FDM-SVC-028

Service Kit Bulletin
Date: February 21, 2023
Bulletin Name: FDM-SVC-028
Model: Oshkosh S-Series
Units Affected: MY 2020-2022
2.0 Cab Door Switch
Purpose:
This bulletin provides instruction for installing an updated cab door switch.
Notice:
• This bulletin should be read and understood in its entirety before performing this procedure.
• All procedures outlined in the bulletin must be performed by skilled service personnel. Refer to the product
service manual for descriptions of maintenance procedures.
SAFETY NOTICE
SAFETY NOTICE
Perform your company’s Lockout/Tagout
procedure. If your company does not have a
Lockout/Tagout procedure, follow OSHA
1910.147 and 1910.146 Confined Space as
appropriate.
Use appropriate Personal Protective
Equipment (PPE) as required by your
company.
Tools and Equipment Required:
Customer to supply:
•
•
•
•
•
•
•
Hand tools
Drill
Drill bits - 29/64” (0.453”) and 0.173”
Tap - 1/2-20 NFT
Heat shrink tubing
Butt splice connectors (qty. 2) or 24-20GA contact size 20 Deutsch pins (qty. 2)
Torque wrench (inch pounds)
Parts Required:
Item
Part Number
Description
1
A000H014
SCR, PAN, XR, TF #10-24 X 0.50 ZC
2
2
A001C828
PLATE, HINGE, FILLER
1
3
A001A648
SWITCH, DPST, NC, MOM, DOOR
1
4
A001C850
CONN, DOOR SWITCH
1
1
Qty.
Procedure:
Lockout/Tagout
1. Place unit on a flat surface, engage parking brake, chock truck tires, and perform your company’s Lockout/
Tagout procedure. If your company does not have a Lockout/Tagout procedure, follow OSHA 1910.147 and
1910.146 Confined Space as appropriate.
2. The vehicle’s BATTERY DISCONNECT switch is located on the left-hand side of the battery box. Use the
battery disconnect switch when performing any maintenance so the vehicle cannot accidentally be started.
a. Turn the battery disconnect switch (Figure A, Item 1) counterclockwise so the hole on the switch aligns
with the hole in the bracket (Figure A, Item 2).
b. Install the safety lockout device ring (Figure B, Item 1) through the holes on the battery disconnect switch
and the bracket.
c. Install a padlock (Figure B, Item 2) onto the safety lockout device ring, lock it, and put the key in your
pocket. If more than one person is working on the vehicle, each person must install his or her own padlock.
1
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ma media ag m rem
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1
2
2
Figure A
Figure B
3. Open cab door.
4. Locate and remove door limiter strap mounting screws, plate, and flat washers from inside cab. See Figure 1.
Mounting
Hardware
Door
Limiter
Strap
Figure 1
2
5. Open cab door at least 90 degrees.
6. Locate magnetic door switch in cab frame. See Figure 2.
7. Loosen and remove jam nut from magnetic door switch. See Figure 2.
8. Remove magnetic door switch from cab frame.
Connector
SW217
Jam Nut
Magnetic
Door
Switch
Figure 2
9. Locate connector SW217 and disconnect magnetic door switch from cab harness. See Figure 3.
Cab
Harness
Connector
SW217
Figure 3
3
10.
Use one of the following installation options for connecting new switch connector harness (A001C850) to
cab harness connector SW217.
Option A.
a. Cut connector SW217 with 3 to 4 inches of wire from magnetic door switch. Discard magnetic door
switch.
b. Select any two of the three wires on new switch connector harness (A001C850) and connect them to
any two wires of connector SW217 using customer supplied butt splice connectors and heat shrink
tubing.
c. Cut off the third unused wire from the switch connector harness.
Option B.
a. Unpin magnetic door switch wires from connector SW217. Discard magnetic door switch.
b. Install new pins on any two of the three wires on new switch connector harness (A001C850).
c. Insert wires into connector SW217.
d. Cut off the third unused wire from the switch connector harness.
11.
Reconnect connector SW217 with connector harness (A001C850) to cab harness. See Figure 4.
Cab Harness
Connector Harness
Figure 4
12.
Drill out existing door frame hole where magnetic switch was removed in Step 8 to 29/64 inch (0.453
inch).
13.
Tap hole drilled in Step 12 to 1/2-20 NFT.
14.
Install door switch (A001A648) into hole tapped in Step 13.
15.
Connect door switch connector harness (A001C850) installed in Step 10 to door switch installed in
Step 14.
4
16.
Locate and remove magnet from end of door. See Figure 5. Discard magnet.
Magnet
Figure 5
17.
Insert hinge filler plate (A001C828) into notch of door hinge where magnet was removed in Step 16. See
Figure 6.
18.
Mark top and bottom filler plate slots and drill two 0.173 in holes. See Figure 6.
19.
Secure filler plate to door with screws (A000H014). See Figure 6.
Hinge
Filler
Plate
Ø 0.173 Holes
Figure 6
5
20.
Reinstall door limiter strap, screws, plate and flat washers inside cab. See Figure 7. Apply Loctite® #242
to mounting screws and final tighten to 75 in. lbs.
Plate
Flat
Washers
Screws
Figure 7
21.
Close cab door to set new door switch plunger height.
22.
Remove lockout/tagout and tire chocks.
23.
Test operation of door switch.
Continuous Improvement:
The change included in this document is part of the
McNeilus Continuous Improvement Process.
McNeilus’s quality policy is providing customer satisfaction
through innovative products, dedicated service, and a
constant focus on continuous improvement.
6
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