Replacing Bonded Windows {7310} Caterpillar

Caterpillar Products

All Machines

Introduction

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Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke. Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

This information lists the procedures that are required in order to replace the bonded glass in the cab of Caterpillar machines.

Do not perform any procedure that is outlined in this publication, or order any parts until you understand this information.

Reference: Information Release Memo, PEGJ0075, 03, January 2010, "CAT LOCTITE GLOBAL CROSSOVER LIST"

Reference: To procure Sika Products locally, go to www.sika.com for distributors for your region.

Tools, Parts, and Adhesives that are Required

Loctite 595 CL RTV 300ML is for glass to glass joints. Adhesive will be fully dry in 24 hours.

Loctite RTV Silicon Clear 300ML can only be used if the temperature is above 0 °C (32 °F).

Sika 255 FC Adhesive (black), should be used when a slow cure time is needed. Adhesive will be fully dry in 4 to 6 hours at 24 °C (75 °F) with 50% humidity to 75% humidity. Increased temperature and humidity will greatly decrease adhesive dry time.

Sika Tack-Plus Booster Adhesive (black), should be used when a faster cure time is required. Adhesive will be fully dry in 1 to 2 hours at 24 °C (75 °F) with 50% humidity to 75% humidity. Increased temperature and humidity will greatly decrease adhesive dry time.

Sika Activator Primer must be used with Sika Tack-Plus Booster Adhesive.

Sika 206 G & P Primer should be used with Sika 255 FC, or withSika Tack-Plus Booster for glass that does not have a ceramic coating (fretting).

Sika 209 D should be used when you are bonding to a polycarbonate.

Sika Activator UH-2 LUM is used to clean and give improved adhesion on glass, ceramic-coated glass, the cut face of old polyurethane adhesive beads, polyurethane coated window glass, and paints.

Sika 295 UV is a polyurethane adhesive/sealant used to bond polycarbonate.

Procedure for Replacing Windows

Refer to previous tables for the tools, parts, and adhesives in order to replace windows on machines.

Remove any components that may interfere with the removal of the window. This process will aid in the removal and installation of the seals and the adhesives.

Removal of the Existing Silicone Joint

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Illustration 1	g00681473

1. Start a cut at the top edge of the silicone strip that bonds the two windows. Use the utility knife in order to initiate the cut.
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   Illustration 2	g00681478

2. Cut a piece of 121-9777 Wire that is approximately 91.4 cm (36 inch) long. Install one end of the wire into the 121-9780 Handle. Insert the other end of the wire through the hole in the silicone strip that was previously cut. Install this end of the wire into the other handle.
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   Illustration 3	g00681497
   (1) Silicone strip (2) Wire (3) Handle

3. Pull back and forth on each of the handles (3). The wire (2) will cut through the silicone strip (1). Cut the silicone strip for the entire length of the window. Remove the wire from the window when the silicone seal is cut.
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   Illustration 4	g00681535

4. Use the utility knife in order to remove the silicone seal, as shown. Clean the remainder of the silicone with the 222-3117 Cleaner ( 189-6296 Cleaner (EAME Only).

Removing the Glass

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Illustration 5	g00681569

1. Start a cut at the left edge of the urethane adhesive that bonds the window to the cab. Use the utility knife in order to initiate the cut.
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   Illustration 6	g00681607

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   Illustration 7	g01475227
   (A) 2.5 ± .5 mm (0.10 ± 0.02 inch) (4) Old seal (5) Cab

2. Insert the wire and attach the handles. Make sure that you leave 2 mm (0.08 inch) to 3 mm (0.1 inch) (A) of the old seal (4) on the cab (5). Use the wire in order to cut the urethane adhesive. Pull the wire back and forth in order to cut the urethane.

3. Remove the handles and the wire after the urethane adhesive has been cut. Attach the holders to the glass and remove the glass from the cab. Use the utility knife in order to level the remaining urethane adhesive on the cab. The urethane surface should be consistent. Check the area of the cab door or window that will be bonded for any excess weld or weld splatter. The area should be free from any weld splatter. Remove the weld from the area for bonding so that the weld is flush with the surface for bonding. For the weld that is excessive on the cab, contact the Dealer Solution Network (DSN) for instructions to rework. Areas that are not flush with the surface will cause extra stress on the glass. The extra stress on the glass may cause the glass to break.

4. Apply the appropriate primer and paint to any scratches that may have been caused by removing the window or preparing the bonded surface. This procedure will prevent rust from starting. Rust will cause water leaks at the seals.

Installation of Single Glass Pane (Tempered Glass or Laminated Glass)

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Illustration 8	g01475233
(6) 25.4 mm (1.00 inch) Exposed area (7) Glass

1. Lay the new glass on a flat work area. The new glass may have a ceramic fretting around the border. This surface should face Upward. Some glass does not have the ceramic fretting around the edge. Use tape in order to cover the inside area of the glass (7). Installer should leave a 25.4 mm (1 inch) area (6) exposed around the edge of the glass.

2. Clean the exposed area of the glass by using glass cleaner. Apply the appropriate activator from Table 3 to the glass surface with the fretting. The activator could also be applied to the point of contact between the adhesive and the glass. Wait for 5 seconds and wipe the glass by using a lint free cloth. Apply one coat of the appropriate activator from Table 3 to the exposed area of the glass.

   Note: Do not apply more than two coats of the appropriate activator from Table 3. Problems with the adhesive may occur if you apply more than two coats of activator. Wait at least 10 minutes but not more 2 hours before you apply the urethane adhesive. Wait between 30 seconds and 30 minutes before you apply the urethane adhesive.

3. Clean the sheet metal of the cab with 222-3117 Cleaner ( 189-6296 Cleaner EAME Only). If the paint is scratched, apply Sika 209 D primer and allow 10 minutes for the primer to dry. Apply the appropriate activator from Table 3 to the cleaned area of the cab and allow 15 minutes for the activator to dry. Do not touch the activator.
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   Illustration 9	g00681931

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   Illustration 10	g01473898
   (7) Glass (8) Adhesive (9) 110-7524 Button (10) Sheet metal

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   Illustration 11	g01473899
   (7) Glass (8) Adhesive (9) 110-7524 Button (10) Sheet metal

4. Make sure that the new glass will fit the opening for the window. 110-7524 Buttons (9) are placed around the opening for the window in order to allow you to maintain a uniform thickness of the adhesive. The 110-7524 Buttons (9) may also be used in order to hold the glass off the steel locating tabs. The 110-7524 Buttons (9) may also be used in order to hold the glass off the sheet metal on the cab. Refer to Illustration 10 and Illustration 11. Use a caulking gun in order to apply an even layer of adhesive around the sheet metal or around the edge of the glass. Cutting a groove into the tip of the caulking gun will help in the even application of the adhesive. Refer to Illustration 9.

5. Apply a layer of adhesive approximately 6 mm (0.24 inch) in height. The adhesive should be approximately 3 mm (0.12 inch) from the outer edge of the window.

   Note: The window must be installed within 15 minutes after the adhesive is applied.

6. Install the glass. Use the holders in order to install the glass. Make sure that no adhesive contacts the interior of the cab or area of the sheet metal that is not primed. Press the glass onto the adhesive. Align the window evenly with the opening on all sides. Apply firm pressure and even pressure when you are pressing the glass. Hold the glass in position by using several pieces of tape. Leave the tape in position for 2 hours in order for the adhesive to cure.

7. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the sheet metal and from the glass. Follow the recommendations from the manufacturer of the adhesive.

   Note: Avoid slamming the door of the cab for 24 hours or leave a window open in the cab. The excessive air pressure in the cab could loosen the window. The pressure could also cause potential water leaks.

Installation of Multiple Glass Panes (Tempered Glass and Laminated Glass) Applies to Medium and Large Wheel Loaders

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Illustration 12	g01475233
(6) 25.4 mm (1.00 inch) Exposed area (7) Glass

1. Lay the new glass on a flat work area. The new glass may have a ceramic fretting around the border. This surface should face Upward. Some glass does not have the ceramic fretting around the edge. Use tape in order to cover the inside area of the glass (7). Installer should leave a 25.4 mm (1 inch) area (6) exposed around the edge of the glass.

2. For Series K-Series Medium Wheel Loaders, apply 289-9584 Seal to the top and bottom of the Glass.
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   Illustration 13	g02699917
   Cross section of the top

3. Clean the exposed area of the glass by using glass cleaner. Apply the appropriate activator from Table 3 to the glass surface with the fretting. The activator could also be applied to the point of contact between the adhesive and the glass. Wait for 5 seconds and wipe the glass by using a lint free cloth. Apply one coat of the appropriate primer from Table 3 to the exposed area of the glass.

   Note: Do not apply more than two coats of the appropriate primer from Table 3. Problems with the adhesive may occur if you apply more than two coats of primer. Wait between 30 seconds and 30 minutes before you apply the urethane adhesive.

4. Clean the sheet metal of the cab with 222-3117 Cleaner ( 189-6296 Cleaner EAME only). Apply the appropriate primer from Table 3 to the cleaned area of the cab. Wait for 15 minutes in order to allow the primer to dry. Do not touch the primer.

5. Ensure that the glass will fit into the opening for the window.
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   Illustration 14	g01474097
   (7) Glass (8) Adhesive (10) Sheet metal (11) 7X-2634 Seal

6. Install the 7X-2634 Seal (11) onto the sheet metal. Align the edge of the seal with the edge of the sheet metal opening.

7. Use a caulking gun in order to apply an even bead of the appropriate primer from Table 3 around the 7X-2634 Seal (11). The bead of adhesive should be 9.5 mm (0.37 inch) tall and 5.0 mm (0.20 inch) wide.

   Note: The multiple panes of glass must be installed within 15 minutes after the adhesive is applied.

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   Illustration 15	g02699682

8. Install the center pane first so that the pane can be centered in the opening. Leave a 5 mm (0.20 inch) gap between the windows. Press on the glass with a firm and even pressure. Use several pieces of tape in order to hold the glass in position. Leave the tape in position for 2 hours in order for the adhesive to cure.

9. Install the side panes. Leave a 5 mm (0.20 inch) gap between the windows. Press on the glass with a firm and even pressure. Use several pieces of tape in order to hold the glass in position. Leave the tape in position for 2 hours in order for the adhesive to cure.
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   Illustration 16	g02699803

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   Illustration 17	g02699837
   High risk water leak area

10. To ensure proper sealing, apply another bead of the appropriate urethane between the edge seal and cab. See Illustrations 16 and 17.

11. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the sheet metal and from the glass. Follow the recommendations from the manufacturer of the adhesive.

12. Allow the adhesive to cure for a minimum of 45 minutes before bonding the joint between the windows.

    Note: Avoid slamming the door of the cab for 24 hours or leave a window open in the cab. The excessive air pressure in the cab could loosen the window. The pressure could also cause potential water leaks.

Bond the Joint Between the Side Window and the Center Window

1. Clean the surface of the glass by using glass cleaner. Allow the cleaner to dry. Wipe the glass by using a lint free cloth.
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   Illustration 18	g00682092
   Top view of the windows (1) Front window. (2) Tape. (3) Tape. (4) Silicone. (5) Side window. (A) 4 ± 1 mm (0.15 ± 0.04 inch) (B) 37.5 mm (1.5 inch)

2. Apply a piece of tape that is (3) 76.2 mm (3 inch) wide across the inside of the glass seam. Approximately 38.1 mm (1.5 inch) (B) of tape should be on each piece of glass. See illustration 18.

3. Apply a piece of tape that is (2) 25.4 mm (1 inch) wide to each piece of glass. This tape should be on the outside of the cab. The tape should be approximately 4 ± 1 mm (0.15 ± 0.04 inch) (A) from the seam. See illustration 18.

4. Use the caulking gun in order to apply or the appropriate silicone from Table 3. The silicone should be applied from the outside of the glass. The tape (3) that was applied earlier will prevent the silicone from entering the inside of the cab. The silicone (4) should completely fill the glass seam. See illustration 18.
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   Illustration 19	g00682156

5. Remove any excess silicone from the seam by using a clean cloth. The seam of silicone should be smooth and level with the glass, as shown. Immediately remove the tape from the outside of the glass. The tape should be removed within 1 to 2 minutes after the application of the silicone.

   Note: Remove only the outside tape. The tape on the inside of the glass should be left in place for 24 hours. The silicone should not tear when the tape is removed.

   Note: Avoid slamming the door of the cab for 24 hours or leave a window open in the cab. The excessive air pressure in the cab could loosen the window. The pressure could also cause potential water leaks.

Installing the Polycarbonate Window

1. The mounting surface must be milled down 0.5 mm (0.02 inch) around the edge of the polycarbonate window. This procedure is necessary for a good adhesion. This area is 25.4 mm (1 inch) wide around the border of the polycarbonate window.

   Note: some polycarbonate windows may already have the edge milled, if so, disregard the Step 1.

2. Lay the window on a flat work area. The milled area should be facing Upward. Remove the plastic covering from the surface of the window. Clean the milled surface with 222-3117 Cleaner ( 189-6296 Cleaner EAME only) in order to remove any dirt and oil from the window.

3. Cover the inside of the window. Leave the milled area exposed. Apply Sika 209 D primer to the milled area and allow 10 minutes to dry. Apply the appropriate activator from Table 3 to the milled area of the window and allow 10 minutes to dry. Do not touch the activator.

4. Clean the sheet metal of the cab with 222-3117 Cleaner ( 189-6296 Cleaner EAME only). If the paint is scratched, apply Sika 209 D primer and allow 10 minutes for the primer to dry. Apply the appropriate activator from Table 3 to the cleaned area of cab and allow 15 minutes for the activator to dry. Do not touch the activator. Apply Sika 295 UV to the window and bond to the cab. Install the window within 15 minutes.

Note: Avoid slamming the door of the cab for 24 hours or leave a window open in the cab. The excessive air pressure in the cab could loosen the window. The pressure could also cause potential water leaks.

Installing Custom Glass

Illustration 20	g00750897
Typical Chemically Tempered Laminated Glass (A) Protective Fiberglass Tape (B) Bonded area on cab (C) Glass (D) Glass (E) PVB

Illustration 21	g00750892
Typical Thermo-pane Laminated Glass (A) Bonded area on cab (B) Spacer Bar (C) Air Space (D) Glass (E) Glass

1. Install any of the following custom glass products. Use the required adhesives that are specified in Table 2.

   • Chemically Tempered Laminated Glass Windows

   • Thermo-pane Laminated Glass

2. When you install chemically tempered laminated glass, apply protective fiberglass tape to the following areas.

   • Each side of the glass

   • Edge of the glass

3. The fiberglass tape must be left on the glass. The fiberglass tape must be painted to a black color before you install the glass. Refer to Illustration 12.

4. Determine the side of the glass that will be bonded to the cab. Lay the glass on a flat work area.

5. Clean the fiberglass tape with 222-3117 Cleaner ( 189-6296 Cleaner EAME only). Wait for 5 seconds and wipe this area with a lint free cloth. Apply one coat of the appropriate activator from Table 3.

6. Clean the sheet metal of the cab with 222-3117 Cleaner ( 189-6296 Cleaner EAME only). Wait for 5 seconds and wipe this area by using a lint free cloth. Wait for 15 minutes in order to allow the primer to dry. Do not touch the primer.
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   Illustration 22	g00681931

7. Make sure that the new glass will fit the opening for the window. Buttons may be placed around the opening for the window. This procedure will allow you to maintain a uniform thickness of the adhesive. Use a caulking gun in order to apply an even layer of adhesive around the sheet metal or around the edge of the glass. Cutting a groove into the tip of the caulking gun will help in the even application of the adhesive.

8. Apply a layer of adhesive approximately 6 mm (0.24 inch) in height. The adhesive should be approximately 3 mm (0.12 inch) from the outer edge of the window.

   Note: The window must be installed within 15 minutes after the adhesive is applied.

9. Install the glass. Use the holders in order to install the glass. Make sure that no adhesive contacts the interior of the cab or area of the sheet metal that is not primed. Press the glass onto the adhesive. Apply firm pressure and even pressure when you are pressing the glass. Hold the glass in position by using several pieces of tape. Leave the tape in position for 2 hours in order for the adhesive to cure.

10. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the sheet metal and from the glass. Follow the recommendations from the manufacturer of the adhesive.

    Note: Avoid slamming the door of the cab for 24 hours or leave a window open in the cab . The excessive air pressure in the cab could loosen the window. The pressure could also cause potential water leaks.