0336180 JOHNSON PLATE, Retaining

This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4176" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the December 3, 1997 Service Letter. A harness assembly was added to both options of the Parts Needed.
Termination Date
December 31, 1999Problem
Both engine shut-off switches have failed on certain 5130 Excavators due to material packing and vibration. The ground level switch has been relocated to reduce material entry. The secondary shut-off switch has been moved from the engine to the enclosure wall to reduce vibration.
Affected Product
Model & Identification Number
5130 (7TJ7 5ZL21-124 )
Parts Needed
Option A
2 - 4D1836 Switch-Toggle15 - 7K1181 Strap-Cable40 - 3S2093 Strap-Cable 4 - 7T1099 Link 2 - 8T4121 Washer-Plate 2 - 8T4137 Bolt 7 - 8T8730 Socket 1 - 1028808 Kit 1 - 1028809 Kit 1 - 1088420 Film 1 - 1126797 Plate 2 - 1306968 Film 1 - 1430073 Harness Assembly 1 - 1475216 Plate 1 - 1485471 Harness AsOption B
2 - 4D1836 Switch-Toggle15 - 7K1181 Strap-Cable40 - 3S2093 Strap-Cable 4 - 7T1099 Link 2 - 8T4121 Washer-Plate 2 - 8T4137 Bolt 3 - 8T8730 Socket40 - 9X6772 Straps (Option B Only - See Rework Procedure) 1 - 1028809 Kit 1 - 1088420 Film 1 - 1126797 Plate 2 - 1306968 Film 1 - 1430073 Harness Assembly 1 - 1470780 Harness (Option B Only - See Rework Procedure) 1 - 1475216 Plate 1 - 1485471 Harness AsAction Required
See the attached procedure.
Service Claim Allowances
This is a 6-hour job. A maximum of $25.00 U.S. will be allowed for labor and material to fabricate the bracket assembly.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
REWORKING PRIMARY SHUT-OFF SWITCH MOUNTED ON THE LEFT HAND MODULE:
1. REMOVE AND DISCARD EXISTING ENGINE SHUT-OFF SWITCH AND HARDWARE FROM MODULE. KEEP (1) 3E-5169 SWITCH GUARD IF IN REUSABLE CONDITION.
2. FILL OR COVER HOLE IN FRAME SHOWN IN ILLUSTRATION 1.3. REMOVE EXISTING LADDER LAMP SWITCH FROM 108-7686 PLATE. THEN REMOVE PLATE AND HARDWARE FROM CURRENT LOCATION SHOWN ON ILLUSTRATION 1.4. ENLARGE EXISTING 120 MM DIAMETER HOLE TO 150X150 MM OPENING WITH R20 2 MM CORNERS AS SHOWN IN ILLUSTRATION 1 AND 2.5. FABRICATE (1) 111-4489 BRACKET AS. AS SHOWN IN ILLUSTRATION 10.6. INSTALL (1) 111-4489 BRACKET AS. AS SHOWN IN ILLUSTRATION 3.7. INSTALL (1) 112-6797 PLATE WITH (2) 8T-4137 BOLTS AND (2) 8T-4121 WASHER AS SHOWN IN ILLUSTRATION 4.8. REINSTALL THE LADDER LAMP SWITCH REMOVED IN STEP 3 AS SHOWN IN ILLUSTRATION 4.9. INSTALL (1) 108-8420 FILM ABOVE LADDER LAMP SWITCH.10. INSTALL (1) 130-6968 FILM ON LEFT SIDE OF 112-6797 PLATE.11. INSTALL (1) 4D-1836 SWITCH AND (1) 3E-5169 SWITCH GUARD TO 112-6797 PLATE AS SHOWN IN ILLUSTRATION 4.12. LOCATE THE THREE WIRES FORMERLY CONNECTED TO THE SHUT-OFF SWITCH (REMOVED IN STEP 1). CUTOFF THE CURRENT TERMINALS. INSTALL (3) 8T-8730 SOCKETS, (1) 3E-3367 PLUG AS., AND (1) 3E-3368 WEDGE. TERMINATE AS SHOWN IN ILLUSTRATION 5. (1) 102-8808 PLUG-KIT CONTAINS (1) 3E-3367 PLUG AS. AND (1) 3E-3368 WEDGE
13. CONNECT ONE END OF (1) 148-5471 TO REWORKED HARNESS FROM PREVIOUS STEP.14. CONNECT THE OTHER END OF THE 148-5471 HARNESS TO THE 4D-1836 (SHUT-OFF) SWITCH AS SHOWN IN ILLUSTRATION 4: 15. SECURE 148-5471 HARNESS TO EXISTING MAIN HARNESS BY USING (25) 3S-2093 STRAPS AND (15) 7K-1181 STRAPS. MACHINES THAT CURRENTLY HAVE A SECONDARY SHUT-OFF SWITCH MOUNTED ON THE ENGINE SHOULD ALSO PERFORM OPTION A. (5ZL51-124) MACHINES THAT CURRENTLY DO NOT HAVE A SECONDARY SHUT-OFF SWITCH MOUNTED ON THE ENGINE SHOULD ALSO PERFORM OPTION B (7TJ7, 5ZL21-50).
OPTION A - REWORKING SECONDARY SHUT-OFF SWITCH MOUNTED ON THE ENGINE:
1A. INSTALL (1) 147-5216 PLATE AND (4) 7T-1099 LINKS INTO LOCATION SHOWN ON ILLUSTRATION 6-8.2A. REMOVE AND DISCARD EXISTING SHUT-OFF SWITCH AND HARDWARE FROM ENGINE. KEEP (1) 3E-5169 SWITCH GUARD IF IN REUSABLE CONDITION.
3A. LOCATE THE THREE WIRES FORMERLY CONNECTED TO THE SHUT-OFF SWITCH. CUTOFF THE CURRENT RING TERMINALS. INSTALL (4) 8T-8730 SOCKETS, (1) 3E-3373 PLUG AS., AND (1) 3E-3374 WEDGE. TERMINATE AS SHOWN IN ILLUSTRATION 9. (1) 102-8809 PLUG-KIT CONTAINS (1) 3E-3373 PLUG AS. AND (1) 3E-3374 WEDGE
4A. INSTALL (1) 130-6968 FILM ON 147-5216 PLATE INSTALLED IN STEP 1.5A. INSTALL (1) 4D-1836 SWITCH AND (1) 3E-5169 GUARD.6A. CONNECT ONE END OF (1) 143-0073 HARNESS AS. TO REWORKED HARNESS FROM STEP 3.7A. CONNECT THE OTHER END OF THE 143-0073 HARNESS TO 4D-1836 (SHUT-OFF) SWITCH AS FOLLOWS: 8A. SECURE HARNESS USING (15) 3S-2093 STRAPS. OPTION B - REWORKING SECONDARY SHUT-OFF SWITCH MOUNTED ON THE ENGINE: (7TJ7, 5ZL21-50)
1B. REMOVE EXITING ENGINE HARNESS AND INSTALL (1) 147-0780 HARNESS.2B. SECURE USING (42) 9X-6772 STRAPS.3B. INSTALL (1) 147-5216 PLATE AND (4) 7T-1099 LINKS INTO LOCATION SHOWN ON ILLUSTRATON 6-8.4B. REMOVE AND DISCARD EXISTING SHUT-OFF SWITCH AND HARDWARE FROM ENGINE. KEEP (1) 3E-5169 SWITCH GUARD IF IN REUSABLE CONDITION.
5B. INSTALL (1) 130-6968 FILM ON 147-5216 PLATE INSTALLED IN STEP 1.6B. INSTALL (1) 4D-1836 SWITCH AND (1) 3E-5169 GUARD.7B. CONNECT ONE END OF (1) 143-0073 HARNESS AS. TO REWORKED HARNESS FROM STEP 3.8B. CONNECT THE OTHER END OF THE 143-0073 HARNESS TO 4D-1836 (SHUT-OFF) SWITCH AS FOLLOWS: 9B. SECURE HARNESS USING (15) 3S-2093 STRAPS. THE MACHINES USING OPTION B NEED TO PURCHASE THE PARTS LISTED WITH THE FOLLOWING CHANGES.
Illustration 1
Illustration 2
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Illustration 4
Illustration 5
Illustration 6
Illustration 7
Illustration 8
Illustration 9
Illustration 10 - Fabricate Bracket