PRODUCT SUPPORT PROGRAM FOR REWORKING THE REAR WINDOW JOINTS ON CERTAIN 966K, 972K, AND 980K WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE REAR WINDOW JOINTS ON CERTAIN 966K, 972K, AND 980K WHEEL LOADERS

Usage:

REBE7601-00

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07Oct2011

U-434

O-383

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE REAR WINDOW JOINTS ON CERTAIN 966K, 972K, AND 980K WHEEL LOADERS
7301 7310		PS43403

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43403" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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

31Oct2012

PROBLEM

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The joints around the rear window and the top of the cab in the rear light pockets, need to be inspected and reworked on certain 966K, 972K, and 980K Wheel Loaders. The existing joint sealant may be inadequate to prevent water leaks into the cab at certain locations.

AFFECTED PRODUCT

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Model	Identification Number
966K	TFS00110-00111, 114-120, 122-126, 133-136, 138-140, 142-155, 157-161, 163-165, 167, 169, 171-173, 175-177, 179-183, 185-186, 188-192, 194-195, 197-199, 201, 203-204, 206-208, 210, 212-213, 215, 217, 219, 221-222, 243, 245-246, 249
972K	Z4W00114-00116, 118-122, 126-133, 135, 137, 139-140, 142, 144, 147-148, 150, 153-157, 159-160, 162, 164, 166, 168-169, 171, 173, 176-178, 188

PARTS NEEDED

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Qty	Part Number	Description
1	1213908	SEALANT-URETHANE
1	2223117	CLEANER-BRAKE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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Requires inspection and possible rework to joints around the rear window and the top of the cab in the rear light pockets. Refer to the attached Rework Procedure for detailed instructions.

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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%
0-5000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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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Light Pocket:

The first potential leak location is between the skip welds in the cab rear light pockets. Refer to Image1.1.1. The arrows indicate the source of the leaks. Some of the skip weld joints may not contain adequate sealant.

Image1.1.1

Top of Rear Window:

The second,and more common, potential leak location is at the top of the rear window. Sealant is present, but direct water impact substantiates the leak. Refer to Image1.2.1. The arrows indicate the source of the leaks.

Image1.2.1

To address leaks in the joint area at the top of the rear window, repairs involving the application of sealant may have been attempted on some cabs. Image 1.3.1 (arrows indicate source of leaks) contains an example of an attempted repair. Attempted repairs may still not contain enough sealant.

Image1.3.1

Procedure for the Light Pocket:

1. Inspect the skip weld joints in the rear light pockets of the cab. Refer to Image1.1.1 for adequate sealant. If sealant has been adequately applied to the skip weld joints, no further action is required. If adequate sealant is not present, proceed to Step 2.

2. Clean the surface and corner joints of the rear light pocket joints with 222-3117 Cleaner (189-6296 EAME only)(aerosol), or 9U-6917 Cleaner (189-8679 EAME only)(pour top quart). Refer to Image1.5.1.

Image1.5.1

3. Add additional 121-3908 Urethane Sealant (commercial equivalent to Sikaflex 255FC Adhesive Black) to the skip weld joints in the rear light pockets of the cab. If applicable, cut the tip of the tube to extrude a thin bead of urethane sealant.

4. Holding the injector at a 45 degree angle, gently inject urethane sealant into the corners of the rear light pockets completely filling the joints. Refer to Image1.13.1 for an example of sealant application.

5. Smooth the bead to make urethane sealant form a tight seal with the bottom and sides of the rear light pocket. Use a finger or stick to smooth urethane sealant. Refer to the example in Image1.14.1.

6. After the sealant has had time to set, leak test the rear light pockets and the rear windows of the cab. If repairs are required for the top of the rear window, leak testing should be completed after both repair procedures have been completed.

Procedure for the Top of the Rear Window:

1. Inspect the rear window bonding for adequate sealant. An example of inadequate sealant is shown in Images1.2.1 and 1.3.1. If additional sealant has been added, the cab was repaired at the factory and no further action is required. If additional sealant is not present, proceed to Step 2.

2. Clean the surface and corner joints of the rear window joints with 222-3117 Cleaner (189-6296 EAME only)(aerosol), or 9U-6917 Cleaner (189-8679 EAME only)(pour top quart). Refer to Image1.5.1. Using masking tape, mask both sides of the rear window joints. Refer to Image1.11.1.

Image1.11.1

3. Add additional 121-3908 Urethane Sealant (commercial equivalent to Sikaflex 255FC Adhesive Black) to the rear window of the cab. If applicable, cut the tip of the tube to extrude a thin bead of urethane sealant.

4. Gently inject urethane sealant to the gap between cab and glass seal as shown in Image1.13.1. Hold the injector in a 45 degree position while injecting urethane sealant. Fill the gap completely all the way around. Ensure that urethane injection is filled to the point that cab and seal surface on glass are even.

Image1.13.1

5. Smooth the bead to make urethane sealant even with cab and seal on glass. Use a finger or stick to smooth urethane sealant. Refer to Image1.14.1.

Image1.14.1

6. Inject urethane sealant on both corners (the meeting point of glass).

Note: Corners are high risk water leak areas. Adding a little extra urethane sealant on the corners prevents water leak. Refer to Images1.15.1 and 1.15.2.

Image1.15.1

Image1.15.2

7. Images1.16.1, 1.16.2 and 1.16.3 contain examples of correctly performed repairs to the top of the rear window.

Image1.16.1

Image1.16.2

Image1.16.3

8. After the sealant has had time to set, leak test the rear light pockets and the rear windows of the cab. If repairs are required for the rear light pockets, leak testing should be completed after both repair procedures have been completed.