1999/09/27 Caterpillar

928G (6XR, 7SR) Wheel Loaders;
IT28G (8CR, 9AR) Integrated Toolcarriers

Reference: Special Instruction, SEHS9615, "Servicing DT Connectors."

Description of Change: A new fuel level sender has replaced the former 119-0102 fuel level sender. The new 166-7446 Fuel Level Sender, which has a DT connector plug rather than soldered terminal lugs, provides increased service life over the old fuel level sender.

Adaptable To: The new 166-7446 Fuel Level Sender is effective with the 928G (6XR1725, 7SR1118) Wheel Loader and IT28G (8CR1932, 9AR0554) Integrated Toolcarrier. The new 166-7446 Fuel Level Sender is adaptable to the listed machines having the former 119-0102 Fuel Level Sender.

Retrofit Procedure For Installing The New Fuel Level Sender

1. Disconnect wires 447B (PK) and 200N (BK) from the terminals of the current fuel level sender.

NOTE: Wires 447B (PK) and 200N (BK) are part of the 113-3892 Rear Frame Harness.

2. Cut off the 4K-6494 Solder Terminals on the ends of harness wires 447B (PK) and 200N (BK).

Illustration 1.
Connector plug configuration.

(2) 8T-8730 Socket Connectors

(3) 155-2269 Connector Plug

(4) 155-2261 Plug Lock Wedge

(8) 133-3892 Rear Frame Harness wires

(9) 3E-3364 Connector Receptacle (part of the new 166-7446 Fuel Level Sender)

3. Install the 8T-8730 Socket Connectors (2) on the ends of harness wires 447B (PK) and 200N (BK). See Illustration 1.

NOTE: Strip the insulation from the end of each wire and use the 1U-5804 Crimp Tool (7) to install the socket connectors.

4. Insert the socket connector with wire 447B (PK) in Position 1 of the 155-2269 Connector Plug (3).

5. Insert the socket connector with wire 200N (BK) in Position 2 of the 155-2269 Connector Plug (3).

6. Install the 155-2261 Plug Lock Wedge (4) to lock the socket connectors in place.

7. Unbolt and remove the old fuel level sender.

8. Remove and discard the old gasket.

9. Install the new 166-7446 Fuel Level Sender (1) using the new 9R-7240 Gasket (6).

NOTE: Torque the bolts to 1.3 N·m (12 lb in).

10. Mate the DT connector on the new fuel level sender to the newly installed 155-2269 Connector Plug (3) on the 113-3892 Rear Frame Harness (8).

Illustration 2.
The new 166-7446 Fuel Level Sender as installed.

(1) 166-7446 Fuel Level Sender

(3) 155-2269 Connector Plug

(5) 7K-1181 Cable Strap

(8) 113-3892 Rear Frame Harness

(9) 3E-3364 Connector Receptacle (part of the 166-7446 Fuel Level Sender)

11. Secure the cable for the new fuel level sender and DT connector (3, 9) to the weld link on the fuel tank using the 7K-1181 Strap (5). See Illustration 2.

12. Fill the tank with fuel and verify correct operation of the new fuel level sender.