BEARING-CONNECTING ROD 8N8222 - Caterpillar

System Operation Description:This procedure covers the following diagnostic codes:
96-03 Fuel Level Sensor open/short to +batt
96-04 Fuel Level Sensor short to groundThe fuel level sensor is a component that is installed by the Original Equipment Manufacturer (OEM) for the vessel. The sensor is a passive sensor. The sensor does not require an operating voltage from the Electronic Control Module (ECM).When the fuel tank is full, the fuel level sensor has a resistance of 33 Ohms. When the fuel tank is empty, the fuel level sensor has a resistance of 240 Ohms. The resistance from the fuel level sensor varies between these values as the fuel level varies.The sensor's variable resistance affects the pull-up voltage that is created by the ECM. When the sensor's resistance is low, the pull-up voltage is low. When the sensor's resistance is high, the pull-up voltage is high. Refer to Table 1.
Table 1
Relationship Between the Sensor's Resistance and the Voltage on the Signal Wire    
Fuel Level     Resistance     Approximate Voltage on the Signal Wire    
Full     33 Ohms     0.15 VDC    
Empty     240 Ohms     1.8 VDC    If the voltage on the signal wire falls below 0.15 VDC, a 96-04 diagnostic code is activated. If the voltage on the signal wire rises above 1.8 VDC, a 96-03 diagnostic code is activated. There is an eight second delay before either code is activated.A diagnostic code is probably caused by a problem in a wiring harness. The next likely cause is a problem with the fuel level sensor. The least likely cause is a problem with the ECM.
Illustration 1 g01155130
Schematic for the fuel level sensorTest Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01147202
Left side engine view (typical example) (1) J2/P2 ECM connectors
Thoroughly inspect connectors (1). Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
Illustration 3 g01155286
P2 terminals that are associated with the fuel level sensor (P2-26) Fuel level sensor signal (P2-42) Sensor return
Illustration 4 g01155187
P803 Fuel level sensor connector (P803-1) Fuel level (P803-2) Sensor return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel level sensor.
Check the allen head screw on the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the fuel level sensor to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and the wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or the wiring.Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. Verify that the repair eliminates the problem.STOPTest Step 2. Check the Sensor's Resistance at the Sensor
Disconnect the J803/P803 connectors.Note: Be sure to wiggle the harness during the following measurement in order to reveal an intermittent condition.
Measure the sensor's