Usage:
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.
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3878" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3878" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
November 30, 1996Termination Date
May 31, 1997Problem
Moisture may short the start switch causing the starter to engage on certain TH62, TH63, TH82 and TH83 Telehandlers. The current 9G7641 Start Switch needs to be replaced with a new start switch, mounting wedge and needed hardware to provide additional protection against moisture entry.
Affected Product
Model & Identification Number
TH62 (3LN1-578, 3LN585 4TM1-790 , 4TM795, 4TM798, 4TM816)
TH82 (3KN1-426 3JN1-485 , 3JN487, 3JN488)
TH63 (3NN1-463, 3NN481, 3NN493 5WM1-729 , 5WM734, 5WM740, 5WM746, 5WM747, 5WM751, 5WM756, 5WM757, 5WM760, 5WM763, 5WM766, 5WM767, 5WM769, 5WM771, 5WM775, 5WM776, 5WM790)
TH83 (3RN1-469, 3RN482, 3RN486, 3RN487, 3RN489)
Parts Needed
Action Required
A new 1107883 start switch, 1338860 Spacer Assembly and 1324394 Decal need to be installed. See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
NOTE: This is a 1.5-hour job.
NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.
- (1-Owner Notification)
- (2-Rework Procedure)
Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
The purpose of the change is to orient the drain hole on the switch to point downward, and to add a wedged spacer to position the switch to have it more nearly horizontal (within 30 degrees). A modification to the aperture opening used for the former start switch needs to be made before mounting the 1107883 Start Switch. To make the modifications and install the new start switch and related parts, use the following instructions:
1. Remove the key from the switch.
2. Disconnect the battery or batteries.
3. Remove the radio blanking plate above the start switch by loosening the two phillips screws and sliding the blanking plate to release the gripping brackets. Pull the plate out and set it aside.
4. Remove the existing start switch by removing the nut. Pull the switch assembly and chassis wire harness through the radio opening.
NOTE: If the machine is equipped with a radio, the dash may need to be disassembled from below.
5. Remove the wire from the existing switch. Discard the switch.
6. Remove the existing tag as shown in Illustration 1. Remove the existing start switch position decal and discard.
7. Modify the start switch opening as shown in Illustration 2 to provide clearance to the three gussets on the body of the 1107883 Start Switch. A small die grinder works very well for this operation. Be sure that the face of the key switch fits flush with the wedged 1338860 Spacer assembly and not the dash panel.
Illustration 1
Illustration 2
8. Once the hole is modified, connect the chassis wires to the 1107883 start switch terminal locations as follows:
9. Push the new start switch through the hole and place the 1338860 Spacer Assembly over the switch to use a template to drill two 3 mm holes as shown in Illustration 3. Ensure that the drain hole on the 1107883 Start Switch is on the bottom.
Illustration 3
10. Secure the 1338860 Spacer and the 1324394 Decal with the (2) self tapping 6R7921 Screws.
11. Secure the Start Switch to the spacer using the provided nut. Tighten to a torque of 1.6 N·m minimum. Ensure that the drain hole location is still on the bottom.
12. Install the radio blanking plate. Reconnect the battery (batteries).