Procedure to Align the Dial on the Fuel Sender{1273, 7481, 7857} Caterpillar

Procedure to Align the Dial on the Fuel Sender{1273, 7481, 7857} [REHS4449]

FUEL SYSTEM

GAUGE GP

Procedure to Align the Dial on the Fuel Sender{1273, 7481, 7857}

1.1. Introduction

2.1. Procedure to Align the Dial on the Fuel Sender

Articulated Truck:
735 (S/N: WWC1-UP; B1N1-UP; AWR1-UP)
740 (S/N: WWD1-UP; AXM1-UP; B1P1-UP)
740 EJECTOR (S/N: WWE1-UP; B1R1-UP; AZZ1-UP)
D250E (S/N: 5TN1-UP)
D300E (S/N: 7FN1-UP)
Landfill Compactor:
816F Series 2 (S/N: BZR1-UP)
816F (S/N: 5FN1-UP; BMR1-UP)
826G Series II (S/N: AYH1-UP)
826G (S/N: 7LN1-UP)
826H (S/N: AWF1-UP; ZXT1-UP)
836G (S/N: BRL1-UP; 7MZ1-UP)
836H (S/N: BXD1-UP; XTR1-UP)
Soil Compactor:
815F Series 2 (S/N: BYN1-UP)
815F (S/N: BKL1-UP; 1GN1-UP)
825G Series II (S/N: AXB1-UP)
825G (S/N: 6RN1-UP)
825H (S/N: ZHC1-UP; AZW1-UP)
Excavator:
322B (S/N: 3NR1-UP; 5CR1-UP; 8MR1-UP)
322B L (S/N: 8NR1-UP; 1AS1-UP; 1YS1-UP; 1ZS1-UP; 2ES1-UP)
324D L (S/N: LAB1-UP)
324D LN (S/N: EJC1-UP)
324D (S/N: MND1-UP)
324D L (S/N: T2D1-UP; BYE1-UP; JJG1-UP)
324D (S/N: ECH1-UP)
324D LN (S/N: TRH1-UP)
324D L (S/N: BTK1-UP; SYM1-UP)
324D (S/N: AWN1-UP)
324D L (S/N: TSN1-UP; DFP1-UP)
324D (S/N: JZR1-UP)
324D L (S/N: JAT1-UP; PYT1-UP)
324D (S/N: CJX1-UP)
325B (S/N: ABD1-UP; 8GM1-UP)
325B L (S/N: 6DN1-UP)
325B (S/N: 7EN1-UP)
325B LN (S/N: 8FN1-UP)
325B L (S/N: 2JR1-UP)
325B (S/N: 8PR1-UP)
325B L (S/N: 8RR1-UP; 1GS1-UP; 4DS1-UP; 5BS1-UP)
325B (S/N: 5LW1-UP)
325C (S/N: BLA1-UP)
325C L (S/N: CRB1-UP; JLC1-UP)
325C MH (S/N: S2C1-UP)
325C L (S/N: BTD1-UP)
325C (S/N: JLD1-UP)
325C L (S/N: BFE1-UP)
325C (S/N: DTF1-UP; AMH1-UP; BKH1-UP)
325C LN (S/N: CSJ1-UP)
325C L (S/N: BMM1-UP; BKT1-UP)
325C (S/N: BKW1-UP)
325C L (S/N: BLX1-UP)
325D L (S/N: GPB1-UP; KBE1-UP)
325D LN (S/N: PKE1-UP)
325D (S/N: KDG1-UP; DBH1-UP)
325D L (S/N: PEH1-UP)
325D (S/N: CJM1-UP)
325D L (S/N: AZP1-UP)
325D MH (S/N: GBR1-UP)
325D L (S/N: SCR1-UP; CYW1-UP)
330B (S/N: 9HN1-UP)
330B L (S/N: 2RR1-UP; 3YR1-UP)
330B LN (S/N: 5LR1-UP)
330B L (S/N: 6DR1-UP)
330B (S/N: 8SR1-UP)
330B L (S/N: 8TR1-UP; 1JS1-UP; 4RS1-UP; 5LS1-UP)
330B (S/N: 4YW1-UP; 3ZZ1-UP; 5EZ1-UP)
330C L (S/N: CYA1-UP; HAA1-UP)
330C (S/N: MCA1-UP; JAB1-UP; NAB1-UP; D3C1-UP; JCD1-UP)
330C L (S/N: KDD1-UP)
330C (S/N: GAG1-UP; RBH1-UP)
330C L (S/N: JNK1-UP)
330C (S/N: BTM1-UP)
330C L (S/N: MKM1-UP; CAP1-UP; GKX1-UP; DKY1-UP)
330C LN (S/N: CGZ1-UP)
330D L (S/N: RDA1-UP)
330D (S/N: KAB1-UP)
330D L (S/N: GBC1-UP)
330D (S/N: PFC1-UP)
330D L (S/N: NBD1-UP; R2D1-UP)
330D LN (S/N: GGE1-UP)
330D L (S/N: NEF1-UP; B6H1-UP)
330D (S/N: EAH1-UP; LCJ1-UP)
330D L (S/N: THJ1-UP)
330D (S/N: C5K1-UP)
330D L (S/N: FFK1-UP)
330D (S/N: PCK1-UP)
330D L (S/N: RDK1-UP)
330D MH (S/N: PEL1-UP)
330D (S/N: JJM1-UP; LEM1-UP)
330D L (S/N: LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP; EDX1-UP)
330D (S/N: MEY1-UP)
330D L (S/N: T2Y1-UP)
UNDERCARRIAGE (S/N: L3M1-UP)
Industrial Tractor:
TK371 (S/N: WBG1-UP)
TK381 (S/N: WBH1-UP)
Wheel Feller Buncher:
HA770 (S/N: HAB1-UP)
HA771 (S/N: HAF1-UP)
HA870 (S/N: HAE1-UP)
HA871 (S/N: HAG1-UP)
TK380 (S/N: WBE1-UP)
Integrated Toolcarrier:
IT62G Series II (S/N: AYA1-UP)
IT62G (S/N: BBE1-UP; AKP1-UP; 6PS1-UP)
Motor Grader:
120M (S/N: B9C1-UP; B9N1-UP; CBS1-UP; B9W1-UP)
12M Series II (S/N: M9F1-UP)
12M (S/N: B9R1-UP)
140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)
14M (S/N: B9J1-UP)
160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)
16M (S/N: B9H1-UP)
Mobile Hydraulic Power Unit:
324D MHPU LN (S/N: KJR1-UP)
325C MHPU (S/N: MSG1-UP)
330C MHPU (S/N: MSD1-UP; MSL1-UP)
330D MHPU L (S/N: D3D1-UP; H3D1-UP; M3D1-UP)
330D MHPU LN (S/N: GMN1-UP)
Pipelayer:
572R Series II (S/N: DSC1-UP)
583T (S/N: CMX1-UP)
587T (S/N: FAT1-UP)
Track-Type Loader:
931C (S/N: 2XK1-UP)
953C (S/N: 2ZN1-UP; BBX1-UP)
953D (S/N: LBP1-UP)
963C HD (S/N: BBD1-UP)
963C LGP HD (S/N: 2DS1-UP)
963D (S/N: LCS1-UP)
973C HD (S/N: BCP1-UP)
973C (S/N: LDX1-UP)
973C HD (S/N: 3RZ1-UP)
973D (S/N: LCP1-UP)
Track-Type Tractor:
D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP)
D6R Series III XL (S/N: RFC1-UP)
D6R Series III (S/N: TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP)
D6R Series III XW (S/N: MTJ1-UP)
D6R Series III (S/N: DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP)
D6R Series III LGP (S/N: DLM1-UP)
D6R Series III (S/N: LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP; B1Z1-UP)
D6T STD (S/N: JHB1-UP)
D6T PAT (S/N: ZEB1-UP)
D6T STD (S/N: SMC1-UP)
D6T PAT (S/N: JWD1-UP)
D6T XL (S/N: LBD1-UP; LAE1-UP)
D6T PAT (S/N: DJG1-UP; WCG1-UP; WFH1-UP)
D6T LGP (S/N: LKJ1-UP; SNK1-UP)
D6T STD (S/N: DHL1-UP)
D6T LGP (S/N: KJL1-UP)
D6T XW (S/N: SKL1-UP)
D6T XL (S/N: KLM1-UP; GCT1-UP)
D6T PAT (S/N: RLW1-UP)
D6T XL (S/N: LAY1-UP)
D6T XW (S/N: RAY1-UP)
D6T STD (S/N: PEZ1-UP)
D7R Series II STD (S/N: AEC1-UP)
D7R Series II DS LGP (S/N: ABJ1-UP)
D7R Series II DS XR (S/N: AGN1-UP)
D8T (S/N: J8B1-UP; KPZ1-UP)
Wheel Dozer:
814F Series 2 (S/N: BXG1-UP)
814F (S/N: BGF1-UP; 9DM1-UP)
824G Series II (S/N: AWW1-UP)
824G (S/N: 4SN1-UP)
824H (S/N: ZBD1-UP; ASX1-UP)
834G (S/N: BPC1-UP; 6GZ1-UP)
834H (S/N: XDC1-UP; BTX1-UP)
854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)
854K (S/N: 2211-UP)
Wheel Loader:
950F (S/N: 7ZF1-UP; 6YG1-UP)
950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)
950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)
960F (S/N: 9ZJ1-UP; 4CL1-UP; 6XL1-UP; 1YM1-UP)
962G Series II (S/N: BTA1-UP; BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)
962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)
966F (S/N: 4YG1-UP; 3XJ1-UP; 6ML1-UP; 8BG1-UP)
970F (S/N: 7SK1-UP; 9JK1-UP; 7PL1-UP)
980F Series II (S/N: 8JN1-UP)
980F (S/N: 8CJ1-UP; 3HK1-UP; 5XJ1-UP)
980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)
980G (S/N: BGC1-UP; 9CM1-UP; 2KR1-UP; 2SR1-UP)
980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)
988G (S/N: BNH1-UP; 2TW1-UP)
988H (S/N: BXY1-UP)
991K (S/N: 5301-UP)
992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)
992K (S/N: H4C1-UP)
994G (S/N: BEH1-UP; 8FR1-UP)
Wheel Skidder:
515 (S/N: 4LR1-UP)
522C PS (S/N: 2WL1-UP)
525 (S/N: 1DN1-UP)
525B (S/N: 3KZ1-UP)
525C (S/N: 5251-UP)
535B (S/N: AAE1-UP)
535C (S/N: 5351-UP)
545 (S/N: 2FZ1-UP)
545C (S/N: 5451-UP)
Wheel Tractor-Scraper:
613C Series II (S/N: 8LJ1-UP)
613G (S/N: DXA1-UP; ESB1-UP; DBE1-UP; DBJ1-UP)
615C Series II (S/N: 9XG1-UP)
615C (S/N: 5TF1-UP; 2XG1-UP)
621G (S/N: DBB1-UP; ANG1-UP; CEN1-UP; ALP1-UP; CEP1-UP; DBX1-UP)
623G (S/N: AWB1-UP; DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)
627G (S/N: DBD1-UP; AXF1-UP; AYK1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)
631G (S/N: DFA1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; AXZ1-UP)
637G (S/N: AWE1-UP; CEH1-UP; CEJ1-UP; DFJ1-UP; CEM1-UP; AYN1-UP; AXT1-UP; DEX1-UP; DEY1-UP)
657G (S/N: W1B1-UP; W1C1-UP; W1E1-UP; W1F1-UP; A4G1-UP; GER1-UP)

Introduction

This procedure covers the process in order to align the dial on the fuel sender after removal.

Note: Do not perform any procedure in this publication until you read the information and you understand the information.

Show/hide table

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Show/hide table

Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system.

Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.

Show/hide table

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates.

Procedure to Align the Dial on the Fuel Sender

Follow the steps below in order to align the pointer within the dial on the fuel sender. Refer to the table below for part numbers of affected fuel senders.

Show/hide table

Table 1
Part Numbers of Affected Fuel Senders
317-9186	Repair Kit
317-9182	Dial Sensor Kit
317-9184	Repair Kit
317-9183	Sensor Kit
317-9187	Dial Sensor Kit
317-9188	Repair Kit
317-9189	Dial Sensor Kit
317-9191	Dial Sensor Kit
317-9190	Dial Sensor Kit
169-3506	Dial Sensor Kit
180-6989	Repair Kit
246-1526	Sensor Kit
282-6493	Repair Kit
283-9502	Dial Sensor Kit
283-9503	Dial Sensor Kit
283-9504	Dial Sensor Kit
112-9863	Dial Sensor Kit
115-1782	Fuel Level Sender As
116-4759	Dial Sensor Kit
119-8981	Dial Sensor Kit
123-9813	Dial Sensor
124-0290	Dial Sensor
126-9023	Dial Sensor Kit
128-7934	Dial Sensor Kit
136-2094	Dial Sensor Kit
138-0444	Repair Kit
139-8661	Dial Sensor Kit
139-8662	Dial Sensor Kit
139-8663	Dial Sensor Kit
139-8665	Dial Sensor Kit
139-8666	Dial Sensor Kit
139-8667	Fuel Level Sender As
139-9314	Dial Sensor Kit
140-7721	Dial Sensor Kit
149-7210	Fuel Level Gauge Gp
153-4180	Dial Sensor Kit
159-0647	Dial Sensor Kit
159-0652	Dial Sensor Kit
162-8207	Dial Sensor Kit
178-3056	Repair Kit
180-6989	Repair Kit
194-8535	Dial Sensor Kit
204-7458	Sensor Kit
246-1526	Sensor Kit
254-5671	Sensor Kit

Show/hide table




Illustration 1	g01949664
(A) Pointer (B) Mounting Flange

Remove the two mounting screws for the fuel sender from the mounting flange (B) and save the screws.

Remove the fuel sender. If the assembly is equipped with an O-ring behind the fuel sender, remove the O-ring and discard the O-ring.
Note: Removing the O-ring reduces the stress that is placed on the fuel sender. The reduced stress eliminates the moisture that may enter resulting from cracks in the fuel sender.

Prior to installing the new fuel sender, estimate the amount of fuel in the tank. If the tank is less than half full, position the pointer (A) on the dial to the left hand side of the 1/2 full indicator. If the tank is more than half full, position the pointer (A) on the dial to the right hand side of the 1/2 full indicator. If the tank is half full, position the pointer (A) on the dial to the 1/2 full indicator.

Rotate a magnet or a magnetized body such as a stem of a screwdriver at the back of the fuel sender in order to reposition the pointer (A) to the desired position.