0787069 JOHNSON SERVICE MANUAL - ENGINE

Introduction
Note: This Special Instruction can only be used for the machines with certain engine arrangements. Refer to Table 1 for the arrangement numbers that are applicable.The engine serial number will not change after this procedure is completed. The arrangement number of the engine will change.
Table 1
65 Challenger Engine Arrangement Numbers    
Original     Engine Serial Number     New    
7W-4152     (S/N: 08Z)     284-3323    This Special Instruction provides the information in order to install a 3306 Engine Emissions Upgrade Group (EUG) for a 65 Challenger. Tier I emission levels can be achieved by replacing certain components on the existing unregulated engine. This Emissions Upgrade procedure should be completed at the time of the engine overhaul.When the Emissions Upgrade procedure has been completed, a label will be provided by Caterpillar. This label will verify that the Emissions Upgrade procedure has been performed for that individual 3306 Engine.In order to obtain an Emissions Upgrade Label, the following criteria must be met:
All procedures in this Special Instruction must be completed by a Caterpillar dealer. The Caterpillar Dealership will be required to verify the Emissions Upgrade procedure.
The engine that receives the Emissions Upgrade procedure must be tested on a dynamometer. The data will be submitted on the emissions upgrade validation form. The form must be approved by Caterpillar Engineering prior to installing the engine back on the machine.
The EUG must be registered as outlined in Special Instruction REHS5097.Note: A label will not be issued for the Emissions Upgrade procedure if all of the criteria has not been met.Return the component cores according to Reman Policies and Core Management, SELD0122. Refer to the following web site for more information.https://reman.cat.com
This Special Instruction does not include all of the procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Reference Service Manual, Parts Manual, Operation and Maintenance Manual, Engine Reusability GuidelinesRegister the Retrofit
When performing a retrofit installation, record the vital information in Table 2. Note: If the procedure is performed by the customer, ask the customer to record the proper information.
Table 2
Repair Date        
Product Serial Number        
Service Hours or Service Meter Units        
Removed Component Part Number (1)        
Removed Component Serial Number (1)        
Installed Component Part Number (2)        
Installed Component Serial Number (3)        
( 1 ) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
( 2 ) Record the highest level retrofit kit, arrangement, or group part number.
( 3 ) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.
Update the product configuration by entering the information from Table 2 into SIMSi.
For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".Safety
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
Do not attempt to assemble this machine until you read and you understand the assembly instructions.Improper assembly procedures could result in injury or death.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting