Front Docking Light Switch - 2017 Jayco White Hawk

SRP 19-011 – Front Light Switch May 2019 Page 1 of 7
Front Docking Light Switch
Incident:
Front docking light switch on trailer sticks and rubber boot may be melted. Replace switch.
Affected Units:
Various Jayco White Hawks
Parts:
 1 – Exterior Light Switch with square mounting hole (#0700300)
 4 – Screw - pan quad #8 x 1”
Bulletin Type:
SRP
Bulletin #(s):
19-011
Job Code(s):
**
Flat Rate(s):
**
** If affected unit has warranty remaining, submit your claim following the normal process.
Publication Date:
May 2019
Make(s):
Jayco
Model(s):
White Hawk
Model Year(s):
2017
Screw #8 x 1 inch
Switch (#0700300)
SRP 19-011 – Front Light Switch May 2019 Page 2 of 7
Misc. Tools &
Supplies:
 Screw gun w/#2 square drive bit
 Air saw with metal cutting blade
 Putty stick tool & putty knife
 Hammer and a tapered punch
 Tape measure & tape
 Utility Knife
 Gloves – Nitrile (not Latex)
 S-solvent blend (S-1693)
 Isopropyl alcohol & clean rags
 4 x 6” cardboard template with rectangular hole in center measuring 1-7/8” Long X 1-1/8 Wide
 Tube Sealant - Geocel 2300 black (or equivalent)
INSTRUCTIONS
Disconnect power from the trailer before repairing.
FIG 1:
 Switch is located on the front diamond plate (arrow).
FIG 2:
 Close up of the switch that must be replaced.
4 x 6” cardboard template with rectangular hole in center measuring 1-7/8” Long X 1-1/8” Wide
Tools
FIG 2 FIG 2FIG 2
FIG 1 FIG 1FIG 1
Geocel 2300 black (0402835)
SRP 19-011 – Front Light Switch May 2019 Page 3 of 7
FIG 3:
 Remove the two screws from the switch
FIG 4:
 Use the putty knife to GENTLY pry the switch bezel from the diamond plate.
 Putty tape is holding the bezel to the diamond plate.
FIG 5:
 Use the putty stick tool to GENTLY scrape away any excess putty tape.
 Make sure you push the tool in the direction of the hole, to prevent putting a dent or scratch in the diamond plate which may be visible after the new switch is installed.
FIG 6:
 Wear safety glasses and Nitrile gloves (not Latex) as the S-1693 solvent will destroy the Latex gloves.
 This solvent is very harmful to the skin.
FIG 3 FIG 3FIG 3
FIG 4 FIG 4FIG 4
FIG 5 FIG 5FIG 5
FIG 6 FIG 6FIG 6
SRP 19-011 – Front Light Switch May 2019 Page 4 of 7

FIG 7:
 Use a clean rag with the S-1693 solvent to clean all around the switch location.
 Then clean the area again with isopropyl alcohol and a clean rag to remove traces of the solvent.
FIG 8:
 Unplug the wires from the old switch and tuck the wires into the hole.
FIG 9:
 Apply tape around the hole as shown. Apply enough tape that the template will fit on it.
FIG 10:
 Measure down 1-1/2” from the top of the diamond plate to the top of the cardboard template.
FIG 7 FIG 7FIG 7
FIG 8 FIG 8FIG 8
FIG 9 FIG 9FIG 9
FIG 10 FIG 10FIG 10FIG 10
1-1/2” 1/2” 1/2” 1/2”
SRP 19-011 – Front Light Switch May 2019 Page 5 of 7
FIG 11:
 Trace the rectangular hole in the center of the template onto the tape as shown.
FIG 12:
 The rectangular hole is closer to the top of the existing hole than the bottom.
FIG 13:
 Use the air saw with a metal cutting blade and CAREFULLY enlarge the hole to the size of the rectangular hole drawn on the tape.
 DO NOT PULL THE SAW TOO FAR OUT OF THE HOLE while cutting or the blade could easily jump and cut or gouge the diamond plate under the tape or next to the taped area.
 Make sure you move the wires out of the way as you enlarge the hole. DO NOT CUT THE WIRES!
FIG 14:
 There is a plywood backer that will need to be cut out also deeper in the hole.
FIG 11 FIG 11FIG 11FIG 11
FIG 12 FIG 12FIG 12FIG 12
Top of the Top of the Top of the Top of the Top of the Top of the Top of the existing holeexisting hole existing hole existing holeexisting holeexisting hole existing holeexisting hole
FIG 13 FIG 13FIG 13FIG 13
Plywood Plywood Plywood Plywood Plywood Plywood Plywood backerbackerbackerbacker backer
FIG 14 FIG 14FIG 14FIG 14
SRP 19-011 – Front Light Switch May 2019 Page 6 of 7
FIG 15:
 This is the switch hole completely cut out.
 Test fit the new switch to make sure it fits correctly in the hole. Trim further if necessary.
FIG 16:
 Remove all the tape, pull the wires out of the hole and plug the wires onto the new switch.
 It makes no difference which wire goes to which terminal.
FIG 17:
 Use a hammer and the tapered punch and tap the screw holes from the previous switch to push them in.
 Holes should be pushed in so that the new switch will fit flush to the diamond plate.
FIG 18:
 Apply Geocel sealant in both the old screw holes.
FIG 15 FIG 15FIG 15FIG 15
FIG 16 FIG 16FIG 16FIG 16
FIG 17 FIG 17FIG 17FIG 17
FIG 18 FIG 18FIG 18FIG 18
SRP 19-011 – Front Light Switch May 2019 Page 7 of 7
FIG 19:
 Apply Geocel sealant around the back of the switch gasket and over each screw hole (4).
FIG 20:
 Install the switch with the closed end at the top (to guard against water intrusion).
 Make sure the switch is lined up square and install the 4 screws.
 Use the putty stick tool to clean up excess around the switch.
 Clean with the isopropyl alcohol and clean rag.
TEST THE SWITCH:
 Turn power back on to the trailer.
 Flip the switch and the front cap docking lights (2) should light.
 Flip the switch again and they should go out.
Jayco’s sole obligation under our limited warranty is to repair or replace defective materials and/or workmanship deemed our responsibility as determined by Jayco in our sole discretion. Jayco reserves the right to use new and/or remanufactured parts or materials of similar quality to complete any work, and to make parts and/or design changes as appropriate without notice to anyone. Jayco designs and/or materials changes are done without obligation to incorporate such changes in previously manufactured product. Jayco makes every reasonable effort to ensure field remedies will not adversely affect performance and/or safety of the unit. This field remedy is not intended to extend to future performance of this RV, or any of its materials, components or parts beyond the standard warranty period. The RV owner’s obligation to notify Jayco, or one of its independent, authorized dealers, of a claimed defect does not modify any obligation placed on the RV owner to contact Jayco directly when attempting to pursue remedies under state or federal law. Jan. 2019.
903 South Main Street • P.O. Box 460 • Middlebury, IN 46540
FIG 19 FIG 19FIG 19FIG 19
FIG 20 FIG 20FIG 20FIG 20
Closed end Closed end Closed end Closed end Closed end Closed end Closed end Closed end Closed end UP