PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FUEL LEVEL SENDER ON CERTAIN 415F2, 416F, 416F2, 420F, 420F2, 422F, 422F2, 427F2, 428F, 428F2, 430F, 430F2, 432F, 432F2, 434F, 434F2, 444F, AND 444F2 BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FUEL LEVEL SENDER ON CERTAIN 415F2, 416F, 416F2, 420F, 420F2, 422F, 422F2, 427F2, 428F, 428F2, 430F, 430F2, 432F, 432F2, 434F, 434F2, 444F, AND 444F2 BACKHOE LOADERS

Usage:

TEBE5555-03

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04Jan2017

(Revised 26Jul2017)

U-9

A-9

D-9

O-9

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FUEL LEVEL SENDER ON CERTAIN 415F2, 416F, 416F2, 420F, 420F2, 422F, 422F2, 427F2, 428F, 428F2, 430F, 430F2, 432F, 432F2, 434F, 434F2, 444F, AND 444F2 BACKHOE LOADERS
1273		PS53380

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53380" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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NOTE:	This Revised Service Letter replaces the 04Jan2017 (Revised 16Jun2017) Service Letter. Changes have been made to the Rework Procedure, Step 7, OHMS (empty).

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TERMINATION DATE

31Jan2019

PROBLEM

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The electrical connection on the existing fuel level sender may not seal correctly and allow water and debris to contaminate the electrical connection on certain 415F2, 416F, 416F2, 420F, 420F2, 422F, 422F2, 427F2, 428F, 428F2, 430F, 430F2, 432F, 432F2, 434F, 434F2, 444F, and 444F2 Backhoe Loaders. This can cause a bad signal to the gauge cluster. The fuel level gauge is likely to read HIGHER than it should in this case.

IMPORTANT: This Service Letter DOES NOT cover mechanical or electrical failure of the sender itself. It only covers electrical issues associated with the electrical connection between the sender and the machine harness.

AFFECTED PRODUCT

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Model	Identification Number
415F 2	HWA00150-00470, 50177 PF400150-00156, 158-490
416F	LWT00150-00785
416F 2	HWB00150-01104 LBF01000-02405 LYA00150-00374
416F ST	KSF00150-02254
420F	LKH00150-00151, 153-516 LTG00150-01210, 1215-2342
420F 2	HWC00150-02006 LBS00150-00457 LYB00150-00466, 468-545
420F 2 IT	HWD00150-01605 LYC00150-00419, 421, 423-442
420F IT	JWJ00150-03288
420F ST	SKR00150-05380, 6996, 45157
422F	LRH00150-02375
422F 2	LYF00150-00340, 342-801
427F 2	HWK00150-00302
428F	LBH00150-05614, 33976 RAK00150-00610 SJW00150-00425, 430-707
428F 2	HWN00150-00614 LYG00150-00696, 711-1802, 1804-1807
430F	LDY00150-00281 LNH00150-00208
430F 2	HWE00150-00325, 327-576 LYD00150-00193
430F 2 IT	HWG00150-00234, 236-451 LYE00150-00201
430F IT	RGS00150-00376, 378-762
430F ST	RDF00150-00332, 334-870
432F	LNR00150-00754, 756-1287 PXR00150-00893 SEJ00150-00445, 447-824, 833-895
432F 2	HWP00150-01037 LYJ00150-00581
434F	FLY00150-00263 LDH00150-00947 MTR00150-00241
434F 2	HWR00150-00228 LYK00150-00327
444F	FBN00150-00246 JXR00150-00346 LJJ00150-00528
444F 2	HWS00150-00298, 301-379 LYL00150-00355

PARTS NEEDED

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Qty	Part Number	Description
1	1519272	RECEPTACLE KIT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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IMPORTANT: Do NOT remove the fuel level sender out of the fuel tank.

1. Before you start, make a note of what the fuel level gauge is reading on the display, and approximately the level of fuel in the tank.

2. In order to gain access to the fuel level sender wiring you need to remove the top tread plate from the top of the fuel tank. Refer to Image1. Remove the seven bolts that retain this plate, then slide it off.

3. Clean the area around the fuel level sender, and then disconnect the electrical connector from the machine wiring harness. Refer to Image2.

4. Check inside both of the connectors for signs of water or dirt. Clean and dry both connections, if needed.

5. Remove the wedge and receptacle from the two wires on the sender unit.

6. Using a multi meter, check the resistance between the two wires connected to the fuel level sender. Refer to Image3. The reading should be between the numbers listed below:

Empty = 246 to 252 OHMS
Full = 27 to 33 OHMS

7. If the sender is giving a reading outside of this range check, then the fuel level sender has a different fault. It may also be a ground fault on the machine somewhere. Further troubleshooting may be needed.

Also, if the reading is near 246 to 252 OHMS (empty), but it is obvious that there is plenty of fuel in the tank, then it is possible that there is a mechanical problem with the float on the fuel level sender, and it needs to be replaced. Adding more fuel to the tank may be necessary to double check the level reading.

Note: Replacement of the fuel level sender is NOT part of this Service Letter program.

8. If the fuel sender is giving a good reading on the multi meter, which matches the actual fuel level in the tank, install the new 151-9272 Receptacle Kit onto the two wires on the fuel level sender.

9. Ensure that the pins in the main harness are clean and then reconnect the sender to the machine harness.

10. Turn the key to the ON position and check the fuel level gauge. It should now be reading the correct fuel level. If it is not, then there is a fault somewhere else in the system, and NOT with the fuel sender. Further troubleshooting is needed.

11. Re-install the cover plate on the fuel tank.

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Image1

Image2

Image3

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%
0-3000 hrs, 0-24 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
Note: This Service Letter is only for the electrical connection issues between the fuel level sender and the machine harness (DT connector). It does NOT cover mechanical or electrical failures of the fuel level sender itself. Only the parts listed in the Parts Needed can be claimed for in this Service Letter. Failures outside of this Service Letter program should be dealt with as per the standard warranty agreement.

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