PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

TEBE0531-00

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23Dec2013

U-660

A-464

D-544

O-558

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE HYDRAULIC OIL LEVEL SWITCH TO A SENSOR ON CERTAIN 793D OFF-HIGHWAY TRUCKS
7422 1408		PS44145

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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 "PS44145" 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 torque converter oil level switch may fail on certain 793D 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
793D	FDB01179-01813

PARTS NEEDED

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Qty	Part Number	Description
1	7K1181	STRAP-CABLE
1	1305300	CLIP
1	1305301	CLIP
5	2042281	STRAP-CABLE
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 15% 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 torque converter oil level switch on the torque converter.

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 torque converter. The switch will not be reused. Install the new 430-9455 Liquid Level Sensor into this location.

Image1.3.1

Install a new 130-5300 Harness Clips at location "A" identified below. This new clip will be installed on top of the existing clip, but facing the opposite direction.

Image1.4.1

Image1.4.2

Install a new 130-5301 Harness Clip at location "B" identified below. The new clip should face opposite the existing clips.

Image1.5.1

Image1.5.2

Install the connector, from the new liquid level sensor, onto the harness clip as shown below. Plug the HN-C2 (B) 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.

Image1.6.1

Plug the HN-C1 connection, of the new jumper harness, into the mating connector from the hydraulic oil temperature sensor (A).

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

Image1.7.1

Secure the new level sensor harness with a new 7K-1181 Tie Strap at location (B) in the illustration below. Make certain the harness is not pulled too tight to pull on the top of the sensor.

Image1.8.1

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 204-2281 Tie Straps (A) as needed.