PRODUCT SUPPORT PROGRAM FOR ADDING CAB GUARD BOSSES ON CERTAIN 320D, 324D, 325D, AND 330D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR ADDING CAB GUARD BOSSES ON CERTAIN 320D, 324D, 325D, AND 330D EXCAVATORS [REBE1314]

OPERATOR STATION

CAB GP

PRODUCT SUPPORT PROGRAM FOR ADDING CAB GUARD BOSSES ON CERTAIN 320D, 324D, 325D, AND 330D EXCAVATORS

REBE1314-00

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03Nov2006

U-713

A-685

D-670

O-696

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR ADDING CAB GUARD BOSSES ON CERTAIN 320D, 324D, 325D, AND 330D EXCAVATORS
7301 7182 7315		PS42284

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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 "PS42284" 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 AVSpare product analyst.

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TERMINATION DATE

30Nov2008

PROBLEM

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The cab guard bosses may not have been welded to the cabs on certain 320D, 324D, 325D, and 330D Excavators. These bosses are required for installation of the front guard.

AFFECTED PRODUCT

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Model	Identification Number
320D	CXY00149-00152, 157-181, 183-184, 189, 192-196 DHK00125-00171, 173-196, 198-370, 373-377, 380-381, 384-406, 410-419, 422-426, 428-445
320D LLR	EBY00113-00114
320D LRR	FXK00190-00197
324D	CJX00175-00181, 185-187 DFP00130-00141, 143-144, 146-151, 155-156, 158-160, 162-178
325D	KDG00148-00169 SCR00249-00256, 267-270, 274-287, 289-298, 323, 325-330, 347-349, 352-354, 363, 368-369, 372-377, 385-387, 389-395, 405, 407
330D	MEY00171-00176, 178-198 NBD00139-00141, 143-152, 160-169, 172, 175-176, 199, 201, 207-208, 225, 247, 249, 251-252, 280, 283, 287-292, 294-295, 310-313

PARTS NEEDED

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Qty	Part Number	Description
8	4I6602	BOSS

ACTION REQUIRED

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Weld the eight missing 4I-6602 Bosses on the cab front structure in order to fix the cab front window guard. Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 8.0-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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Prepare 8 pieces of 4I-6602 Boss.

Park the machine as mentioned in the Operator Maintenance Manual, SEBU8286.
Stop the engine and shut-off the disconnect switch. Open the door.

Open up the front upper window and remove the front lower window. The image below is of a cab removed from the machine. This procedure can be completed without removing the cab from the machine.

Image1.1.1

Remove the wiper arm in order to avoid damage from the welding process.

Image1.2.1

Remove the window washer nozzle and washer hose in order to avoid damage from the welding process.

Image1.3.1

Connect a wire to the washer hose.

Image1.4.1

Push the wire in order to remove the hose from the cab pillar.

Image1.5.1

Remove the rubber window seal in order to avoid damage from the welding process.

Image1.6.1

Image1.6.2

Image1.6.3

Cover the cab right side window, monitor panel, skylight hatch, and cab interior.

Image1.7.1

Image1.7.2

Image1.7.3

The image below lists the weld dimensions for the bosses.

Image1.8.1

Use a proper grinder and remove the paint for boss welding. Parts have to be clean of oil, moisture, grease, paint or any other contaminants in the weld joint prior to welding. Weld shall be free of weld spatter or slag that pose assembly or contamination problems.

Image1.9.1

Image1.9.2

Image1.9.3

May prepare a locating tooling referring to the bosses dimension

Image1.10.1

In case making the locating tooling or using current front guard, use existing roof bosses as locating base point.

Image1.11.1

The cab door striker can be used for grounding the welder.

Image1.12.1

Cab pillar plate thickness is 3mm. Welding size should be 3mm. Weld shielding gas should be CO2 or mixed gas Argon/CO2=80:20. Welder should be properly qualified to weld with Gas Metal Arc Welding. Filler metal diameter should be 0.9 mm or equivalent to AWS A5. 18. Do NOT use diameter 1.2mm.

If manual welding is the only available option, use any electrode corresponding to norm E6013-AWS A5.1.

Image1.13.1

Image1.13.2

After eight bosses welded, parts have to be clean of scale, spatter or any other contaminants.

Image1.14.1

Image1.14.2

Paint undercoating and black coating.

Image1.15.1

Image1.15.2

Image1.15.3

When paint dries completely, remove the covers for cab right side window, monitor panel, skylight hatch. Assemble the window washer nozzle and washer hose.

Image1.16.1

Connect the hose with washer nozzle.

Image1.17.1

Image1.17.2

Install the wiper arm assembly.

Image1.18.1

Tighten to a torque of 14 +/- 2 Nm.

Image1.19.1

Use Chloroprene rubber adhesive in order to install the rubber window seal.

When the adhesive for the window seal dries completely, install the front upper window and front lower window.
Check that the window seals and that the window wiper works.