SHAFT 1003071 - Caterpillar

SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE STARTER MOTOR SOLENOID ASSEMBLY
MODELS INVOLVED - 826H, 836G, and 836H Landfill Compactors
Dear Caterpillar Product Owner:
The starter motor solenoid needs to be replaced on the products listed below. The existing starter solenoid can fail due to moisture entry which could cause melting of the B+ terminal on the solenoid. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 21Jun2010 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 21Jun2010 Service Letter
Rework Procedure
Refer to the starter service manual, SENR3860, as necessary.
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Image1.1.3
Image1.1.4
1. Open the battery disconnect switch. Use a multimeter to confirm 0 volts between the starter B+ terminal and the machine battery ground connection.
2. Remove engine compartment access panel(s) as necessary to access the starter motor.
3. Remove the starter motor using the CAT fabricated tool FT3089.
The fasteners in this procedure are referred to by the size of the wrench that is used rather than the size of the threads.
4. Use a 3/4 inch wrench and remove nut (1) on the solenoid motor terminal "MTR".
5. Use a 3/4 inch wrench and remove nut (field terminal) (2) at the frame.
6. Remove the stamped metal connector strap (3).
7. Use a 3/8 inch wrench to remove nut (4) from ground terminal "G".
8. Disconnect the flexible ground cable (5) from the "G" terminal.
9. Remove access plug (9) and gasket (10) from the rear of the lever housing. Make sure that the gasket is removed.
10. Hold the plunger securely in order to prevent rotation. Then, remove the 5M3034 Nut (plunger) (11) carefully so that the nut (plunger) does not drop into the motor. Dispose of the nut. Use a 1/2 inch wrench.
11. Remove four existing E8 Torx Head screws (NOT SHOWN) that mount the solenoid to the motor frame.
12. Remove the complete solenoid and remove the plunger assembly from the lever housing.
13. Remove boot clamp (8), remove the clamp by inserting a screwdriver into the portion of the clamp that is serrated. Pry upward. Install the starter solenoid.
14. Install the new 3R8801 boot clamp (8). Tighten the boot clamp with a pair of pliers.
15. Place the new solenoid onto the starting motor by sliding the plunger boot into the hole of the lever housing. Note: Make sure that the threaded rod (plunger) (14) goes through the hole in the shift lever.
16. Install the new 5M3034 Nut (plunger) (11) by hand. Tighten by hand.
Use of force can rotate