Usage:
NOTE: 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 "PS8906" 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.
Termination Date
April 30, 1998Problem
A swing out oil cooler needs to be added to certain 834B and 836 Compactors. The new swing out oil cooler that makes cleaning of the cooler and radiator easier. The 1428397 Cooler Group provides the components needed to update the current field population with the enhanced design.
Affected Product
Model & Identification Number
834B (92Z453)
836 (3RL1-111 7FR1-264 )
Parts Needed
- 1 - 1428397 Cooler Group
Action Required
See the attached rework procedure.
Service Claim Allowances
NOTE: This is a 16-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1413188 Guard Group - Radiator (See Illustration 1 and 2) General Rework Instructions.
1. Before starting the rework, review the instructions for modifications required for the 1413191 Scoop Assembly (Illustration 5 and 6) and 1413189 Radiator Guard Assembly (Illustration 7 and 8).
2. Remove the top panel from the radiator guard assembly to provide access to the oil cooler core assembly.
3. Remove the lower plate from the bottom of the bumper to provide access to various lines, etc.
4. Safely drain the hydraulic oil from the machine.
5. Remove the hydraulic oil cooler, hardware, and lines going to the relief valve.
6. Weld 5T1213 Plates over hose clearance holes in lower baffle (3mm fillet skip weld - low hydrogen process) See Illustration 2, top view.
7. Locate the 1369769 Latch Pivot Block on the left side of the radiator guard assembly using the catch block on scoop assembly as a guide.Weld the block in place.(6mm fillet weld - low hydrogen process).See Illustration 2, View H-H.
8. Reassemble the top panel from the radiator guard assembly.
9. Assemble 1366816 Scoop Retainer, 1366817 Lever Assembly, 1369770 Handle Assembly, 1369771 Plate Assembly and all related hardware and brackets.
10. Install 5P6301 Seal and 2G6684 Bumpers.
11. Adjust latch assembly using 1369774 Bolt.
12. Locate and tack weld the latch catch assembly components in place (3B8601 Pin, 3K8280 Pin, 1369776 Plate, and 1369775 Plate Assembly).
13. Test for proper function of latching assembly before finish welding. (5mm fillet weld - low hydrogen process) See Illustration 1, Section E-E.
14. Install the hydraulic oil cooler and lines per the attached instructions (Ref. 1352674/">1352674)
Scoop modification required for all machines with a serial number prefix of 3RL that did not have the added air inlet ports on the side and rear of the scoop. See 1413191 Scoop Assembly, Illustration 5.
1. Cut off the grab iron from the left hand side of the scoop and grind the surface area smooth.
2. Cut off the rod hold open tab on the scoop and grind the surface area smooth.
3. Cut off the screen door retainer tab and grind the surface area smooth.
4. Remove the square section foam seal from the scoop and discard.
5. Remove the screen door assembly.
6. Remove the latch from the left side of the side of the scoop.
7. Cut openings in the right side, left side and back of the scoop assembly as shown in Illustration 6, View A-A.
8. Locate 1413192 Sheet Assembly on lower channel of scoop assembly and weld as shown (5 mm fillet weld 2-places - low hydrogen process).
9. Locate 1369771 Latch Plate Assembly on left side of scoop assembly and weld as shown (6 mm fillet weld, 1.5 penetration- low hydrogen process).
10. Locate 1370309 Handle on left side of the scoop assembly and weld (5 mm fillet weld, 2-places).
11. Locate 2Q4266 Screens (right and left sides) and 2Q4267 Screen (rear) on the inside of the scoop assembly and weld (3 mm fillet - skip weld).
12. Locate and weld 2Q4278, 1370310 and 2Q4269 Support Strips on the inner right and left side of the scoop assembly. (3 mm fillet - skip weld).
13. Locate and weld 1371595 and 2Q4271 Support Strips on the inside rear face of the scoop assembly. (3 mm fillet - skip weld).
14. Locate and weld 2Q4268 Screen to the top of the scoop assembly. (3 mm fillet - skip weld)
15. Locate 1393408 Seal Mounting Strip at top of scoop assembly as shown in Illustration 5, Section F-F and weld (3 mm fillet weld, Illustration 6, Section G-G).
16. Locate 1400436 Seal Mounting Strip on left side of scoop assembly as shown in Illustration 6, Section E-E and weld (3 mm fillet weld, Illustration 6, Section G-G.
17. Locate 1393407 Seal Mounting Strip on right side of scoop assembly as shown in Illustration 6, Section G-G and weld. (3 mm fillet weld).
18. Locate 1413193 Seal Mounting Angle Strip at bottom of scoop assembly as shown in Illustration 5, Section D-D and weld. (3 mm fillet weld).
19. Drill 14 mm Diameter holes in existing angle using the slots in 1400436 Strip as a guide.
Scoop modification required for all machines with a serial number prefix of 7FR or 3RL machines that have the added air inlet ports on the side and rear of the scoop. See 1413191 Scoop Assembly, Illustrations 5 and 6.
1. Cut off the grab iron from the left hand side of the scoop and grind the surface area smooth.
2. Cut off the rod hold-open tab on the scoop and grind the surface area smooth.
3. Cut off the screen door retainer tab and grind the surface area smooth.
4. Remove the square section foam seal from the scoop and discard.
5. Remove the screen door assembly.
6. Remove the latch from the left side of the side of the scoop.
7. Locate 1413192 Sheet Assembly on lower channel of scoop assembly and weld as shown (5 mm fillet weld 2-places - low hydrogen process).
8. Locate 1369771 Latch Plate Assembly on left side of scoop assembly and weld as shown (6 mm fillet weld, 1.5 penetration - low hydrogen process).
9. Locate 1393408 Seal Mounting Strip at top of scoop assembly as shown in Illustration 5, Section F-F and weld (3 mm fill weld, Illustration 6, Section G-G).
10. Locate 1400436 Seal Mounting Strip on left side of scoop assembly as shown in Illustration 6, Section E-E and weld (3 mm fill weld, Illustration 6, Section G-G).
11. Locate 1393407 Seal Mounting Strip, on right side of scoop assembly as shown in Illustration 6, Section G-G and weld (3 mm fill weld, Illustration 6, Section G-G).
12. Locate 1413193 Seal Mounting Angle Strip at bottom of scoop assembly as shown in Illustration 5, Section D-D and weld (3 mm fillet skip weld, Illustration 5, Section D-D)
13. Drill 14 mm diameter holes in existing angle using the slots in 1400436 Strip as a guide.
Radiator Guard required for all machines. See Illustrations 7 and 8, 1413189 Guard Assembly - Radiator.
1. Remove and save upper right hand baffle from the top rear of the radiator. The baffle and hardware are to be reinstalled.
2. Disassemble rear harness that goes from the right hand light box to the backup alarm. The harness and hardware are to be reinstalled.
3. Cut of the latch mounting tapped block from the left hand rear side of the radiator guard assembly and grind the surface area smooth.
4. Cut off the scoop assembly hold-open rod bracket and grind the surface area smooth.
5. Cut a clearance slot in the rear channel for clearance of the bulkhead fitting per Illustration 8, Section E-E.
6. Drill two 37 mm diameter holes in the rear channel for clearance of bulkhead fittings per Illustration 8, Section B-B.
7. Locate the 1352632 and 1352634 Tube Support Angle Assemblies and weld in place. (5 mm fillet weld - low hydrogen process) Illustration 8, View F-F.
8. Weld 3J5169 Nut onto 1352636 Channel (two assemblies - projection weld) See Illustration 7, View A-A.
9. Use the 1350302 Cooler Frame Assembly, as a location fixture for 1352638 and 1352637 Gussets and 1352636 Channel Assemblies. Position the gussets (Illustration 8 View C-C) and channel assemblies (Illustration 7, View A-A) per the dimensions given. Tack weld the components in place.
10. Remove 1350302 Frame and finish welding components in place. 1352638 and 1352637 Gussets (6 mm fillet weld, both sides - low hydrogen process) See Illustration 7, rear view of radiator. 1352636 Channel Assemblies (5 mm fillet weld - low hydrogen process). See Illustration 7, View A-A.
11. Weld on 1362637 Cooler Hold Open-Bracket. (6 mm fillet weld - low hydrogen process). Illustration 8 View C-C.
12. Weld on 1413190 Scoop Assembly Hold-Open Bracket Assembly. (5 mm J-fill weld - low hydrogen process). Illustration 8 View C-C.
13. Reinstall the top right hand baffle onto the rear of the radiator.
NOTE: You will need to cut a slot in the rubber section of the baffle to provide clearance for the new 1352638 Cooler Frame Support Gusset.
14. Reinstall the rear harness from the backup alarm , through the hole in the new cooler frame lower support gusset, to the light box.
Oil Cooler Line Installation required for all machines. See Illustration 3 and 4, 1352674 Lines Group - Oil Cooler.
1. Install 1350302 Oil Cooler Frame Assembly to radiator guard group.
2. Attach the oil cooler hold-open to the oil cooler frame per Illustration 4, View A-A.
3. Install 1352963 Oil Cooler Core Assembly and vibration isolation mounts as shown in Illustration 3, Section C-C and Illustration 4, Section D-D.
4. Install 1357747 and 1357746 Tube Assemblies using 8T1889 and 8T1890 Clips.
5. Install the fitting and hoses between the oil cooler and the tubes.
6. Check for any interference between the mounted hoses and the oil cooler and scoop thought the normal movement between fully open to securely latching the scoop assembly closed.
7. Install the hoses and fittings between the tubes and the system relief valve.
8. Refill hydraulic and check for leaks.
NOTE: Unless otherwise specified, all bolts and nuts are to be tightened to the following values based on thread size:
Illustration 1
Illustration 2
Illustration 3
Illustration 4
Illustration 5
Illustration 6
Illustration 7
Illustration 8