Usage:
TH62 (3LN, 4TM),
TH63 (3NN, 5WM),
TH82 (3JN, 3KN),
TH83 (3RN) Telehandler
Description of Change: Two service repair kits and a decal are available to repair two problems that develop under some operating conditions with 123-6816 Monocoque Cowl Assembly. The cowl latch and gas strut bracket fasteners have become detached from the cowl assemblies. Cracking has also occurred at the front left corner adjacent to the hinge.
Adaptable To: The fasteners can be reattached and the area of attachment reinforced by using 132-2033 Cowl Fastener Kit. Cracking in the front left corner can be repaired and the area reinforced by using 132-2034 Cowl Structure Kit. These two kits are can be used on any model of Telehandler that uses 123-6816 Monocoque Cowl Assembly.
124-2456 Instructional Film ,(28), is now installed on the engine cowl during production. This is a "NO STEP" decal. It can be ordered and installed on the engine cowl to warn people not to use the engine cowl as a step. This will prevent damage to the machine and prevent injuries to people working on and around the machine.
The procedures to repair both problems are as follows.
Reattaching Latch and Strut Bracket Fasteners
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Personal injury can result from the improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any product used to clean the components. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of cleaning agents.
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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.
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Dust generated when grinding or cutting non-metallic materials may be very fine, abrasive, flammable, and or explosive. Material being removed may contain crystalline silica, quarts, glass fibers, and/or other fine materials. Prolonged breathing of the dust may cause cancer, and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and Mine Safety and Health Administration (MSHA). In the event of contact with the skin, flush with plenty of water. If dust material gets into the eyes, flush with an approved flushing system and seek medical attention. Before smoking, or eating, clean hands thoroughly. Keep the work-site clean and dispose of all dust and particles in containers approved for flammable material. Refer also to the Technical Bulletin from the Helene® Products Division of the B.F. Goodrich Company, entitled, "Process Dust Handling and Disposal", contained in REHS0034 Special Instruction, Guide for Repair of Non-metallic Fenders and Hoods. Telene® is a brand name of a PDCPD material.
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Material published by the manufacturers of repair products contains the following information: Resins, activators, and/or catalysts used in the repair of plastics, including fiber glass, may be flammable. Do not use near heat, sparks, or open flames. Use only with adequate ventilation to avoid fumes. Wear protective gloves to avoid contact with the skin. Avoid prolonged breathing of vapor or spray mist. Do not take internally. Keep out of reach of children. Before smoking, eating, and after using, cleanse hands thoroughly. In the event of contact with the skin, flush with plenty of water. For eyes, get medical attention. Read, understand, and follow both the instructions for use, and warnings, which are packaged with, or printed on, the repair material containers for the specific repair products you are using.
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Reference: Special Instruction; Guide for Repair of Non-metallic Fenders and Hoods; REHS0034 (3/97)
Illustration 1.
Strut Bracket and Latch Fasteners
1. Raise the cowl and support it so it cannot close unexpectedly. Detach the strut from the cowl by removing the nut and washer attached to bracket (1) at location (2). Remove the four bolts, four washers, and four nuts that attach 121-2770 Plate Assembly to its supports. Remove the two bolts, the four washers, and the two nuts that connect the strut from the radiator to 121-2770 Plate Assembly.
2. Remove the cowl and support it securely on a stand. Check the condition of the strut bracket (1), strut bracket fasteners (3), and latch fasteners (4).
Illustration 2.
Bracket Position and Removal.
3. Mark the position of bracket (1) on the cowl assembly at location (5) and remove bracket (1).
4. Remove detached fasteners (6) from bracket (1). Discard the fasteners, nuts, and washers.
5. Remove loose or damaged material from the repair area with abrasive paper.
NOTE: If repairing a hole, sand or grind an area at least one inch out from the edge of the hole. The repair area must be clean, dry, and free from grease, rust, and paint.
Illustration 3.
Fastener Fit-Up.
6. Remove and save plastic sleeve (11) from 132-2247 Special Fasteners (7). The sleeves come on special fasteners (7) from the manufacturer. Install special fasteners (7) on bracket (1) and install over the fasteners still attached to the cowl. Check that the base of the special fasteners contact the cowl assembly at location (8). Mark the approximate position where special fasteners (7) contact the cowl.
NOTE: 132-2247 Special Fasteners (7) in 132-2033 Cowl Fastener Kit have a larger diameter head than the fasteners used in the manufacturing of the cowl. The thread specifications are the same on both fasteners.
Illustration 4.
Special Fastener Installation.
7. Remove bracket (1) from the cowl. Mix 132-2243 Epoxy Adhesive (9) following the manufacturer's instructions which are on the container or enclosed in the kit. Coat the base of special fasteners (7) and their contacting surfaces on the cowl with epoxy adhesive (9). Install special fasteners (7) on the cowl assembly at location (10). Install bracket (1) on the original fasteners still on the cowl. Secure bracket (1) in position with light pressure to the cowl assembly for the time needed for the adhesive to harden according to the manufacturer's instructions.
8. Remove bracket (1) from the cowl.
Illustration 5.
Reinforcing Patches.
9. Reinstall plastic sleeves (11) over special fastener (7) threads at location (12).
10. Take two 132-2244 Fiber Glass Patches (13) for each special fastener being installed and make intersecting cuts in the middle of each patch at location (14).
11. Install one fiber glass patch over each special fastener indicated at location (15).
12. Mix 132-2245 Polyester Resin (16) with 132-2246 Catalyst (17) according to the manufacturer's instructions printed on the product or enclosed in the kit. Brush the resin and catalyst mixture well into the patch. Place a second fiber glass patch over the special fasteners turning the patch 45 degrees out of alignment with the first patch as shown at location (18). Brush the resin and catalyst mixture well into the second patch. Allow curing time for the resin to fully harden as stated in the manufacturer's instructions.
NOTE: Additional layers of patching can be added as in the instructions, or after the preceding layer has hardened. Additional layers must be added within 12 hours of the preceding layer. After 12 hours has passed, the surface must be sanded before adding another layer of fiberglass.
NOTE: When the gas strut bracket fasteners break away from the cowl, the outer surface of the cowl can be damaged. This is a colored plastic surface which has the pigment mixed into the plastic during the manufacturing process. It may be necessary to fill in the outer surface of the repair area with the resin mixture, sand the area, and then paint the repaired area.
13. Remove sleeve (11) from the special fasteners. Reinstall the cowl on the machine. Reinstall the 4 bolts, 4 washers, and 4 nuts to the plate assembly that were removed in Step (1). Reattach the nut and washer from the gas strut to bracket (1) at location (2). See Illustration 1. Reattach the two bolts, the four washers, and the two nuts that connect the strut from the radiator to 121-2770 Plate Assembly.
Left Corner Crack Repair Procedure
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Dust generated when grinding or cutting non-metallic materials may be very fine, abrasive, flammable, and/or explosive. Material being removed may contain crystalline silica, quarts, glass fibers, and/or other fine materials. Prolonged breathing of the dust may cause cancer, and irreversible lung damage. Wear goggles, gloves, and a dust respirator certified by the National Institute for Occupational Safety and Health (NIOSH) and Mine Safety and Health Administration (MSHA). In the event of contact with the skin, flush with plenty of water. If dust material gets into the eyes, flush with an approved flushing system and seek medical attention. Before smoking, or eating, clean hands thoroughly. Keep the work-site clean and dispose of all particles in containers approved for flammable materials. Refer also to the Technical Bulletin from the Telene® Products Division of the B.F. Goodrich Company, entitled, "Process Dust Handling and Disposal", contained in REHS0034 Special Instruction, Guide for Repair of Non-metallic Fenders and Hoods. Telene® is a brand name of a PDCPD material.
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1. Raise the cowl and support it so it cannot close unexpectedly. Detach the strut from the cowl by removing the nut and washer attached to bracket (1) at location (2). Remove the four bolts, four washers, and four nuts that attach 121-2770 Plate Assembly to its supports. Remove the two bolts, the four washers, and the two nuts that connect the strut from the radiator to 121-2770 Plate Assembly.
2. Remove the cowl and support it securely on a stand.
Illustration 6.
Plate Placement.
3. Attach 132-2035 Cowl Rework Plate (19) to the outside of the front left corner of the cowl as shown at location (20). Use two 6V-7357 Bolts (21), four 8T-4205 Washers (22), and two 6V-7743 Locknuts (23) to secure plate (19) in place at location (28). Place one washer (22) under the head of bolt (21) and one washer under nut (23). Refer to Section A-A in Illustration 6.
4. Use the plate as a template and drill two 9 mm holes into the inner cowl flange at location (24). Attach plate (19) to the inner cowl flange with two 8T-4908 Bolts (25), four 8T-4224 Washers (26), and two 6V-9189 Locknuts (27) at (24). Place one washer (26) under the head of bolt (25) and one washer under locknut (27). Please refer to Section B-B in Illustration 6.
5. Remove two bolts (21), four washers (22), and two locknuts (23) from plate (19) at (28).
6. Place the cowl back onto the machine making sure to slide the hinge between plate (19) and the inner cowl flange (29). Refer to section A-A in Illustration 6.
7. Open the cowl and prop it securely so it will not close unexpectedly.
8. Reinstall two bolts (21), four washers (22), and two locknuts (23) into the two holes in plate (19) at (28). Refer to Section A-A in Illustration 6. Reinstall 13 hinge bolts, 13 washers, and 13 nut removed from the hinge in Step 1. Two bolts, two washers, and two nuts will be left over because 15 were removed in Step 1.
9. Reattach the nut and washer from the gas strut to bracket (1) at location (2). See Illustration 1. Reattach the two bolts, the four washers, and the two nuts that connect the strut from the radiator to 121-2770 Plate Assembly.