U-6392 8-11 Welding Goggles 1U-8103 8-24
Relief Valve Cartridge 9U-5892 8-11 Welding Helmet 1U-8097 8-23
Series Hydraulic Test Benches 9U-5000 8-8 Welding Helmet 1U-8100 8-23
Series Hydraulic Test Centers 1U-9400 8-6 Welding Jacket — 8-24
Test Port Adapters — 8-12 Welding Respirator 237-5181 8-22
Automatic Welding 8-12

Automatic Welding Groups — 8-14
Bore Welding Groups — 8-13
Wire Feeder 161-6202 8-14
Boring Bar 8-15

Hydraulic and Portable Boring Bars — 8-15
Uninterruptible Power Supply 8-16

Caterpillar UPS View Software Group for UPS 250 NEXG5041 8-17
Drain Service Group 224-3145 8-17
Rotar Position Sensor Shim Kit 216-7886 8-17
Uninterruptible Power Supply Tools — 8-16
Home Dealer Service Tools 2006

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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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Major Equipment Search
Hydraulic Cylinder Service Hydraulic Cylinder

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Hydraulic Test Centers

Hydraulic Cylinder Repair Stands -
30,000 and 40,000 ft lb (40.8 and 54.4 kN·m) torque Automatic Welding
SMCS Code: 0685
Model: Caterpillar Hydraulic Cylinders Boring Bar
Warranty: Six Months
European Union compliant, CE marked (152-4249, 152-4251) Uninterruptible
Power Supply
Extended Cylinder Cylinder Diameter Gas Cutting/

Part No. Description Torque Capacity Length Capacity Capacity Welding Equipment
125-0079 HCS-30 30,000 ft lb (40.8 kN·m) 30 cm (1.0 ft) to 5.9 m (19.5 ft) 380 mm (15.0 in)
152-4249 HCS-30 CE 30,000 ft lb (40.8 kN·m) 30 cm (1.0 ft) to 5.9 m (19.5 ft) 380 mm (15.0 in) Weld Protection
152-4250 HCS-40 40,000 ft lb (54.4 kN·m) 30 cm (1.0 ft) to 7.9 m (26.0 ft) 560 mm (22.0 in)
152-4251 HCS-40 CE 40,000 ft lb (54.4 kN·m) 30 cm (1.0 ft) to 7.9 m (26.0 ft) 560 mm (22.0 in)
• All machines require 3-phase power supply; customer must specify • Designed to use a waste barrel to capture hydraulic fluid during
50 Hz or 60 Hz and required voltage when ordering. overhaul procedures
• Used to remove and install threaded barrel caps and piston retaining • Adjustable support stand provides vertical, horizontal, and diagonal
nuts of hydraulic cylinders being overhauled adjustment to prevent seal damage during assembly due to
• Repair stand is operated from one side (saves valuable floor space misalignment
by installing unit next to wall) • Eye-level torque gauge gives operator applied torque and break-away
• Hydraulic nut runner, conical mounting bushings, double acting torque readings (assures factory torque specifications are met during
torque head, indexing cylinder assembly)
• Adjustable tailstock for various cylinder lengths • Unit is completely wired and ready for installation (comes complete
with mounting hardware and installation instructions)
• Fast and powerful rod extension and retraction
• Conical rod eye adapters make cylinder installation, with various rod
eye diameters, much faster and easier (no need to search for just the Reference
right size adapter) NEDG6005
• Heavy-duty pendant control provides on/off, torque/detorque,
screw/unscrew, and extend/retract functions at operator’s finger tips
(pendant uses a 8 m (25 ft) cable for operator convenience and safety)
Adapters for Spline Drive Sockets

Part No. Description
263-9036 Adapter, Spline 30 and 40
263-9037 Pan Kit, Telescopic Drip ID: C54988T1
263-9038 Crown Wrench Group
263-9039 Wing Group, Offset Chuck Cylinder extension 244 cm (8.0 ft) in less than one minute
263-9040 Wing Group – D11 Chuck Head nut runner capacity 5440 N·m (4000 lb ft)
263-9041 Adapter – D11 Head nut runner speed 6 rpm
263-9042 Bushing Kit, Larger Conical Indexing cylinder travel 122 cm (4.0 ft)
Small and medium size conical adapters 25 mm (1.0 in) to 146 mm (5.75 in) diameters
Large size conical adapter (optional) 152 mm (6.0 in) to 203 mm (8.0 in) diameters
Electric motor 5 hp
Hydraulic tank capacity 38 L (10 gal)
Dealer Service Tools 2006 8-1

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Hydraulic Cylinder
Service Hydraulic Cylinder Repair Stands - 60,000 ft lb (81.6 kN·m) torque
SMCS Code: 0685
Hydraulic Test Centers Model: Caterpillar Hydraulic Cylinders
Automatic Welding European Union compliant, CE marked (152-4252, 152-4255)
Boring Bar Extended Cylinder Cylinder Diameter

Part No. Description Torque Capacity Length Capacity Capacity
127-4904 HCS-60 60,000 ft lb (81.6 kN·m) 7.3 m (24.0 ft) 508 mm / 762 mm (20.0 in / 30.0 in)
Uninterruptible
152-4252 HCS-60 CE 60,000 ft lb (81.6 kN·m) 7.3 m (24.0 ft) 508 mm / 762 mm (20.0 in / 30.0 in)
Power Supply
152-4254 HCS-60-L 60,000 ft lb (81.6 kN·m) 10.4 m (34.0 ft) 508 mm / 762 mm (20.0 in / 30.0 in)
Gas Cutting/ 152-4255 HCS-60-L CE 60,000 ft lb (81.6 kN·m) 10.4 m (34.0 ft) 508 mm / 762 mm (20.0 in / 30.0 in)
Welding Equipment
Weld Protection • All machines require 3-phase power supply; customer must specify • Conical rod eye adapters make cylinder installation, with various rod
50 Hz or 60 Hz and required voltage when ordering. eye diameters, much faster and easier (no need to search for just the
• Used to remove and install threaded or bolt-on barrel caps and piston right size adapter)
retaining nuts of hydraulic cylinders being overhauled • Heavy-duty pendant control provides on/off, torque/detorque,
• Unit includes universal spanner and high-torque wrench (eliminates screw/unscrew, and extend/retract functions at operator’s finger tips
buying expensive conventional sockets) (pendant uses a 8 m (25 ft) cable for operator convenience and safety)
• Repair stand is operated from one side (saves valuable floor space • Eye-level torque gauge gives operator applied torque and break-away
by installing unit next to wall) torque readings (assures that factory torque specifications are met
during assembly)
• Hydraulic workstation moves automatically between work position and
park position (also has gauge that reads and records applied torque) • Unit is completely wired and ready for installation (comes complete
with mounting hardware and installation instructions)
• Conical mounting bushings, double acting torque head, indexing
cylinder
• Adjustable tailstock for various cylinder lengths Reference
NEDG6005
• Fast and powerful rod extension and retraction
Adapters for Spline Drive Sockets

263-9037 Pan Kit, Telescopic Drip
263-9038 Crown Wrench Group
263-9039 Wing Group, Offset Chuck
263-9040 Wing Group – D11 Chuck
263-9041 Adapter – D11
263-9042 Bushing Kit, Large Conical
263-9043 Adapter, Deep Socket
263-9044 Insert, 5 in hex
263-9045 Insert, 5.5 in hex
ID: C54989T1
263-9051 Insert, 8.6 in hex Head nut runner capacity 5440 N·m (4000 lb ft)
263-9052 Insert, 130 mm square Head nut runner speed 6 rpm
263-9053 Insert, 130 mm hex Indexing cylinder travel 122 cm (4.0 ft)
263-9054 Insert, 135 mm hex Conical adapters 38 mm (1.5 in) to 203 mm (8.0 in) diameters
263-9055 Insert, 145 mm hex Electric motor 7.5 hp
263-9056 Insert, 145 mm square Hydraulic tank capacity 19 L (5 gal)
263-9057 Insert, 155 mm square
263-9058 Insert, 170 mm hex
263-9059 Adapter, Spline 60
8-2 Dealer Service Tools 2006

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Hydraulic Cylinder
250-6597 Cylinder Washer Tank Group Service
SMCS Code: 7562-070
Model: Hydraulic Cylinders Hydraulic Test Centers
Automatic Welding
NEW TOOL
European Union compliant, CE marked
Boring Bar
• Replaces canceled 120-9143 and 232-4686 Cylinder Washer Tank Groups
• Used to clean honing oil and metal particles from inside of reconditioned cylinders (provides quick and efficient cleaning method) Uninterruptible
• Operates completely by air pressure (no electricity) Power Supply
• Cleans cylinders ranging from 101 to 343 mm (4.0 to 13.5 in) diameter and 1.8 to 3.6 m (up to 12 ft) in length (attachment sold separately) Gas Cutting/
• Unit can be positioned at end of manual or automatic hone group (allows cylinders to remain clamped in hone group during cleaning procedure) Welding Equipment
• Washer uses an air powered drill (sold separately) to rotate cleaning brushes (sold separately) while a pump supplies cleaning solvent to brush head
• Uses disposable filter bags to capture contaminants (keeps fluid clean and makes cleanup and disposal easier) Weld Protection
• Uses a three-step process to filter cleaning solution
1. Two magnet assemblies catch large ferrous materials
2. Dual filter bags capture particles 25 microns and larger
3. Final synthetic, spin on filter cleans fluid before it is pumped to cleaning brush assembly
Reference
NEHS0927-01 Tool Operating Manual; Procedures for Using the 250-6597 Cylinder Washer Tank Group
Additional Tooling (Sold Separately) for Complete Cylinder Tube Cleaning System
Part No. Description Qty.
120-9144 Rotating Valve Group 1
120-9146 Brush Assembly, Including Spray Nozzle 1
120-9148 Brush, 76 mm (3.0 in), used for 6
ID: D00703T1
100 to 190 mm (4.0 to 7.5 in) diameter cylinder bores
120-9147 Brush, 152 mm (6.0 in), used for 6 Service/Repair Parts
190 to 343 mm (7.5 to 13.5 in) diameter cylinder bores
184-2319 Filter Bag (25 micron)
120-9154 Arbor Tube, 1.8 m (6.0 ft) 1
198-3150 Filter Element (2 micron)
120-9153 Arbor Tube, 3 m (10.0 ft) 1
9U-6983 Filter Element (5 micron)
120-9152 Arbor Tube, 3.6 m (12.0 ft) 1
9U-5870 Filter Element (15 micron)
135-7643 Nozzle Adapter, optional 1
171-5688 Pneumatic Drill (or equivalent) 1
Cylinder Cleaning and Storage

When cleaning a hydraulic cylinder—especially important after honing—the primary objective is to remove
harmful contaminants. Testing has shown that this is best accomplished by the scrubbing action of rotating
brushes, used with a cleaning solution that flushes the contamination out of the cylinder. Caterpillar offers
a cylinder washer, tooling, and a water-based cleaning chemical (1U-5490) that is very effective in cleaning
honed cylinders.
After the cylinder is clean, it is important to keep rust from forming on the bare metal surface of the bore.
The recommended Caterpillar cleaning chemical provides mild rust protection. However, if the cylinder will not
be assembled into a group for an extended period of time, depending on the environment, oxidation of the
smooth surface can be a problem.
Options to deal with this include arranging the process so that cylinders are assembled within a few days of being
washed, or taking additional storage precautions with additional rust inhibitors that can provide longer term
protection. Spraying the bore with a light, clean oil may be sufficient to extend the rust protection. Other stronger
products such as 1U-8809 Caterpillar 450 Rust Preventive Oil could also be used. The amount of protection
required depends on several factors such as storage time, ambient conditions, other packaging, etc. If a cylinder
is to be sealed on the ends, it must be completely dry and in a dry environment.

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Hydraulic Cylinder
Service 9U-6803 Cylinder Tester
188-3926 Cylinder Tester
SMCS Code: 7562-032
Model: Hydraulic Cylinders Pump capacity 80 lpm (21 gpm)
Automatic Welding Warranty: Six Months Reservoir 227 L (60 gpm)
European Union compliant, CE marked (188-3926)
Boring Bar
• Used to test hydraulic cylinders after reconditioning or repair (ensures
Uninterruptible that cylinders perform to correct specifications)
Power Supply • Provides an efficient and simple method of testing cylinders
• Pressures can be regulated between 2067 and 20670 kPa (300 and 3000 PSI)
Gas Cutting/
Welding Equipment • Remote controlled, pressure-compensated pump provides fast cycling of cylinders
• Large hydraulic reservoir allows unit to test all Caterpillar and most other
Weld Protection double-acting cylinders
• Control panel simplifies testing and gauges are large and easy to read
• After cylinder has been tested, oil is removed by using shop air pressure
• Unit is equipped with low-friction caster wheels
• Operates on 440 Volt, three phase power (can be customer adapted
to 220 Volt, three phase)
Reference
NEHS0595 Tool Operating Manual, Cylinder Tester
ID: C54992T1
Flange Adapters
SMCS Code: 5050-030, 032, 038, 082
Model: All Models
• Used to aid mechanic in flow testing of various hydraulic systems —

specifically used when flange-type XT3 and XT5 adapters are needed
• Straight, 45°, and 90° fittings available to orientate test hoses for easier
accessibility to vehicle’s hydraulic components
• Longer length for faster/easier installation (allows use of conventional socket
wrenches rather than flat wrenches used on former short adapters)
ID: D00427T1
• Used with existing high pressure adapters and quick disconnects for flow
testing on-vehicle or in shop
• Features 9⁄16-18 thread diagnostic “T” port for pressure
testing operating systems Working pressure Fitting end Nominal size flange
XT3 Fittings 27 560 kPa (4000 PSI) 1 inch NPT female thread 1⁄ to 11⁄2 inch
2
Reference XT5 Fittings 41 340 kPa (6000 PSI) 1 5/16 inch STOR male thread 3⁄ to 11⁄2 inch
4
NEHT5000; NEHT6000 through NEHT6045 Test Procedures
Item Part No. Name Description Item Part No. Name Description
1 9U-7442 Adapter 1⁄ inch Flange Adapter 7 9U-7438 Adapter 1⁄inch Flange Adapter
2 2
4J-5140 Seal O-ring 1P-3702 Seal O-ring
1P-4574 Flange 1⁄ inch Split Flange 1P-5765 Flange 1⁄inch Split Flange
2 2
9U-7443 Adapter 3⁄ inch Flange Adapter 9U-7439 Flange 3⁄inch Flange Adapter
4 4
4J-5267 Seal O-ring 1P-3703 Seal
1P-4576 Flange 3⁄ inch Split Flange 1P-5766 Flange 1 inch Split Flange
4
9U-7444 Adapter 1 inch Flange Adapter 9U-7440 Adapter 11⁄4 inch Flange Adapter
1P-4577 Flange 1 inch Split Flange 1P-5767 Flange 11⁄4 inch Split Flange
9U-7445 Adapter 11⁄4 inch Flange Adapter 9U-7441 Adapter 11⁄2 inch Flange Adapter
1P-4578 Flange 11⁄4 inch Split Flange 5P-8077 Flange 11⁄2 inch Split Flange
9U-7446 Adapter 11⁄2 inch Flange Adapter 7M-8485 Seal O-ring for — 16 Stor Threads
4J-0524 Seal O-ring 8 1U-8302 Fitting -16 Stor Port — 16 Stor Thread-Straight
1P-4579 Flange 11⁄2 inch Split Flange
7M-8485 Seal O-ring for 16 Stor Threads 9 1U-8305 Fitting -16 Stor Port — 16 Stor Thread-45°
2 1U-8300 Fitting 1 inch Pipe to 16 Stor Port-Straight 10 1U-8303 Fitting -16 Stor Port — 16 Stor Thread-90°
3 1U-8304 Fitting 1 inch Pipe to 16 Stor Port-45° 11 8C-9032 Nipple Assembly -16 Stor non-valved QD
4 1U-8301 Fitting 1 inch Pipe to 16 Stor Port-90° 12 8C-7544 Coupler 1 inch NPT female non-valved QD
8C-7545 Nipple 1 inch NPT female non-valved QD (Not shown)
5 8C-7544 Nipple 1 inch NPT male QD
6 8C-7545 Coupler 1 inch NPT female QD
7X-7646 Nipple 1 inch NPT female QD (Not shown)

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Hydraulic Cylinder
Manual Hone Components Service
SMCS Code: 7562-049, 0673
Model: Hydraulic Cylinders Hydraulic Test Centers
• Manual hone components need to be ordered separately. Automatic Welding
Manual Hone Boring Bar

• Less expensive alternative when reconditioning cylinders (no longer necessary to send cylinders to outside suppliers)
• Unit works best in low production shops Uninterruptible
• Honing ensures a quality, long-lasting repair by renewing the bore surface and removing irregularities or other cylinder damage Power Supply
• Capable of honing 3.6 m (12 ft) long cylinders with diameters ranging from 63.5 to 406 mm (2.50 to 16 in) Gas Cutting/
• Power for hone is supplied by a four-speed electric drill Welding Equipment
• A drill coupler absorbs forward and reverse thrust, removing direct force from drill gears and making drills last longer by reducing wear
• Used with a specially formulated honing oil Weld Protection
Reference
SEHS9538, Tool Operating Manual for Manual Hone Group
Manual Hone (order for a complete unit) Service/Repair Parts for Manual or Semi-Automatic Hone
Part No. Description Electrical requirements Part No. Description Size
9U-5797 or Drill 110 Volts, 60 Hz, single phase 9U-6478 Finish Stone Set 119 to 381 mm (4.7 to 15.0 in)
9U-5888 Drill 220 Volts, 50/60 Hz, single phase 9U-6479 Rough Stone Set 119 to 381 mm (4.7 to 15.0 in)
9U-6467 Thrust Coupler and Clamp Coupler 9U-6481 Finish Stone Set 89 to 140 mm (3.5 to 5.5 in)
9U-6463 Hone Group 9U-6480 Rough Stone Set 89 to 140 mm (3.5 to 5.5 in)
9U-6476 Drill Support Stand Group 6V-7865 Finish Stone Set 68 to 104 mm (2.7 to 4.1 in)
9U-6477 Barrel Cradle Stand Group 9U-6483 Rough Stone Set 68 to 104 mm (2.7 to 4.1 in)
9U-6759 or Drain Tank and Pump 110 Volts, 60 Hz, single phase 6V-7866 Finish Stone Set 63 to 68 mm (2.5 to 2.7 in)
1U-9031 Drain Tank and Pump 220 Volts, 50/60 Hz, single phase
9U-6746 Rough Stone Set 63 to 68 mm (2.5 to 2.7 in)
9U-6749 Master Holder Set 203 to 304 mm (8.0 to 12.0 in)
9U-6748 Dressing Stick
9U-6484 Honing Oil
ID: C54990T1
1U-7608 Chain Wrench

SMCS Code: 5102-017
Model: D6H, D7H and motor graders prior to April 1987 G-Series production
• Used to remove and install threaded crowns on hydraulic cylinders

• Can be used on threaded crowns up to 203.0 mm (8.00 in) in diameter
• Can be used with breaker bars, ratchets, and torque wrenches
• Grips cylindrical objects for assembly or disassembly
• Black oxide finish, high carbon steel
• 19.0 mm (.75 in) square drive
• Rated capacity: 1360 N·m (1000 ft-lb) Head length 114.3 mm (4.50 in)
• Service part: 1U-7609 Standard Coupler Head width 54.0 mm (2.13 in)
Head thickness 34.9 mm (1.38 in) ID: C58234T1
Chain length 711.2 mm (28.00 in)

Weight .86 kg (1.90 lbs)

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Hydraulic Cylinder Hydraulic Test Centers

Service

1U-9400 Series Hydraulic Test Centers
Automatic Welding SMCS Code: 0784
Model: Caterpillar Pumps, Motors and Transmissions
Boring Bar
Available in 380/415/460/575 Volt, 50/60 Hertz, 3-Phase electrical, 200 to 400 HP
Uninterruptible
• Complete test centers designed for testing and adjusting all
Power Supply
Caterpillar pumps, motors, hydrostatic and powershift
Gas Cutting/ transmissions
Welding Equipment • Unlike traditional test benches on the market that are primarily
designed to test transmissions, the 1U-9400 Series is designed for
Weld Protection complete pump, motor, and hydrostatic transmission testing
• Caterpillar test centers are developed for greater performance but
use traditional-sized components where possible to minimize costs
• Using digital electronic control output, drive speed can be
maintained regardless of load
• Main manifold design allows for versatility in test configuration
ID: D00463T1
Reduced voltage motor starter Regeneration/closed loop flow log (1)
Main oil tank capacity 1136 L (300 gal) Main pump diagnosic ports (2)
High capacity work support Supercharge in/out ports (2)
with integral sump 4545 kg (10000 lb) Flowmeter loops (6)
Output shaft torque (at full motor 19-795 lpm (5-210 gpm) loadable
displacement) 1722 N·m (1275 lb ft) 19-795 lpm (5-210 gpm) non-loadable
RPM range 0-2550 11-322 lpm (3-85 gpm) loadable
11-322 lpm (3-85 gpm) non-loadable
Modes of operation 3 4-8 lpm (1-2 gpm) low pressure. case drain
Displacement (fully manual) 2-19 lpm (.5-5 gpm) low pressure case drain
Speed (maintains test speed during changing loads)
Motor test (loaded rotating motor testing) 100 mm (4 in.) gravity supply (1)
Auxiliary pump Test ports connected to panel gauges (16)
215 lpm (0-57 gpm) elec. displacement control Internal 3 micron high capacity kidney loop filtration system
0-41340 kPa (0-6000 PSI) 12 kW thermostat-controlled tank heater
High pressure signal port (1) 0-51680 kPa (0-7500 PSI) Separate internal heat exchanger for closed loop hydrostatic
Low pressure signal port (1) 0-4134 kPa (0-600 PSI) pump testing
Tank return ports (2)
Optional Features
• Multiple suction ports for testing tandem and triple pumps
• Additional signal pressure ports
• Extended external and internal filtration systems for gear pump testing (recommended for dealers who rebuild and test gear pumps frequently)
• Extended internal filtration systems for highly contaminated environments
• Additional sound attenuation
• Custom work support sump configurations
• Data acquisition system capable of monitoring and recording 9 flows, 14 pressures, 2 temperature channels as well as RPM and torque
Ordering Information
Each 1U-9400 Series Hydraulic Test Centers is built one at a time. This allows design of the system tailored to a specific machine population
and component requirements.
Contact the Dealer Service Tools Division for quotations, specifications, and recommended tooling. The 1U-9400 Series Test Center is purchased
outside of the Caterpillar parts network via a purchase order.

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Service/Repair Parts Hydraulic Cylinder

Part No. Description Part No. Description Service
Gauges Oil Filter Elements and Replacement Parts
21⁄2 inch Diameter, Panel Mount, Back Connection Circulation/Kidney loop
8T-0850 Gauge, 0-4135 kPa (0-600 PSI) 205-7380 Oil Filter Element
4C-4615 Gauge, 0-1380 kPa (0-200 PSI) Sump return Automatic Welding
205-7381 Oil filter element
4C-4614 Gauge, 0-689 kPa (0-100 PSI)
Super Charge filter systems
8T-0848 Gauge, 0-415 kPa (0-60 PSI) 4C-3052 Oil Filter Element (1) Boring Bar
4C-4616 Gauge, 0-52500 kPa (0-7500 PSI) 4C-6112 Oil Filter Seal Kit
8T-0852 Gauge, 0-34450 kPa (0-5000 PSI) F1 Flowmeter/Closed Circuit Loop Uninterruptible
8T-0851 Gauge, 0-13780 kPa (0-2000 PSI) 4C-4878 Ring1 (2) Backup rings for regenerative circuit Power Supply
9U-5966 Oil Filter Element (2)
4 inch Diameter, Panel Mount, Lower Back Connection 4C-6110 Oil Filter Seal Kit Gas Cutting/
8T-0840 Gauge, 30/0/30, 30 In/Hg-0-30 PSI Return filter (top of tank) Welding Equipment
9U-6099 Gauge, 0-4130 kPa (0-600 PSI) 4C-3054 Oil Filter Element (2)
4C-6111 Oil Filter Seal Kit Weld Protection
1U-9697 Gauge, 0-52500 kPa (0-7500 PSI)
Pump and motor inlet control circuits
4C-4617 Gauge, 0-6890 kPa (0-1000 PSI)
4C-4877 Ring1 (2) Backup rings for pump and motor control filters
Differential Pressure Gauge 4C-3056 Oil Filter Element (1)
1U-5793 Gauge, 0-500 PSI 238-6876 Oil Filter Element (1) (optional)
4C-6108 Oil Filter Seal Kit
Super Charge inlet filter
238-6877 Oil Filter Element (1)
Main charge filter
4C-5096 Oil Filter Element (1)
Motor control circuit (double length)
4C-5095 Oil Filter Element (1)
238-6875 Oil Filter Element (1) (optional)
1 Replacement elements contain new bowl O-rings but not new backup
rings. Backup rings are used to support the filter bowl O-rings.
Replacement backup rings are serviced by themselves or within the filter
seal kits. The double length elements have been installed on some
machines but not all.
Hydraulic System Replacement Parts

4C-8686 Flowmeter - Webster LT-760, 7-210 gal/min., 11⁄2 inch SAE 4 bolt flange, 6000 PSI. (F1 and F4)
4C-8687 Flowmeter - Webster LT-500, 4-130 gal/min., 11⁄2 inch SAE 4 bolt flange, 6000 PSI. (F2 and F3)
4C-8688 Flowmeter - Hedland 701-002, .1-2.0 gal/min., 3⁄4 inch NPT port, 3000 PSI. Measures case drain
4C-8689 Flowmeter - Hedland 701-005, .5-5.0 gal/min., 3⁄4 inch NPT port, 3000 PSI. Measures case drain
4C-8690 Valve - Vickers DG17V-3-2C10. Directional control for drive shaft table lift
4C-8656 Valve - Rexroth EL-24VDC-832575. Proportional control for main and auxiliary pumps
4C-8682 Valve - Rexroth 4WS2EM10-40. Servo valve for fluid motor control
4C-8684 Strainer - 4 inch, 100 mesh, 200 GPM for oil supply inside reservoir
4C-8685 Strainer - 11⁄2 inch, 100 micron, 50 GPM for work table sump. Two needed (small sumps)
4C-8692 Coupler - Snap-Tite VHC-16-16-EF, 15⁄16 inch female SAE thread valved. Super Charge outlet on manifold
Mechanical Parts
4C-8695 Bearing - Motion Industries 22313KTS drive shaft bearing
Electrical Parts
4C-8691 Potentiometer - Allen Bradley 800TU24 pot with a JS-1 SPST switch attached
4C-8589 Tachogenerator - Rexroth TDPO.7/8-3-836706 low voltage tach generator (located on end of fluid motor)
4C-8693 Torque Sensor - Lebow 1805-15K drive shaft torque sensor
4C-8694 Relay - Red Lion PRS1-103-1/A overspeed relay

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Hydraulic Cylinder
Service 9U-5000 Series Hydraulic Test Benches
SMCS Code: 5050-036
Hydraulic Test Centers Model: All Models
Automatic Welding Available in 230/380/415/460/575 Volt, 50/60 Hertz, 3-Phase electrical, 125 or 150 HP
• Used to test hydraulic pumps, motors, cylinders, and transmissions
Boring Bar (including some hydrostatic)
• Designed as an economical option 'or testing current
Uninterruptible and future components within the 125 or 150 hp range limit
Power Supply • A "mini" bench having many of the same features as larger
1U-9400 Hydraulic Test Center including elevated component oil
Gas Cutting/ tank, full instrumentation, full filtration (down to 5 micron) with
Welding Equipment control panel indicator lights. two pressure oil supplies, and large,
low-profile testing bed
Weld Protection • Additional features: two digital flow meters, connection for
external flow meters, digital flow and temperature readouts,
automatic heating and cooling of testing oil supply, automatic
oil level control of work table sump, built-in protection circuits, and
digital RPM readout
• Caterpillar test benches are direct competitive replacements
for 100/125 hp class test benches.
Reference
NEHS0563 Tool Operating Manual
Reduced voltage soft-start motor starter
ID: D00469T1
Horsepower 125 or 150
Maximum drive output 2600 rpm
Gravity feed oil supply (flooded suction) 102 mm (4.0 in) diameter
Ordering Information Adjustable hydraulic supply #1 189 Ipm at 20 670 kPa (50.0 gpm at 3000 PSI)
Contact the Dealer Service Tools Division for
quotations, specifications and recommended Adjustable hydraulic supply #2 19 Ipm at 2756 kPa (5.0 gpm at 400 PSI)
tooling. The 9U-5000 Series Hydraulic Test Two flow meters 484 lpm (125 gpm)
Bench is purchased outside of the Caterpillar External flow meter connections pressure up to 46 850 kPa (6800 PSI) with flow rates
parts network via a purchase order of 8 to 800 l/min (2 to 210 gpm)
Indicator lights for all filters
Service/Repair Parts
Part No. Description Part No. Description
Gauges 9U-5194 Tube - supply/return tube for flowmeter
4C-4617 Gauge, 0-6890 kPa (0-1000 PSI) - 102 mm (4.0 in) diameter 9U-5873 Valve - on/off water control
9U-5851 Gauge, 0-20 000 kPa (0-3000 PSI) - 102 mm (4.0 in) diameter 9U-5848 Valve - 20 670 kPa (3000 PSI) pressure regulating (main oil supply pressure)
9U-5852 Gauge, 0-20 000 kPa (0-3000 PSI) - 64 mm (2.5 in) diameter 9U-5849 Valve - 3445 kPa (500 PSI) pressure reducing (control oil)
1U-9161 Minder Gauge - protects lower range gauges, located inside control panel 9U-5849 Valve - 3000 kPa (400 PSI) control pressure adjustment
Oil Filter Elements 9U-5850 Valve - supply flow On/Off, two-way ball valve
4C-9479 Element - hydrostat charge oil (13 Micron) 9U-5875 Valve - water control valve to hydrostatic oil cooler
9U-5870 Element (13 micron absolute) - main pump case return, bypass, and sump filter 9U-5878 Valve - water control valve to bypass oil cooler
9U-5871 Element (10 micron absolute) - main oil supply Mechanical Parts
Electrical 9U-5880 Winch - drive motor height adjustment
9U-5856 Fan - main electrical panel Miscellaneous Hardware
9U-5853 Indicator - control console digital rpm readout 9U-5192 Adapter - drive adapter assembly with magnetic pickup gear
9U-5881 Magnetic Pickup - for digital rpm readout 9U-5212 Bolt - sliding drive plate mounting
9U-5845 Sump Pump - 230/46OV, 3-phase, 6O Hz application only 9U-5854 Cable - pump displacement/direction control
9U-5847 Sump Pump - 230/38OV, 3-phase, 5O Hz application only 9U-5855 Cable - motor speed control
9U-5846 Switch - three level sump pump float switch 9U-5865 Coupling - electric motor/pump drive couplings
9U-5876 Switch - dirty filter indicator 9U-5826 Artwork Decal - decals for control console
9U-5877 Switch - high level, low level reservoir float switch 9U-5210 Guard - short coupling guard
Hydraulic System Replacement Parts 9U-5211 Guard - long guard for drive shaft
9U-5859 Cooler - hydrostatic and bypass oil cooler 9U-5872 Insert - used with 9U-5865 Coupling
9U-5860 Heater - hydraulic reservoir Repair Kits
9U-5866 Nipple - 12 mm (4.0 in) gravity flow supply line 9U-5082 Kit - for Snap-Tite nipple
9U-5861 Strainer - inside oil reservoir 102 mm (4.0 in) diameter 9U-5864 Kit - charge pressure relief valve
9U-5862 Strainer - inside oil reservoir 50 mm (2.0 in) diameter 9U-5868 Kit - main hydraulic pump (60 Hz applications)
9U-5867 Strainer - inside oil reservoir 32 mm (1.25 in) diameter 9U-5869 Kit - main hydraulic pump (5O Hz applications)
4C-9910 Tester - digital flow meter 9U-5874 Kit - 9U-5873 Valve
9U-5879 Kit - fluid motor

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Hydraulic Cylinder
Mounting and Drive Hardware for Hydraulic Pump and Motor Testing Service
SMCS Code: 0784
Model: Caterpillar Pumps, Motors and Transmissions Hydraulic Test Centers
• Used for hydraulic pump and motor testing Automatic Welding

• Mounting plates used with 1U-9130 Mounting Stand
• Drive adapters work with any size 27 drive shaft, standard on Boring Bar
Aidco, Wolff and Schroder benches; drive adapters also work
with 1U-9359 Adapter and can be used with size 55 drive shaft Uninterruptible
on Caterpillar Hydraulic Test Center Power Supply
ID: D00457T1
Gas Cutting/
Pump and Motor Drive Adapters Pump and Motor Drive Adapters Welding Equipment
Part No. Spline Data Remarks Part No. Spline Data Remarks
1U-9840 10T- Parallel side spline 136-3648 20T-8/16 Weld Protection
1U-9837 11T-12/24 9U-5745 20T-12/24
1U-9836 11T-16/32 9U-5230 20T-B4OX36X30 DIN 5482 MDL
9U-5746 12T-20 DEG JIS DEG 1.75
1U-9835 13T-8/16 133-2329 21T-16/32
1U-9838 13T-12/24 9U-5277 N45X2X30X21X9g DIN 5480 - 21T
1U-9833 13T-1632 1U-9132 23T-16/32
1U-9841 14T-10/20 1U-6433 N5OX2X3OX24X9g DIN 5480 -24T
1U-9834 14T-12/24 142-8576 N55X2X3OX26X9g DIN 5480 - 26T
9U-5747 14T-20 DEG JIS 128-0794 27T-16/32 SPL
131-6452 N30X2X3OX14X9g DIN5480 - 14T 131-8620 N60X2X3OX28X9g DIN 5480 - 28T
9U-7519 15T-8/16 4C-4705 30T-16/32
9U-5744 15T-12/24 4C-4703 32T-16/32 External Spline

1U-9843 7⁄ SAE B Keyed shaft
4C-4088 15T-16/32 8
9U-7520 15T-10/20 1U-9844 11⁄4 SAE B Keyed shaft
9U-7063 16T-20 DEG JIS 1U-9845 13⁄4 SAE B Keyed shaft

9U-5276 16T B30X27X30 DIN 5482 MDL 1U-9846 1 taper Keyed shaft
DEG 1.75 1U-9847 11⁄16 taper Keyed shaft
9U-7521 17T-8/16 1U-9848 11⁄4 taper Keyed shaft
131-6456 17T-10/20 9U-5743 13⁄8 taper Keyed shaft
1U-9394 17T-12/24 136-3602 13⁄4 taper Keyed shaft
9U-5748 17T-20 DEG JIS
246-1588 18T-8/16 Adapter Assembly
9U-5275 N40X2X3OX18X9g DIN 5480 - 18T Part No. Description Use
1U-9842 19T-16/32 1U-9359 Adapter Assembly for large drive shaft
4C-4385 19T-24/48
Adapter Plates and Stand Assembly

SMCS Code: 0784
Model: Most Caterpillar Models
• Adapter plates and stand assembly used to mount hydraulic pumps and motors for bench testing; eliminates use
of clamps, chains, and turnbuckles to secure test component to test bench bed
• Adapter plates slide into 1U-9130 Stand Assembly, becoming integral part of stand and creating sturdy free-standing fixture
• 1U-9130 Stand Assembly can be used on any test bench bed with mounting rail centerline width of 37.5 inch
and minimum rail slot width of 3⁄4 inch
• Tooling designed to accommodate any horsepower rated pump or motor that Caterpillar has in current production
• Adapter plate assemblies hold pumps and motors that have SAE-style mounting flanges, and either
2- or 4-hole mountings
• Safe, quick way to mount pumps and motors having standard SAE A, B, C, D, E and F style mounting configurations
ID: C26898T1
Mounting Adapter Plates Used with 1U-9130 Mounting Stand
Mounting Mounting SAE Flywheel
Part No. Pilot Diameter Configuration Part No. Pilot Diameter Configuration Part No. Adapter Plates Configuration
1U-9126 84.15 mm (3.313 in) SAE-A 4C-4702 191.00 mm (7.720 in) 9U-5750 511.18 mm (20.125 in) SAE No. 1
1U-9127 103.60 mm (4.079 in) SAE-B 131-8683 153.00 mm (6.024 in) 1U-5738 447.80 mm (17.630 in) SAE No. 2
1U-9128 128.55 mm (5.061 in) SAE-C 131-8476 262.00 mm (10.315 in) 4C-4622 409.58 mm (16.125 in) SAE No. 3
1U-9129 180.50 mm (7.106 in) SAE-D-E-F 128-0929 223.00 mm (8.780 in) 4C-4623 361.95 mm (14.250 in) SAE No. 4
9U-5751 200.25 mm (7.884 in) 131-8477 195.00 mm (7.677 in)
130-1986 280.25 mm (11.033 in)
Home
Hydraulic Cylinder
Service 1U-9832 Drive Shaft 4C-4336 Drive Shaft Adapter
SMCS Code: 0784 SMCS Code: 0784
Hydraulic Test Centers Model: Most Caterpillar models Model: Most Caterpillar Models
Warranty: Manufacturer’s Six Months Warranty: Six Months
Automatic Welding • Universal Drive Shaft Size 27 (Aidco, Wolff, Schroder Standard • Allows 1U-9400 Hydraulic Test Center owners to install optional
Shaft) 1U-9832 Drive Shaft to drive hub on test center
Boring Bar • Also allows Caterpillar 1U-9400 Test Bench owners to run smaller • When bench testing small pumps and motors on 1U-9400, a smaller
components with small drive shaft (requires 4C-4336 Adapter) drive shaft is required due to the mass of standard drive shaft; if any
misalignment occurs during pump installation, large shaft could
Uninterruptible
Power Supply Repair Information overwhelm small component splined shaft causing vibration and severely
Parrish Power Products Inc. loading component shaft
Gas Cutting/ P.O. Box 955 bearing; smaller, optional
Welding Equipment Toledo, OH 43697-0955 1U-9832 Drive Shaft
corrects this situation
Phone: (419) 729-1601 but 4C-4336 Adapter
Weld Protection ID: D00451T1
plate must be used
Reference to couple it with
NEHT5000 Bench Testing Hydraulic Components—complete listing 1U-9400 Hydraulic
of general test bench tooling Test Center
• Plate adapts from
SAE size 55 drive
Motor Stall Adapters shaft configuration
to SAE size 27
SMCS Code: 0784 pattern
ID: C27095T1
• Used to stall test hydraulic fluid motors
Part No. Spline ID: D00439T1
4C-4679 32T-16/32 External

4C-4680 19T-16/32 Internal
4C-4681 13T-8/16 Internal
Bench Testing Hydraulic Components Fittings and Drive Connections

SMCS Code: 0784
• General oil connection fittings used while testing hydraulic pumps, motors, and transmissions
• Used when testing variety of Caterpillar and competitive hydraulic components
• Good low to medium pressure base to support test bench needs
ID: C27135T1
Item Part No. Description Item Part No. Description

1 2-Bolt Flanges (BHC = Bolt Hole Center) 2 4-Bolt Flanges
1U-9849 Flange 1⁄2 in Pipe X 17⁄8 in BHC 1U-9871 Flange 3⁄4 in Pipe
1U-9850 Flange 1 in Pipe X 21⁄2 in BHC 1U-9872 Flange 1 in Pipe
1U-9851 Flange 1 in Pipe X 1 in BHC 1U-9869 Flange 11⁄4 in Pipe
1U-9852 Flange 1 in Pipe X 21⁄2 in BHC 1U-9870 Flange 11⁄2 in Pipe
1U-9854 Flange 1 in Pipe X 23⁄4 in BHC 1U-9874 Flange 21⁄2 in Pipe
1U-9856 Flange 1 in Pipe X 3 in BHC 1U-9867 Flange 31⁄2 in Pipe
1U-9859 Flange 1 in Pipe X 33⁄7 in BHC 3 Camlock Fittings
1U-9860 Flange 1 in Pipe X 35⁄8 in BHC 1U-9879 Adapter 3 in X 3 in FPT Adapter
1U-9862 Flange 1 in Pipe X 33⁄4 in BHC 1U-9880 Adapter 4 in X 4 in FPT Adapter
1U-9864 Flange 1 in Pipe X 41⁄2 in BHC
1U-9857 Flange 1 in 1⁄2 Pipe X 3 in BHC 4 Suction Hose and Fittings
1U-9861 Flange 2 in Pipe X 35⁄8 in BHC 1U-9875 Coupler 3 in X 3 in Hose Barb
1U-9863 Flange 2 in Pipe X 4 in BHC 1U-9876 Coupler 4 in X 4 in Hose Barb
1U-9865 Flange 21⁄2 in Pipe X 41⁄2 in BHC 1U-9881 Hose 3 in ID. X 12 ft (Not shown)
1U-9882 Hose 4 in ID. X 12 ft (Not shown)
5 Camlock Fittings
1U-9877 Adapter 3 inch Coup. X 4 inch NIP
1U-9878 Adapter 3 inch NIP. X 4 inch Coup. (Not shown)

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Hydraulic Cylinder
4C-3582 Load Sensing Valve Service
SMCS Code: 0784
Model: All Current Motor Graders; D4H, D5H, D6H, D7H and D8N Crawler Tractors; All Backhoe Loader implement circuits Hydraulic Test Centers
• Used in testing and adjusting high pressure cutout and margin • Sense line pressure taken from port marked “Sense Line” and should Automatic Welding
pressures on load sensing pumps be connected to sense port on test pump compensator valve; test pump
• Compact, high pressure manifold containing flow control, relief valve, outlet flow is connected to “In” port and “Out” port oil is then routed
gauge and flow ports; flow control simulates control valve on vehicle; through flowmeter; flow ports have been designed to accept 1 inch Boring Bar
relief valve simulates load condition of implement circuit SAE O-ring style fittings and will mate with Cat XT-5 quick disconnect
fittings mentioned in February 15, 1988 Service Magazine article Uninterruptible
• Flow capacity of test block is 60 GPM with adjustable pressure range
of approximately 50 to 6000 PSI • Can be used in the field with 8T-0454 Flowmeter (Headland) or with Power Supply
hydraulic test bench; if used with test bench, only bench flowmeter
• Margin pressure read by connecting 1U-5796 Differential Pressure Gas Cutting/
should be used
Gauge to manifold gauge ports marked HI and LOW Welding Equipment
• Caterpillar 1U-9400 Series Hydraulic Test Centers have load sensing
system incorporated in their hydraulics and do not require 4C-3582 valve
Weld Protection
Reference
NEHT5000 Bench Testing Hydraulic Components (under procedures for
testing load sensing pumps)
ID: C27112T1
9U-5893 Heat Exchanger

9U-5892 Relief Valve Cartridge
9U-5902 Flow Straightener Block
SMCS Code: 0784
Model: Challenger 65, 65B, and 75
• Used to test pump on any test bench

• Heat exchanger supplies cooled oil for easier and more accurate testing
and adjusting (prevents overheating oil and burning pump)
ID: C54906T1
• Flow straightener block eliminates improperly connected hoses and allows reversing pump direction without changing hoses
• A 1U-6392 Valve with 9U-5892 Relief Valve Cartridge eliminates need for external pressure supply for pump controls
• 9U-5892 Relief Valve Cartridge pressure: 0-3447 kPa (0-500.0 PSI)
Reference
NEHT6041 Test Procedure
1U-6392 Pressure Reducing Valve

SMCS Code: 0784
• Used to regulate pilot or control pressures when bench testing compensating hydraulic pumps
• Valuable for testing the following pumps: 3G-3287, 3G-7230, 8J-1905, 8J-2344, 8J-4380, 8J-6853,
8J-8723, 8J-9362, 9T-5187, 9T-4731, 9T-4732, 9T-6713, and 9T-6714; these pumps are used
on a variety of Caterpillar equipment but are most commonly found on excavators
• These pumps may require more horsepower than what most dealer test benches can deliver; Aidco,
Wolff and Schroder test benches with 125 HP or smaller electric motor need pressure reducing valve
to complete proper pump test and adjustment; Caterpillar Hydraulic Test Center does not need this valve
• In the past dealers have used needle valve assembly identified as item “D” in Special Instruction Bench Testing
Hydraulic Components (SEHS7972); this assembly sends a signal pressure to pump, which destrokes ID: pump output
C26877T1
flow and reduces horsepower demand; valve arrangement is difficult to set and requires constant adjustment to Operating range 517 to 10334 kPa (75 to 1500 PSI)
maintain signal pressure during test Rated flow 18.9 L/M (5.6 GPM)
• 1U-6392 performs same function as former needle valve arrangement, but is much easier and quicker to set, Port sizes
and will automatically maintain specified signal pressure throughout test; this will save time and improve quality Tank 3⁄ -16 SAE port
4
Inlet and test 9⁄ -18 SAE port
of test 16
• Used with desired length hoses, valve will remotely control signal pressure to pump
• Pressure-compensating, cartridge-type, pressure-reducing valve; has a locking hand knob to adjust outlet port
pressure and manifold with 2 test ports for reading inlet (supply) and outlet (regulated) pressures

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Hydraulic Cylinder
Service Hose Assemblies and Quick Disconnects
• Can be used when pressure testing hydraulic systems with pressures up to
41,500 kPa (6,000 PSI); 6D-7726 used for signal pressure source for load sensing
Automatic Welding pumps. 68,900 kPa )10,000 PSI pressure rating
• The new hose assemblies have the same end connections and hose lengths as
Boring Bar the existing hoses, but have a smaller inside diameter, 2 mm (.080 in) versus
3.18 mm (.125 in).
Uninterruptible • The smaller inside (and outside) diameter makes the hose lighter, more flexible,
Power Supply able to be bundled in a tighter coil, stored in a smaller area, and easier to
handle.
Gas Cutting/ ID: D00433T1
• The end connections allow the hose to be used with various existing adapters,
Welding Equipment fittings, and quick disconnects.
Weld Protection Item Part No. Description Inner Diameter Length Connections
1 6V-3966 Nipple 9⁄ inch SAE male-valved
16
6V-3866 Nipple 1⁄ inch NPT male-valved
4
6V-3989 Nipple 1⁄
8 inch NPT female non-valved
2 6V-4143 Coupler 1⁄ inch NPT female-valved

8
6V-4144 Coupler 1⁄ inch NPT female-valved
4
3 6D-7726 Hose 6 mm (.236 in) 3050 mm (10 ft) 1⁄ inch NPT male
4
4 1P-2375 Nipple 1⁄ inch NPT male-valved (68900 kPa)

4
5 1P-2376 Coupler 1⁄ inch NPT female-valved (68900 kPa)

4
6 177-7860 Hose Assembly 2 mm (.080 in) 3050 mm (10 ft) 1⁄ inch NPT male both ends
8
177-7861 Hose Assembly 2 mm (.080 in) 4270 mm (14 ft) 1⁄ inch NPT both ends
8
177-7862 Hose Assembly 2 mm (.080 in) 5486 mm (18 ft) 1⁄
8 inch NPT both ends
1U-5757 Hose Assembly 2 mm (.080 in) 1830 mm (6 ft) 1⁄ inch NPT by 7⁄ -20 X 37° JIC (Not shown)
8 16
Test Port Adapters

SMCS Code: 5058-082, 5068-082, 5070-082 Corresponding
Model: Most Caterpillar Models Adapter Seal
Warranty: Six Months Part No. Part No. Description
8C-6862 8C-5199 M10 x 1 Thread to SAE No. 6
• 3 metric test port adapters each convert different-sized metric DIN 3852 port (9⁄16 inch-18 Thread) Port
to SAE No. 6 (9⁄16 inch-18 thread) port 8C-6863 8C-5200 M12 x 1.5 Thread to SAE No. 6
• Each adapter requires corresponding seal (9⁄16 inch-18 Thread) Port
• DIN 3852 metric ports found on 215B and 225 Excavator hydraulic pumps 8C-6864 8C-5201 M14 x 1.5 Thread to SAE No. 6
(9⁄16 inch-18 Thread) Port
with part numbers 9T-0992, 9T-1054, 9T-4731 and 9T-4732
• Accepts 6V-3965 Valved Quick Disconnect Nipple, making connection
of test equipment much easier
Automatic Welding
Bore Welding Groups

SMCS Code: 0672
Model: All Models
European Union compliant, CE marked (276-2067 and 276-2068)
Part No. Description • Increases welding and machining productivity

276-2066 Bore Welding Group, 69.85 to 304.8 mm (2.75 to 12 in) diameter • Reduces repair and equipment downtime
276-2067 Bore Welding Group, 69.85 to 304.8 mm (2.75 to 12 in) diameter • Extends the life of capital equipment
276-2068 Bore Welding Group, 22.35 to 304.8 mm (0.88 to 12 in) diameter • Extension and torch attachment system eliminates liner installment
when adding and removing components
• Central mount for easy interface with any boring bar
• One switch, one knob; interfaces with your wirefeeder
• Welds in any axis — vertical, horizontal, or inverted
• Lightweight and highly portable

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Service/Repair Parts Service/Repair Parts Additional Service Parts for Hydraulic Cylinder
Part No. Description Part No. Description 276-2068 Bore Welding Group Service
137-2693 Head Extension, 3 in 276-2071 Swivel #2 Part No. Description
137-2694 Head Extension, 6 in 276-2072 Torch Adapter 137-2698 Torch Assembly #00 Hydraulic Test Centers
137-2695 Head Extension, 12 in 276-2073 Tip, 0.045 in 137-3585 Torch Assembly #0
137-2696 Head Extension, 18 in 276-2074 Tip, 0.045 in Automatic Welding

137-2699 Tip #00 276-2075 Nozzle #00
137-2704 Tip, 0.035 in 276-2076 Nozzle #0 Boring Bar
137-2705 Diffuser 276-2077 Liner, 0.023 - 0.045 in
137-2723 Tip, 0.030 in 276-2078 Mounting Rod Uninterruptible
137-2724 Tip, 0.045 in 276-2079 Power Cord Power Supply
137-3387 Nozzle 276-2080 Cable Gas Cutting/
137-3586 Tip #0 276-2081 Cable Welding Equipment
276-2069 Bore Kit, 22.35 to 76.2 mm (0.88 to 3 in) diameter 276-2082 Cable
276-2070 Swivel #1 277-8325 Cable Weld Protection
Bore Welding Groups

Discontinued — Service Parts Available
137-2700 Bore Welding Group (110V)
138-8215 Bore Welding Group (110V with auto-skip)
138-8212 Bore Welding Group (220V)
138-8213 Bore Welding Group (220V with auto-skip)
Reference
Service/Repair Parts Service/Repair Parts Service/Repair Parts

Part No. Description Part No. Description Part No. Description
137-2682 Bulk Liner 137-2687 Wire Feeder 137-2701 Torch Assembly #1
137-2688 Wire Feed Roll, 0.024 in/0.030 in 137-2680 Bore Welder 137-2702 Torch Assembly #2
137-2689 Wire Feed Roll, 0.035 in/0.045 in 140-0458 Control Cable 137-2703 Torch Assembly #3
137-2692 Wire Feed Conduit, 5 ft 138-8765 Control Cable 137-2711 Torch Assembly #4
137-2699 Tip #00 138-8216 Control Box 137-2712 Torch Assembly #5
137-2704 Tip #.035 138-8213 Bore Welding Group 137-2713 Torch Assembly #6
137-2705 Diffuser 138-8212 Bore Welding Group 137-2714 Torch Assembly #7
137-2723 Tip #.030 138-8215 Bore Welding Group 137-2715 Torch Assembly #8
137-2724 Tip #.045 137-2721 Trammel Torch Assembly 137-2716 Torch Assembly #9
137-2728 Conduit Wire, 3 ft 137-2720 Radial Torch Assembly 137-2717 Torch Assembly #10
137-3386 Nozzle Holder 140-0459 Wire Feed Hose, 10176 Bortech# 137-2718 Torch Assembly #11
137-3387 Nozzle 137-2681 Spindle Fittings 137-2719 Torch Assembly #12
137-3586 Tip #0 137-2683 Limit Switch 137-3585 Torch Assembly #0
137-2700 Bore Welding Group, 110V 137-2684 Limit Switch 137-2722 MIG Gun
137-1242 Bore Welder-AskP 137-2685 Worm Gear 137-2725 Offset Support
137-2726 Power Connector 137-2686 Pinion-Rack 137-2727 Counterbalance Torch
137-2709 Power Cable 137-2693 Head Extension, 3 in 138-8209 Main Bearing Adapter
137-2708 Power Cable 137-2694 Head Extension, 6 in 138-8218 Nut-Flange
137-2707 Power Control Cable 137-2695 Head Extension, 12 in 139-1241 Electrode Holder
137-2706 Power Control Cable 137-2696 Head Extension, 18 in 155-4152 Speed Reduction Pulley (used with torches (#9-12)
137-2691 Gas Hose, A1018 Bortech# 137-2697 Radial Mount 155-4153 Speed Reduction Belt (used with torches (#9-12)
137-2690 Control Box 137-2698 Torch Assembly #00 162-2744 Insulating Bushing
All part numbers in the table have a six month warranty

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Hydraulic Cylinder
Service Automatic Welding Groups
Discontinued — Service Parts Available
Automatic Welding
Boring Bar 1U-9600 Automatic Welding Group, 110V, 240V, 60 Hz
1U-9601 Automatic Welding Group, 110V, 240V, 50 Hz
Uninterruptible
Power Supply Reference
NEHS0513 Operating Manual
Gas Cutting/
Welding Equipment
Weld Protection ID: C66995T1

1 1U-9616 Speed Control Assembly 13. 1U-9635 Contact Tip, (.035 in)(1U-9600 only)(qty 5)
2 1U-9604 Column 1U-9638 Contact Tip Short, (.035 in)(1U-9600 only)(qty 5)
1U-9617 Contact Tip, (.08 mm)(1U-9601 only)(qty 5)
3 Tool Group (not serviced) 1U-9637 Contact Tip Short, (.030 in — Short tip for 0.8 mm wire)(1U-9601 only)(qty 5)
Open End Wrench, 17 to 19 mm
Open End Wrench, 14 to 17 mm 14 1U-9614 Nozzle Extension (Long)
Open End Wrench, 8 to 10 mm 1U-9615 Nozzle Extension (Short)
Hex Wrench, 6 mm 15 1U-9623 Nozzle Holder (Long)(qty 2)
Diagonal Pliers 1U-9624 Nozzle Holder (Short)(qty 2)
4 4C-9308 Power Cord — 1U-9600 only 16 1U-9630 Torch body
1U-9609 Power Cord — 1U-9601 only 17 1U-9607 Barrel Extension (Long)(qty 2)
5 1U-9610 Coil Cord 18 1U-9626 Nut
6 Magnetic Base (not serviced) 19 1U-9627 Torch Holder Assembly
1U-9633 Transformer
1U-9602 Electromagnet (qty 4) 20 1U-9612 Torch Adapter (former, 12 mm thread)
1U-9620 Controls Fuse (250 V, 3.15 A) (qty 2) 9U-5135 Torch Adapter (16 mm thread)
1U-9619 Power Fuse (250 V, 2 A) 21 1U-9605 Centering Fixture
7 1U-9625 Bushing (qty 2) 22 1U-9613 Teflon Liner (10 Meter Pkg)
8 1U-9629 Barrel Clamp 23 1U-9608 Adapter (No 3 Morse Taper)
9 1U-9628 Bruch Holder (former, 12 mm thread) 24 1U-9611 Remote Control
1U-5134 Bruch Holder (16 mm thread)
25 1U-9603 Head and Clutch Assembly
10 1U-9639 Torch-Barrel Extention (Short)
26 1U-9634 Drive Motor (1:360 Gear Ratio)
11 1U-9606 Centering Cone 1U-9632 Gear and Clutch Assembly
12 1U-9621 Gas Nozzle (Long) (qty 2) 1U-9631 Drive Motor (Optional 1:500 Gear Ratio)
1U-9622 Gas Nozzle (Short) (qty 2) All part numbers in the table have a six month warranty
1U-9640 Gas Nozzle (Short — 1U-9622 Modified)
161-6202 Wire Feeder

SMCS Code: 0679
Model: All Models
• Used with 1U-9600 Bore Welder to weld worn or distorted bores

(wire feeder designed with Caterpillar specifications)
• Automatic voltage sensing makes this wire feeder perfect for bore
welding and general applications
• Includes stub burn-off to prevent wire from sticking inside bore
• Weld wire is non-conductive until gun trigger is pressed
• Operates entirely on Arc Voltage utilizing a single weld power supply
• Internal contact and gas solenoid valve
• Gas flow meter mounted on unit for ease of use
• Stainless steel case
Reference
NEHS0628 Tool Operating Manual ID: C79162T1
Continuous duty rating 450 Amp with 12 foot MIG gun

Meters voltage, amperage, and wire feed speed
Overall size 44.5 x 23 x 32 cm (17.50 x 9.0 x 12.5 in)
Spool size and weight 8 inch thru 30 lb. spools (including 14 lb.
coils of wire)
Polarity straight or reverse

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Service/Repair Parts Service/Repair Parts Service/Repair Parts Hydraulic Cylinder

Part No. Description Part No. Description Part No. Description Service
1U-6160 Welder Power Supply 1U-6186 Drive Roll Smooth V 1U-9015 Neck
1U-6162 Weld Power Supply 1U-6187 Work Clip Assembly 1U-9016 Switch Assembly Hydraulic Test Centers
1U-6163 Hand Control 1U-6188 Volt Meter 1U-9017 O-ring
1U-6164 Outlet Wire Guide 1U-6190 Inch Switch 1U-9018 Liner, 12 Foot Automatic Welding
1U-6165 Outlet Wire Guide 1U-6191 Drive Roll Key 1U-9019 Liner, 12 Foot
1U-6166 Outlet Wire Guide 1U-6192 Fuse Holder 1U-9020 Liner, 12 Foot Boring Bar
1U-6167 Flow Meter (Four-way) 1U-6193 Outlet Guide 1U-9021 Liner Retaining Nut
1U-6168 Handle 1U-6194 Outlet Guide 1U-9022 Connector Uninterruptible
1U-6171 Drive Roll 1U-7644 Speed Control Dial 1U-9025 Handle Power Supply
1U-6172 Drive Roll 1U-7645 Drive Roll 1U-9026 Neck Assembly Gas Cutting/
1U-6173 Drive Roll 1U-9004 Welding Cable 1U-9027 Switch Welding Equipment
1U-6174 Drive Roll 1U-9005 Nozzle 4C-6610 Input Connector
1U-6175 Drive Roll 1U-9006 Nozzle 4C-6611 Knob Weld Protection
1U-6176 Potentiometer 1U-9007 Contact Tip 4C-6612 Hub Pin
1U-6177 Fuse, 8 Amp 1U-9008 Contact Tip 4C-6613 Cable Assembly
1U-6178 Polarity Switch 1U-9009 Contact Tip 4C-6614 Gun
1U-6179 On-Off Switch 1U-9010 Contact Tip 4C-6618 Gun
1U-6180 Gas Inlet Fitting 1U-9011 Contact Tip 4C-8214 Liner, 15 Foot
1U-6182 Inlet Guide 1U-9012 Contact Tip 4C-8215 Liner, 15 Foot
1U-6183 Connector Gun Switch 1U-9013 Diffuser 4C-8216 Liner, 15 Foot
1U-6184 Drive Roll Smooth V 1U-9014 Insulator 4C-8218 Switch Cable Extension
1U-6185 Drive Roll Smooth V 4C-8219 Remote Switch Assembly
Boring Bar
Hydraulic and Portable Boring Bars

SMCS Code: 0679
Model: All Caterpillar Machines
• Used to repair worn bores — lowers customer machine operating Boring Bar Power Units
costs and increases service shop revenue • Exclusive load sensing hydraulic feed
• Used with 1U-9600 Welding Group • Remote pendant control
• Easy to set-up and operate • Specially designed six-finger centering cones provide quick, accurate
• One set-up for machining and welding (increases efficiency and bar centering, even on badly worn bores
produces more reworked holes per hour) • Adjustable aluminum support bearings will rigidly support bar,
• Mounting hardware allows machining of hole before welding feed/drive unit, and Bore Welder
(helps eliminate impurities in weld) • Prehardened to Rc65 and broached on 101.6 mm (4.00 in) centers
• Two in-line bores can be welded and machined simultaneously for tool holders
(maximizes production by machining one bore while welding the other)
Reference
Portable Boring Bar Unit (110 and 220 Volts) SEHS8985 Special Instruction, Using the 1U-8660 Boring Bar Hydraulic
• Designed as light-duty boring machine Unit and Attachments
• Suited for field applications, small shops, and light machining NEHS0579 Tool Operating Manual, Portable Boring Bar Unit
NEHS0513 Tool Operating Manual, Using the 1U-9600 Welding Group
Hydraulic Boring Bar Unit NEHP5606 Product Brochure, Boring Bar/Bore Welder
• Used to machine bores on dozer frames, loader lift arms, center
hitches, scraper hitches, and many other locations
• Also used to counter bore and spot face
System Back Weight Weight of

Pump relief relief Speed Input Output of power feed and
Part No. Power Gear pump Hydraulic reservoir valve valve pressure Full load rpm No Load rpm watts watts unit drive unit
9U-5730 110 Volts, 3.8 lpm 5.7 lpm 2400 kPa 2070 kPa 965 kPa 4 100/150/260/420 170/250/450/700 900 500 73 kg 33 kg
single phase, (1.0 gpm) (1.5 gpm) (350 PSI) (300 PSI) (140 PSI) (160 lbs) (72 lbs)
60 Hz, 1725 rpm at 1800 rpm
9U-5889 220 Volts, 3.2 lpm 5.7 lpm 2400 kPa 2070 kPa 965 kPa 4 100/150/260/420 170/250/450/700 900 500 73 kg 33 kg
single phase, (.84 gpm) (1.5 gpm) (350 PSI) (300 PSI) (140 PSI) (160 lbs) (72 lbs)
50 Hz, 1425 rpm at 1500 rpm

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Hydraulic Cylinder 1U-8660 Hydraulic Boring Bar

Service Power 45 Amps at 230 VAC, 27 Amps at 460 VAC
Hydraulic fluid capacity 150 L (40 gal)
Hydraulic Test Centers Weight 408 kg (900 lbs)
Automatic Welding
Boring Bar
Uninterruptible
Power Supply
Gas Cutting/
Welding Equipment
ID: C79719T1
Weld Protection
ID: C79199T1
Uninterruptible Power Supply
Uninterruptible Power Supply Tools

SMCS Code: 4480-039
Model: Uninterruptable Power Supply (UPS) 250
Warranty: None
190-8379 Insertion Tool Group • Shims included in kit: (shims are not sold separately)
• Used to insert bearing cartridge onto flywheel assembly 190-8381 Brass Shim — 0.05 mm (.002 in), Qty 8
190-8382 Brass Shim — 0.13 mm (.005 in), Qty 4
190-8385 Removal Tool Group 190-8383 Brass Shim — 0.25 mm (.010 in), Qty 2
• Used to remove bearing cartridge from flywheel assembly 190-8384 Brass Shim — 0.50 mm (.020 in), Qty 1
190-8386 Rotor Shim Tool (4 required) 191-5217 Guide Pin (2 required)
• Used to protect rotor assembly during installation and removal • Used to retain proper alignment of bearing cartridge on flywheel
of bearing cartridge assembly during installation or removal
190-8380 Spare Shim Kit Reference
• Used to shim upper or lower bearing
Other UPS Products:
NEX65029 Caterpillar UPS View Software Group
190-8487 Vacuum Pump Oil
1
3
Item Part No. Description
1 190-8379 Insertion Tool Group
2 190-8385 Removal Tool Group
3 190-8386 Rotor Shim Tool
4 191-5217 Pin Guide
2
4
ID: C80060T1

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Hydraulic Cylinder
224-3145 Drain Service Group Service
SMCS Code: 4480, 0766
+
Model: UPS 300 Hydraulic Test Centers
Essential Tool
Warranty: None
240-1666 Automatic Welding
• Used to service charge drain load cells on Uninterruptable
Power Supply (UPS) 300 Boring Bar
Service/Repair Parts
Uninterruptible
Power Supply
Part No. Description Qty.
229-0670 Contact Strip 4 229-0670 229-0671 Gas Cutting/
229-0671 Test Wedge 1
Welding Equipment
240-1666 Bolt 1
ID: D00985T1
Weld Protection
User Instructions
216-7886 Rotar Position Sensor Shim Kit

SMCS Code: 4480-039
Model: Uninterruptible Power Supply (UPS) 250/500/750 and 300/600/900
• Used to set gap between Rotar Position Sensor and commutation wheel
• Includes ten 5 mil shims with 0.373 OD and 0.165 ID and ten 10 mil shims with 0.390 OD and 0.157 ID
NEXG5041 Caterpillar UPS View Software Group for UPS 250

SMCS Code: 4480-039
Model: Uninterruptable Power Supply (UPS) 250/500/750 and 300/600/900
Warranty: None
Caterpillar UPS View is a monitoring software designed to run on a Specifications/Technical Information

personal computer under Microsoft Windows. With Caterpillar UPS View
you can monitor the Uninterruptible Power Supply (UPS) 250/500/750 or PC Requirements
300/600/900 in real time and display these variables on the computer: • IBM PC compatible with 133 MHz Pentium Processor or a compatible
• Some of the data that is available in current, voltage, rotor speed, processor
temperatures of components and event logs. • 16 Mb of RAM
• Telemetry data, such as voltage, current and temperature are • 3.5 inch 1.44 Mb diskette drive
compared to desired range. • Built-in pointing device or mouse
• Logged telemetry data can be saved to a disk. • TCP/IP Network Protocols and UDP/IP Network Protocols
• Configure data to be displayed as numerals, bar graphs or scrolling • Analog modem for comunicating over analog phone lines
history graphs.
• Network Interface Card (NIC) for remote monitoring over a network
• Screen can be customized to rearrange, group or hide.
• User can monitor UPS’s operation remotely (must use analog phone Software
lines and analog modem must be installed in PC). • Microsoft Windows 95, 98 or NT4.0
• User can setup software with alarm(s) and have operator(s) paged
if alarm occurs. Reference
• Connect to UPS using an analog modem, an RS-232 or RS-485 port SEBU7311 Uninterruptible Power Supply (UPS) 250 Manual
or a network.
Ordering Information
• Caterpillar UPS View software can be ordered through the Corporate
Literature Distribution System.
• NEXG5041 Caterpillar UPS View Software Group includes software
on a floppy disk, a manual, and a DB9 Male/Female Communications
cable 15 feet long.

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Hydraulic Cylinder
Service
Automatic Welding
Boring Bar
Uninterruptible
Power Supply
Gas Cutting/
Welding Equipment
Weld Protection
ID: C80260T1 Other UPS Products

190-8487 Vacuum Pump Oil
190-8379 Insertion Tool Group
190-8380 Spare Shim Kit
190-8385 Removal Tool Group
190-8386 Rotor Shim Tool
191-5217 Pin Guide
216-7886 RPS Shim Kit
Gas Cutting/Welding Equipment
1U-6469 Heavy-Duty Oxy-Acetylene Deluxe Kit

• Complete outfit — V-Series (Victor-Style)

• Cuts to 25.4 mm (1 in), welds to 15.9 mm (5⁄8 in) [cuts to 152.4 mm (6 in) with optional tips]
• Display box not included
Kit Includes Kit Includes

Welding Handle No. 5 Welding Tip
Cutting Attachment (Oxygen/Acetylene) Welding Mixer
HD Oxygen Regulator Twin Hose, 6.35 mm x 6.1 m (1⁄4 in x 20 ft)
HD Acetylene Regulator Striker
No. 1 Cutting Tip Cover Goggles
Instruction Manual ID: C33271T1

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Optional Tips Heating Tips Hydraulic Cylinder

Metal Oxygen Acetylene Oxygen and Heat Output Service
Thickness Pressure Pressure Acetylene Pressure Range
Part No. (Inches) (PSIG) (PSIG) Part No. Range (PSIG) BTU/Hour Hydraulic Test Centers
Cutting Tips 1U-6479 2-6 30,000-51,000
1U-6458 5⁄ 5
16- ⁄8 30-40 7 1U-6480 3-7 44,000-74,000 Automatic Welding
1U-6459 5⁄
8-1 40-50 7
1U-6460 1-2 45-55 8
Boring Bar
1U-6461 2-3 50-60 9 Replacement Parts
1U-6462 3-4 60-75 10 Part No. Description Uninterruptible
1U-6463 4-6 70-80 12 Power Supply
1U-6472 Torch Handle
Welding Tips 1U-6477 Mixer Gas Cutting/
1U-6445 1⁄
64 1 1 1U-6474 Cutting Attachment Welding Equipment
1U-6446 1⁄
32 1 1 4C-4132 Oxygen Regulator, Two Stage HD
Weld Protection
1U-6447 3⁄ 2 2 4C-4129 Oxygen Regulator, Single Stage HD
64
1⁄ 4C-4128 Acetylene Regulator, Single Stage HD
1U-6448 16 3 3
1⁄
4C-4131 Surge Guard for Oxygen Regulator
1U-6449 8 5 5
1U-6466 Valve Reverse Flow Oxygen
1U-6450 3⁄ 4 4
32
1U-6465 Propane Valve Reverse Flow Acetylen
1U-6451 3⁄ 6 6
16
1U-6453 5⁄ 8 8
16
1U-6454 3⁄ 9 9
8
1U-6455 1⁄ 10 10
2
1U-6470 Heavy-Duty Oxy-Acetylene Deluxe Kit —Vac Pac

• Display box not included Kit Includes

Welding Handle
Cutting Attachment
Oxygen Regulator
Acetylene Regulator
No. 1 Cutting Tip
No. 5 Welding Tip
Welding Mixer
Twin Hose, 4.76 mm x 6.1 m (3⁄16 in x 20 ft)
Striker
Cover Goggles
Instruction Manual
ID: C33272T1
4C-4113 Heavy-Duty Oxy-Propane Deluxe Kit — Vac Pac

• Cuts to 25.4 mm (1 in) metal [to 152.4 mm (6 in)
with optional tips]
• Heating output to 30,000-100,000 BTU/hour. Optional Tips
• Display box not included Metal Oxygen Propane
Thickness Pressure Pressure
Part No. (Inches) (PSIG) (oz)
Cutting Tips
Kit Includes
4C-4114 3⁄ -5⁄ 30-40 4-7
8 8
Welding Handle
4C-4115 5⁄ -1 35-50 4-7
8
Cutting Attachment (Propane)
HD Oxygen Regulator 4C-4116 1-2 40-55 4-7
HD Propane Regulator 4C-4117 2-3 45-60 4-7 ID: C33271T1
Striker 4C-4118 3-6 50-75 4-7 Replacement Parts

Cover Goggles Brazing Tips Part No. Description
Twin T-Hose, 6.35 mm x 6.1 m (1⁄4 in x 20 ft) Tip Oxygen Fuel Gas 4C-4158 Torch Handle
Instruction Manual Part No. Size PSI PSI 4C-5833 Mixer
9U-6715 4N 20 4 oz 4C-4159 Cutting Attachment
9U-6716 6N 25 4 oz to 2 lb 4C-4130 Propane Regulator single stage HD
9U-6717 10N 40 4 oz to 2 lb 4C-4131 Surge Guard

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Hydraulic Cylinder
Service MIG/TIG Flowmeter Regulators
• Construction incorporates regulator and flowmeter into one compact unit.
• Flow to 70 S.C.F.H.
Automatic Welding
• Strong easy-to-read Lexan flow tube and cover
• Flow tube is easily changed for different gases.
Boring Bar • Dual calibration on argon/carbon dioxide flow tube
• Regulator is pre-set at 50 P.S.I.G.
Uninterruptible
Power Supply • Flowmeter is not affected by downstream pressure variations.
• Sensitive needle valve for fingertip control
Gas Cutting/ • U.L. listed
Welding Equipment Flow Delivery
Capacity Cylinder Rate
Gas Part No. (SCFH) Connection (SCFH) ID ph2, C33393T1
Weld Protection
Argon 4C-4125 0-70 580 70
Carbon Dioxide 4C-4126 0-70 320 70
MIG/TIG Flowgauge Regulators

• For accurate measurement of gas flow to 40 S.C.F.H.

• Sensitive brass adjusting key provides smooth action, and fingertip control.
• Lightweight, rugged design
• Easy-to-read gauges
• U.L. listed
Flow Delivery
Capacity Cylinder Rate
Gas Part No. (SCFH) Connection (SCFH)
Argon 4C-4123 0-40 580 40
Carbon dioxide 4C-4124 0-40 320 40
ID: C33281T1
Welding Hose
Check Valves
• External type for easy inspection

• For use on any torch with “B” hose connections (9⁄16 inch-18 threads)
• Stops reverse flow of gas
Oxygen or Fuel Gas Inlet

1U-6465 Fuel Gas
ID: C33283T1 1U-6466 Oxygen
Part No. Description Dimensions

1U-8215 Twin Welding Hose 4.76 mm x 3.66 m (3⁄16 in x 12 ft)
1U-6573 Circle Cutting Attachment

• For cutting circles up to 762 mm (30 in) in diameter as well

as straight line burning
• A swivel nut permits circle cutting without tangling hoses.
• Wheels are adjustable for individual torch height.
• Makes better quality cuts possible with hand torches ID: C58189T1

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Hydraulic Cylinder
Heating and Flame Cleaning Equipment Service
Warranty: Manufacturer’s Six Months
Automatic Welding
Boring Bar
Uninterruptible
Item Part No. Description ID: D01531T1
Power Supply
1 4C-5830 Mixer Gas Cutting/
Part No. Description Length
2
ID: C58187T1 4C-5823 Handle Welding Equipment
4C-5831 Tip Tube 914.4 mm (36 in)
9U-6718 Tip Tube 711.2 mm (28 in)
Repair Information Weld Protection
4C-5832 Tip Tube 381 mm (15 in)
Harris Calorific Division
All part numbers in the table have no warranty
The Lincoln Electric Company
2345 Murphy Boulevard
Gainesville, GA 30504 Heating Tips
Phone: (770) 536-8801 Oxygen Propane
Fax: (770) 535-0544 Pressure Flow Pressure Flow Heat Output
Part No. PSIG CFH PSIG CFH BTU/Hr.
4C-4160 10 160 4 40 101,200
25 320 12 80 202,400
4C-4161 15 220 7 55 139,150
45 520 22 130 328,900
4C-4162 25 340 8 85 215,050
70 920 25 230 581,900
4C-4163 50 640 10 160 404,800
110 1300 30 325 822,250
4C-4164 60 720 14 180 455,400
135 1600 40 400 1,012,000
All part numbers in the table have no warranty
ID: C58188T1
8T-7792 Mini Cutting Torch

• Will cut cast iron, stainless steel, high alumina refractory, and slag
• Can be used indoors, because the noise and smoke levels are very low
• Faster and less expensive than carbon arc and requires oxygen only
• Durable, comfortable, and less fatiguing to use
• Large squeeze trigger-type handle control delivers oxygen precisely.
• Excellent tool for gouging hard facing. Unlike carbon arc, the rods contain
no carbon, thus reducing the grinding requirement.
Rod Sizes Used by Mini Cutting Torch

General purpose rods for removing small bolts and pins by piercing
4.76 mm x 55.24 cm (3⁄16 in x 213⁄4 in)
6.35 mm x 55.24 cm (1⁄4 in x 213⁄4 in)
Rods for piercing track pins, washing away welds, and gouging hard facing
9.52 mm x 46.67 cm (3⁄8 in x 183⁄8 in)
ID: C10294T1
Cut off and gouging rod for piercing longer pins and rough cutting
9.52 mm x 91.44 cm (3⁄8 in x 36 in)

Included with Mini Cutting Torch Purchase separately
1 8T-7792 Mini Cutting Torch 5 8T-7697 Rod, 9.52 mm x 914.4 mm (3⁄8 in x 36 in)
2 8T-9110 Washer 6 8T-7696 Rod, 6.35 mm x 55.24 cm (1⁄4 in x 213⁄4 in)
3 8T-7795 Collet, 4.76 mm (3⁄8 in) 7 8T-7698 Rod, 4.76 mm x 45.72 cm (3⁄8 in x 18 in)
4 8T-7794 Collet, 6.35 mm (1⁄4 in) Not shown 8T-9201 Rod, 4.76 mm x 55.24 cm (3⁄16 in x 213⁄4 in)
Not shown 8T-9202 Collet, 4.76 mm (3⁄16 in) Not shown 8T-7699 Igniter
Not shown 8T-7793 Striker Plate Not shown 9U-5614 Shield
Not shown 8T-9287 Washer Not shown 9U-5615 Collet Nut-Brass
Not shown Form SEHS8923

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Hydraulic Cylinder
Service Plasma Arc Cutting
Warranty: None
Hydraulic Test Centers Before plasma cutting came into existence, service shops wanting to cut steel, stainless steel, or aluminum typically used several different methods.
For example, they would use oxygen fuel flame cutting for steel and mechanical means such as shears or power saws for stainless steel and aluminum.
With plasma arc cutting (PAC) these shops can now cut all common or exotic metals that conduct electricity.
Automatic Welding
Plasma arc cutting (PAC) with air uses electricity to create a superheated gas (called plasma) to melt metal and blow it away. The temperature at the
nozzle opening of the cutting torch can reach 33 315.6°C (60,000°F). As a result, the arc melts and removes small portions of metal quickly, leaving
Boring Bar behind a smooth, clean cut and a narrow heat affected zone (the area near the cut in which metallurgical changes often occur).
Uninterruptible Plasma Arc Cutting Benefits

Power Supply • Cost savings — Even though the initial cost of PAC equipment can be higher than with other cutting methods, the payback per cut can be better with
Gas Cutting/ PAC. For example, with faster cutting speeds, and because air and consumables are relatively inexpensive with PAC compared to the cost of gases
Welding Equipment for oxy-fuel, the payback per cut is less expensive with PAC than with oxyfuel.
• Cutting speed — PAC can cut much faster than oxy-fuel, especially on a thickness of less than one inch (see chart below). Besides faster cutting
Weld Protection speeds, PAC requires no preheating of the metal, as does oxy-fuel.
• Versatile cutting capability — Besides mild steel, PAC does an excellent job of cutting stainless steel and aluminum. It will also do a good job on
stacked material.
• Precision cuts — Because the faster cutting speeds (along with no preheating) produces a narrow heat-affected zone, metal distortion is minimal.
It also causes a very clean cut which means PAC can eliminate the secondary operations needed of other cutting methods.
• Air versus other gases — The main advantage of cutting with air is, of course, the availability of air. Where air and power is available, PAC can be
easily moved because of its portable design. Using air is inexpensive and safe compared to other cutting gases such as CO2. PAC, because it uses
air, requires no mixing controls. Low volume compressed air is preferred (i.e., 70 PSI at 300 Cubic Feet Per Hour).
• Ease of use — PAC requires minimum training and is an easy process to use.
Speed Comparison Using Mild Steel
(inches per minute — IPM)
Steel PAC Oxy-Fuel
Thickness IPM IPM
3 mm (1⁄8 in) 80-120 20-30
6.4 mm (1⁄4 in) 34-60 18-20
10 mm (3⁄8 in) 18-40 16-18
The speed of the cut varies and is determined
by the output of the PAC equipment and the
thickness of material being cut.
Weld Protection
237-5181 Welding Respirator

• Meets NOISH 42 CFR 84 N95 requirements. TC-84A0454

• Cool flow exhalation valve promotes worker comfort by offering easy exhalation
for cooler, dry comfort.
• Contours easily to provide a comfortable, good seal
• Economical all-filter design with no spare parts to clean
• Suggested applications: welding, brazing, soldering, torch cutting, metal pouring,
grinding, sanding, sweeping, bagging, general maintenance and operations involving
liquid or non-oil based particle from sprays that do not emit harmful vapors
• Quantity: 10 respirators per box
ID: C80261T1

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Hydraulic Cylinder
235-6479 Half Facepiece Respirator Service
• Swept-back design of the filters/cartridges improves balance and visibility 295-2853 Polypropylene Respirator Cartridge,
• Reusable — just dispose of the cartridge/filters when used to capacity 41⁄2 inch diameter Automatic Welding
• Comfortable, lightweight facepiece and easy-to-adjust head straps • NIOSH approved P100 filter, 99.97% efficient
• Size: medium • Protects against solid and liquid particulates that may contain oil
Boring Bar
• Package quantity: 6 respirators • Easy-breathing, low-resistance, no other holders required
• Filter not included • Off-center adapters for optimal peripheral vision
Uninterruptible
• Package quantity: ten filters Power Supply
Replacement Filters
236-6597 P100 High Efficiency Filter Gas Cutting/
236-6598 Organic Vapor Cartridge • For applications including welding, brazing, torch cutting, pouring Welding Equipment
• Provides respiratory protection from certain organic vapors at and soldering, as well as protection against OSHA substance-
concentrations up to 10 times the Permissible Exposure Limit (PEL) with specific particle exposures such as lead, asbestos, cadmium,
half facepieces Weld Protection
arsenic and MDA
• Package quantity: ten 2-packs of filters • Package quantity: ten 2-packs of filters
ID: D01567T1
ID: D00282T1
1U-8097 Welding Helmet 1U-8100 Welding Helmet
Warranty: Six Months Warranty: Six Months
• 51 mm x 108 mm (2 in x 41⁄4 in), “shade 10” lens • Features a shade 10 lens but in a larger size — 114 mm x 133 mm (41⁄2 in x 51⁄4 in)
• Ratcheting headgear adjusts to fit any head size. • Has ratcheting head gear
• Nylon material is lightweight and durable. • Made of sturdy nylon material
Replacement Lens for 1U-8097

and 1U-8100 Welding Helmets
Lens
Part No. Type Use For:
1U-8098 Shade 5 Tinted Glass1 1U-8097
1U-8099 Plastic Cover Plates3 1U-8097
1U-8102 Plastic Cover Plates3 1U-8100
1 Shade 5 lens used for medium to heavy gas
torch cutting [25 mm (1 in) and up] and light to
medium gas torch welding [up to 13 mm (1⁄2 in)]
2 Shade 10 lens used for welding with manual
weld electrodes
3 Two needed, one inside and one outside of your
ID: C34434T1 ID: C44003T1
tinted glass lens
Replacement Parts for Ultrashade Welding Helmets

Model: 221-1376 and 221-1377 Ultra Shade Welding Helmets
Warranty: Manufacturer’s
• Removable lens frame with replaceable front and inside covers Part No. Description Package Qty.
• Curved design ensures optical quality and visibility 235-0876 Front Lens Cover Kit 10 lenses
• Made from high-temperature plastic—withstands 150°C (302°F) 235-0877 Inside Lens Cover Kit 5 lenses
235-0878 Lens Frame
Repair Information
Harris Calorific Division
The Lincoln Electric Company
2345 Murphy Boulevard
Gainesville, GA 30504
Phone: (770) 536-8801
Fax: (770) 535-0544

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Hydraulic Cylinder
Service 1U-8103 Welding Goggles 1U-8104 Welding Goggles
Warranty: Six Months with Lift Front Lens
Hydraulic Test Centers Warranty: Six Months
• Feature a shade 5 lens, good ventilation, and a light-tight fit
Automatic Welding • Feature the shade 5 lens with a hinged front-lift door
Boring Bar
Uninterruptible
Power Supply
Gas Cutting/
Welding Equipment
Weld Protection
ID: C44001T1
ID: C41322T1
1U-8105 Eye Cup Welding Goggles

• Shade 5 lens eye goggles that conform to eye area assuring tight and safe seal
• Feature anti-fog ventilation
Replacement Lens for 1U-8105 Eye Cup Welding Goggles

1U-8106 Shade 5 tinted replacement lens1
1U-8107 Clear replacement lens
1 Shade5 lens used for medium to heavy gas torch cutting [25 mm (1 in)
and up] and light to medium gas torch welding [up to 13 mm (1⁄2 in)]
ID: C41321T1
Welding Jacket
• Made of flame resistant, sturdy 269 g (9 oz) sateen fabric treated for permanent fire retardant
• Finished in a dark green color
• Lightweight and provides excellent protection from flash, flame, and sparks
• Black no-glare snaps
• Adjustable snaps at the cuff Part No. Description Size
• Roll collar can be turned up 1U-6586 Welding Jacket Large
• Flame retardant good up to 50 washes in mild soap 1U-6587 Welding Jacket Extra Large
ID: C41311T1
185-0151 Welding Coat (Large)

185-0152 Welding Coat (Extra Large)
• 30 inch leather jacket with raglan shoulder design for utmost mobility
• Double stitched seams with 5 ply Kevlar thread provide superior strength
• Multiple position snap adjustment provides maximum protection and comfort
• Roll-up collar with three-snap adjustment
• Locker handling loop, soap stone shoulder pocket, and inner leather pocket
Part No. Description Chest Size

185-0151 Welding Coat (Large) 44 inch to 46 inch
ID: C41308T1
185-0152 Welding Coat (Extra Large) 48 inch to 50 inch

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Hydraulic Cylinder
185-0143 Cape (Large) 185-0153 Leather Welding Gloves Service
185-0144 Cape (Extra Large) Hydraulic Test Centers
185-0150 Bib
Warranty: Six Months • Chrome tanned, split Automatic Welding
leather glove with
European Union compliant, CE marked Cat logo
• Premium glove for an Boring Bar
• Leather cape with raglan shoulder sleeves economical price
for mobility Uninterruptible
• Gunn pattern with
• Double stiched seams with 5 ply Kevlar a straight thumb Power Supply
thread • Comfortable full Gas Cutting/
• Roll-up collar with three snap adjustment semi-sock, flame Welding Equipment
• Includes locker hanging loop and soap retardant lining
stone shoulder pocket • One-piece back Weld Protection
• Bib is cut extra wide — • Welted thumb and forefinger
22 inches wide x 20 inches long for extra life
ID: C41307T1 • One size: large
ID: C41312T1
Welding Blanket
Warranty: Five years against manufacturer’s defects
• Made of a fiberglass textile material

• Light gold neoprene coating on one side to reduce fraying
• Hemmed and seamed with Kevlar thread
• Retains heat
• Protects welding area
Repair Information
Singer Safety Company
2300 N. Kilbourne Avenue
Chicago, IL 60639
Part No. Description Dimensions
Phone: (800) 621-0089
4C-9616 Blanket 183 cm x 183 cm (6 ft x 6ID:ft)C44239T1
4C-9617 Blanket 183 cm x 244 cm (6 ft x 8 ft)
4C-9618 Blanket 183 cm x 305 cm (6 ft x 10 ft)

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Hydraulic Cylinder Service 8-1 Gas Cutting/Welding Equipment 8-18

Automatic Welding 8-12

Boring Bar 8-15

Uninterruptible Power Supply 8-16

Home Dealer Service Tools 2006

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

Hydraulic Cylinder Service Hydraulic Cylinder

Hydraulic Test Centers

Extended Cylinder Cylinder Diameter Gas Cutting/

Adapters for Spline Drive Sockets

Dealer Service Tools 2006 8-1

Automatic Welding European Union compliant, CE marked (152-4252, 152-4255)

Boring Bar Extended Cylinder Cylinder Diameter

Adapters for Spline Drive Sockets

8-2 Dealer Service Tools 2006

Cylinder Cleaning and Storage

Dealer Service Tools 2006 8-3

• Used to aid mechanic in flow testing of various hydraulic systems —

8-4 Dealer Service Tools 2006

• Manual hone components need to be ordered separately. Automatic Welding

Manual Hone Boring Bar

1U-7608 Chain Wrench

• Used to remove and install threaded crowns on hydraulic cylinders

Chain length 711.2 mm (28.00 in)

Dealer Service Tools 2006 8-5

Hydraulic Cylinder Hydraulic Test Centers

Hydraulic Test Centers

8-6 Dealer Service Tools 2006

Service/Repair Parts Hydraulic Cylinder

Hydraulic System Replacement Parts

Dealer Service Tools 2006 8-7

8-8 Dealer Service Tools 2006

• Used for hydraulic pump and motor testing Automatic Welding

1U-9835 13T-8/16 133-2329 21T-16/32

1U-9838 13T-12/24 9U-5277 N45X2X30X21X9g DIN 5480 - 21T

1U-9833 13T-1632 1U-9132 23T-16/32

1U-9841 14T-10/20 1U-6433 N5OX2X3OX24X9g DIN 5480 -24T

1U-9834 14T-12/24 142-8576 N55X2X3OX26X9g DIN 5480 - 26T

9U-5747 14T-20 DEG JIS 128-0794 27T-16/32 SPL

131-6452 N30X2X3OX14X9g DIN5480 - 14T 131-8620 N60X2X3OX28X9g DIN 5480 - 28T

9U-7519 15T-8/16 4C-4705 30T-16/32

9U-5744 15T-12/24 4C-4703 32T-16/32 External Spline

9U-7520 15T-10/20 1U-9844 11⁄4 SAE B Keyed shaft

9U-7063 16T-20 DEG JIS 1U-9845 13⁄4 SAE B Keyed shaft

Adapter Plates and Stand Assembly

Part No. Spline ID: D00439T1

4C-4679 32T-16/32 External

Bench Testing Hydraulic Components Fittings and Drive Connections

Item Part No. Description Item Part No. Description

8-10 Dealer Service Tools 2006

9U-5893 Heat Exchanger

• Used to test pump on any test bench

1U-6392 Pressure Reducing Valve

Dealer Service Tools 2006 8-11

2 6V-4143 Coupler 1⁄ inch NPT female-valved

4 1P-2375 Nipple 1⁄ inch NPT male-valved (68900 kPa)

5 1P-2376 Coupler 1⁄ inch NPT female-valved (68900 kPa)

Test Port Adapters

Bore Welding Groups