3500 (sn=9kf1-up, 6tj1-up, 2wk1-up)

3500Locomotive Engines

Introduction

Date Created: ### Serial Number: 9KF1-UP, 6TJ1-UP, 2WK1-UP

This work book contains the service tooling information compiled from Service Manual SENR4640 for the 3500 Locomotive Engines.

The last worksheet is a summary document of all tools listed and maximum quantities required with duplicates removed.

This document was created from the original documents in SIS and contain all the entries. Dealers can cut and paste from this document to customize the information for their own use.


Introduction

This work book contains the service tooling information compiled from Service Manual SENR4640 for

The last worksheet is a summary document of all tools listed and maximum quantities required with

This document was created from the original documents in SIS and contain all the entries. Dealers can cut and paste from this document to customize the information for their own use.


Service Tools

New Tools Date:

Part Number Part Name Tool Function

Testing and Adjusting Serial Number: 9KF1-UP, 6TJ1-UP, 2WK1-UP3500 Locomotive EnginesMedia Number -SENR4637-02 Publication Date -01/12/2005

Date Updated -22/12/2005

Fuel Pressure

SMCS - 1250-081 i02388767

Tool Part Number Part Description

- 1U-5470 Pressure Gp.-Eng

Finding the Top Center Position for the No. 1 Piston

SMCS - 1105-531 i02389395


- 9S-9082 Engine Turning Tool

Camshaft Timing

SMCS - 1210 i02492603

Timing Check



Timing Adjustment



- 6V-3010 Puller Group

- 8S-9089 Bolts

- 5P-1076 Hard Washers

Engine Speed Measurement

SMCS - 1901 i01493152


- 9U-7400 Multitach

Fuel Injector Timing

SMCS - 1290-025 i01374151


- 5P-4160 Indicator Contact Point

- 1U-8869 Dial Indicator

- 9U-5138 Setting Gauge

- 9U-5233 Magnetic Fixture Group


Fuel Injector Synchronization

SMCS - 1290-025 i01374252


- 8T-2684 Rack Synchronization Gauge

Fuel Setting

SMCS - 1257-025 i01549302


- 9U-5132 Engine Timing Tool Group

- 4C-8753 Extended Collet

- 6V-3075 Dial Indicator

- 5P-7263 Indicator Contact Point

- 8T-2684 Rack Synchronization Gauge

Measuring Inlet Manifold Pressure

SMCS - 1058-082 i02371518


- 1U-5470 Pressure Gp.-Eng

Measuring Exhaust Temperature

SMCS - 1088-082 i02492616


- 164-3310 Thermometer

- 6V-9130 Adapter Gp-Temp

- 237-5130 Multimeter Gp

Cylinder Heads

SMCS - 1100 i01665366

Valves


- 1P-3527 Lifter-Valve

Valve Seat Inserts


- 166-7441 Tool Gp

Valve Guides


- 5P-1729 Bushing-Driver

- 7M-3975 Driver As

Checking Valve Guide Bores


- 5P-3536 Gage Gp- V Guide

Bridge Dowels


- 5P-0944 Puller Gp-Dowel

- 5P-0942 Extractor-Dowel

- 6V-4009 Driver-Dowel

Valve Lash and Valve Bridge Adjustment

SMCS - 1102-036 i02013998


- 147-2060 Wrench

- 147-2059 Torque Wrench

- 148-7211 Bridge Nut Socket

- 145-5191 Gauge Support

- 147-2056 Dial Indicator

- 147-5536 Indicator Contact Point

- 147-2057 Indicator Contact Point

- 147-2058 Indicator Extension

- 147-5537 Dial Indicator (not shown)

Engine Oil Pressure - Test

SMCS - 1304-081 i01473950


- 1U-5470 Engine Pressure Group

Test Tools for the Cooling System

SMCS - 0781; 1350 i02605557


- 4C-6500 Digital Thermometer

- 285-0901 Blowby Tool Gp

- 285-0910 Multi-Tool Gp

- 9U-7400 Multitach Tool Gp

- 9S-8140 Pressurizing Pump

Testing the Cooling System

SMCS - 1350-081 i02492662

Testing for Freeze Protection


- 245-5829 Coolant/Battery Tester Gp

Testing the Radiator Fan (If Equipped)


- 9U-7400 Multitach Tool Gp

Testing the Cooling System for Leaks


- 9S-8140 Pressurizing Pump

Cylinder Block

SMCS - 1201-040 i01491831


- 1P-4000 Tool Gp-Boring

- 1P-3527 Lifter-Valve

Cylinder Liner Projection

SMCS - 1216-082 i02388965


- 1U-9895 Crossblock

- 3H-0465 Push-Puller Plate

- 8F-6123 Bolt

- 3B-1925 Washer (Copper)

- 0S-1575 Bolt

- 8T-0455 Liner Projection Tool Group

- 1P-2403 Indicator-Dial

- 1P-2402 Body-Gauge

- 1P-5507 Gage

Flywheel - Inspect

SMCS - 1156-040 i02391235


- 8T-5096 Dial Indicator Gp

Bore Runout (Radial Eccentricity) of the Flywheel


- 7H-1942 Indicator-Dial

- 7H-1940 Attachment-Univ

Flywheel Housing - Inspect

SMCS - 1157-040 i02391240


- 8T-5096 Dial Indicator Gp

Test Tools for the Electrical System

SMCS - 0785 i03439502


- 4C-4911 Battery Load Tester

- 271-8590 Starting/Charging Analyzer Gp

- 225-8266 Ammeter Tool Gp

- 146-4080 or 257-9140 Digital Multimeter Gp

225-8266 Ammeter Tool Gp


- 6V-6014 Cable

Battery

SMCS - 1401-081 i01305428


- 4C-4911 Load Tester-Batt


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Service Tools

New Tools Date:


Disassembly and Assembly Serial Number: 9KF1-UP, 6TJ1-UP, 2WK1-UP3512 & 3516 Locomotive EnginesMedia Number -SENR4638-00 Publication Date -01/10/1990


Manual Shutoff

SMCS - 7418-010

Remove And Install Manual Shutoff


- 1P-1856 Pliers

- 1P-0510 Driver Gp

Water Temperature Regulators

SMCS - 1355-010

Remove And Install Water Temperature Regulators


- 6V-2156 Link Bracket

- 1P-0520 Driver Gp

Water Pump

SMCS - 1361-010; 1361-015; 1361-016

Disassemble Water Pump


- 5F-7465 Puller Assembly

- 4B-3903 Bolt (5/16"-18 NC X 4 Inch Long)

- 4B-5270 Washer (5/16")

- 4B-5271 Washer (3/8")

- 4B-5273 Washer (1/2")

- 1P-0458 Drive Plate

Assemble Water Pump


- 1P-0510 Driver Gp

Fuel Transfer Pump

SMCS - 1256-011; 1256-012; 1256-015; 1256-016

Assemble Fuel Transfer Pump


- 1P-0510 Driver Gp

- FT-1987 Driver

Oil Pump

SMCS - 1304-010; 1304-017

Remove And Install Oil Pump



Disassemble And Assemble Oil Pump


- 1P-0510 Driver Gp

Oil Filter Housing

SMCS - 1306-010; 1306-017

Remove And Install Oil Filter Housing



Turbochargers

SMCS - 1052-010; 1052-017

Disassemble And Assemble Turbocharger



- FT-2299 Holding Fixture

- 5P-4758 Snap Ring Pliers

- 8T-5096 Indicator Group

Exhaust Elbow (Dry)

SMCS - 1061-010

Remove & Install Exhaust Elbow (Dry)



Aftercooler

SMCS - 1063-010

Remove And Install Aftercooler



Air Inlet Manifold

SMCS - 1058-010

Remove And Install Air Inlet Manifold



Governor Fastener Group

SMCS - 7553-010

Remove And Install Governor Fastener Group


- 1P-0510 Driver Gp

Accessory Drive (Front)

SMCS - 1207-010; 1207-017

Disassemble And Assemble Accessory Drive (Front)


- 1P-0520 Driver Gp

Oil And Water Pump Drive

SMCS - 1313-010; 1313-017

Disassemble And Assemble Oil And Water Pump Drive


- 1P-0520 Driver Gp

Crankshaft Vibration Damper

SMCS - 1205-010

Remove And Install Crankshaft Vibration Damper


- 5P-9736 Link Bracket

Crankshaft Front Seal And Wear Sleeve

SMCS - 1160-011; 1160-012

Remove Crankshaft Front Seal And Wear Sleeve


- 1P-3075 Puller Group

- 5P-7409 Distorter

- 1U-7325 Distorter Adapter

Install Crankshaft Front Seal And Wear Sleeve


- 6V-4003 Locator

- 2N-5006 Bolt [1"-14 NF x 2.5 Inch Long]

- 8T-3099 Installer

- 9S-8858 Nut

Front Drive Housing

SMCS - 1151-010

Remove And Install Front Drive Housing



- 1P-0074 Slide Hammer And Puller

- 8B-7557 Threaded Adapter

- 1P-0520 Driver Group

Flywheel

SMCS - 1156-010

Remove and Install Flywheel



Crankshaft Rear Seal And Wear Sleeve

SMCS - 1161-011; 1161-012

Remove Crankshaft Rear Seal And Wear Sleeve


- 1P-3075 Puller Group

- 5P-7409 Distorter

- 1U-7325 Distorter Adapter

Install Crankshaft Rear Seal And Wear Sleeve


- 6V-4003 Locator

- 2N-5006 Bolt [1"-14 NF x 2.5 Inch Long]

- 8T-3099 Installer

- 9S-8858 Nut

Flywheel Housing

SMCS - 1157-010

Remove And Install Flywheel Housing


- 8B-7548 Push-Puller

- 8H-0684 Ratchet Wrench

- 8B-7559 Adapter

- 8B-7561 Step Plate


Rocker Shaft Assemblies

SMCS - 1102-017

Disassemble And Assemble Rocker Shaft Assembly


- 1P-0510 Driver Gp

Fuel Injectors

SMCS - 1251-011; 1251-012

Install Fuel Injector


- 6V-4062 Injector Spring Compressor

Fuel Injection Control Linkage

SMCS - 1269-011; 1269-012

Remove Fuel Injection Control Linkage


- 1P-0510 Driver Gp


Install Fuel Injection Control Linkage


- 1P-0510 Driver Gp


Valves

SMCS - 1105-010

Remove And Install Valves


- 5S-1330 Pneumatic Valve Spring Compressor

- 8S-2263 Valve Spring Tester

Bridge Dowels

SMCS - 1121-010

Remove And Install Bridge Dowels


- 5P-0944 Dowel Puller Group

- 5P-0942 Extractor

- 6V-4009 Dowel Driver

Valve Seat Inserts

SMCS - 1103-010

Remove And Install Valve Seat Inserts


- 6V-4805 Extractor Gp

- 6V-4196 Extractor

- 1P-0510 Driver Gp

Valve Guides

SMCS - 1104-010

Remove And Install Valve Guides


- 7M-3975 Driver

- 5P-1729 Bushing

Connecting Rod Bearings

SMCS - 1219-010

Remove And Install Connecting Rod Bearings



- - Plastigage

Rear Gear Group

SMCS - 1212-010

Remove And Install Rear Gear Group


- 1P-0520 Driver Gp

Crankshaft Main Bearings

SMCS - 1203-010

Remove And Install Crankshaft Main Bearings


- 9S-9082 Engine Turning Pinion

- 6V-3147 Main Bearing Wrench

- 2P-5517 Tool As-Removal

- 8T-5096 Indicator Gp

Pistons And Connecting Rod Assemblies

SMCS - 1225-011; 1225-012

Remove Pistons And Connecting Rod Assemblies



- 1P-1861 Pliers-Ring

- 6V-4020 Expander Gp

- 5P-8639 Press Gp

- 5P-9725 Cylinder Gp

- 8F-0024 Hose As

- 1P-2375 Coupler As

- 1P-2376 Coupler As

- 5P-8649 Adapter

- 6V-3043 Spacer

- 6V-3042 Adapter

Install Pistons And Connecting Rod Assemblies



- 1P-1861 Pliers-Ring

- 6V-4020 Expander Gp

- 1U-7616 Compr Gp-Ring

Cylinder Liners

SMCS - 1216-011; 1216-012

Remove Cylinder Liners


- 5P-8665 Cylinder Liner Puller

- 6V-4133 Wedge Bracket

Install Cylinder Liners


- 1P-5510 Indicator Gp

- 2P-8260 Liner Installer Gp

- 7N-1961 Bolt

- FT-1543 Plate


- 3H-0465 Plate

- 8F-6123 Bolt [3/4"-16 NF x 5 1/2 Inch Long]

- 3B-1925 Washer (3/4"-Copper)

- OS-1575 Bolt [3/4"-16 NF x 3 Inch Long]

Camshafts

SMCS - 1210-011; 1210-012

Remove Camshaft




- 8B-7559 Adapter

- 8B-7561 Step Plate

- 8H-0684 Ratchet Wrench

- 8T-3168 Pilot As

- 4J-7945 Bolt

- 8T-3167 Guide As

- 8T-3169 Crank As

Install Camshaft



- 8T-3168 Pilot As

- 4J-7945 Bolt

- 8T-3167 Guide As

- 8T-3169 Crank As

Camshaft Bearings

SMCS - 1211-010

Remove And Install Camshaft Bearings


- OS-1621 Bolt

- 6V-4012 Plate

- 6V-4014 Pilot

- 6V-4015 Pulling Bar

- 6V-4005 Spacer

- 6V-4011 Spacer

- 6V-4010 Pulling Plate

- 8S-8292 Short Extension

- 8S-8293 Long Extension

- 6V-4013 Screw

- 4C-4865 Pump Gp-Hand

- 5P-5247 Hydraulic Puller

- 5P-8248 Washer-Hard

- 2J-3506 Nut

Crankshaft

SMCS - 1202-011; 1202-012

Install Crankshaft


- 8T-5096 Indicator Gp


Service Tools

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Service Tools

New Tools Date:


Operation and Maintenance Manu Serial Number: 9KF1-UP, 6TJ1-UP, 2WK1-UP3508, 3512 & 3516 Locomotive Engines Media Number -SEBU6406-00 Publication Date -04/06/1991

Cooling System Specifications


- 5P-3514 Tester Gp



Service Tools

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Service Tools

Tool SummaryNew Tools Date:


Serial Number: 9KF1-UP, 6TJ1-UP, 2WK1-UP

Part Number Part Description

- Plastigage

145-5191 Gauge Support

146-4080 or 257-9140 Digital Multimeter Gp

147-2056 Dial Indicator

147-2057 Indicator Contact Point

147-2058 Indicator Extension

147-2059 Torque Wrench

147-2060 Wrench

147-5536 Indicator Contact Point

147-5537 Dial Indicator (not shown)

148-7211 Bridge Nut Socket

164-3310 Thermometer

166-7441 Tool Gp

1P-0074 Slide Hammer And Puller

1P-0458 Drive Plate

1P-0510 Driver Gp

1P-0520 Driver Gp

1P-1856 Pliers

1P-1861 Pliers-Ring

1P-2375 Coupler As

1P-2376 Coupler As

1P-2402 Body-Gauge

1P-2403 Indicator-Dial

1P-3075 Puller Group

1P-3527 Lifter-Valve

1P-4000 Tool Gp-Boring

1P-5507 Gage

1P-5510 Indicator Gp

1U-5470 Pressure Gp.-Eng

1U-7325 Distorter Adapter

1U-7616 Compr Gp-Ring

1U-8869 Dial Indicator

1U-9895 Crossblock

225-8266 Ammeter Tool Gp

237-5130 Multimeter Gp

245-5829 Coolant/Battery Tester Gp

271-8590 Starting/Charging Analyzer Gp

285-0901 Blowby Tool Gp

285-0910 Multi-Tool Gp

2J-3506 Nut

2N-5006 Bolt [1"-14 NF x 2.5 Inch Long]

2P-5517 Tool As-Removal

2P-8260 Liner Installer Gp

3B-1925 Washer (3/4"-Copper)

3H-0465 Plate

4B-3903 Bolt (5/16"-18 NC X 4 Inch Long)

4B-5270 Washer (5/16")

4B-5271 Washer (3/8")

4B-5273 Washer (1/2")

4C-4865 Pump Gp-Hand

4C-4911 Battery Load Tester

4C-6500 Digital Thermometer

4C-8753 Extended Collet

4J-7945 Bolt

5F-7465 Puller Assembly

5P-0942 Extractor

5P-0944 Dowel Puller Group

5P-1076 Hard Washers

5P-1729 Bushing

5P-3514 Tester Gp

5P-3536 Gage Gp- V Guide

5P-4160 Indicator Contact Point

5P-4758 Snap Ring Pliers

5P-5247 Hydraulic Puller

5P-7263 Indicator Contact Point

5P-7409 Distorter

5P-8248 Washer-Hard

5P-8639 Press Gp

5P-8649 Adapter

5P-8665 Cylinder Liner Puller

5P-9725 Cylinder Gp

5P-9736 Link Bracket

5S-1330 Pneumatic Valve Spring Compressor

6V-2156 Link Bracket

6V-3010 Puller Group

6V-3042 Adapter

6V-3043 Spacer

6V-3075 Dial Indicator

6V-3147 Main Bearing Wrench

6V-4003 Locator

6V-4005 Spacer

6V-4009 Dowel Driver

6V-4010 Pulling Plate

6V-4011 Spacer

6V-4012 Plate

6V-4013 Screw

6V-4014 Pilot

6V-4015 Pulling Bar

6V-4020 Expander Gp

6V-4062 Injector Spring Compressor

6V-4133 Wedge Bracket

6V-4196 Extractor

6V-4805 Extractor Gp

6V-6014 Cable

6V-9130 Adapter Gp-Temp

7H-1940 Attachment-Univ

7H-1942 Indicator-Dial

7M-3975 Driver As

7N-1961 Bolt

8B-7548 Push-Puller

8B-7557 Threaded Adapter

8B-7559 Adapter

8B-7561 Step Plate

8F-0024 Hose As

8F-6123 Bolt [3/4"-16 NF x 5 1/2 Inch Long]

8H-0684 Ratchet Wrench

8S-2263 Valve Spring Tester

8S-8292 Short Extension

8S-8293 Long Extension

8S-9089 Bolts

8T-0455 Liner Projection Tool Group

8T-2684 Rack Synchronization Gauge

8T-3099 Installer

8T-3167 Guide As

8T-3168 Pilot As

8T-3169 Crank As

8T-5096 Indicator Gp

9S-8140 Pressurizing Pump

9S-8858 Nut

9S-9082 Engine Turning Tool

9U-5132 Engine Timing Tool Group

9U-5138 Setting Gauge

9U-5233 Magnetic Fixture Group

9U-7400 Multitach Tool Gp

FT-1543 Plate

FT-2299 Holding Fixture

OS-1575 Bolt [3/4"-16 NF x 3 Inch Long]

OS-1621 Bolt


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3500 (sn=9kf1-up, 6tj1-up, 2wk1-up)

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