ENGINE AR-PRIMARY 4351697 - Caterpillar

Introduction
This Special Instruction provides instructions for troubleshooting the 376-9480 Fuel Level Sender As on the machines listed above.Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.Troubleshooting and Replacing the 376-9480 Fuel Sender Assembly
Illustration 1 g06124298
Remove the floor mat from the front of the operator seat.
Remove the two bolts (2) and washers (3) that secure cover (1).
Illustration 2 g06124300
Unplug the electrical connector from fuel sender (4).
Turn the key switch to the ON position. Use a multi-meter to check for system voltage across the two pins on the machine harness. Voltage should be 5 to 12 VDC. If voltage is under 5 VDC, there could be a blown fuse or a problem in the harness. If the voltage is correct, proceed to the next step.
Disconnect the fuel lines form the tubes on the fuel sender. Plug the lines to prevent fuel leakage and contamination.
Remove the six screws and washers securing the fuel sender to the fuel tank. Carefully remove the fuel sender from the tank. Use caution not to damage the float arm.
Check for any physical damage to the sender float and wires. If there is damage that cannot be repaired, replace the fuel sender.
Illustration 3 g06124315
Schematic symbol
Use a multi-meter to check for continuity across pins "1" and "2" on the fuel sender connector. If there is no continuity, replace the fuel sender.Checking Fuel Sender Float Stroke and Resistance
Illustration 4 g06124307
(A) Full position
(B) Empty position
Table 1
Fuel Sender Specifications
Sales Model Part Number Float Position Stroke mm (inch) Resistance (Ohms)
303.5E2
304E2
305E2
305.5E2 376-9480 Full 33 mm (1.3 inch) 27 to 33
Empty 265 mm (10.4 inch) 246 to 252
Refer to Illustration 4 and Table 1 for the following steps.
With the float arm in the empty position, measure the distance from the bottom of the fuel sender flange to the float pivot point. The proper distance is 265 mm (10.4 inch). If the distance is not correct, replace the fuel sender.
With the float in the empty position, measure the resistance of the sender. If resistance is not 246 to 252 Ohms, replace the fuel sender.
Raise the