Procedure to Modify the Oil Pan for Additional Oil Sensor Ports on Certain 793F, 794AC, and 795F AC Off-Highway Truck Engines {1302, 1408, 1439, 7422}
- Off-Highway Truck/Tractor
- 793F (S/N: SND1-133; SSP1-1227; SXP1-103; D3T1-156; RBT1-223)
- 793F AC (S/N: EMD1-77)
- 794 AC (S/N: MN51-56; MT51-137)
- 795F AC (S/N: ERM1-300)
- 795FAC XQ (S/N: SNT1-105)
- 793F AC (S/N: EMD1-77)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special instruction describes the procedure for modifying the oil pan for additional oil sensor ports and installing the new sensor assemblies.
Safety Section
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals. |
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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed. |
Required Parts
Table 1 contains the new parts required for this change.
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| New Part Number | New Part Name | Quantity |
|---|---|---|
| Sensor Guard As | 3 | |
| Liquid Level Sensor Gp | 3 | |
| Bolt | 4 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Washer | 6 | |
| Spacer | 1 | |
| Spacer | 2 | |
| Connecting Clip Assembly | 3 | |
| O-Ring Plug | 1 | |
| O-Ring Seal | 1 |
Required Tools
Table 1 contains the tools required for this change.
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| Tool Description | Quantity |
|---|---|
| 7/8-14-2B Tap | 1 |
| M10x1.5-6H Tap | 1 |
Installation Procedure
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| Illustration 1 | g06411883 |
| (A) Oil Pan | |
The following procedure modifies the oil pan to add additional oil sensor ports and 2 additional bracket mounting holes.
- Drill one
19.75 mm (0.8125 inch) hole through oil pan (A) at dimension (D1) from the rear face of the oil pan and at dimension (D2) from the top of the pan.- Use the 7/8-14-2B tap to tap the hole through the oil pan at dimension (D1) from the rear face of the oil pan and at dimension (D2) from the top of the pan.
- Drill one
19.75 mm (0.8125 inch) hole through oil pan (A) at dimension (D1) from the rear face of the oil pan and at dimension (D5) from the top of the pan.- Use the 7/8-14-2B tap to tap the hole through the oil pan at dimension (D1) from the rear face of the oil pan and at dimension (D5) from the top of the pan.
- Drill one
10 mm (0.4 inch) hole to a depth of31 mm (1.2 inch) at dimension (D1) from the rear face of the oil pan and at dimension (D3) from the top of the pan.- Use the M10x1.5-6H tap to tap the hole at dimension (D1) from the rear face of the oil pan and at dimension (D3) from the top of the pan to a depth of
23 mm (0.9 inch) .
- Use the M10x1.5-6H tap to tap the hole at dimension (D1) from the rear face of the oil pan and at dimension (D3) from the top of the pan to a depth of
- Drill one
10 mm (0.4 inch) hole to a depth of31 mm (1.2 inch) at dimension (D1) from the rear face of the oil pan and at dimension (D4) from the top of the pan.- Use the M10x1.5-6H tap to tap the hole at dimension (D1) from the rear face of the oil pan and at dimension (D4) from the top of the pan to a depth of
23 mm (0.9 inch) .
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Illustration 3 g06413625 (A) Oil Pan
(1)238-5081 O-Ring Seal
(2)430-9455 Liquid Level Sensor Gp - Use the M10x1.5-6H tap to tap the hole at dimension (D1) from the rear face of the oil pan and at dimension (D4) from the top of the pan to a depth of
- Install 2 O-ring seals (1) onto 2 liquid level sensor groups (2)
- Install the 2 liquid level sensor groups into oil pan (A).
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Illustration 4 g06411958 (2) 430-9455 Liquid Level Sensor Gp
(3)454-8550 Sensor Guard As
(4)6V-3822 Bolt
(5)6V-5839 Washer
(6)127-5447 Spacer
(7)115-3069 Connecting Clip Assembly - Install 2 sensor guard assemblies (3) using bolt (4) with washer (5), connecting clip assembly (7) and spacer (6).
- Install liquid level sensor group (2) into the connecting clip assembly.
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Illustration 5 g06411948 (2) 430-9455 Liquid Level Sensor Gp
(3)454-8550 Sensor Guard As
(4)6V-3822 Bolt
(5)6V-5839 Washer
(6)127-5447 Spacer
(7)115-3069 Connecting Clip Assembly - Install bolt (4) with washer (5), connecting clip assembly (7), and spacer (6) through 2 sensor guard assembly (3).
- Install liquid level sensor group (2) into the connecting clip assembly.
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Illustration 6 g06411946 (2) 430-9455 Liquid Level Sensor Gp
(3)454-8550 Sensor Guard As
(7)032-9828 Grommet - Install 2 liquid level sensor groups (2) and 4 grommets (7) into 2 sensor guard assemblies (3).
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Illustration 7 g06413584 (A) Oil Pan
(1)238-5081 O-Ring Seal
(8)9S-4190 O-Ring Plug - Install O-ring plug (8) with O-ring seal (1) into oil pan (A)
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Illustration 8 g06413590 ( A) Oil Pan
(1)238-5081 O-Ring Seal
(2)430-9455 Liquid Level Sensor Gp - Install O-ring seal (1) onto liquid level sensor group (2).
- Install the liquid level sensor group into oil pan (A).
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Illustration 9 g06411936 (2) 430-9455 Liquid Level Sensor Gp
(3)454-8550 Sensor Guard As
(5)6V-5839 Washer
(7)032-9828 Grommet
(9)6V-6317 Bolt - Install sensor guard assembly (3) over liquid level sensor group (2) using bolt (9) and washer (5).
- Install the liquid level sensor group and 2 grommets (7) into the sensor guard assembly.
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Illustration 10 g06411932 (2) 430-9455 Liquid Level Sensor Gp
(3)454-8550 Sensor Guard As
(4)6V-3822 Bolt
(5)6V-5839 Washer
(6)127-5447 Spacer
(7)115-3069 Connecting Clip Assembly - Install bolt (4), washer (5), connecting clip assembly (7), and spacer (6) onto sensor guard assembly (3).
- Install liquid level sensor (2) into the connecting clip assembly.
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Illustration 11 g06411927 (2) 430-9455 Liquid Level Sensor Gp
(10)520-4384 Sensor Harness As - Install sensor harness assembly (10) into 3 liquid level sensor groups (2).
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Illustration 12 g06411914 (3) 454-8550 Sensor Guard As
(5)6V-5839 Washer
(9)6V-6317 Bolt
(10)520-4384 Sensor Harness As
(11)353-7957 Grommet
(12)8T-1888 Clip
(13)8T-1887 Clip - Install 3 grommets (11), 3 clips (12), and 3 clips (13) around sensor harness assembly (10).
- Install 3 bolts (9) with 3 washers (5) through the clips into 3 sensor guard assemblies (3).
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| Illustration 2 | g06411645 |
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(D1) (D2) (D3) (D4) (D5) (A) Oil Pan | |
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