- Caterpillar Products: All
Important Safety Information
European Union Compliant, ICE marked
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DUST) for the latest available information.
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
Personal Protection/Important Information
|Crushing hazard (foot)|
|Crushing hazard (hand)|
|Electrical Shock - Hazard|
At operating temperature, the hydraulic tank is hot and under pressure.
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.
Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.
Personal injury or death can result from escaping fluid under pressure.
Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Always use a board or cardboard when checking for a leak.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected.
This action also lessens the chance of oil spills.
Using the 4C-6090 Multichannel Temperature Selector
The 4C-6090 Multichannel Temperature Selector (with optional cable pack) can measure 16 individual temperatures. This instrument is used with the 6V-9129 Temperature Adapter and a 6V-7070 Multimeter or a 6V-7800 Multimeter . The serviceman can connect the type K exhaust thermocouples used in the Caterpillar 3500 series captive engines to a selector readout in the cab of the vehicle and check for faulty injectors.
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:USA: 1-800-542-8665, Option 1International:: 1-309-578-7372
Components of the 4C-6090 Multichannel Temperature Selector Group
4C-6090 Multichannel Temperature Selector Includes:
- 4C-6096 Adapter Cable (service/replacement part)
- 4C-6089 Foam Insert
- 4C-6093 Cable Pack , Ch. 1-8 (service/replacement part)
- 4C-6097 Cable Pack , Ch. 9-16 (service/replacement part)
- 4C-6085 Plug-miniature (service/replacement part)
- 4C-6094 Connector - T/C (service/replacement part)
|Input -    ||16 channels, type K thermocouple, miniature connector    |
|Output -    ||switch selectable, any one of 16 inputs, miniature connector    |
|Length:    ||311 mm (12.25 inch)    |
172 mm (6.78 inch)
394 mm (15.5 inch)
4.5 kg (10.0 lb)
For the vehicles using Caterpillar Series 3500 engines and having engine serial numbers after the ones listed, the thermocouples are installed in the engines at assembly.
|99W2034 -    ||D11N & 777    |
|96Z0552 -    ||785    |
|54Z0404 -    ||789    |
If the vehicle has an engine serial number before the numbers listed above, the dealer may retrofit the thermocouples to this equipment. The part numbers for the retrofit are: 7E-6830 Thermocouple , 5N-2126 Fitting , and 6K-8179 Clamp . (See next page) A small amount of 4C-5598 High Temperature Anti-Seize should be applied to the fitting before installation.
To make a temperature test on the engine, remove the 4C-6093 8 Channel Cable Pack from storage compartment in lid and route to engine compartment. The cable pack is separated into odd and even-numbered connectors on one end. To connect thermocouple to cable pack, disconnect protective plug from thermocouple and connect the appropriately numbered cable to the thermocouple, observing connector polarity. Connect the small 4C-6095 Male Connectors to the correct inputs on the 4C-6090 Multichannel Temperature Selector . Plug the 6V-9129 Temperature Adapter into multimeter using the "V"olts and "Com"mon terminals. Connect the short output, 4C-6096 Adapter Cable to the output connector on the 4C-6090 Multichannel Temperature Selector and to the input connector of the 6V-9129 Temperature Adapter , observing polarity. Test the battery in 6V-9129 Temperature Adapter at this time and if output is below 7 V, replace the battery. Determine the correct range on multimeter (see Table 3) and select the desired scale for readout.
|Expected Temperature    ||Vdc Range    |
200° C (390.0° F)
|0-200 m Vdc    |
200° C (390.0° F)
|0-2 Vdc    |
Note: The decimal point is not used when reading temperatures above 199.9° C or 199.9° F.
Example A reading of .565 = 565°, 1.200 = 1200°.
Note: Due to temperature adapter internal limitations, the maximum temperature to be measured should not be more than 900° C (1652.0° F)
With the channel selector switch is in the "OFF" position, the readout should display ambient temperature. Bring engine to operating temperature, load engine, and switch through the individual channels. A difference of 84° C (150.0° F) or more than the average between cylinders would be an indication of trouble at that cylinder.
To load the engine on the trucks, stall the truck against the brakes with the transmission in the highest gear. Be careful not to overheat the oil in the torque converter. On the Series D11N, implement hydraulics or 3F transmission stall should provide sufficient load on the engine. Again be careful to watch oil temperatures.
Cylinder and Valve Location
|Specifications    ||Engine    |
|Number and Arrangement of Cylinders    ||60° V-8    ||60° V-12    ||60° V-16    |
|Valves per Cylinder    ||4    ||4    ||4    |
34.5 L (2105.00 cubic inch)
51.8 L (3158.00 cubic inch)
69.1 L (4210.00 cubic inch)
170 mm (6.7 inch)
190 mm (7.5 inch)
|Compression Ratio    ||13:1    |
|Type of Combustion    ||Direct Injection    |
0.38 mm (0.015 inch)
0.76 mm (0.030 inch)
|Firing Order (Injection Sequence)    |
|Engine    ||SAE Standard Rotation*    ||SAE Opposite Rotation*    |
|3508    ||1-2-7-3-4-5-6-8    ||1-8-7-2-6-5-4-3    |
|3512    ||1-12-9-4-5-8-11-2-3-10-7-6    ||1-4-9-8-5-2-11-10-3-6-7-12    |
|3516    ||1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8    ||1-6-5-4-3-10-9-16-15-12-11-14-13-8-7-2    |
*Direction of rotation (as viewed from flywheel end):
SAE Standard Rotation - Counterclockwise
SAE Opposite Rotation - Clockwise
Note: Front end of engine is opposite the flywheel end. Left side and right side of engine are as seen from flywheel end. No. 1 cylinder is the front cylinder on the right side. No. 2 cylinder is the front cylinder on the left side.
There are available in the Caterpillar parts system, some optional type K thermocouples: 8T-0933 8T-0934 8T-0935 8T-0936 8T-0458 Type K Thermocouples . These thermocouples are used with the following Probe Seal Adapters: except for the 8T-0458 Bead Type Thermocouple .
|5P-2720-    ||1/8" NPT    |
|5P-2725-    ||1/4" NPT    |
|4C-4547-    ||1/2" O-ring    |
|5P-3591-    ||9/16" O-ring    |
|4C-4545-    ||3/4" O-ring    |
Probe lengths are:
8T-0933 Thermocouple Probe , 25.4 mm (1.00 inch) long
8T-0934 Thermocouple Probe , 38.1 mm (1.50 inch) long
8T-0935 Thermocouple Probe , 63.5 mm (2.50 inch) long
8T-0936 Thermocouple Probe , 88.9 mm (3.50 inch) long
These thermocouples will plug into the inputs of the 4C-6090 Multichannel Temperature Selector , but are not designed for exhaust temperature measurements. For exhaust temperature measurements, use 6V-9055 Exhaust Thermocouple .
An optional use of this instrument would be checking temperatures on a marine engine using the above mentioned thermocouples and probe seal adapters. Any engine or transmission temperature may be measured using the previously mentioned components where a digital readout would make the job easier for the serviceman.
Thermocouple Extension Leads
The leads on the 8T-0458 8T-0933 8T-0934 8T-0935 8T-0936 Thermocouple Probes are 1219 mm (48.0 inch) long. If lead is not long enough for the application, an extension lead must be made from 7X-7481 Thermocouple Wire , a 4C-6095 Mini Plug and a 4C-9030 Mini Jack . Length of the extension lead is not critical as long as the following wiring code is used.
"-" red wire
"+" yellow wire
- Cut 7X-7481 Thermocouple Wire extension to length desired. Split and remove approximately 15 mm (0.6 inch) of yellow cover on 7X-7481 Thermocouple Wire .
- Strip approximately 5 mm (0.20 inch) of insulation from each of the wires exposed in Step 1. DO NOT twist bare ends of wire.
- Remove cover (1) from 4C-9030 Mini Jack (2). Loosen the two small screws that are exposed after removing cover (1). Loosen screws only enough to slide exposed wire under split washer. Do not remove screws and split washers from connector body.
- Slide yellow wire under split washer and screw for "+" terminal. Tighten screw. Slide red wire under split washer and screw for "-" terminal and tighten screw. DO NOT WRAP WIRE AROUND SCREWS.
- Discard the elastomeric bushing and give 7X-7481 Thermocouple Wire a slight twist so when replacing cover (1) on 4C-9030 Mini Jack (2), the extension wire will be correctly oriented in opening for reassembly of connector.
Use the same procedure for installing the 4C-6095 Mini Plug on the other end of the extension lead.
These extension leads can also be used with the 6V-9055 Exhaust Thermocouple Probe.
Note: If temperature reading decreases when probe is placed in a hot medium, check for reversed wiring.
If any of the channels read the same temperature as the "OFF" position, the serviceman must locate the shorted connection before testing the engine. The multimeter may be used to continuity check the suspect channel of the cable pack. Disconnect both ends of suspect channel, measure from "+" to "-" on one end of cable: correct reading should be an open circuit. If reading indicates a short, look for a pinched cable or possibility of wiring problem at either connector.
If any of the channels reads in a "floating" manner, that is, reading continually reads higher and will not stabilize, the servicemen must locate the open connection before testing the engine. Use the multimeter for this purpose. Disconnect both ends of suspect channel, measure from the "+" on male connector to "+" on female connector, correct reading should be a short circuit. Make the same measurement on "-" side of connectors, correct reading should be a short circuit.
If cable checks good, next check thermocouple for continuity. A measurement across the pins of the thermocouple plug should provide a reading of ten Ohms or less. If reading indicates an open circuit, change the thermocouple.
The 4C-6090 Multichannel Temperature Selector is warranted against defects in material or workmanship for 1 year following purchase.
If the 4C-6090 Multichannel Temperature Selector should need repair, send instrument, freight prepaid and insured to the address shown in Section ""Additional Contact Information" ". Include company name, customer name, address, customer telephone number, and a description of problem or service required.