PRODUCT SUPPORT PROGRAM FOR REWORKING CABS THAT LEAK WATER ON CERTAIN 422E, 428E, 432E, 434E, 442E AND 444E BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING CABS THAT LEAK WATER ON CERTAIN 422E, 428E, 432E, 434E, 442E AND 444E BACKHOE LOADERS [REBE3610]

OPERATOR STATION

CAB GP

PRODUCT SUPPORT PROGRAM FOR REWORKING CABS THAT LEAK WATER ON CERTAIN 422E, 428E, 432E, 434E, 442E AND 444E BACKHOE LOADERS

REBE3610-01

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01Jul2008

(Revised 07Jul2008)

U-356

A-288

D-293

O-325

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING CABS THAT LEAK WATER ON CERTAIN 422E, 428E, 432E, 434E, 442E AND 444E BACKHOE LOADERS
7301		PS51517

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51517" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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NOTE:	This Revised Service Letter replaces the 01Jul2008 Service Letter. Changes have been made to include the Mail Codes.

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TERMINATION DATE

31Jul2009

PROBLEM

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Some machines may experience a water leak through different parts of the cab assembly, the potential leak areas are:
. Window hold back latches between the latch and the glass.
. The cab roof rails and rear window channels.
. Door and door window.
. Rear side windows.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
422E	HBE00240-00241, 243-252, 254-258, 264-268, 271-275, 279-290, 292-296, 298-320, 322, 330-338, 343-345, 350-352, 354-379, 381, 384, 386-387, 391, 393-394, 396-430, 434-447, 450-456, 458-461, 467-473, 477, 481-487, 489, 492, 494, 496-498, 502-506, 510-512, 515-601, 608-632, 635-667, 675-707, 727-734, 742-749, 751-755, 758-759, 762-765, 773-784, 788-790, 797, 799, 828-839, 841-846, 849, 857, 859, 861-912, 957, 995-1016, 1019-1021, 1024-1040, 1042, 1053-1054, 1077, 1082, 1156-1161, 1164-1204, 1208-1211, 1216-1223, 1246-1247, 1275, 1277-1279, 1281-1282, 1284, 1287, 1305-1307, 1311-1328, 1331-1332, 1334-1340, 1344-1346, 1349-1353, 1355-1372, 1374, 1376-1385, 1388-1391, 1394-1401, 1403-1404, 1600-1604, 1607-1626, 1628-1629, 1631, 1635-1636, 1640, 1657, 1659-1661, 1664, 1666-1667, 1669-1670, 1676, 1704-1706, 1711-1747, 1839, 1842, 1845, 1848, 1850, 1852, 1854, 1856
428E	SNL00150-00151, 155, 192, 194, 214, 405, 408, 475, 477, 483-485, 487-489, 493, 611-612, 639-642, 652, 710-714, 718, 755-759, 858-859, 861, 874-878, 996-1000, 1002-1008, 1010-1011, 1013-1021, 1113-1116, 1397, 1399-1423
434E	FSH00425

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*****Group 2*****
422E	HBE00242, 259-263, 269-270, 276-278, 291, 297, 323-325, 327-329, 339-342, 346-349, 353, 380, 382-383, 385, 388-390, 392, 395, 431-433, 448-449, 457, 462-466, 474-476, 478-480, 488, 490-491, 493, 495, 499-501, 507-509, 513-514, 602-607, 633-634, 668-672, 708-722, 725, 735-741, 791, 794-796, 798, 800-824, 847-848, 850-853, 856, 860, 915-922, 945-951, 961, 964-965, 971, 973, 982-994, 1017-1018, 1022-1023, 1041, 1043-1048, 1050-1052, 1055-1058, 1060, 1062-1076, 1078-1081, 1083-1090, 1092-1104, 1118-1119, 1151-1152, 1162-1163, 1205-1207, 1212-1215, 1224-1230, 1236, 1240-1245, 1248-1252, 1258, 1262-1274, 1276, 1280, 1283, 1304, 1308-1310, 1329-1330, 1333, 1375, 1386-1387, 1393, 1402, 1405, 1627, 1633, 1637-1638, 1641, 1644-1645, 1650-1653, 1655, 1663, 1671-1675, 1677, 1689-1703, 1748-1794, 1797-1820, 1830-1833, 1835-1836, 1838, 1841, 1844, 1847, 1857-1909
428E	SNL00152-00154, 156-187, 189-191, 193, 196-213, 215-404, 406-407, 409-429, 431-447, 453-471, 474, 476, 478, 486, 490-492, 494-534, 536, 538, 540-544, 546, 548-549, 551, 553-610, 613-638, 643-651, 653-668, 670-675, 677-709, 715-717, 719-754, 760-857, 860, 862-873, 879-995, 1001, 1009, 1012, 1022-1025, 1029-1048, 1050, 1052, 1054, 1056-1112, 1117-1121, 1123-1307, 1312, 1322-1383, 1386-1396, 1398, 1424-1468, 1470-1727, 1732, 1734-1745, 1751-1920, 1923-1928, 1930-1946, 1953-1970, 1977-1983, 1991-1995, 2002-2071, 2073, 2200-2205, 2207, 2212-2285, 2287-2288, 2294-2297, 2304-2310, 2318-2348, 2350-2386, 2388-2502, 2504-2527, 2530-2555, 2558-2607, 2609-2667, 2673-2825, 2827-2856
432E	BXE00265, 270, 272, 274, 286-287, 292, 295, 307, 310-311, 316, 323, 325, 335-337, 340-341, 347, 349-351, 353-364, 368-382, 385-390, 393-398, 402-408, 410-411, 413, 415, 428, 430-431, 436-438, 440-443, 446-448, 455-456, 471, 474, 477-479, 484-486, 496-497, 518-530, 536-537, 540-545, 547, 549-553, 565-574, 580-591, 594-596, 599-600, 604, 610-611, 619-621, 632, 634-635, 637-646, 648-660, 665-670, 672, 676, 678, 683-687, 695, 699, 710-714, 717-720, 724-727, 738-741, 743, 756-757, 772, 779-780, 782-793, 795-797, 799, 801-843, 845-846, 848-850, 852-854, 856-867, 878-879, 921-922, 926-929, 931, 933, 953-954, 956-957, 960, 964, 971-974, 983-986, 988-992, 994-1000, 1002-1004, 1026-1027, 1031-1044, 1049-1054, 1065-1066, 1070, 1091-1093, 1095, 1098, 1103, 1120-1122, 1133, 1185-1187, 1197, 1201-1202, 1251, 1254, 1257, 1261, 1266, 1268-1269, 1272, 1274, 1373, 1376-1378, 1392-1394, 1410, 1416-1419, 1424-1430, 1445-1447, 1451, 1456, 1458, 1478, 1484, 1490, 1493-1497, 1500-1503, 1505, 1507-1514, 1517-1518, 1520, 1528-1529, 1532, 1540, 1542-1547, 1563-1565, 1569-1570, 1575, 1611, 1618-1620, 1622-1627, 1631, 1636, 1639-1642, 1650, 1661, 1669-1678, 1680-1686, 1690, 1693-1704, 1708-1711, 1713-1721, 1726-1734, 1736-1738, 1760, 1762-1773, 1775-1776, 1778-1780, 1784-1788, 1790-1792, 1795, 1798-1799, 1801-1802, 1804-1812, 1816, 1818-1820, 1827, 1830-1832, 1835, 1838, 1841, 1844-1845, 1849-1852, 1868, 1870-1873, 1880-1881, 1883-1884, 1889-1890, 1892, 1934-1935, 1938-1945, 1948-1961, 1976, 1990-1991, 1993, 1995-1996, 2000-2002, 2022, 2042, 2044-2046, 2048, 2057, 2205, 2207-2219, 2230-2231, 2237-2239, 2345-2349, 2360-2361, 2368-2373, 2377-2384, 2396-2402, 2414, 2417-2418, 2426-2429, 2434-2437, 2464-2470, 2581-2597, 2636-2637, 2652-2658, 2663-2666, 2698, 2764-2769, 2772-2778, 2782, 2791-2805, 2807-2810
434E	FSH00283, 285, 288, 290-292, 295, 297-299, 305-310, 315-342, 344, 347-349, 351-382, 385-390, 392-396, 398-402, 404-413, 415-418, 420-423, 429, 432-434, 437-440, 442-458, 460-462, 464-473, 476, 478-482, 484-512, 515, 517, 522-524, 529-531, 533-550, 562, 566, 569-575, 578, 582-583, 586, 602-609, 616-636, 638-645, 647-662, 664-666, 673-677, 679, 688, 695-696, 702, 707-716, 718-719, 721-722, 725-727, 729-766, 768, 770, 777, 795, 802-809, 818, 820, 824, 826-830, 902-914, 918-942, 944-947, 949, 951-969, 971-972, 981-982, 984-995, 997-998, 1001-1006, 1010-1013, 1015-1018, 1020, 1024-1029, 1034-1052, 1054-1059, 1062-1063, 1065
442E	GKZ00297, 300-301, 306-307, 310-311, 326, 332, 343, 348-351, 356-361, 367, 370-371, 374-376, 379-380, 387, 403-404, 415-430, 433-438, 440, 449, 454, 458, 497, 511, 600-602, 606, 608, 611-614, 616, 618, 623, 646, 650, 654
444E	LBE00317, 323, 327, 408, 411

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*****Group 3*****
432E	BXE00264, 266-269, 271, 273, 275-285, 288-291, 293-294, 296-306, 308-309, 312-315, 317-322, 324, 326-334, 338-339, 342-346, 348, 352, 365-367, 383-384, 391-392, 399-401, 409, 412, 414, 416-427, 429, 432-435, 439, 444-445, 449-454, 457-470, 472-473, 475-476, 480-483, 487-495, 498-517, 531-535, 538-539, 546, 548, 554-564, 575-579, 592-593, 597-598, 601-603, 605-609, 612-618, 622-631, 633, 636, 647, 661-664, 671, 673-675, 677, 679-682, 688-694, 696-698, 700-709, 715-716, 721-723, 728-737, 742, 744-755, 758-771, 773-778, 781, 794, 798, 800, 844, 847, 851, 855, 868-877, 880-920, 923-925, 930, 932, 934-952, 955, 958-959, 961-963, 965-970, 975-982, 987, 993, 1001, 1005-1025, 1028-1030, 1045-1048, 1055-1064, 1067-1069, 1071-1090, 1094, 1096-1097, 1099-1102, 1104-1119, 1123-1132, 1134-1184, 1188-1196, 1198-1200, 1203-1250, 1252-1253, 1255-1256, 1258-1260, 1262-1265, 1267, 1270-1271, 1273, 1275-1372, 1374-1375, 1379-1391, 1395-1409, 1411-1415, 1420-1423, 1431-1444, 1448-1450, 1452-1455, 1457, 1459-1477, 1479-1483, 1485-1489, 1491-1492, 1498-1499, 1504, 1506, 1515-1516, 1519, 1521-1527, 1530-1531, 1533-1539, 1541, 1548-1562, 1566-1568, 1571-1574, 1576-1610, 1612-1617, 1621, 1628-1630, 1632-1635, 1637-1638, 1643-1649, 1651-1660, 1662-1668, 1679, 1687-1689, 1691-1692, 1705-1707, 1712, 1722-1725, 1735, 1739-1759, 1761, 1774, 1777, 1781-1783, 1789, 1793-1794, 1796-1797, 1800, 1803, 1813-1815, 1817, 1821-1826, 1828-1829, 1833-1834, 1836-1837, 1839-1840, 1842-1843, 1846-1848, 1853-1867, 1869, 1874-1879, 1882, 1885-1888, 1891, 1893-1933, 1936-1937, 1946-1947, 1962-1975, 1977-1989, 1992, 1994, 1997-1999, 2003-2021, 2023-2028, 2030-2031, 2035-2041, 2043, 2047, 2049, 2053-2056, 2058-2060, 2200-2204, 2206, 2220-2229, 2232-2236, 2240-2344, 2350-2359, 2362-2367, 2374-2376, 2385-2395, 2403-2413, 2415-2416, 2419-2425, 2430-2433, 2438-2463, 2471-2580, 2598-2603, 2605-2635, 2638-2651, 2659-2662, 2667-2697, 2699-2763, 2779-2781, 2783-2790, 2811
434E	FSH00284, 286-287, 289, 293-294, 296, 300-304, 311-314, 343, 345-346, 350, 383-384, 391, 397, 403, 414, 419, 424, 426-428, 430-431, 435-436, 441, 459, 463, 474-475, 477, 483, 513-514, 516, 518-521, 525-528, 532, 551-561, 563-565, 567-568, 576-577, 579-581, 584-585, 587-601, 610-615, 637, 646, 663, 667-672, 678, 680-687, 689-694, 697-701, 703-706, 717, 723-724, 728, 767, 769, 771-776, 778-794, 796-801, 810-817, 819, 821-823, 825, 900-901, 915-917, 943, 948, 950, 970, 973-980, 983, 996, 999-1000, 1007-1009, 1014, 1019, 1021-1023, 1030-1033, 1053
442E	GKZ00293-00296, 298-299, 302-305, 308-309, 312-325, 327-331, 333-342, 344-347, 352-355, 362-366, 368-369, 372-373, 377-378, 381-386, 388-402, 405-414, 431-432, 439, 441-448, 450-453, 455-457, 459-496, 498-510, 603-605, 607, 609-610, 615, 617, 619-622, 624-635, 637-640, 644-645, 647-649, 651-653, 655-657, 659-660
444E	LBE00315-00316, 318-322, 324-326, 328-339, 407, 409-410, 412-498, 600-645

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1853986	SEALANT-SILICONE
1100	3228414	SEAL- BULK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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*****
2	1853986	SEALANT-SILICONE
1450	3228414	SEAL- BULK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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*****
2	1853986	SEALANT-SILICONE
2150	3228414	SEAL- BULK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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

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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%
*****Group 1*****
0-4500 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 1

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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%
*****Group 2*****
0-4500 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 2

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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%
*****Group 3*****
0-4500 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

1)
Water leakage between the hold back latch and the glass.
If the machine is exhibiting this issue start the rework procedure with this repair, this is to keep the silicon sealant nozzle at its smallest size.

REWORK
. Remove the latch from the glass and add a thin bead of silicon sealant as highlighted below.
. Re-fit the latch back on to the glass and clean off excess sealant.
. Allow the sealant to cure.

NOTE:
This should prevent the majority of rainwater entering this area, but will not prevent water leaking through the center of the latch when a water hose is directed straight at it.

Image1.1.1

2)
The roof section may allow water to leak in between the gaps in the weld connecting the roof rail to the roof.

REWORK
. Clean off any dirt or grease.
. Apply a bead of silicon sealant where required.

Image1.2.1

3)
The rear window frame to C-Post may allow water to leak in through the open ends of the channel.

REWORK
. Clean off any dirt or grease.
. Apply silicon sealant to fill in the open space at the end of both channels.

Image1.3.1

4)
The door seal could allow water to leak past due to insufficient seal compression.

REWORK
. Open the door and clean the door aperture making sure that it?s free of any dirt or grease.
. Measure the door aperture and cut the seal to one continuous length approximately 3410 mm. as highlighted below in Image 1.4.1.
. Peel off the paper backing strip and stick the seal on to the frame making sure that the open part of the seal faces outwards and upwards. This will form a natural channel for the rain to drain away.
. If you see any small gaps between the back of the new seal and the frame fill in with a small amount of silicon sealant.
. Make sure that the lip on the new seal is aligned with the bulb on the door seal as highlighted in Image 1.4.2

NOTE:
You may need to adjust the striker bolt to allow the door to fully close.

Image1.4.1

Image1.4.2

5)
The door window seal could allow water to leak past due to insufficient seal compression.

REWORK

. Open the door window and clean the window aperture making sure that it?s free of any dirt or grease.
. Measure the window aperture and cut the seal to one continuous length approximately 3650 mm as highlighted below in Image 1.5.1.
. Peel off the paper backing strip and stick the seal on to the frame making sure that the open part of the seal faces outwards and upwards. This will form a natural gully for the rain to drain away.
. If you see any small gaps between the back of the new seal and the frame fill in with a small amount of silicon sealant.
. Make sure that the lip on the new seal is aligned with the bulb on the window seal similar to that in Image 1.4.2.

NOTE:
With the addition of the new seal you may need to remove shims from behind the keeper to allow the handle to engage. See Image 1.5.2.

Image1.5.1

Image1.5.2

6)
The Rear side window could allow water to leak past due to insufficient seal compression.

REWORK
. Open the rear side window and clean the window aperture making sure that it?s free of any dirt or grease.
. Measure the window aperture and cut the seal to one continuous length approximately 3540 mm as highlighted below in Image 1.6.1.
. Peel off the paper backing strip and stick the seal on to the frame making sure that the open part of the seal faces outwards and upwards. This will form a natural channel for the rain to drain away.
. If you see any small gaps between the back of the new seal and the frame fill in with a small amount of silicon sealant.
. Make sure that the lip on the new seal is aligned with the bulb on the window seal similar to that in Image 1.4.2.

NOTE:
You may need to remove some shims from behind the keepers to allow the window handle to engage. See Image 1.6.2.