PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 797F OFF-HIGHWAY TRUCKS
Usage:
TEBE0518-00
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| 06Jan2014 |
U-5
A-3
D-4
O-4
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| Before/After | PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 797F OFF-HIGHWAY TRUCKS |
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| 7422 1408 7560 7857 | PS44149 |
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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 "PS44149" 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 |
| 31Jan2016 |
PROBLEM
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| The existing oil level switch on the torque converter or hydraulic oil tank can fail on certain 797F Off-Highway Trucks. If the existing oil level switch fails, it should be updated to the improved capacitance level sensor. |
AFFECTED PRODUCT
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| Model | Identification Number |
| 797F | LAJ00152-00487 |
| 797F XQ | WSP00100-00124 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 4 | 8T4136 | BOLT-HEX HEAD |
| 2 | 1305300 | CLIP |
| 11 | 2042281 | STRAP-CABLE |
| 4 | 2048000 | MOUNT-TIE WRAP |
| 2 | 2385081 | SEAL-O-RING-STOR |
| 2 | 4309455 | SENSOR GP-LEVEL |
| 1 | 4488191 | HARNESS AS |
| 1 | 4488192 | HARNESS AS |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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. |
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ACTION REQUIRED
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| Refer to the attached Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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0-36 mo |
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| NOTE: This is a 1.5-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. |
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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 rear of the hydraulic tank. Note: The tank and the sensor location may differ slightly depending on type of tank that is installed. |
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| Image1.2.1 |
| Install the new 238-5081 O-Ring Seal onto the new 430-9455 Liquid Level Sensor. Remove the cover over the existing 172-8660 Level Switch. Remove the switch from the hydraulic tank. The switch will not be reused. Install the new 430-9455 Liquid Level Sensor into this location. |
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| Image1.3.1 |
| Install two new 130-5300 Harness Clips at two locations identified below. These clips need to face inward toward the hydraulic tank. |
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| Image1.4.1 |
| Install the connector, from the new liquid level sensor (B), onto the harness clip as shown below. Plug the HN-C2 connection, of the new jumper harness, into the mating connector of the liquid level sensor. Install the HN-C4 (A) connector, of the new jumper harness, onto the harness clip. Plug the existing chassis harness into 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. |
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| Image1.5.1 |
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| Image1.5.2 |
| Install the connector of the hydraulic temperature sensor onto the harness clip. Plug the HN-C1 (B) connection, of the new jumper harness, into the mating connector from the hydraulic oil temperature sensor. Install the HN-C3 (A) connector, of the new jumper harness, onto the harness clip. Plug the existing chassis harness into 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. |
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| Image1.6.1 |
| Route new 448-8191 Jumper Harness between the new liquid level sensor and the hydraulic oil temperature sensor as shown in the image below. Secure the harness with tie straps to the existing saddle clips (A). |
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| Image1.7.1 |
| Locate the existing Oil level Switch on the Torque Converter and remove the cover. |
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| Image1.8.1 |
| Install the new 238-5081 O-Ring Seal onto the new 430-9455 Liquid Level Sensor. Remove the existing 172-8660 Level Switch. This switch will not be reused. Install the new 430-9455 Liquid Level Sensor into this location. |
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| Image1.9.1 |
| Remove the existing P Clips (A), at the two locations identified below, and replace them with new 204-8000 Clips and longer 8T-4136 Mounting Bolts. |
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| Image1.10.1 |
| Install the connector of the new liquid level sensor onto the DT Clip. Insert the HP-C2 connection (A), of the new jumper harness, into the mating connector of the new sensor. Plug the existing chassis harness into the HP-C4 connector (B) of the new jumper harness. |
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| Image1.11.1 |
| Strap the excess pigtail harness length back to the new saddle clip (A) with the 204-2281 Tie Strap. Secure the harness connection to the new harness (A) using the 204-2281 Tie Strap. |
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| Image1.12.1 |
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| Image1.12.1 |
| Plug the connector of the hydraulic temperature sensor into HP-C1 connection (A) of the new jumper harness. Plug the existing chassis harness into the HP-C3 connector (B) of the new jumper harness. Bundle the excessive harness length and the harness connection using the 204-2281 Tie Strap. |
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| Image1.13.1 |
| Secure both harnesses using the 204-2281 Tie Straps (A) and reinstall the cover over the new hydraulic oil sensor. |
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