- Caterpillar Products
- All Machines
Introduction
This Special Instruction contains the procedure for the repair of 5C-6108 Refueling Switch on Certain Excavators.
Important Safety Information
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.
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 should 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 that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.
Note: Caterpillar recommends that each customer conducts a risk assessment for remote control operation and establish layers of protection in and around the area of the remote controlled machine and establish safe job site procedures. Examples may include personnel training, warning signs, and barricades.
Note: Prior to operation of the machine read the Operation and Maintenance Manual.
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Do not disassemble the remote control console or remote control receiver. Any attempt to disassemble the remote control console or remote control receiver will void the warranty of the component. |
- Only mount the machine and dismount the machine at locations that have steps and/or handholds.
- Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary. Repair the steps and the handholds, if necessary.
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| Illustration 1 | g00037367 |
- Face the machine when you are mounting and dismounting.
- Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and one hand are in contact or one foot and two hands are in contact.
- Never get on a moving machine or off a moving machine.
- Never jump off the machine.
- Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line to pull equipment up to the operator's platform.
- Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .
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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform. |
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Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness. |
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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury. |
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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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
| Parts Required for the repair of 5C-6108 Refueling Switch | ||
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| Quantity | Part Number | Description |
| 1 | Fuel Level Switch and Wire Gp | |
| Contents of 547-7976 Fuel Level Switch and Wire Gp | ||
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| Quantity | Part Number | Description |
| 18 | Cable Strap | |
| 1 | Ring Terminal | |
| 60 | Electrical Wire | |
| 2 | Connector Socket | |
| 1 | Connector Plug As | |
| 1 | Liquid Level Switch | |
Installation Procedure
- Prepare the required parts listed in 547-7976 Fuel Level Switch and Wire Gp.
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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.
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Illustration 3 g06260207 230-4011 Connector Plug As to418-6596 Liquid Level Switch mini schematic - Connect 230-4011 Connector Plug As to 418-6596 Liquid Level Switch.
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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.
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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) .
