KIT-SERVICE 1604816 - Caterpillar

Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.Prevent possible injury by performing the procedure that follows before working on the machine.Move the machine to a smooth and level location that is away from working machines and personnel.Ground all implements.Engage the parking brake. Stop the engine.Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door.Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
Required Parts
Table 1
Parts Required for the repair of 5C-6108 Refueling Switch
Quantity Part Number Description
1 547-7976 Fuel Level Switch and Wire Gp
Table 2
Contents of 547-7976 Fuel Level Switch and Wire Gp
Quantity Part Number Description
18 3S-2093 Cable Strap
1 3T-4696 Ring Terminal
60 6A-3361 Electrical Wire
2 9W-0844 Connector Socket
1 230-4011 Connector Plug As
1 418-6596 Liquid Level Switch Installation Procedure
Prepare the required parts listed in 547-7976 Fuel Level Switch and Wire Gp.
Illustration 2 g06257222
418-6596 Liquid Level Switch
Uninstall 5C-6108 Refueling Switch on the machine and replace the switch with 418-6596 Liquid Level Switch. The recommended torque for 418-6596 Liquid Level Switch is 150 20 N m (110.6 14.7 lb ft).
Remove the ring terminal from the signal wire connected to 5C-6108 Refueling Switch. Crimp 9W-0844 Connector Socket in place of the ring terminal. Insert the wire into Pin 1 of 230-4011 Connector Plug As.
Insert 6A-3361 Electrical Wire with 9W-0844 Connector Socket into Pin 2 of 230-4011 Connector Plug As.
Illustration 3 g06260207
230-4011 Connector Plug As to 418-6596 Liquid Level Switch mini schematic
Connect 230-4011 Connector Plug As to 418-6596 Liquid Level Switch.
Illustration 4 g06260210
Ground wire routing
Route 6A-3361 Electrical Wire from 230-4011 Connector Plug As to the machine chassis ground. Determine the proper routing path to avoid wire damage. 3S-2093 Cable Straps can be used to secure the wire on the machine.
Illustration 5 g06260211
Ground wire routing
Use 3T-4696 Ring Terminal to connect 6A-3361 Electrical Wire to the machine chassis ground. The recommended torque for M10 bolt is 30 7 N m (22.1 5.1 lb ft).