Procedure for Replacement of the Transmission Shift Lever or Hoist Lever Sensor on Certain Off-Highway Trucks and Articulated Trucks{3065, 5063, 5737} Caterpillar

Articulated Truck:

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

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

730 EJECTOR (S/N: B1W1-UP)

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

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

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

Off-Highway Truck/Tractor:

770 (S/N: BZZ1-UP)

772 (S/N: RLB1-UP)

773F (S/N: EED1-UP; EXD1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

793F (S/N: SSP1-UP)

797F (S/N: LAJ1-UP)

Quarry Truck:

775F (S/N: EYG1-UP; DLS1-UP)

Wheel Tractor-Scraper:

621G (S/N: DBB1-UP; DXB1-UP; DXD1-UP; CEN1-UP; ALP1-UP)

623G (S/N: DBC1-UP; CES1-UP; ARW1-UP)

627G (S/N: DBD1-UP; AXF1-UP; DXJ1-UP; CEX1-UP)

631G (S/N: DFA1-UP; DXE1-UP; AWK1-UP; CLR1-UP)

637G (S/N: CEH1-UP; DFJ1-UP; DXM1-UP; AXT1-UP)

657G (S/N: W1B1-UP; W1C1-UP; DXG1-UP)

Introduction

This Special Instruction provides the procedure for retrofitting the rotary position sensor. These sensors are used on the transmission shift control groups of certain Off Highway Trucks, Wheel Tractor Scrapers, and Articulated Trucks. The same procedure can be applied to the hoist control groups on certain Off Highway Trucks and Articulated Trucks.

The new rotary position sensor contains an electrical connector configuration that is different from the electrical connector on the former position sensor groups. The connector on the machines electrical harness will need to be changed when replacing the rotary position sensor.

The rotary position sensor detects the transmission gear selector lever position.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Required Tools

Rotary Position Sensor Cross Reference

Replacement Procedure

1. Identify the proper replacement sensor and mating connector from Table 2.

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Illustration 1	g02195273

2. Use the 214-7324 Torx Bit Set to remove the plastic accessory cover or arm rest that is shown in Illustration 1.

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Illustration 2	g02195413

3. Remove the four torx fasteners shown in Illustration 2 that secure the transmission shift and or hoist control group to the console. Lift the transmission shift and hoist control group out being careful not to pull any wires that may be taught or tangled. Removing the transmission shift and or hoist control group will allow you to gain access to the rotary position sensor.

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Illustration 3	g02195493

4. Unplug the existing rotary position sensor by depressing the release tabs (1) on either side of the connector and pulling on the mating plug. Wiggling from left to right while pulling on the plug may help unplug the sensor. Refer to Illustration 3.

   Note: Unplug the transmission sensor first and proceed with the instructions. Do not unplug the hoist sensor yet.

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Illustration 4	g02195473
(1) Release tab (2) Locking wedge (3) Screwdriver pry slot

5. Once the rotary position sensor is unplugged, remove the locking wedge (2) from the connector that the rotary position sensor was plugged into. The locking wedge can be removed with a straight blade screwdriver. Place a straight blade screwdriver in the slot (3) at the base to pry off the wedge. Refer to Illustration 4.

   Note: Wedge removal may require prying and pulling simultaneously. Do not pull on the wires.

6. Locate the pin identification on the replacement connector. The replacement connector can be determined in Table 2.

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Illustration 5	g02197175
(4) Replacement locking tab (5) Replacement connector wedge

7. With the correct replacement connector in hand make sure the locking tab (4) and wedge (5) are positioned as shown in Illustration 5. If the lock tab (4) and wedge (5) are not in the correct position, then slide both into the correct position.

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Illustration 6	g02197354

8. Locate the pin identification numbers on the wire end of the original harness plug. Refer to Illustration 6.
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   Illustration 7	g02198235

   1. Insert a small straight blade screwdriver between the socket lift tab (6) and the corresponding metal socket for pin one. Refer to Illustration 7.

   2. Pry up on the lift tab while pulling only the wire for pin one. The lift tab should allow only the wire from pin one to be released from the connector. If the wire will not release, then the tab has not been fully lifted.

      Note: Use caution not to damage the metal socket when prying.

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Illustration 8	g02198456

9. Insert the wire from pin one that was removed from the original connector in Step 8.b to socket one of the replacement connector. Refer to Illustration 8 for the location of socket one. Continue to push the wire and socket into the plug until an audible click is heard. Verify that the electrical socket is locked into the connector shell by performing a pull test on the wire.

10. Repeat Steps 8.a through 9 for wire two placed in replacement connector socket two. Then repeat Steps 8.a through 9 for wire three placed in replacement connector socket three.

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Illustration 9	g02199119

11. With all three harness wires transferred from the original connector, push the locking wedge (5) inward towards the center of the plug. An audible click will verify that the locking wedge (5) is seated correctly.

12. Remove the two M4 fasteners that secure the original rotary position sensor to the transmission shift control. Then remove the original rotary sensor.

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Illustration 10	g02199195

13. Slide the new rotary position sensor over the transmission shift control input shaft and two positioning pins. The sensor rotor and the input shaft are indexed for proper alignment. Be certain that the sensor and shaft are aligned properly or damage to the sensor will occur and a diagnostic fault may become active. The new rotary position sensor uses the same orientation as the former rotary position sensor. Use the two fasteners that were removed in Step 10 to secure the new rotary position sensor into the mounting location. Torque the fasteners to 1.7 N·m (15 lb in).

    Note: The new rotary position sensor is determined by using Table 2.

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Illustration 11	g02199255

14. Plug the new rotary position sensor into the machine harness. Slide the locking tab (4) inward toward the new rotary position sensor. The connector is now locked into place. Pull slightly on the harness connector to insure that the harness is secured and locked to the new rotary position sensor.

15. To replace the hoist sensor, repeat Step 4 through Step 14.

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Illustration 12	g02199258

16. Reinstall the transmission control and or the hoist control that was removed in Step 3.

17. Perform a calibration of the shift lever sensor. The calibration procedure can be found in the System Operation, Testing & Adjusting manual for the machine that you are working on.

18. With the calibration complete, start the machine and shift the transmission from neutral into a forward gear. Then shift the transmission into reverse. Verifying that the transmission will go into all gears verifies that the new rotary position sensor is operating correctly.

The procedure for replacing the transmission shift lever or hoist lever sensor on certain Off-Highway Trucks and Articulated Trucks is now complete.