PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 795F AC OFF HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 795F AC OFF HIGHWAY TRUCKS

Usage:

TEBE0463-00

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23Dec2013

U-659

A-463

D-543

O-557

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 795F AC OFF HIGHWAY TRUCKS
7560 7857 7422 1408		PS44144

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44144" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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TERMINATION DATE

31Dec2015

PROBLEM

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The existing hydraulic oil level switch can fail on certain 795F AC Off-Highway Trucks. If the existing hydraulic oil level switch fails, it should be updated to the improved capacitance level sensor.

AFFECTED PRODUCT

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Model	Identification Number
795F AC	ERM00154-00284

PARTS NEEDED

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Qty	Part Number	Description
1	8T4136	BOLT-HEX HEAD
2	1305300	CLIP
4	2042281	STRAP-CABLE
2	2048000	MOUNT-TIE WRAP
1	2385081	SEAL-O-RING-STOR
1	4309455	SENSOR GP-LEVEL
1	4488191	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-20000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Refer to the Service Manual if/as necessary.

Prepare the truck for electrical work as outline in the OMM and follow all safety rules.

Locate the hydraulic steering oil level switch on the inside of the hydraulic tank.

Image1.2.1

Install the new 238-5081 O-Ring Seal onto the new 430-9455 Liquid Level Sensor. Remove the existing 172-8660 Level Switch from the hydraulic tank. The switch will not be reused. Install the new 430-9455 Liquid Level Sensor into this location.

Image1.3.1

Install the two new 130-5300 Harness Clips into the location identified below. The clip will need to face inward toward the hydraulic tank.

Image1.4.1

Install the harness connector from the new liquid level sensor onto the top of the harness clip (A) and plug the HN-C2 connection, of the new jumper harness, into the mating connector of the liquid level sensor.

Install the HN-C4 connector, of the new jumper harness, onto the top inside of the harness clip (B) and plug the existing chassis harness into the this mating connector.

Strap the excess pigtail harness length back to the new sensor body with the 204-2281 Tie Strap. Make certain the harness makes a 1" diameter loop on the back side of the sensor.

Secure the harness down as needed using the 204-2281 Tie Straps.

Image1.5.1

Image1.5.2

Install the connector of the hydraulic temperature sensor (A) onto the bottom of the harness clip and plug the HN-C1 connection of the new jumper harness into the mating connector from the hydraulic oil temperature sensor.

Install the HN-C3 connector (B), of the new jumper harness, onto the bottomed inside of the harness clip and plug the existing chassis harness into this mating connector.

Secure the harness down as needed using the 204-2281 Tie Straps.

Image1.6.1

Using the new 8T-4136 Bolt, replace the existing P-clip with the new 204-8000 Saddle Clip in the location identified below.

Image1.7.1

Route new 448-8191 Jumper Harness between the new liquid level sensor and the hydraulic oil temperature sensor as shown in the image below. Coil and secure the extra harness length with the tie strap to the upper saddle clip.