TERMINATION DATE

PROBLEM

Some issues have been identified on early production 301.6C, 301.8C and 302.5C Mini Hydraulic Excavators. These issues need to be corrected. In some cases an inspection is all that is necessary. In other cases rework must be undertaken.

Twelve separate issues are addressed in this program. A group of machines has been identified for each issue. In some cases the serial numbers affected are the same for more than one group of machines, but parts identification is easier if each issue is addressed separately.

AFFECTED PRODUCT

PARTS NEEDED

Table 1: Table to show which Reworks need to be carried out, in relation to Machine Serial Number.
 

A shaded cell in the above Table (Table 1) indicates that a rework must be carried out.

ACTION REQUIRED

SERVICE CLAIM ALLOWANCES

****************************Group 1***************************

Product smu/age whichever comes first

Parts

****************************Group 2***************************
 

Product smu/age whichever comes first

Parts

****************************Group 3***************************
 

Product smu/age whichever comes first

Parts

****************************Group 4***************************
 

Product smu/age whichever comes first

Parts

****************************Group 5***************************

Product smu/age whichever comes first

Parts

****************************Group 6***************************
 

Product smu/age whichever comes first

Parts

****************************Group 7***************************
 

Product smu/age whichever comes first

Parts

****************************Group 8***************************
 

Product smu/age whichever comes first

Parts

****************************Group 9***************************
 

Product smu/age whichever comes first

Parts

****************************Group 10***************************
 

Product smu/age whichever comes first

Parts

****************************Group 11***************************
 

Product smu/age whichever comes first

Parts

 ****************************Group 12***************************

Product smu/age whichever comes first

Parts

PARTS DISPOSITION

Attach. (1-Rework Procedure)

Issue 1 ? Replace the Latch that Holds the Door Open. (Machines Equipped with a Cab)

1. Remove the existing 250-0381 Receiver As. and 277-5686 Striker As. from the door and from the side of the cab.
2. Attach the new 250-0381 Receiver As. and 277-5686 Striker As. in position. Open the door and engage the latch in order to ensure proper alignment. Then tighten the screws to a torque of 0.75 Nm +0.25 Nm.

Issue 2 ? Check Bonding of Polycarbonate Window (Machines Equipped with a Cab)

1. Inspect 249-2874 Window (the curved window at the upper front of the cab) for correct bonding. If the window is loose it must be removed and re-bonded.
2. Prepare 249-2874 Window and the cab opening by removing all bonding residue and clean with 222-3124 Remover (Sika 208).
3. Apply 187-4863 Cleaner (Sika 205) to the window and to the cab opening and allow to cure for 10 minutes.
4. Apply 189-8653 Primer (Sika 209C) to 249-2874 Window and to the cab opening and allow to cure for 30 minutes.
5. Apply Mastic to 249-2874 Window in a continuous triangular shaped bead along the fritted edges. The bead must be continuous (no gaps).
6. Fit 249-2874 Window to the cab opening by applying even pressure. Ensure there is an equal thickness of mastic of 3-5 mm all around.
7. Allow the mastic joint to cure as per instructions on the mastic.

Issue 3 ? Check Hydraulic Filter Mounting for Leakage

Figure 1: Image to show potentially leaking Joint

1. Inspect the joint between the hydraulic filter housing and the tank for leakage, as seen in Figure 1 above.
2. If there is evidence of leakage, remove the filter head.
3. Remove 278-3355 Gasket and 278-3353 Shim and discard both pieces.
4. Fit new 278-3355 Gasket and 278-3353 Shim. Ensure that the cut out on both Shim and Gasket are opposite the breather.
5. Press 278-3355 Gasket firmly into the seat, ensuring that the gasket is flat all round.
6. Clean the adapter plate on top of the tank, ensuring that the threaded bolt holes are dry and free from oil. Use degreaser if necessary.
7. Place the filter assembly into the tank. Carefully hold the gasket and shim so that they do not become dislodged from their seats. Ensure that the gasket is sitting flat and is not trapped anywhere around the gasket joint.
8. Tighten the filter bolts evenly to a torque of 20 + 2 Nm. The holes for the bolts must be free from oil.
9. Inspect the fitted gasket to ensure it is evenly compressed and not trapped.

Issue 4 ? Check Oil Tank Suction Strainer for Leakage

1. Inspect the joint between the oil tank suction strainer and the tank for leakage, as indicated in Figure 2 above.
2. If there is evidence of leakage, drain the hydraulic oil tank.
3. When the tank is drained, back off the lock nut as far as possible, and ensure the seal-o-ring is pushed back as far as possible in the groove. The seal-o-ring should be lubricated prior to final assembly.
4. Screw the strainer into the tank thread by hand until the seal-o-ring contacts the tank face, and resistance is felt.
5. Orientate the strainer by backing off counter clockwise, up to a maximum of one turn, until the notch in the strainer lip is pointing directly upwards.
6. Hold the strainer head in place with one wrench, and tighten the locknut and washer to a torque of 15 + 2 Nm.

Issue 5 ?Finish on Cab Roof (Machines Equipped with a Cab)

1. Inspect the cab roof to check if it is sealed around the weld seams.
2. If it is not sealed, ensure the roof is clean, and apply black silicone sealant to the weld seams.

Issue 6 ? Rework Aperture for Interior Light (Machines Equipped with a Cab)

1. Remove the 084-4227 Lamp Gp.-Dome from the 250-0374 Bracket.
2. Fabricate plate as in Figure 3 above, and affix over the 250-0374 Bracket using high strength adhesive.
3. Insert the 084-4227 Lamp Gp.-Dome into the smaller hole in the plate.

Issue 7 - Fitment of plate and insulation behind seat

1. Check that 256-4593 Insulation and 250-7804 Plate (301.6C and 301.8C) and 248-7079 Cover and 269-4617 Insulation (302.5C) are present behind the seat.
2. If the parts are missing, fasten the plate/cover to the upper frame, and affix insulation into position using Velcro strip.
3. Ensure the bottom of the insulation is tucked under the seat.

Issue 8 ? Fitment of Main Power Supply Cable

1. To locate the terminal, open the door under the seat deck using a standard CAT Key. For 301.6C and 301.8C machines, the terminal can now be seen in the upper right corner of the compartment. On 302.5C machines, the 269-0699 Plate on the right hand side of the compartment needs to be removed in order to inspect the terminal.
2. The terminal should be fitted so that its crimp barrel faces away from the panel into which the power stud is mounted. Refer to Figure 4 above.
3. If the terminal is not fitted as described, remove the terminal and refasten so the crimp barrel faces away from the panel.
4. Reinstall 269-0699(302.5C Only) and close the door.

Issue 9 ? Installation of Speaker Covers (Machines Equipped with a Cab)

1. Check the 262-9568 Cover-Speaker is installed firmly.
2. If the 262-9568 Cover-Speaker is damaged or missing, replace with a new part. If the 262-9568 Cover-Speaker is not damaged, the original part can be reused.

Issue 10 ? Check Washer Bottle Cap

1. Inspect the 212-9334 Bottle Group to check to see if the cap fits well with the tank.
2. If the fit between the tank and cap is poor, remove and replace with a new 212-9334 Bottle Group.

Issue 11 ? Fitment of Side Window (Machines Equipped with a Cab)

1. Inspect the small clips at the bottom of the 261-2713 Window Group.
2. If the fasteners have a circular shape on the lever, there is no problem.
3. If the fasteners have an oval shape on the lever, as seen in Figure 5 below, insert 2 8U-7803 Screws, one in each end of the window base, as indicated in Figure 6 below.

Figure 5: Oval Shape Fastener means rework must occur

Figure 6: Locations for 8U-7803 Screw

Issue 12 ? Replace Glow Plug Timer and Wiring (302.5C Machines only)

1. Disconnect the negative battery terminal. The terminal is located under the hinged flap below the left hand side of the floor mat. Use an 8mm wrench.
2. Open the toolbox door using a standard CAT Key.
3. Remove the two uppermost relays 3E-9362 Relay Assemblies (12 VDC), and retain for re-use.
4. Remove the remaining 3E-9362 Relay Assembly (12 VDC) and discard. This relay may be damaged.





 
5. Remove the three plastic screws retaining the relay bases with an 8mm socket.
6. Remove the plastic guard panel to the inboard side of the fuse panel by removing two screws with a 13mm socket.
7. Cut and remove the tie strap holding the relay base wires.
8. Identify the start aid relay base (the lower of the three) with wires 877YL (10awg), 104RD (10awg), 308YL (18awg) and L987WH (18awg). Unclip the relay base.
9. Remove the secondary lock from the relay base.