Improved Method for Installing the Actual Gear Position Sensor {1439, 3061} Caterpillar

Articulated Truck:

735 (S/N: B1N1-UP)

740 (S/N: AXM1-UP)

740 (S/N: B1P1-UP)

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

D250E Series II (S/N: 4PS1-UP)

D300E Series II (S/N: 5KS1-UP)

D350E Series II (S/N: 2XW1-UP)

D350E (S/N: 9LR1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

D400E (S/N: 2YR1-UP)

Transmission:

TH48-E80 (S/N: FRT1-UP)

TH55 - KRESS (S/N: KCH1-UP)

Off-Highway Truck/Tractor:

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

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

768C (S/N: 02X1-UP)

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

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

770 (S/N: BZZ1-UP)

772 (S/N: RLB1-UP)

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

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

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

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

776 (S/N: 14H1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER1-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

789C (S/N: 2BW1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

Quarry Truck:

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

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

775E (S/N: BEC1-UP)

Underground Articulated Truck:

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

AD45 (S/N: BKZ1-UP)

AD45B (S/N: CXM1-UP)

AD55 (S/N: ANW1-UP; DNW1-UP)

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

Wheel Tractor-Scraper:

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

621F (S/N: 4SK1-UP)

621G (S/N: DBB1-UP; CEN1-UP; ALP1-UP; CEP1-UP; DBX1-UP)

623E (S/N: 6YF1-UP)

623G (S/N: DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)

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

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

627G (S/N: DBD1-UP; AXF1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)

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

631G (S/N: DFA1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP)

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

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

637G (S/N: CEH1-UP; CEJ1-UP; DFJ1-UP; AXT1-UP; DEX1-UP)

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

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

657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; GER1-UP)

Introduction

The following Special Instruction will guide you through the process of inspection and repair for Error Code CID 0700 - FMI 02.

Important Safety Information

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. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Parts List

Inspection of the Gear Position Sensor

Inspect the 120-9288 Transmission Harness As . Ensure that the harness is not coming loose from the 216-0280 Position Sensor Gp . Also, inspect the harness for a poor connection at the 216-0280 Position Sensor Gp and the 216-0281 Position Sensor Gp . Verify that the harness connector is properly seated into the connector on the gear sensor. Also check the pins of the harness connector that is rectangular on the 120-9288 Transmission Harness As and ensure that those pins are inserted and locked in the connector. Also, ensure that the connector is not cracked or broken.

Improved Procedure for Installing the Actual Gear Position Sensor

Use the following procedure in order to secure the connection if the harness connection between the gear sensor and the mating connector that is on the 120-9288 Transmission Harness As is loose.

1. Disconnect the 8-pin connector from the 216-0280 Position Sensor Gp .

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Illustration 1	g01824933

2. Remove the 216-0280 Position Sensor Gp from the housing. Refer to Illustration 1.

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Illustration 2	g01824937

3. Insert a cable tie through the hole on the 216-0280 Position Sensor Gp . The cable tie should be 355 mm (13.976 inch) in length and 2.31 mm (0.09094 inch) in width. Refer to Illustration 2.

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Illustration 3	g01824939

4. Bring the cable tie through the hole on the opposite side of the sensor group. Refer to Illustration 3.

   Note: Tightly pull the tie in order to ensure that the tie is flat to the bottom of the sensor.

5. Connect the 8-pin connector. Ensure that the connector is completely seated.

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Illustration 4	g01824942

6. Slide the 40 mm (1.574 inch) heat shrink tube onto the tie. Refer to Illustration 4.

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Illustration 5	g01824945

7. Route the tie with the heat shrink tube through the empty space of the 8-pin connector. Refer to Illustration 5.

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Illustration 6	g01824951

8. Use your hand in order to pull the tie through the lock. Make sure that the tie is snug on top of the 8-pin connector. Refer to Illustration 6.

   Note: You can tighten the tie on the outside of the housing in order to have easier access.

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Illustration 7	g01824953

9. Remove the excess tie. Refer to Illustration 7.

10. Install the 216-0280 Position Sensor Gp in the housing.