H0F_Expired TI -

XXXXXXXXXXXXXXXXXXXXXXX IMPORTANT UPDATE XXXXXXXXXXXXXXXXXXXXXX
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COLD CLIMATE STATES ONLY
CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI & WV and District of
Columbia
TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN H0F
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CERTAIN 2007 - 2008 MODEL YEAR TUNDRA
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CORROSION-RESISTANT COMPOUND APPLICATION
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COLD CLIMATE STATES ONLY
CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI & WV and District of
Columbia
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UPDATED 12-8-2017
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Update 12.8.17
• Update to Technician Certification Requirements
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The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this repair are required to successfully complete the most current version of the E-Learning course “Safety
Recall and Service Campaign Essentials”. The Technician must also be fitted for a NIOSH approved
respirator. To ensure that all vehicles have the repair performed correctly, technicians performing this repair
are required to currently hold at least one of the following certification levels:
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• Maintenance Certified Technician and above
Always check which technicians can perform the recall remedy by logging on to
https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above
certification level or greater to perform this repair. Carefully review your resources, the technician skill level,
and ability before assigning technicians to this repair. It is important to consider technician days off and
vacation schedules to ensure there are properly trained technicians available to perform this repair at all
times.
•
I.
For a complete list of site selection guidelines and, applicable fire, building, and zoning
code information for your state, please refer to the Dealer Information Packet. Please
ensure your dealership complies with all requirements and regulations set forth in the
applicable Dealer Information Packets and any Supplements.
Keep records to comply with Federal/State/Local regulations and requirements. See the
Dealer Packet for C0D and any Supplements to that Guide.
OPERATION FLOW CHART
Verify Vehicle Eligibility:
1. Check the TIS vehicle Inquiry system
Yes
Is the vehicle registered in one of the Cold Climate States?
Yes
Did the vehicle pass the ZH7 frame inspection?
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No
No further action required.
No
Contact your regional
representative for assistance.
No
Yes
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Remove the rust and clean the frame.
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Was perforation 10mm or larger found in the locations identified in
green below (during the rust removal and/or cleaning process)?
If applicable, proceed with Frame
Replacement as outlined in the
ZH7 TI.
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Apply the 712AM Internal CRC to the areas of the frame outlined in the
Technical Instructions.
Yes
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Install the Body Plugs after applying the 712AM
and before applying the Noxudol 300S.
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Apply Noxudol 300S (External Application) to the top, bottom and
sides of the frame as outlined in the TI.
After applying the CRCs place a CRC Customer Information
Hang Tag on the rear-view mirror.
After 24 hours, return the vehicle to the customer.
Campaign Completed.
Note: Ensure to follow the entire procedure and perform all steps completely (e.g. inspection,
cleaning/rust removal, CRC application, one kit per vehicle, etc.); any deviation will be subject to
warranty claim debit.
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IDENTIFICATION OF COVERED VEHICLES
A.
•
•
•
COVERED VIN RANGE
Vehicles currently registered in the Cold Climate States* or the District of Columbia (D.C.) that do
not have significant corrosion found are eligible for Corrosion-Resistant Compound (CRC)
application to the frame if it did NOT previously have the frame sprayed and/or had the frame
previously replaced.
Check TIS to confirm the VIN is covered in H0F. This will verify the vehicle is covered and has
not already been completed prior to dealer shipment or by another dealer.
TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not covered
or were completed by another dealer.
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II.
* CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, and WV
**Refer to section V. for inspection procedures and criteria
III. PREPARATION
PARTS
Please be aware that only dealers in Cold Climate States will be allowed to order the following CRC kit.
Model
Tundra
Part No.
00289-T00KT-DS
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The necessary CRC kits can be ordered through the chemical program provided by Dealer Tire
(Complete Maintenance Care). The CRC kits will be shipped directly from AMREP. Your dealership
should not order kits until you have confirmed an appointment. However, please keep in mind it will take
at least 5 business days for CRC kit delivery. Deliveries are only scheduled on business days.
Saturday deliveries are not available.
Part Description
T00-Corros Res Kit (CRC Kit)
Qty/Unit
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The kit above includes the following parts:
Noxudol 300S – 3 Liters
Parker 712AM – 1 Liter
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1. When Ordering CRC Kits Please Note:
• Each kit will contain the exact amount of CRC for one vehicle.
• The CRC kits listed will be drop-shipped from AMREP, not your local PDC. Do not order
more than your immediate needs, as these materials are not returnable or refundable.
• Orders for these parts should be placed separately from orders of other drop ship
chemicals.
• Refer to the Appendix for the Safety Data Sheet (SDS).
2. When Storing the CRC Kits Please Note:
• Follow local, state and federal regulations for hazardous materials storage and disposal
that are explained in the Hazardous Waste Management Section of the Federal, State and
Local Requirements Guide of the Dealer Information Packet.
• Store the CRC kits at room temperature (refer to the SDS for detailed instructions).
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SUPPORT MATERIALS
•
The following support materials can be ordered through the dealer’s facing PDC:
Part Number
Part Description
04007-18234
Tundra Plug Kit
Qty
1 per vehicle
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The kit listed above includes the following parts:
Qty
2
8
3
6
8
2
10
2
2
2
2
1
The following support materials can be ordered through the dealer’s facing PDC:
Part Number
Part Description
04007-23234
Plug Kit
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Part Description
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
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Part Number
90950-01A24
90950-01987
90950-01990
90950-01994
90950-01993
90950-01988
90950-01A09
90950-01A11
90950-01A06
90950-01986
90950-01826
90480-19374
Qty
1 per vehicle
The kit listed above includes the following parts:
Qty
2
4
The following support materials can be ordered through the MDC:
Part Number
Part Description
Corrosion-Resistant Compound Customer Information Hang Tag*
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00411-11004
Qty
1 per
vehicle
Additional CRC Customer Information Hang Tags can be ordered in packages of 50 through the MDC.
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*
Part Description
PLUG,HOLE
PLUG,HOLE
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Part Number
90950-01A31
90480-A0002
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STANDARD TOOLS & EQUIPMENT
• Standard hand tools
• Flat chisel
• Scraper
• Wire brush
• Air nozzle
• Infrared thermometer
• Air coupler (quantity 2)
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C.
SPECIAL EQUIPMENT
The following equipment was shipped to your dealership prior to the launch of LSC H0F.
Note: Due to federal, state and local regulations, each dealer is only allowed to have one set of
spray guns. Any old previous spray guns from previous campaigns should be disposed of in
accordance with local regulations.
As a result, each participating dealer will have 2 total spray guns in their possession:
Equipment
Purpose
Application Area
Spray Gun
Noxudol 300S
Exterior Frame CRC Application
Spray Gun
712AM
Interior Frame CRC Application
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The items below were previously shipped to your dealership for previous CRC campaigns.
Magnet Kit
• 30 Rare Earth Magnets – See section VI.C.1 “Attach Plastic Sheet” for details.
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MATERIALS & SUPPLIES (Locally Procured by Dealer)
• Protective eyewear
• Dust mask
• Appropriate NIOSH approved respirator** (Follow all Federal, State, Local
Environmental, Health and Safety Requirements such as OSHA Regulations. Please
refer to the SDS for details on the appropriate mask for each CRC.)
Example of a NIOSH**Notes:
approved respirator
• Refer to the SDS located in the Appendix for additional information on respirator use.
• It is up to the individual dealership to ensure compliance with OSHA regulations.
• If you require further assistance in regards to NIOSH approved respirators, we have found
3M® to be a useful reference/source.
3M® Technical Assistance:
1-800-243-4630
3M® Customer Service:
1-800-328-1667
3M® Web Site:
www.3m.com/occsafety
• Protective gloves
• Chemical Resistant Gloves (refer to SDS for specific type)
• Masking tape
• Duct tape
• Fire-retardant poly sheeting (tarp) or covering (if you cannot purchase the tarp from a local supplier,
please refer to CRC Tips and Examples located on the C.L.E.A.N. DEALER website
(http://cleandealer.com) for a list of possible suppliers)
• Plastic (Saran Wrap) sheet (for spray gun storage)
• Partitions (The type, size, and number of partitions used will depend on each dealer’s facility.)
• Shop cloth/paper towels
• Funnel (quantity = 2)
• Plastic sheet to contain the dripping 712AM during frame application, 3m x 3m (118in x 118in)
• Garbage Bags
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*Follow the CRC Support link located in the left bottom corner of the C.L.E.A.N DEALER webpage.
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IV. BACKGROUND
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Toyota has received a number of reports regarding Frame Corrosion on 2005 – 2010 model year Tacoma vehicles,
2007-2008 Tundra vehicles, and 2005-2008 Sequoia vehicles. In these reports, customers have indicated that
vehicles operated in specific cold climate areas with high road salt usage may exhibit more-than-normal corrosion
to the vehicle’s frame. This condition is unrelated to and separate from normal surface rust which is commonly
found on metallic surfaces after some years of usage and/or exposure to the environment.
• Because of variations in state and local laws, dealerships conducting H0F in certain states may
require government approvals prior to starting the campaign. Depending upon the state, dealerships
also may be subject to restrictions on the number of vehicles to which the CRC can be applied in any
single day, week, or month. Please refer to Dealer Informaton Packet and any Supplements for
important information about any such approvals or restrictions that may apply to your dealership.
Your dealership must adhere strictly to these requirements.
• For a complete list of site selection guidelines, and fire, building, and zoning code information for
your state, please refer to the Dealer Information Packet (provided at the time of launch) as well as
any Supplements. Please ensure your dealership complies with all regulations and all issued
packets and instructions.
V.
VEHICLE INSPECTION WORK PROCEDURE
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Vehicle frame inspection is performed under WEP ZH7. Reference
the Technical Instructions for WEP ZH7 to determine the repair
procedure for each vehicle.
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WORK AREA SETUP (SUGGESTED)
1. INITIAL SETUP CONSIDERATIONS & GUIDELINES
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a) Work with your Service Manager to locate a dedicated work area and lift with the following
requirements.
i. In well ventilated area.
ii. Away from other vehicles to minimize the possibility of overspray.
iii. In a location that can be sectioned off by partitions.
iv. In an area that provides sufficient distance from neighboring stalls.
v. In an area that meets the minimal space requirements as outlined in Site Selection Guide of the
Dealer Information Packet (provided at the launch of H0F) and any Supplements.
• A fire extinguisher, rated “B”, “AB” or “ABC”, must be located in an area that is within
at least 30’ of application area.
• Important Reminder: Because of specific fire and building code requirements, make
sure to review the Site Selection Guide of the Dealer Information Packet (provided at
the launch of H0F) and any Supplements to ensure that the area where you will
conduct the CRC application is compliant with the appropriate requirements.
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Due to the flash point of the CRC materials, allow sufficient time for the vehicle and
exhaust to cool down before beginning the application process. By following the
FRAME APPLICATION WORK PROCEDURE in these Technical Instructions, the
vehicle will have additional time to cool before the CRC’s are applied. Please refer to
the SDS (Located in the Appendix) for flash point temperatures.
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VI. FRAME APPLICATION WORK PROCEDURE
Note: area set up may vary depending on dealership layout. The following information is just
one example of how an area might be set up for frame CRC application.
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1. MASK THE LIFT SWING ARMS
a) Cover the lift swing arms with fire-retardant poly sheeting (tarp).
b) Secure the tarp with masking tape.
2. WORK AREA SETUP
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Notes:
• A two post above-ground lift is shown for reference
purposes.
• Inspect the tarp on a daily basis for damage (cuts, tears,
etc.) and replace as necessary.
• Dispose of old tarps in the same manner as other regulated
waste at your dealership. Refer to the Dealer Information
Packet for more info.
a) Cover any exposed section(s) of the lift with fire-retardant poly
sheeting (tarp), and secure with masking tape.
b) Place the fire-retardant tarp(s) as shown in the illustration to
protect the floor.
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Notes:
• When laying out the tarp on the floor, be sure it is secure
and does not create a slipping hazard when walked upon.
• Inspect the tarp on a daily basis for damage (cuts, tears,
etc.) and replace as necessary.
• Dispose of old tarps in the same manner as other regulated
waste at your dealership. Refer to the Dealer Information
Packet for more information.
• A two post above-ground lift is shown for reference purposes.
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a) Setup partitions according to the facility needs of your
dealership.
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Notes:
• The type, size, and number of partitions used will depend on
each dealer’s facility.
• Set up partitions according to the guidelines established in
the Fire, Building, and Zoning Code section of the Dealer
Information Packet (provided at the time H0F launch) and
any Supplements.
• Partitions should minimize any overspray to nearby stalls,
while ensuring adequate ventilation.
• Inspect the partition(s) on a daily basis for damage (cuts,
tears, etc.) and repair/replace as necessary.
• Dispose of used partitions in the same manner as other
regulated waste at your dealership. Refer to the Dealer
Information Packet for more information.
c) Position the partitions around the vehicle to prevent overspray,
as shown in the illustration.
Note: The partitions shown are just an example of what can be
used.
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B.
VEHICLE PREPARATION AND REMOVAL OF FRAME RUST
1. PREPARE THE VEHICLE
a) It may be necessary to pressure wash the vehicle’s
frame, depending on its cleanliness.
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Note: Time has been allotted to pressure wash the frame in the
flat rate time.
b) Place the vehicle on the lift.
Strap the vehicle to the lift with safety straps. Once
the vehicle is raised to the desired height, install
screw jacks to the front and back of the vehicle.
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Raise up the vehicle and remove the wheels.
Remove the engine under cover.
Remove the rear mudguards. (IF Equipped)
Remove the license plate light assy LH/RH
Remove the rear bumper plate. (With Trailer Hitch)
Remove the rear bumper assy.
Cover any identifying label (i.e., VIN label, etc.) on the frame
with tape.
Cover all exposed electrical connectors with tape to protect
from over spray.
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c)
d)
e)
f)
g)
h)
i)
2. REMOVE RUST FROM THE FRAME AND CROSS-MEMBERS.
Notes:
• Be careful not to damage the wire harness or brake line and
fuel line when removing rust.
• Make sure to wear protective eyewear, gloves, and a dust
mask when removing rust and cleaning frame.
• Be extremely cautious not to injure your hands.
• DO NOT scratch or remove the identifying labels (i.e., VIN
label, etc.) from the frame.
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a) Using a scraper / chisel or any power tools (ex : Air needle
scaler), remove loose rust and rust scales from the frame and
cross-members shown on the left.
b) If rust perforation of 10mm or larger and/or component corrosion
damage is found in the blue area during the rust removal
process proceed to the appropriate campaign for repairs.
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3. CLEAN THE FRAME
a) Use a wire brush and remove any remaining rust or dirt from the
frame.
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Ensure to follow the procedure and perform all steps completely
(e.g. inspection, cleaning/rust removal, CRC application, one kit
per vehicle, etc.) any deviation will be subject to warranty claim
debit.
b) Use an air nozzle and remove any loose rust.
Notes:
• Make sure to wear protective eyewear, gloves, and a dust
mask when performing this step.
• A slightly wet frame surface (no water droplets) is
acceptable when applying the frame CRC.
Sample of Sufficient Frame Cleaning
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After
FINAL FRAME RUST CORROSION PERFORATION INSPECTION
1. VISUALLY INSPECT FOR FRAME PERFORATION AFTER
RUST REMOVAL
a) Visually inspect the specific area highlighted in blue to ensure
no perforation was uncovered during the rust removal
process
b) If rust perforation of 10mm or larger is found in the blue
areas, proceed to Frame Replacement work procedure.
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Note: A slightly wet frame surface (no water droplets) is acceptable when applying the frame CRC.
VEHICLE PROTECTION
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D.
1. ATTACH MASKING MATERIALS
a) Using an infrared thermometer ensure the exhaust has cooled.
b) Cover the driveshaft(s) and exhaust, with fire-retardant poly
sheeting (tarp) and secure with masking tape.
c) Cover the front and rear brake/hub assemblies with garbage
bags and secure with masking tape.
Notes:
• Cover the air suspension, and shock absorber (if necesary)
with masking sheets.
• Overspray onto the driveshaft may cause vehicle vibration.
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2. COVER SPARE TIRE CONTACT SURFACES ON REAR CROSSMEMBER
a) Cover the underside of the rear cross-member with duct tape
where the spare tire contacts the rear cross-member.
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Notes:
• Tape will prevent Noxudol 300S from sticking to the tire.
Front
PREPARE FOR APPLICATION OF CORROSION-RESISTANT COMPOUND (CRC)
Attach to Floor Pan
Plastic Sheet Size
• 3m x 3m(118inx118in)
• Thickness = 2 mil
1. ATTACH PLASTIC DRIP SHEET
a) Before spraying 712AM to the internal frame, fit the plastic sheet
on the frame utilizing the supplied magnet kit.
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Magnet
2. SPRAY GUN SET UP FOR 712AM INTERNAL CRC
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Notes:
• Use a dedicated spray gun for the 712AM internal CRC and
mark/label the gun for 712AM.
• Make sure to wear protective eyewear, impervious gloves
(Viton, PVOH, etc.) appropriate Niosh approved respirator,
and refer to the MSDS located in the Appendix when
handling and spraying CRC.
Note: If the 712AM is below 72º F, place the 712AM container in
a bucket of hot water (<104º F) for 15 minutes and allow it
to warm so the proper viscosity is achieved.
b) Shake the 712AM container well so that the contents are mixed
thoroughly. Settling may occur as it sits over time.
c) Fill the dedicated tank with 712AM, and attach to the spray gun.
d) Connect the 8mm spray tube, as shown in the illustration.
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a) Check the temperature of the 712AM.
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e) Adjust the spray gun nozzle flow/volume.
1. Turn the adjustment screw to fully closed position
(clockwise).
2. Then loosen the adjustment screw 4 complete turns.
f)
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The air regulator is extremely sensitive; always follow
instruction to avoid damage to the gun!
Adjust the air pressure regulator.
Place the nozzle in a clean empty box or pail.
Adjust the air regulator completely closed (No Air Flow)
Attach the air hose to gun.
Fully press the spray gun trigger, and slowly adjust the air
pressure to 72.5 psi.
Note: The air regulator has a slight delay and may take up to 10
seconds before the air pressure stabilizes. Move the
adjustment knob in very small increments (1/8 turn).
5. Recycle the amount sprayed out and use it during the
application process.
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1.
2.
3.
4.
712AM INTERNAL FRAME CRC APPLICATION
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1. 712AM INTERNAL FRAME APPLICATION
a) Insert the spray nozzle into the selected holes located throughout
the frame. Reference the next page for the location, depth, and
application rate.
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b) Once the location, depth, and application rate is confirmed, begin
applying CRC to the internal frame.
c) When inserting the nozzle, insert so the nozzle touches the
opposite side of the frame as illustrated on the left. See Diagram
1 through 8 for applying CRC.
Note: Make sure the quick coupler on the spray tube does not
come into contact with the frame when applying the
712AM. Contacting the frame with the quick coupler may
lead to a hose disconnection.
d) After the 712 AM has been applied, wipe away any wax on the
frame’s exterior with cloths or paper towels.
Notes:
• Follow all MSDS guidelines for the 712AM which can be
found in the Appendix.
• Follow the given application speeds when applying the
712AM to the inner surface of the frame.
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Diagram 1: Internal CRC Application
712AM Internal CRC Application
Tube Insert Locations, Depth, and Application Speed
CRC Temperature
Application Speed
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Step 1 & 2
22°C (72°F)
0.2 m/sec (8 in/sec)
30°C (86°F)
0.3 m/sec (12 in/sec)
Note: m/sec = meters/second
Front
90cm
(35 in)
Step 1 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 90cm (35 in) into the
side-rail.
b) Continue applying the 712AM while removing the nozzle.
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STEP ①
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Note: The illustrations of the steps 1 to 2 show application
procedure only for the right side of the vehicle. Perform
application for the left side of the vehicle in a similar
manner.
Step 2 (refer to the table above for application rate):
a) Insert the nozzle 5 cm (2 in.) towards the front of the frame
for 2 seconds.
b) Move the nozzle in a circular motion while applying the 712AM.
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STEP ②
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Repeat Step 1 for a total of 2 laps
Note: Make sure to only insert the nozzle 5cm (2 in) to avoid over
spraying onto the engine.
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Notes:
• Follow all MSDS guidelines for the 712AM which can be found in the Appendix.
• Only one side is given. Please apply 712AM for opposite side of the frame in similar manner.
• Follow the given application speeds when applying the 712AM to the inner surface of the frame.
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Diagram 2: Internal CRC Application
712AM Internal CRC Application
Tube Insert Locations, Depth, and Application Speed
CRC Temperature
Application Speed
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Front
22°C (72°F)
0.2 m/sec (8 in/sec)
30°C (86°F)
0.3 m/sec (12 in/sec)
Note: m/sec = meters/second
Step 1, 2 & 3
Notes:
• The frame to be applied in the steps 1 and 2 has a double structure.
Take care not to apply to different cavity.
• Do not insert the nozzle forcibly, otherwise the nozzle may be broken.
Step 1 (refer to the table above for application rate):
STEP ①
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Note: Apply the 712AM into the smaller inner cavity as indicated
in the illustration.
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30cm
(12 in)
a) While applying the 712AM, insert the nozzle 30cm (12 in) into the
side-rail.
b) Continue applying the 712AM while removing the nozzle.
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Repeat Step 1 for a total of 1 lap
Step 2 (refer to the table above for application rate):
STEP ②
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40cm
(16 in)
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Note: Apply the 712AM into the smaller inner cavity as indicated
in the illustration.
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STEP ③
a) While applying the 712AM, insert the nozzle 40cm (16 in) into the
side-rail.
b) Continue applying the 712AM while removing the nozzle.
Repeat Step 2 for a total of 1 lap
Step 3 (refer to the table above for application rate):
a) Insert the nozzle 5 cm (2 in.) towards the front of the frame
for 2 seconds.
b) Move the nozzle in a circular motion while applying the 712AM.
Note: Make sure to only insert the nozzle 5cm (2 in) to avoid over
spraying onto the engine.
Notes:
• Follow all MSDS guidelines for the 712AM which can be found in the Appendix.
• Only one side is given. Please apply 712AM for opposite side of the frame in similar manner.
• Follow the given application speeds when applying the 712AM to the inner surface of the frame.
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Diagram 3: Internal CRC Application
712AM Internal CRC Application
Tube Insert Locations, Depth, and Application Speed
Step 2 & 3
Application Speed
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CRC Temperature
Step 1
22°C (72°F)
0.2 m/sec (8 in/sec)
30°C (86°F)
0.3 m/sec (12 in/sec)
Note: m/sec = meters/second
Front
STEP ①
Step 1 (refer to the table above for application rate):
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100cm
(39 in)
Note: Apply the 712AM into the larger inner cavity as indicated in
the illustration.
a) While applying the 712AM, insert the nozzle 100cm (39 in) into
the side-rail. (contact the top center of the frame while inserting
nozzle).
b) Continue applying the 712AM while removing the nozzle.
c) Repeat the step a) to c) two more times (Total: 1 lap)
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Repeat Step 1 for a total of 3 laps
20cm
(8 in)
Step 2 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 20cm (8 in) into the
#2 cross-member.
b) Continue applying the 712AM while removing the nozzle.
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STEP ②
Front
20cm
(8 in)
Step 3 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 20cm (8 in) into the #
2 cross-member.
b) Continue applying the 712AM while removing the nozzle.
Repeat Step 3 for a total of 2 laps
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STEP ③
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Repeat Step 2 for a total of 2 laps
Front
Notes:
• Follow all MSDS guidelines for the 712AM which can be found in the Appendix.
• Only one side is given. Please apply 712AM for opposite side of the frame in similar manner.
• Follow the given application speeds when applying the 712AM to the inner surface of the frame.
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Diagram 4: Internal CRC Application
712AM Internal CRC Application
Tube Insert Locations, Depth, and Application Speed
Front
CRC Temperature
Application Speed
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Step 2 & 3
22°C (72°F)
0.2 m/sec (8 in/sec)
30°C (86°F)
0.3 m/sec (12 in/sec)
Note: m/sec = meters/second
Step 1
10cm
(4 in)
Step 1 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 10cm (4 in) into the
#3 cross-member.
b) Continue applying the 712AM while removing the nozzle.
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STEP ①
Repeat Step 1 for a total of 2 laps
40cm
(16 in)
Step 2 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 40cm (16 in) into the
# 1 cross-member.
b) Continue applying the 712AM while removing the nozzle.
on
STEP ②
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Front
40cm
(16 in)
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STEP ③
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Front
d
Repeat Step 2 for a total of 2 laps
Step 3 (refer to the table above for application rate):
a) While applying the 712AM, insert the nozzle 40cm (16 in) into the
# 1 cross-member.
b) Continue applying the 712AM while removing the nozzle.
Repeat Step 3 for a total of 2 laps
Front
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Notes:
• Follow all MSDS guidelines for the 712AM which can be found in the Appendix.
• Only one side is given. Please apply 712AM for opposite side of the frame in similar manner.
• Follow the given application speeds when applying the 712AM to the inner surface of the frame.
2. LET EXCESS 712AM DRIP
a) With a cloth wipe off any drips of 712AM dripping from the frame.
b) Before installing the body plugs, confirm that the excess 712AM has stopped dripping from the frame.
3. REMOVE THE PLASTIC DRIP SHEET
15
G.
BODY PLUG INSTALLATION
Qty
2
8
3
6
8
2
10
2
2
2
2
1
Part Number
90950-01A31
90480-A0002
KIT 04007-23234
Part Description
PLUG,HOLE
PLUG,HOLE
Qty
2
4
ay
KIT 04007-18234
Part Description
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
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d
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Part Number
90950-01A24
90950-01987
90950-01990
90950-01994
90950-01993
90950-01988
90950-01A09
90950-01A11
90950-01A06
90950-01986
90950-01826
90480-19374
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1. INSTALL THE BODY PLUGS
・The illustrations below show the body plugs installed only on one side of the frame if the
installation points are similar for both sides of the frame rails. Be sure to install the plugs on
both frame rails even though only one side is shown on the illustrations.
・Install the plugs to prevent dripping and to limit water/road spray from entering the frame rails
and cross-members.
16
17
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PREPARE FOR NOXUDOL 300S EXTERNAL CRC APPLICATION
1. SETTING UP THE SPRAY GUN FOR NOXUDOL 300S
EXTERNAL FRAME CRC APPLICATION
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Notes:
• Use a dedicated spray gun for the NOXUDOL 300S and
mark/label the gun for NOXUDOL 300S (external CRC).
• Make sure to wear protective eyewear, chemical resistant gloves,
appropriate NIOSH approved respirator, and refer to the MSDS
located in the Appendix when handling and spraying CRC.
a) Check the temperature of the Noxudol 300S.
Note: If the Noxudol 300S is below 72º F, place the Noxudol 300S
container in a bucket of hot water (<104º F) for 15 minutes
and allow it to warm so the proper viscosity is achieved.
b) Shake the Noxudol 300S container well so that the contents are
mixed thoroughly. Settling may occur over time.
c) Fill the dedicated tank with Noxudol 300S and attach it to the
spray gun.
d) Connect the external spray tube, as shown in the illustration.
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e) Adjust the spray gun nozzle flow/volume.
1. Turn the adjustment screw to the fully closed position
(clockwise).
2. Then loosen the adjustment screw 3.5 turns.
on
Caution: Air regulator is extremely sensitive; always
follow instruction to avoid damage to the gun!
Adjust the air pressure regulator.
1. Place the nozzle in a clean empty box or pail.
2. Completely close the air regulator (No Air Flow).
3. Attach the air hose to the gun.
4. Fully press the spray gun trigger, and slowly adjust the
air pressure to 50 psi.
Note: The air regulator has a slight delay and may take up to
10 seconds before the air pressure stabilizes; Move the
adjustment knob in very small increments (1/8 turn).
5. Recycle the amount sprayed out and use it during the
application process.
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f)
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g) For Noxudol 300S, it will be necessary to refill the spray gun.
1. Disconnect the air hose.
2. Loosen the bottle to slowly discharge the pressure
through the threads of the bottle.
3. After all the pressure is discharged, detach the bottle.
Notes:
• DO NOT remove the bottle until the pressure is released.
• DO NOT pull the spray gun trigger when the air hosed is
disconnected, this causes CRC to backflow into the air inlet.
• Thoroughly shake the Noxudol 300S liter before use.
• Apply all three liters of Noxudol 300S to the left and right frames
and the cross-members. (No product is allowed to remain.)
18
I.
UNDER VEHICLE NOXUDOL 300S CRC APPLICATION
1. AFTER REVIEWING THE APPLICATION PROCESS OUTLINED BELOW, BEGIN APPLYING
NOXUDOL 300S TO THE REMAINING PORTIONS OF THE EXTERNAL FRAME
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Step① Coat outer and bottom surfaces of right side frame. (Start from front of the vehicle)
Step② Coat inside surfaces of right side frame. (Start from rear of vehicle)
Step③ Coat No.0, No.1, No.2, No.3, No.4, No.5, No.6, rear cross-members and receiver hitch bracket subassembly from front to back. (Start from front of vehicle)
Step④ Coat inside surfaces of left side frame. (Start from rear of vehicle)
Step⑤ Coat outer and bottom surfaces of left side frame. (Start from front of vehicle)
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STEP ②
Inside of Right Side Frame
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STEP ①
Top side & Outer & Bottom
Sides of Right Side Frame
STEP ④
Inside of Left Side Frame
Start
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receiver hitch bracket
sub-assembly
STEP ⑤
Top side & Outer & Bottom
Sides of Left Side Frame
d
STEP ③
No.0, No.1, No.2, No.3,
No.4, No.5, No.6,
Rear Cross-members
Discharge rate varies depending on CRC temperature. Make adjustments to spray rate as needed, but
do not change air pressure (air pressure must be 50 psi).
19
J.
RESTORE THE VEHICLE
1.
RESTORE THE VEHICLE
a) Re-install the engine undercover.
b) Re-install wheels and torque to spec.
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Aluminum Wheel
Torque Spec: 131 N m (1336 kgf cm, 97 ft lbf)
Steel Wheel
Torque Spec: 209 N m (2131 kgf cm, 154 ft lbf)
c) Lower the vehicle.
d) For areas where the lift arms touched, remove any rust present
and apply Noxudol 300S.
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CONFIRM ALL 3 LITERS OF NOXUDOL
300S HAVE BEEN APPLIED TO THE
EXTERNAL PORTION OF THE FRAME!
on
Raise the vehicle.
Remove all masking tape, fire retardant sheeting, and plastic coverings.
Lower the vehicle.
Install the spare tire.
Remove protective tape from the identifying labels (VIN label, etc.) on the frame.
Place a Corrosion-Resistant Compound information Hang Tag on the rear-view mirror.
Let CRC cure approximately 24 hours before returning vehicle to customer.
d
e)
f)
g)
h)
i)
j)
k)
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Ensure to follow the procedure and perform all steps
completely (e.g. inspection, cleaning/rust removal, CRC
application, one kit per vehicle, etc.) any deviation will be
subject to warranty claim debit.
Spray Gun Storage. (when the spray guns are not in use follow the procedure outlined below)
•
712AM Internal Frame Application Spray Gun:
- Remove the air hose from the spray gun.
- Loosen the spray gun from the canister to release the air pressure. To minimize exposure to
the air, once the air pressure is released retighten the spray gun to the canister.
- Leave the spray tube on the spray gun and place the originally equipped nozzle cap on the tip.
•
NOXUDOL 300S External Frame Application Spray Gun:
- Remove the air hose from spray gun.
- Loosen the spray gun from the canister to release the air pressure. To minimize exposure to
the air, once the air pressure is released retighten the spray gun to the canister.
- Leave the spray tube on the spray gun and wrap the tube tip with saran wrap. Seal the saran
wrap with a rubber band.
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STORING THE SPRAY GUN (Spray Guns do not require cleaning if they are properly stored)
RECORD-KEEPING AND OTHER REQUIREMENTS
To make sure that your dealership can satisfy specific state and local requirements, please refer to
your specific state Dealer Information Packet (provided at the time of H0F launch). Critical
requirements are described in the Air Regulation, Air Recordkeeping, and Fire, Building, and Zoning
Code Sections of the Federal, State and Local Requirements Guide and in the Site selection Guide, all
found in the Dealer Information Packet and Supplements.
20
VII. APPENDIX
A. 712AM & NOXUDOL 300S DISPOSAL
B. REPLACEMENT OF 712AM APPLICATOR NOZZLE
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712AM & Noxudol 300S used in the application of the frame CRC as well as any materials, such as
tarps with residue, must be disposed of in the same manner as other hazardous waste at your
dealership and in accordance with all applicable local, state, and federal regulations. Please refer to the
Dealer Information Packet for additional information.
1. NOZZLE REMOVAL AND INSTALLATION
In the event the tip separates from the hose, follow these
procedures for repair.
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a) Twist and remove the nozzle from the hose.
b) Screw the nozzle onto the threaded section of the NEW hose
at the nozzle connection.
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c) Holding both the nozzle and the hose pull to ensure they are
securely attached.
2. COUPLER REMOVAL AND INSTALLATION
a) Immerse the entire coupler in 70C (158 F) or hotter water for
10 seconds. This will loosen the coupler and allow it to be
removed more easily.
WARNING: Wear insulated gloves, while performing
the coupler removal and installation process. The
items may be hot.
21
b) Immediately after removing the coupler from the hot water,
twist and pull to separate the coupler from the hose using
pliers and a paper towel.
21
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9
Notes:
• Place the paper towel between the pliers and the coupler
to avoid damage.
• Be careful to place the pliers so as to not damage the
connection joint for the spray guns.
• The coupler and nozzle hose may be hot.
c) Immerse approximately 10mm (0.4 in.) of the non-threaded
section of the NEW nozzle hose in 70C (158F) or above hot
water for 10 seconds.
d) Immediately after removing the nozzle hose from the hot
water, install the coupler to the hose by twisting it.
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Notes:
• The coupler should be inserted all the way into the hose
to ensure it will not detach.
• If the hose has cooled and the coupler cannot be inserted,
reheat it with hot water.
• The coupler and hose may be hot.
REINSTALL THE FOLLOWING PARTS
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Rear Mudguards(IF Equipped)
Rear Bumper Pad Sub-Assy (IF Equipped)
Rear Bumper Assy
License Plate Light Assy LH/RH
Ex
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a)
b)
c)
d)
d
1. REINSTALL THE FOLLOWING PARTS
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e) Once the nozzle hose has cooled to room temperature, hold
both the coupler and hose and pull to ensure that they do not
separate.
22
D. SPRAY GUN TROUBLESHOOTING
Actual Spray
Nozzle
2. IF RESETTING AIR PRESSURE IS NOT
SUFFICENT, CLEAN THE SPRAY NOZZLE
WITH SHOP AIR.
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Quick
Couple
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1. CONDITION: CRC FLOWS AS LIQUID
(NOXUDOL 300S)
Cause: Increasing the air pressure too quickly
and having to reduce the regulator pressure.
Background: This condition occurs when the
bottle pressure exceeds the regulated air
pressure coming into the gun.
Remedy:
a) Disconnect the Air Hose.
(Do not pull the trigger)
b) Slowly loosen the bottle to release the air
pressure.
c) Release all air pressure from the tank.
d) Turn regulator off, completely shut.
e) Reconnect the air hose.
f) Fully pull the trigger.
g) Slowly adjust the regulator to the required air
pressure (1/8 turn at a time allowing the,
regulator time for the pressure to stabilize.
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E. SDS Sheets
Disconnect External Spray Wand.
Remove Quick Coupler. (Brass Color)
Remove Spray Nozzle. (Silver Colored)
Clean Spray Nozzle orfaces with shop air.
Reassemble in reverse order.
Note: Ensure not to damage or loose the
o-ring that is behind the spray nozzle.
d
on
Spray
Nozzle
a)
b)
c)
d)
e)
page 24
• 712AM………………………………………………………………………………………………
page 33
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• Noxudol 300S……………………………………………………………………………………...
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25
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32
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LS
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712AM MSDS
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712AM MSDS
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712AM MSDS
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712AM MSDS
36