PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RIGHT HAND SIDE WINDOW IN THE CAB WITH A POLYCARBONATE WINDOW ON CERTAIN 365B L II, 365B L II FS, 365C L, 365C L FS, 365C L OEM, 385B, 385B L, 385C, 385C FS, 385C L AND 385C OEM EXCAVATORS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RIGHT HAND SIDE WINDOW IN THE CAB WITH A POLYCARBONATE WINDOW ON CERTAIN 365B L II, 365B L II FS, 365C L, 365C L FS, 365C L OEM, 385B, 385B L, 385C, 385C FS, 385C L AND 385C OEM EXCAVATORS

Usage:

REBE5820-01

16Sep2010
(Revised 08Feb2011)


U-374
A-295
D-323
O-327

 
Safety
  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RIGHT HAND SIDE WINDOW IN THE CAB WITH A POLYCARBONATE WINDOW ON CERTAIN 365B L II, 365B L II FS, 365C L, 365C L FS, 365C L OEM, 385B, 385B L, 385C, 385C FS, 385C L AND 385C OEM EXCAVATORS

7310
PI10821
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10821" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10821" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

 
NOTE:

This Revised Service Letter replaces the 16 Sep 2010 Service Letter. Changes have been made to the Affected Product, Action Required, and to the Parts Needed to correct errors to the Lift Capacity Charts in Groups 7, 11, 12, and 13.



PROBLEM

The right side cab window needs to be replaced with a new polycarbonate window on certain 365B L Series II, 365B L Series II FS, 365C L, 365C L FS, 365C L OEM, 385B, 385B L, 385C, 385C FS, 385C L and 385C OEM Excavators. Certain field applications have the potential to expose the right side cab window to conditions that can result in an unexpected failure of the tempered safety glazing for the window. Failure of the tempered glazing, in conjunction with other factors or circumstances, may result in a risk of serious injury to the operator. In addition, a Stick / Boom Potential Crush Warning film may be applied to both sides of the stick, if not already installed. This warning film emphasizes the need for ground personnel to remain clear of the excavator when the machine is in operation.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
385B  ANS00227-00346
*******Group  2*******
365B L II  BTH00156-00180
*******Group  3*******
385B BKX00121-00181

BLY00151-00152
*******Group  4*******
365B L II  CFJ00178-00199
*******Group  5*******
385B BKF00206-00208

BLY00153-00168
*******Group  6*******
365C L ELC00156-00495

FEN00117-00149

MCS00178-00191, 193-507

MCY00185-00482

MEM00171-00274
365C L FS  PAR00250-00272
365C L OEM  GSZ00116-00123, 125-128, 132-133, 135, 138, 141-143
*******Group  7*******
385C JCM00175-00183

KBC00201-00240

KKK00123-00208

MNZ00124-00163
385C FS EAM00264-00290

MMA00245-00267

T2F00181-00188
385C L EDA00189-00503

KGB00275-00445

SBE00168-00386, 389-391

T2E00291-00341
*******Group  8*******
365C L ELC00496-00538, 541-544

FEN00150-00154

MCY00483-00522
365C L OEM  GSZ00144-00145
*******Group  9*******
385C JCM00184-00185

KKK00209-00210

MNZ00164-00172
385C FS EAM00291-00292, 295-296

MMA00268-00275
385C L KGB00446-00473

SBE00387-00388, 392-429, 431-462, 469-470
385C OEM  MSF00114
*******Group  10*******
365C L  MCS00508-00529
*******Group  11*******
385C FS  EAM00293
385C L  EDA00504-00536
*******Group  12*******
365B L II DER00101-00263

JMB00276-00557
365B L II FS  PEG00111-00122
*******Group  13*******
385B CLS00206-00277

RCD00152-00276
385B L FDL00151-00283

MYA00291-00292

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2157179 FILM-LIFT CAP.
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3601597 WINDOW-RH
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 2*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3573912 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 3*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3573912 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 4*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3573913 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 5*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3573913 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 6*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2247717 FILM-WARN SEATBE
1 2253305 FILM-WARN UNIV
1 2289253 FILM-DANGER
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2674495 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3199203 FILM-LITING CAP
1 3224582 FILM-WARN TIPOVE
1 3576158 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 7*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2288219 FILM-LIFT CAP.
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3576158 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 8*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2358911 GLASS
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 9*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1275295 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2358911 GLASS
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 10*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2358911 GLASS
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3199203 FILM-LITING CAP
1 3224582 FILM-WARN TIPOVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 11*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2033901 FILM-CONTROLS
1 2218045 FILM-WARN SEATBE
1 2230486 FILM-CONT STICK
1 2240554 FILM-WARN UNIV
1 2288219 FILM-LIFT CAP.
1 2289254 FILM-DANGER
1 2301341 FILM-WARN LINK
1 2358911 GLASS
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2553173 FILM-WARN CRUSH
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
1 2665431 FILM-WARN CRUSH
1 2690120 FILM-WARN
1 2690121 FILM-WARN
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 12*******
1 1R6245 FILM-WARNING
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 7Y0003 FILM-WARNING
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1529656 FILM-WARNING
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2023024 FILM-LIFT CAP.
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3576164 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*******Group 13*******
1 4I8472 FILM-INSTRUCTION
1 7I1565 FILM-NOTICE
1 1275250 FILM-INSTRUCTION
1 1275252 FILM-INSTRUCTION
1 1756296 FILM-INST
4 1785574 SPACER
1 1936800 FILM-WARNING
1 2022897 FILM-LIFT CAP.
1 2033901 FILM-CONTROLS
1 2230486 FILM-CONT STICK
1 2247717 FILM-WARN SEATBE
1 2253305 FILM-WARN UNIV
1 2289253 FILM-DANGER
1 2508054 FILM-HAMMER
1 2553171 PLATE-CONTROL
1 2560191 FILM-WARN CRUSH
1 2560192 FILM-WARN CRUSH
1 2634816 FILM-CONTROLS
1 2634817 FILM-CONTROLS
1 2634818 FILM-BUKT/HAMMER
2 2984282 FILM-WARN
1 3224582 FILM-WARN TIPOVE
1 3576164 GLASS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

It is recommended to have an outside vendor glass company perform this rework.

If the machine is in group 1-9 or 12-13, the right side window must be replaced with the thicker (12.7 mm) polycarb window that this letter calls for, even if the machine is currently equipped with the thinner (8 mm) polycarb window.

If the machine falls into group 10-11 please inspect the machine before performing this letter. If the machine is equipped with polycarb, no further action is required. If the machine is equipped with tempered safety glass, please perform this letter and change the right hand glass to the polycarb. An allowance has been added to inspect the machine in this group.

For all machine groups:
Remove the existing right hand side window in the cab and replace with a new piece of Polycarbonate glass. Refer to the attached Rework Procedure. Replace all window warning and reference decals according to the specific machine group.

NOTE: If your machine is equipped with a 4I-2885 Case, the case is to be reused.

Refer to the Operation and Maintenance Manual (OMM) documentation for the specific machine and the original window to confirm the exact safety warning, lifting or attachment film decals and placement locations. Image 1 is a reference illustration graphic that shows a typical example of these warnings.

Review the OMM and the existing right side window to prepare all replacement warning, attachment or lifting film decals to be properly placed on the new polycarbonate window. Be certain to affix these decals as required to the new window before returning the machine to operation with the customer.
Image1

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 1
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 2
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 3
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 4
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 5
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 6
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 7
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 8
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 9
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 10
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 11
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 12
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 0.5-hour job for Group 13
If the dealer replaces the window, an additional 2 hours will be allowed. If an outside vendor replaces the window, submit the cost of the invoice from the vendor. Retain a copy of the repair invoice in the dealer?s records for audit purposes.


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE RIGHT SIDE WINDOW IN THE CAB WITH A POLYCARBONATE WINDOW

MODELS INVOLVED - 365B L II, 365B L II FS, 365C L, 365C L FS, 365C L OEM, 385B, 385B L, 385C, 385C FS, 385C L AND 385C OEM EXCAVATORS

Dear Caterpillar Product Owner:

The right side cab window needs to be replaced with a new polycarbonate window on the products listed below. Certain field applications have the potential to expose the right side cab window to conditions that can result in an unexpected failure of the tempered safety glazing for the window. Failure of the tempered glazing, in conjunction with other factors or circumstances, may result in a risk of serious injury to the operator. In addition, a Stick / Boom Potential Crush Warning film may be applied to both sides of the stick, if not already installed. This warning film emphasizes the need for ground personnel to remain clear of the excavator when the machine is in operation

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 16Sep2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.



Caterpillar Inc.

Identification #(s)



Attached to 16Sep2010 Service Letter


Rework Procedure


 
Before to initiate the rework procedure, check to which group the machine belongs.

Review the OMM and the existing right side window to prepare all replacement warning, attachment or lifting film decals to be properly placed on the new polycarbonate window. Be certain to affix these decals as required to the new window before returning the machine to operation with the customer.

If the machine belongs to the group 10 or 11, the cab of the machine could have been built either with the right hand side glass made of tempered glass or with polycarbonate.

If the cab is equipped with a tempered glass, execute the following rework procedure. If it is equipped with a polycarbonate, no further action required.

The tempered glass is recognizable to the stamp applied to the bottom side of the glass. Refer to picture 1.1.1
Image1.1.1
 
It is recommended that an outside vendor is used to complete this service rework.

The following consumables should be used for this rework:
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:
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 image 1.2.1
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.
Image1.2.1
 
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 (image 1.3.1) to safely access the external side of the
right hand side window.
Image1.3.1
 
3 - Install 2 suction cup holders on the external side of the right hand side
window to hold it during cutting operations. (image 1.4.1)
Image1.4.1
 
4 - Sit in the cab, using an electric oscillating cutting tool,(image 1.5.1),
separate the existing adhesive from the window and the frame of the cab.
Image1.5.1
 
5 - Usage of electric oscillating cutting tool is not possible behind the
monitor area. Use the cutting wire and handles,(image 1.6.1), 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.
Image1.6.1
 
6 - When adhesive is completely separated, using suction cup holder, remove
the right hand side glass and store it in a safe area. (image 1.7.1)
Image1.7.1
 
7 - Remove any excess of adhesive material from the frame of the cab using oscillating cutting tool or Cutout knife. Make sure that the thickness of residual adhesive remains between 1 and 2mm width. (image 1.8.1 & image 1.8.2)
Image1.8.1
Image1.8.2
 
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. (image 1.9.1 & image 1.9.2)
Image1.9.1
Image1.9.2
 
Preparation of the window.

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

Polycarbonate window could be delivered with two different configurations.

Configuration 1 - with a milling all around the window and black painted area.

Configuration 2 - with a milling all around the window without black paint.

Prepare the new polycarbonate window by applying primer Sika? primer 209 to the milled area around the window. (image 1.10.1 & 1.10.2)
Use a foam brush to evenly apply primer.
For configuration 2: A second layer of Sika? primer 209 is needed. Apply it immediately after de first one without drying time.
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 tightly container immediately after use.
Image1.10.1
Image1.10.2
 
10 - Using a caulking gun, apply an even layer of Sikaflex? 295 - UV, (Polyurethane windscreen adhesive) all around of the window. (image 1.11.1)
Image1.11.1
 
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). (image 1.12.1)

Cutting a groove into the tip of the cartridge will help in the even application of the Sikaflex? 295 - UV. (image 1.12.2)
Image1.12.1
Image1.12.2
 
11 - To avoid window moving and ensure 5mm clearance between the edge of the window and the edge of the frame, install spacers as shown here under.

a) For 357-6164 Polycarbonate 12.7mm, refer to image 1.13.1
b) For 357-3912 Polycarbonate 12.7mm, refer to image 1.13.2
c) For 357-3913 Polycarbonate 12.7mm, refer to image 1.13.3
d) For 360-1597 Polycarbonate 12.7mm, refer to image 1.13.4
e) For 357-6158 Polycarbonate 12.7mm and 235-8911 Polycarbonate 8mm, refer to image 1.13.5
Image1.13.1
Image1.13.2
Image1.13.3
Image1.13.4
Image1.13.5
 
12 - Install 2 Suction cup holders on the internal and 2 on the external side of the window to hold it during installation operations. First operator handles the window whilethe second one takes place into the cab. (image 1.14.1)
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. Make sure that the clearance between the edge of the window and the edge of the frame is maintained at 5mm (0.2 inch, read paragraph 10) . (image 1.15.1)

After complete installation of the polycarbonate window, thichness of the adhesive must be 5mm thick. (image 1.15.2)
Image1.15.1
Image1.15.2
 
14 - Remove eventual excess of Sikaflex? 295 - UV using appropriate method, for example of folded sheet of cardboard can be used to facilitate this operation. (image 1.16.1)
Image1.16.1
 
15 - Wet stains or residues of Sikaflex? 295 - UV can be removed using Sika? Remover 208 (image 1.17.1) . 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. 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 4 hours.

Cleaning instructions for polycarbonate glazing.

Special care is required for cleaning plastic windows:
- Do not use abrasive or highly alkaline cleaners.
- Never scrape the sheet with squeegees, razor blades or other sharp instruments.
- Do not clean polycarbonate glazing in hot sun or at elevated temperatures.
- For removal of paints, marking pens, labels, stickers etc. the use of naphtha, kerosene or white spirit is generally effective. (See attached instruction)
- Afterwards, a warm final wash (not exceeding 50?C) should be made, using a mild soap and ending with a thorough rising with cold water. Free from additives and perfumes.

When rework is done, apply on the right and left side of the stick the 298-4282 film. (image 1.18.1)
This film has to be stuck in such a way it will always remain visible. Chart location is given as an example and could vary according attachments. (image 1.18.2)
Image1.18.1
Image1.18.2
 
 

Caterpillar Information System:

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 212-3086, 212-3088, 195-5583, 195-5580 AND 195-5481 LINKAGE PIN ASSEMBLIES ON CERTAIN 345C, 345C L, 345D L, 365C L, 385C AND 385C L EXCAVATORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE 212-3086, 212-3088, 195-5583, 195-5580 AND 195-5481 LINKAGE PIN ASSEMBLIES ON CERTAIN 345C, 345C L, 345D L, 365C L, 385C AND 385C L EXCAVATORS
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PRODUCT SUPPORT PROGRAM FOR REPLACING THE HYDRAULIC TANK ON CERTAIN 330D, 330DL, AND 336DL EXCAVATORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE HYDRAULIC TANK ON CERTAIN 330D, 330DL, AND 336DL EXCAVATORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PIN FROM THE BOOM TO THE BOOM CYLINDERS (PT2 PIN) ON CERTAIN 320D, 323D, 330D AND 336D HYDRAULIC EXCAVATORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE PIN FROM THE BOOM TO THE BOOM CYLINDERS (PT2 PIN) ON CERTAIN 320D, 323D, 330D AND 336D HYDRAULIC EXCAVATORS
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PRODUCT SUPPORT PROGRAM FOR REPAIRING D3:C4 NAV 10.4 DISPLAYS (239-9531, 239-9532, 236-2534, 277-0493, OR 291-2199) ON MACHINES THAT ARE EQUIPPED WITH COMPUTER AIDED EARTHMOVING SYSTEM (CAES) OR AQUILA DRILL & DRAGLINE SYSTEMS PRODUCT SUPPORT PROGRAM FOR REPAIRING D3:C4 NAV 10.4 DISPLAYS (239-9531, 239-9532, 236-2534, 277-0493, OR 291-2199) ON MACHINES THAT ARE EQUIPPED WITH COMPUTER AIDED EARTHMOVING SYSTEM (CAES) OR AQUILA DRILL & DRAGLINE SYSTEMS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE SLOW RETURN CHECK VALVE ON CERTAIN 345D L EXCAVATORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE SLOW RETURN CHECK VALVE ON CERTAIN 345D L EXCAVATORS
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PRODUCT SUPPORT PROGRAM FOR REPLACING THE REACH STICK, IF CRACKED, ON CERTAIN 345C EXCAVATORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE REACH STICK, IF CRACKED, ON CERTAIN 345C EXCAVATORS
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PRODUCT SUPPORT PROGRAM FOR MODIFICATIONS IN THE SWING PILOT CIRCUIT IN ORDER TO PREVENT SWING VIBRATION ON CERTAIN 345D EXCAVATORS PRODUCT SUPPORT PROGRAM FOR MODIFICATIONS IN THE SWING PILOT CIRCUIT IN ORDER TO PREVENT SWING VIBRATION ON CERTAIN 345D EXCAVATORS
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