PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW POLYCARBONATE WINDSHIELD ON CERTAIN 320C L EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW POLYCARBONATE WINDSHIELD ON CERTAIN 320C L EXCAVATORS

Usage:

REBE1174-01

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08Jan2007

(Revised 12Sep2007)

A-10

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW POLYCARBONATE WINDSHIELD ON CERTAIN 320C L EXCAVATORS
7325 7158 7301 7310		PI10566

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10566" 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 "PI10566" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the January 8, 2007 Service Letter. Changes have been made to Affected Product.

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PROBLEM

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The existing 239-4842 Polycarbonate Windshield needs to be replaced on certain 320C L Excavators. The existing polycarbonate windshield can experience breakage caused by a high velocity impact produced by a broken saw chain, which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
320CL	SBN00250, 256, 260, 266, 272, 274, 287, 291, 294, 296, 301, 308, 310, 321-322, 324, 328, 336, 341, 348-349, 352-353, 364, 367, 372, 375, 397-398, 405, 410-411, 415-416, 420, 423, 426, 431, 477, 488, 501, 505, 515, 550, 570, 586, 591, 597, 602, 698, 734, 765, 770, 773, 782, 791, 800, 804, 884, 891, 893, 897, 901, 930, 951, 954, 960, 1020, 1068, 1076, 1085, 1147, 1151, 1205, 1223, 1260, 1305, 1310, 1368, 1412-1413, 1484, 1611, 1620, 1634, 1638, 1666-1667, 1682, 1753
320CLRR	GAD00186-00215

PARTS NEEDED

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Qty	Part Number	Description
1	2964188	WINDSHIELD-LEXAN

ACTION REQUIRED

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****Parts Stock ****

Remove all 239-4842 Windshield - Polycarbonate from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all 239-4842 Windshield - Polycarbonate that are removed from dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - Product Improvement Program For Installing A New Polycarbonate Windshield

MODELS INVOLVED - 320C L Excavators

Dear Caterpillar Product Owner:

The existing 239-4842 Polycarbonate Windshield (9.5mm thickness) needs to be replaced on the products listed below. The existing polycarbonate windshield can experience breakage caused by a high velocity impact produced by a broken saw chain, which may result in personal injury or death. You will not be charged for the service performed.

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 08Jan2007 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 08Jan2007 Service Letter

Rework Procedure

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TOOLS AND ADHESIVES THAT ARE REQUIRED:

Required Tools
Item Part Number Description
1 121-9777 Wire
1 4C-4870 Utility Knife
1 121-9780 Wire Handles

1 175-2935 SIKA Tack Ultrafast Adhesive
1 121-3911 SIKA Primer 206 G+P
1 - SIKAFlex221

REWORK PROCEDURE:

The 239-4842 Windshield ? 9.5mm (thickness) should be replaced by new 296-4188 Windshield ? Polycarbonate 12.7mm (thickness).
Note: For additional information refer to SEHS9824 Special Instruction.
Step 1 ? Remove the 3 bolts from one side of 139-7101 Window bracket and remove it from the cab.

Image1.1.1

Step 2 - Remove the window seal or ( see next slide )

Image1.2.1

Step 3 ? Cut the seal adhesive instead to remove it. Independent of the seal actions manner used, the final finish surface of seal should be reconstituted again as per steps 12/13/14 of this instruction.

Image1.3.1

Image1.3.2

Step 4 ? Put the wire of Wire Handle tool into the groove between the polycarbonate and the frame corner of the windshield.

Image1.4.1

Step 5 ? Pull back and forth on each of the handles starting to cut the material in the corner of the polycarbonate.

Image1.5.1

Step 6 ? Lift the polycarbonate corner and Insert the other end of the wire through the hole in the polycarbonate plate.

Image1.6.1

Step 7 - Install another end of the wire into the other handle wire tool.

Image1.7.1

Step 8 ? Start to pull back and forth on each of the handles initiating to cut the adhesive and separate the polycarbonate plate from the steel frame in all window sides.

Image1.8.1

Step 9 ? Remove all residue of adhesive from the window frame surface edge using a knife or scraper.

Image1.9.1

Step 10 - Put a layer of 121-3911 Sika Primer 206 G+P Primer on the polycarbonate plate and over the window frame places where the adhesive will be disposed.

Image1.10.1

Image1.10.2

Step 11 - Put an amount of 175-2935 Sikatack Ultrafast Adhesive in all side of steel window frame.

Image1.11.1

Step 12 ? Install the 296-4188 Polycarbonate plate in the steel window frame. Protect the window seal as indicated to be ready to receive the adhesive.

Image1.12.1

Step 13 ? Put adhesive SIKAFLEX 221 in all seal extension.

Image1.13.1

Step 14 ? Make the surface finish in all extension of the seal.

Image1.14.1

Step 15 - The new polycarbonate plate will be positioned about 6mm out of window frame. Finally reinstall the 139-7101 Window front gp ? in the Cab and remove the plastic covering from the surface of the window.