PRODUCT SUPPORT PROGRAM FOR REBONDING THE RIGHT HAND SIDE POLYCARBONATE WINDOW IN THE CAB ON CERTAIN 385C, 374D, AND 390D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REBONDING THE RIGHT HAND SIDE POLYCARBONATE WINDOW IN THE CAB ON CERTAIN 385C, 374D, AND 390D EXCAVATORS

Usage:

TEBE0331-00

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10Sep2013

U-411

A-280

D-340

O-343

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REBONDING THE RIGHT HAND SIDE POLYCARBONATE WINDOW IN THE CAB ON CERTAIN 385C, 374D, AND 390D EXCAVATORS
7310		PS52508

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52508" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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TERMINATION DATE

30Sep2015

PROBLEM

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The right side 8mm polycarbonate window could come unstuck and need to be rebonded on certain 385C, 374D, and 390D Excavators.

AFFECTED PRODUCT

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Model	Identification Number
374D L	PAP00121-00329 PAS00131-00204, 400-913 PAX00111-00164, 300-451 PJA00141-00154
374D OEM	JNZ00100-00148
385C L MH	WAW00227-00246
390D	BYP00121-00139 KCZ00151-00180
390D L	WAG00131-00255 WAP00171-00585 WBT00141-00302
390D L OEM	M1M00100-00110, 10010

PARTS NEEDED

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Qty	Part Number	Description
5	5J5003	PLUG
3	1785574	SPACER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-2000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
6001-10000 hrs, 25-36 mo	7.0%	5.0%	0.0%	0.0%	70.0%	95.0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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It is recommended that an outside vendor is used to complete this Rework Procedure.

The following consumables should be used for this Rework Procedure:

Sika? cleaner 205, grease remover.
Sika? primer 209, primer.
Sikaflex? 295-UV, polyurethane windscreen adhesive.
Sika? Remover 208, to clean eventual spots.
Using any other compound or product may damage glazing and prevent waterproofness.

The following tooling should be used for this Rework Procedure:

Platform, to safely access to external side of right hand side cab window.
Electric oscillating cutting tool, to cutout right hand side cab window sealant. Refer to Image1.1.1.

Cutting wire, to cutout sealant behind monitor.
Handles, handles for cutout wire.
Cutout knife, to remove eventual residues of old sealant.
Handgun, to apply Sikaflex? 295-UV.
Suction cup holder, to handle glass.
Foam brush, to evenly apply primer.

Image1.1.1

Rework Procedure:

1. In order to have the best access to the external side of the right hand side window, put boom cylinders in vertical position if possible.

2. Install platform in order to safely access the external side of the right hand side window. Refer to Image1.2.1.

Image1.2.1

3. Install two suction cup holders on the external side of the right hand side
window in order to hold it during cutting operations. Refer to Image1.3.1.

Image1.3.1

4. Sit in the cab, using an electric oscillating cutting tool, refer to Image1.4.1,
separate the existing adhesive from the window and the frame of the cab.

Image1.4.1

5. Usage of electric oscillating cutting tool is not possible behind the monitor area. Use the cutting wire and handles, refer to Image1.5.1, to finish separating the adhesive. Keep cutting wire as close as possible to the window to avoid scratches on the frame of the cab. Two people are needed for this operation. The one inside of the cab has to take care of not damaging monitor or right console.

Image1.5.1

6. When adhesive is completely separated, using suction cup holder, remove the right hand side glass and store it in a safe area. Refer to Image1.6.1.

Image1.6.1

7. Remove any excess of adhesive material from the frame of the cab using oscillating cutting tool or cutout knife. Ensure that the thickness of residual adhesive remains between 1 and 2mm width. Refer to Image1.7.1 and Image1.7.2.

Image1.7.1

Image1.7.2

8. Clean the flanged area on the frame with Sika? cleaner 205. This step will clean the frame from residual material or grease and will prepare the surface to receive the polyurethane windscreen adhesive. Refer to Image1.8.1 and Image1.8.2.

Image1.8.1

Image1.8.2

Preparation of the window.

9. Lay the polycarbonate window on a stable and flat surface.

The 8 mm polycarbonate window has a 20mm milled area all around the window and black painted area to protect the bonding material against UV exposition. Be careful while removing the polyurethane adhesive to not alter that black paint layer.

Use a cutout knife in order to remove the remaining adhesive from the polycarbonate perimetrical milled surface (20mm width).

Prepare the polycarbonate window by applying primer Sika? primer 209 to the milled area around the window. Refer to Image1.9.1 and1.9.2.

Use a foam brush to evenly apply primer.

Allow the primer to dry at least 30 minutes and no more than 24 hours at 23?C (73?F). Do not apply at temperature below 10?C or above 35?C.
Care must be taken that this application gives adequately dense coverage.

Reseal the container tightly and immediately after use.

Image1.9.1

Image1.9.2

10. Using a caulking gun, apply an even layer of Sikaflex? 295 - UV, (polyurethane windscreen adhesive) all around of the window as close as possible to its edge. Refer to Image1.10.1.

Image1.10.1

Dimensions for the width and the height of the adhesive are 10 - 15mm (0.39 to 0.59 inch) (width) and 10mm (0.39 inch) (depth).

Depending on work environment, operator could prefer either to glue the polycarbonate window (Refer to Image1.11.1) or the cab frame (Refer to Image1.11.2)

Cutting a groove into the tip of the cartridge will help in the even application of the Sikaflex? 295 - UV. Refer to Image1.11.3.

Image1.11.1

Image1.11.2

Image1.11.3

11. To avoid window moving and ensure 5mm clearance between the edge of the window and the edge of the frame, install three 178-5574 Spacers on cab metallic frame as shown in Image1.12.1.

Image1.12.1

To insure proper glue thickness after glass application, locate five self-adhesive 5J-5003 Plugs (Bumpers) at the locations shown in Image1.13.1.

Note: The bumpers should be located as close as possible to the glue as illustrated in Step 10.

Image1.13.1

12. Install two suction cup holders on the internal and two on the external side of the window in order to hold it during installation operations. The first operator handles the window, while the second takes place into the cab. Refer to Image1.14.1.

Image1.14.1

13. Put pressure onto the polycarbonate window and hold in place for 10 minutes. You can use suction cup holders to do so. Ensure that the even gap all around between the edge of the window and the edge of the frame is maintained (Read Step 10). Refer to Image1.15.1.

After complete installation of the polycarbonate window, thickness of the adhesive must be 5mm thick. Failure to do so could conduct in glass unstucking after thermal expansion. Refer to Image1.15.2.

Image1.15.1

Image1.15.2

14. Remove eventual excess of Sikaflex? 295 - UV using appropriate method, for example, a folded sheet of cardboard can be used to facilitate this operation. Refer to Image1.16.1.

Image1.16.1

15. Wet stains or residues of Sikaflex? 295 - UV can be removed using Sika? Remover 208. Refer to Image1.17.1. Once Sikaflex? 295 - UV is dry, it can only be removed using a manual tool like a cutout knife. Cleaning of the hands and skin has to be carried out immediately using an adapted soap. Do not use solvents.

Image1.17.1

16. Sikaflex? 256 will cure in 12 to 24 hours. Do not expose the cab to temperature below 10?C during 24 hours for proper adhesive curing. Do not slam the cab door for 24 hours. The excessive air pressure in the cab from slamming the door may loosen the window. It is strongly recommended to NOT MOVE or OPERATE the machine during the 24 hours following this Rework Procedure. Failure to do so will eventually cause the window seal to leak.

Note: Apply tape to keep the window secured in the opening for a minimum of four hours.

Cleaning instructions for polycarbonate glazing.

Special care has to be taken to clean polycarbonate windows.

- Never clean polycarbonate glazing in hot sun or at elevated temperatures
- Never use a cleaning solvent on polycarbonate windows.
- Never use a dry cloth or paper towels on polycarbonate windows.
- Never scrape the sheet with squeegees, razor blades or other sharp instruments.
- Wash polycarbonate windows with a mild soap or a detergent using a soft sponge and warm water.
- For removal of paints, marking pens, labels, stickers etc. the use of naphtha, kerosene or white spirit is generally effective.
- Afterwards, a warm final wash (not exceeding 50?C) should be made, using a mild soap and ending with a thorough rinsing with cold water free from additives and perfumes.