2005/08/22 Caterpillar

Articulated Truck:

730 EJECTOR (S/N: B1W1-UP)

D20D (S/N: 9MG1-UP)

D250B (S/N: 5WD1-UP)

D250D (S/N: 6NG1-UP)

D250ESeries II (S/N: 4PS1-UP)

D250E (S/N: 5TN1-UP)

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D300B (S/N: 4SD1-UP)

D300D (S/N: 5MG1-UP)

D300ESeries II (S/N: 5KS1-UP)

D300E (S/N: 7FN1-UP)

D30C (S/N: 7ZC1-UP)

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

D350C (S/N: 8XC1-UP)

D350D (S/N: 9RF1-UP)

D350ESeries II (S/N: 2XW1-UP)

D350E (S/N: 9LR1-UP)

D35C (S/N: 2GD1-UP)

D400 (S/N: 1MD1-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)

725 (S/N: B1L1-UP; AYW1-UP; AFX1-UP)

730 (S/N: AGF1-UP; B1M1-UP; AYX1-UP)

735 (S/N: B1N1-UP; AWR1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

D30D (S/N: 3AJ1-UP; 1PK1-UP)

D400D (S/N: 8TF1-UP; 4EJ1-UP)

D400ESeries II (S/N: APF1-UP; 8PS1-UP)

Engine:

C-15 (S/N: 9NZ1-UP)

Excavator:

325C (S/N: M2K1-UP)

322B (S/N: 1YS1-UP)

325B (S/N: 2JR1-UP)

330B (S/N: 6DR1-UP)

330C (S/N: B2L1-UP; B4N1-UP)

Integrated Toolcarrier:

IT62G (S/N: AKP1-UP; 6PS1-UP)

Knuckleboom Loader:

539 (S/N: 1PZ1-UP)

Landfill Compactor:

826GSeries II (S/N: AYH1-UP)

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

816F (S/N: 5FN1-UP)

826H (S/N: AWF1-UP)

836H (S/N: BXD1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

Load Haul Dump:

R1300 (S/N: 6QW1-UP)

R1300G (S/N: LJB1-UP)

R1600G (S/N: 9PP1-UP)

R1700G (S/N: 8XZ1-UP)

R2900 (S/N: 5TW1-UP)

R2900G (S/N: GLK1-UP)

R1600 (S/N: 9XP1-UP; 9EW1-UP)

Motor Grader:

120H (S/N: CAF1-UP)

163H (S/N: ARL1-UP)

12H (S/N: CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP; 1251-UP)

140H (S/N: CCA1-UP; 2ZK1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3FR1-UP; 3AS1-UP; 1261-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14H (S/N: ASE1-UP; 7WJ1-UP)

160H (S/N: ASD1-UP; 9EJ1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 3HR1-UP; 2HS1-UP)

Pipelayer:

572R (S/N: 2HZ1-UP)

Soil Compactor:

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

815F (S/N: BKL1-UP)

Track Feller Buncher:

TK1051 (S/N: 9HZ1-UP)

Track-Type Loader:

963B (S/N: 9BL1-UP)

963C (S/N: 2DS1-UP)

973C (S/N: 3RZ1-UP)

963C (S/N: BBD1-UP)

973C (S/N: BCP1-UP)

953C (S/N: 2ZN1-UP; BBX1-UP)

Track-Type Tractor:

D6M (S/N: 4JN1-UP)

D8R (S/N: 7XM1-UP)

D8T (S/N: KPZ1-UP)

D6RSeries II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BMJ1-UP; AFM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4MN1-UP; 5LN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; 1RW1-UP)

D7RSeries II (S/N: AEC1-UP; ABJ1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; BNX1-UP)

D7R (S/N: 9HM1-UP; 2EN1-UP; 3DN1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; ACS1-UP)

D8RSeries II (S/N: AKA1-UP; 6YZ1-UP)

Underground Articulated Truck:

AD30 (S/N: CXR1-UP)

AD45 (S/N: BKZ1-UP)

AD55 (S/N: ANW1-UP)

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

AD55 (S/N: DNW1-UP)

Wheel Dozer:

824GSeries II (S/N: AWW1-UP)

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

824H (S/N: ASX1-UP)

854G (S/N: A4W1-UP; AMP1-UP; 1JW1-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

Wheel Feller Buncher:

533 (S/N: CDR1-UP)

543 (S/N: ASJ1-UP)

Wheel Loader:

950GSeries II (S/N: AXR1-UP; AYS1-UP; BAA1-UP; AYB1-UP; AYL1-UP; AXX1-UP)

970F (S/N: 7SK1-UP)

980H (S/N: JMS1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

962GSeries II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXY1-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

966FSeries II (S/N: 9YJ1-UP; 1SL1-UP)

980GSeries II (S/N: AWH1-UP; AYT1-UP)

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

988G (S/N: BNH1-UP; 2TW1-UP)

992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)

Wheel Skidder:

515 (S/N: 4LR1-UP)

525 (S/N: 1DN1-UP)

525B (S/N: 3KZ1-UP)

535B (S/N: AAE1-UP)

545 (S/N: 2FZ1-UP)

Wheel Tractor-Scraper:

615CSeries II (S/N: 9XG1-UP)

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

613CSeries II (S/N: 8LJ1-UP)

637G (S/N: CEH1-UP)

621G (S/N: CEN1-UP; ALP1-UP)

623G (S/N: CES1-UP; ARW1-UP)

627G (S/N: AXF1-UP; CEX1-UP)

Service Magazine SEPD0798, 08 08 2005, "Troubleshooting Column - Type Fuel Level Senders". Dis-regard the above-referenced article. Refer to the following information.

Introduction

The sensor kit is a serviceable part of the column type fuel level sender. Use this procedure in order to determine whether the sensor kit or the entire fuel level sender should be replaced.

Check Wiring To Sender

1. If fuel level reading is erratic or inaccurate, check wiring for loose connections or broken wires to the sender.

2. If wiring checks OK, proceed to check the sensor kit.

Check Sensor Kit

Illustration 1	g01189750

(1) Sensor Kit

1. Turn the ignition switch off.

2. Remove the sender from the tank only if access to the sensor kit is restricted.

3. Remove the sensor kit from the sender by removing the two #6 sensor kit retaining screws.

4. Using a digital meter, monitor the sensor kit resistance while rotating the pointer by placing the tip of a small magnetized tool on the back of the dial.

5. Full and Empty calibration resistance values should agree with the values in Table 1 and the resistance between should be continuous.

6. If the resistance measurement is erratic install a new sensor kit on the sender. If the Full or Empty values do not agree with the values in Table 1, install a new sensor kit on the sender.

Check Sender

1. If the wiring and the sensor kit check out OK proceed to the replacement of the sender.

2. Remove the sender from the tank by loosening the six M6X1 locking bolts.

3. Turn the sender upside down in order to check for float movement. The float should move freely without sticking or dragging at any point during the total float travel. If the float moves freely, check for gasket sealant residue at the tube interface. Sealant should not be used in place of a gasket. Sealant can block the two sender vent holes that are required for the sender to vent air in order for the float to move properly.

4. If the float binds or drags, replace the sender. The replacement gasket is 6C-3060 Gasket .

Illustration 2	g01189749

(2) Vent hole

Note: Make sure that the two sender vent holes are not blocked by sealant. The two holes are 180° apart.

Illustration 3	g01195477

Refer to Illustration 3 for the part number location.

Table 1

Sensor Resistance Range
Sender Part Number	Sensor Kit Part Number	Resistance Range (Ohms) Empty-Full
138-0443	138-0444	95-0
150-2995	138-0444	95-0
151-1399	138-0444	95-0
157-8829	138-0444	95-0
157-8830	169-3506	95-0
157-8831	169-3506	95-0
157-8832	169-3506	95-0
157-8833	169-3506	95-0
157-8836	138-0444	95-0
157-8837	138-0444	95-0
157-8838	159-0647	240-30
157-8839	159-0647	240-30
157-8840	159-0647	240-30
157-8844	138-0444	95-0
157-8847	138-0444	95-0
157-8848	138-0444	95-0
157-8849	138-0444	95-0
157-8850	180-6989	66-0
157-8851	138-0444	95-0
157-8852	138-0444	95-0
157-8853	138-0444	95-0
157-8854	139-9314	83.5-0
157-8855	139-9314	83.5-0
157-8856	138-0444	95-0
157-8857	138-0444	95-0
157-8858	169-3506	95-0
157-8859	169-3506	95-0
160-1823	138-0444	95-0
162-8208	162-8207	240-30
162-8349	138-0444	95-0
162-8350	138-0444	95-0
166-3388	138-0444	95-0
170-9215	138-0444	95-0
173-2018	194-8535	240-30
193-8252	138-0444	95-0
200-1138	138-0444	95-0
219-0660	138-0444	95-0
220-0546	162-8207	240-30
239-5938	138-0444	95-0
244-1943	246-1526	95-0
259-8455	162-8207	240-30
262-2812	138-0444	95-0
263-1029	138-0444	95-0
263-5792	138-0444	95-0
269-1021	162-8207	240-30
269-1022	162-8207	240-30
273-0122	138-0444	95-0
277-6993	162-8207	240-30
283-5595	246-1526	95-0