0305269 JOHNSON LEVER, Reverse locking

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4298" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
December 31, 1998Problem
The drive plate bolt in certain generators packaged into Larne sourced generator sets and powered by 3306B and 3406C Engines may not be tightened to the proper torque value.
Affected Product
Model & Identification Number
3406C (8FS480, 8FS482, 8FS484, 8FS486, 8FS488-490, 8FS492, 8FS493, 8FS499, 8FS500, 8FS502 , 8FS505, 8FS507, 8FS511, 8FS512, 8FS514, 8FS518, 8FS519, 8FS521-523, 8FS525 , 8FS526, 8FS529, 8FS532, 8FS533, 8FS536-538, 8FS540-543, 8FS546-562, 8FS566-568 , 8FS571, 8FS573-579, 8FS581-585, 8FS587-590, 8FS592-594, 8FS596 , 8FS598-617, 8FS619-625, 8FS627-640, 8FS642-647, 8FS649-655, 8FS657 , 8FS659, 8FS662-668, 8FS670-677, 8FS679, 8FS681, 8FS682, 8FS684, 8FS686-693 , 8FS695-699, 8FS701-708, 8FS710, 8FS713, 8FS714, 8FS716, 8FS717, 8FS719 , 8FS722, 8FS723, 8FS727-730, 8FS732-737, 8FS739-740, 8FS744, 8FS746, 8FS748 , 8FS750, 8FS752, 8FS753, 8FS758, 8FS760-765, 8FS767, 8FS770, 8FS771, 8FS773-776 , 8FS778, 8FS780-788, 8FS794-797, 8FS799-814, 8FS819-821, 8FS823 , 8FS841, 8FS844-849, 8FS851, 8FS852, 8FS858, 8FS859, 8FS861, 8FS862, 8FS864 , 8FS865, 8FS868-870, 8FS873-875, 8FS877-880, 8FS883-885, 8FS888, 8FS891 , 8FS892, 8FS894, 8FS896, 8FS900, 8FS904, 8FS919, 8FS923, 8FS941-943, 8FS949 , 8FS951, 8FS953-957, 8FS960, 8FS961, 8FS972-974 8FS3306B9DS322-325, 9DS330-333, 9DS336, 9DS342, 9DS345, 9DS378, 9DS381, 9DS382, 9DS387 , 9DS390-395, 9DS397, 9DS398, 9DS401-403, 9DS407-411, 9DS413, 9DS414 , 9DS417, 9DS418, 9DS420, 9DS421, 9DS424-446, 9DS448-454, 9DS456-460 , 9DS464, 9DS466-469, 9DS471-474, 9DS477, 9DS479-489, 9DS491-495 , 9DS499-504, 9DS506, 9DS509-513, 9DS516-525, 9DS530, 9DS532-535 , 9DS540, 9DS544, 9DS545, 9DS549-553, 9DS555, 9DS556, 9DS558-560 , 9DS562, 9DS568, 9DS574-577, 9DS580-590, 9DS593, 9DS595, 9DS597 , 9DS599, 9DS600, 9DS602, 9DS604-606, 9DS611, 9DS612, 9DS615, 9DS618-619 , 9DS621, 9DS623, 9DS624, 9DS626, 9DS627, 9DS629-633, 9DS666, 9DS673-692 , 9DS696, 9DS697, 9DS699, 9DS703, 9DS705, 9DS706, 9DS708, 9DS709, 9DS713 , 9DS717, 9DS719-721, 9DS724-728, 9DS730, 9DS732-734, 9DS739, 9DS741 , 9DS745-748, 9DS750, 9DS752-756, 9DS758-766, 9DS768, 9DS778, 9DS780-782 , 9DS784-786, 9DS791, 9DS793, 9DS797, 9DS804, 9DS805, 9DS807, 9DS808 , 9DS811, 9DS812, 9DS814, 9DS815, 9DS826-828, 9DS831, 9DS837, 9DS840-846 , 9DS849, 9DS851, 9DS858, 9DS864, 9DS866)
To make sure the Generator Set Package being considered for this Program is eligible, refer to the Generator Set Serial Number Film located on the Generator barrel. The engine Serial Number, located at the bottom of this film, must appear on the list published in this Program. Also, check to see if this package has been reworked. If there is an "F1" stamped on the engine cylinder block, at the left rear of the 3306 and the right rear of the 3406, this package has already been reworked and this program does not apply. If it is not on the list, this Program does not apply. If it is listed, check the Generator Serial Number on the Film. The Generator Serial Number appears about halfway on the film. Record the Generator Serial Number from the Film on the work order and on the warranty claim even if it does not agree with the Generator Serial Number listed for the Engine Serial Number published in this program.
Parts Needed
No parts are needed for this program.
Action Required
See the attached rework procedure.
When the reworked has been completed, stamp "F1" on the engine cylinder block at the left rear of the 3306 and the right rear of the 3406.
Service Claim Allowances
Record the Generator Serial Number for the package in the story of the Service Claim.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Generator Drive Plate Bolt Torque
This Procedure requires moving the engine and radiator forward approximately 150 mm for a packaged Gen Set without an enclosure. This Procedure requires moving the generator backwards approximately 150 mm for a packaged Gen Set with either a sound attenuated or a weather proof enclosure. Therefore, all pipe work and wiring not shown in this procedure must be given adequate slack or be disconnected.
For Gen Set Packages Without Enclosures:
Disassembly of engine from generator
1. Cut the tywraps which secure the wiring harnesses on both sides of the generator.2. Remove the right hand terminal box side cover and remove the tywraps attaching the wiring harnesses to the central cross member inside the terminal box. This will give enough slack in the wiring harnesses to allow the engine to move forward.3. Remove the Battery hold-down clamps, the Battery Drip Tray and the Batteries and tie the cables out of the way. Remove the fuel supply and return hoses at the base connections and tie them out of the way (cap all openings).4. Remove the bottom rear Radiator Support to Engine Support Bolt from each side. (Clean the threads in the bolt hole.) Place a lifting device into the hole the bolt was removed from and secure to the supports.5. Remove the Generator Drip Cover and Screen.6. Loosen the Terminal Box lower front cover and slide it down in it's slots to allow the Generator to move about on the mounts. Loosen the engine vibration mount bolts removing the nuts and washers but leaving the bolts in position.7. Turn the engine over to TDC before removing the flywheel housing to generator housing bolts. Support the Generator with wood blocks in front of and behind the generator crossbeam to keep the generator positioned for re-assembly. Using an overhead crane with a spreader bar, fit hooks through the each of the Radiator/Engine Support lifting devices (Reference Step 4) and sling under the engine flywheel housing and take up enough slack to support the weight of the engine. Remove the top flywheel housing to generator housing bolt and install a guide bolt. Remove the remaining flywheel housing to generator housing bolts and the drive plate to