Failures of the 305-6843 Guide Spring on Certain Engines{1102, 1121, 1123, 1209} Caterpillar

Articulated Truck:

D35-HP (S/N: 3FD1-UP)

D350E (S/N: 9LR1-UP)

D400 (S/N: 1MD1-UP)

D400D (S/N: 8TF1-UP)

D400E (S/N: 2YR1-UP)

D40D (S/N: 2JJ1-UP)

D44 (S/N: 2LD1-UP)

D44B (S/N: 8SD1-UP)

D550 (S/N: 4RD1-UP)

D550B (S/N: 5ND1-UP)

Backhoe Loader:

436C (S/N: 1FR1-UP)

Cold Planer:

PM-465 (S/N: 5ZS1-UP)

PM-565 (S/N: 3TK1-UP)

PM-565B (S/N: 8GS1-UP)

PR-1000C (S/N: 5XC1-UP)

PR-450C (S/N: 7PJ1-UP)

PR-750C (S/N: 7CK1-UP)

Landfill Compactor:

826C (S/N: 87X1-UP)

826G (S/N: 7LN1-UP)

836 (S/N: 3RL1-UP; 7FR1-UP)

Soil Compactor:

825C (S/N: 86X1-UP)

825G (S/N: 6RN1-UP)

Electric Power Generation:

3412 (S/N: 4BZ1-UP)

Engine:

3406B (S/N: 4TB1-UP; 7XC1-UP; 3ZJ1-UP; 9PL1-UP)

3406C (S/N: 2WB1-UP; 3ZJ1-UP; 2AM1-UP; 2MZ1-UP)

3408 (S/N: DLA1-UP; 67U1-UP; 99U1-UP; 78Z1-UP)

3408B (S/N: 9TD1-UP; 67U1-UP; 99U1-UP; 78Z1-UP)

3408C (S/N: TAM1-UP; 9XM1-UP; 67U1-UP; 99U1-UP; 78Z1-UP)

3412 (S/N: 7HG1-UP; 2WJ1-UP; 5RL1-UP; 7BL1-UP; 60M1-UP; BCS1-UP; 38S1-UP)

3412C (S/N: BAK1-UP; 5FL1-UP; 60M1-UP; DJN1-UP; 9EP1-UP; RLR1-UP; 8AR1-UP; 9BR1-UP; TFT1-UP; BCW1-UP; LRY1-UP; RTY1-UP)

3412E (S/N: TGC1-UP; 4CR1-UP)

CG137-08 (S/N: WWF1-UP)

CG137-12 (S/N: WRX1-UP)

G3406 (S/N: 4FD1-UP; R7E1-UP; 1RK1-UP; KAR1-UP)

G3408 (S/N: 6NB1-UP; 6RJ1-UP; CNZ1-UP)

G3408C (S/N: 8YR1-UP; BAZ1-UP)

G3412 (S/N: GNA1-UP; R7A1-UP; 7DB1-UP; KAP1-UP)

G3412C (S/N: 6ZM1-UP; 9RR1-UP)

Generator Set:

3406 (S/N: NKM1-UP; 4ZR1-UP)

3406B (S/N: 2WB1-UP)

3406C (S/N: ZKC1-UP; C2G1-UP; C5G1-UP; C8G1-UP; KPS1-UP; 1LS1-UP; 9ES1-UP; LRX1-UP; C2Y1-UP)

3406C (S/N: PFH1-UP; 4BM1-UP)

3412C (S/N: BAX1-UP)

C18 (S/N: NKM1-UP)

Industrial Engine:

3406 (S/N: 6TB1-UP; 90U1-UP)

3406C (S/N: 3ER1-UP; 4GW1-UP)

3408C (S/N: 9ER1-UP)

3408E (S/N: BFD1-UP; ECP1-UP; BKY1-UP)

3412 (S/N: BLJ1-UP; BKS1-UP)

3412C (S/N: 38S1-UP)

3412C (S/N: B1A1-UP)

3412E (S/N: BDT1-UP)

3412E (S/N: BNF1-UP)

Marine Engine:

3406C (S/N: 4TB1-UP; 1SS1-UP)

3412D (S/N: REA1-UP)

3412E (S/N: 9KS1-UP; 9PW1-UP)

C32 (S/N: RXB1-UP; SLT1-UP)

Pumper:

HT400 (S/N: 7141-UP)

SCT673 (S/N: 4TZ1-UP)

SPS342 (S/N: 2LZ1-UP)

SPT342 (S/N: 3CZ1-UP)

Excavator:

245 (S/N: 95V1-UP; 82X1-UP)

245B Series II (S/N: 6MF1-UP)

245B (S/N: 1SJ1-UP)

245D (S/N: 7ZJ1-UP; 4LK1-UP)

375 (S/N: 8XG1-UP; 8WJ1-UP; 6NK1-UP; 6RL1-UP)

375L (S/N: 9WL1-UP; 1JM1-UP)

5080 (S/N: 6XK1-UP; 8SL1-UP)

5110 (S/N: 7GN1-UP; 8HN1-UP)

5110B (S/N: AAA1-UP; AAK1-UP; AAT1-UP)

UNDERCARRIAGE (S/N: L5N1-UP)

Motor Grader:

16G (S/N: 93U1-UP)

16H (S/N: 6ZJ1-UP; 3JR1-UP)

24H (S/N: 7KK1-UP)

Off-Highway Truck/Tractor:

69D (S/N: 9SS1-UP)

73D (S/N: 1GW1-UP)

769 (S/N: 99F1-UP; 35W1-UP)

769B (S/N: 99F1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

772B (S/N: 64W1-UP)

773B (S/N: 63W1-UP)

773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP; KEG1-UP; ASK1-UP)

Quarry Truck:

771C (S/N: 3BJ1-UP)

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 8AS1-UP)

775E (S/N: BEC1-UP)

Petroleum Engine:

3412E (S/N: Z2D1-UP)

Pipelayer:

578 (S/N: 8HB1-UP)

583R (S/N: 2XS1-UP)

587R (S/N: BXL1-UP)

589 (S/N: 31Z1-UP)

Power Module:

PM3412 (S/N: CAJ1-UP)

Reclaimer Mixer:

RM-250C (S/N: AWG1-UP)

Road Reclaimer/Soil Stabilizer:

RM-350 (S/N: 5FK1-UP)

RM-350B (S/N: AXW1-UP)

RM350B (S/N: 7FS1-UP)

RR-250 (S/N: 6ED1-UP)

RR-250B (S/N: 3RR1-UP)

SM-350 (S/N: 1RM1-UP)

SS-250 (S/N: 6DD1-UP)

SS-250B (S/N: 5GR1-UP)

Track-Type Loader:

983B (S/N: 58X1-UP)

Track-Type Tractor:

D10N (S/N: 2YD1-UP; 3SK1-UP)

D10R (S/N: 3KR1-UP; AKT1-UP)

D8 (S/N: 76V1-UP)

D8K (S/N: 76V1-UP)

D8L (S/N: 4FB1-UP; 7YB1-UP; 53Y1-UP)

D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)

D8R (S/N: RJM1-UP; 7XM1-UP; 9EM1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP; 5FJ1-UP; 6XJ1-UP)

D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

Underground Articulated Truck:

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AE40 II (S/N: BLW1-UP; 1ZZ1-UP)

Wheel Dozer:

824C (S/N: 85X1-UP)

824G (S/N: 4SN1-UP)

834B (S/N: 7BR1-UP; 92Z1-UP)

844 (S/N: BBN1-UP; 2KZ1-UP)

Wheel Loader:

950G (S/N: 2JS1-UP)

966D (S/N: 99Y1-UP)

966E (S/N: 99Y1-UP)

980C (S/N: 13B1-UP; 2EB1-UP; 2XD1-UP; 63X1-UP)

980F Series II (S/N: 5XJ1-UP; 4RN1-UP; 8JN1-UP)

980F (S/N: 8CJ1-UP; 3HK1-UP)

980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)

988B (S/N: 50W1-UP; 62Y1-UP)

988F Series II (S/N: 2ZR1-UP)

988F (S/N: 8YG1-UP)

990 Series II (S/N: BCR1-UP; 4FR1-UP)

990 (S/N: 7HK1-UP)

992C (S/N: 42X1-UP; 49Z1-UP)

992D (S/N: 7MJ1-UP)

Wheel Tractor-Scraper:

621 (S/N: 2DB1-UP)

621B (S/N: 2GB1-UP; 6XB1-UP; 7KC1-UP; 8HC1-UP; 9AC1-UP; 45P1-UP)

621E (S/N: 6AB1-UP; 6BB1-UP)

621F (S/N: 4SK1-UP; 5JK1-UP; 8PL1-UP; 9NL1-UP)

623B (S/N: 46P1-UP)

623E (S/N: 6CB1-UP; 6DB1-UP; 6YF1-UP; 5SG1-UP)

623F (S/N: 5SG1-UP; 6BK1-UP; 5EW1-UP)

627B (S/N: 14S1-UP)

627E (S/N: 6EB1-UP; 6GB1-UP; 7CG1-UP)

627F (S/N: 4YK1-UP; 1DL1-UP)

631D (S/N: 24W1-UP)

631E Series II (S/N: 1AB1-UP; 3ND1-UP)

631G (S/N: AWK1-UP; CLR1-UP; CMT1-UP)

633D (S/N: 25W1-UP)

633E Series II (S/N: 2PS1-UP)

637D (S/N: 26W1-UP; 27W1-UP)

637E Series II (S/N: 1FB1-UP)

637E (S/N: 1JB1-UP)

637G (S/N: CEH1-UP; CEJ1-UP; AXT1-UP)

639D (S/N: 99X1-UP)

651B (S/N: 67K1-UP)

651E (S/N: 4YR1-UP; 5XR1-UP; 89Z1-UP)

657B (S/N: 68K1-UP)

657E (S/N: 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP; 90Z1-UP; 91Z1-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

Failures of the 305-6843 Guide Spring have been identified due to inconsistencies in the part during production.

Solution

Before the installation of a 305-6843 Guide Spring , inspect the spring using the information below.

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Illustration 1	g02950296
(A) Measure maximum free diameter in this region

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Illustration 2	g02950457
Example of measuring the free diameter of the spring

1. Measure the free diameter of the guide spring. The diameter of the spring should be between 29.31 mm (1.15 inch) and 29.67 mm (1.17 inch). Do not use the spring if the spring is not within the specification.

   Note: Do not measure below the horizontal line in Illustration 1.

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Illustration 3	g03649848
Measuring the width of the tang of the guide spring

2. Measure the width of the tang of the guide spring. The width of the spring should be between 7.30 mm (0.287 inch) and 7.48 mm (0.294 inch). Do not use the spring if the spring is not within the specification.

   Note: Measure the clip tang as shown with the caliper jaws parallel to the clip tang. Measuring the clip tang in any other orientation can give false readings.

   Note: When installing the lifter and guide spring, 5P-2405 Compressor must be used as shown in Disassembly and Assembly, RENR2336.