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Special Instruction
Replacing Bonded Windows{7310}
Media Number -SEHS9824-15

Publication Date -17/06/2010

Date Updated -17/06/2010

i03995907

Replacing Bonded Windows{7310}


SMCS - 7310
Caterpillar Products: All

Introduction

Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing


the vapors in enclosed areas without adequate ventilation and do not
smoke.
Isopropyl alcohol is flammable. Do not use near open flame, welding
operations, or around heated surfaces exceeding 482C (900F).

This information lists the procedures that are required in order to replace the bonded glass in the
cab of Caterpillar machines.
Do not perform any procedure that is outlined in this publication, or order any parts until you
understand this information.

Tools and Adhesives that are Required


Table 1
Required Tools
Item

Part Number

Description

121-9777

Wire

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4C-4870

Utility Knife

121-9778

Cut Out Knife

121-9782

Suction Cup Holder

121-9781

Caulking Gun

1U-6707

Tape

110-7524

Button

246-5181

Glove

121-9779

Blade

10

121-9780

Wire Handles

11

127-6383

Brush (Sponge)

12

4C-6856

Pneumatic Knife

13

7X-2634

Seal

14

175-2936

Oven (Adhesive)

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Note: The 127-6421 Window Tool Kit contains items (1) through item (11).
Table 2
Required Adhesives
Item

Part Number

Description

119-0781

Silicone Adhesive
Clear

8T-9014

Silicone Sealant
Clear

121-3908

SIKA 255FC Adhesive


Black

175-2935

SIKA Tack-Plus Booster Adhesive


Black

175-2934

SIKA Activator Primer

121-3911

SIKA 206 G + P Primer

9U-6917

Cleaner and Primer

166-1359

SIKA 215 Primer

166-1358

SIKA 209 Primer

Adhesive (1) can be used in place of sealant (2) if the temperature is below 0 C (32 F). Adhesive
(1) is for glass to glass joints. Adhesive will be fully dry in 24 hours.

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Sealant (2) can only be used if the temperature is above 0 C (32 F). Adhesive (2) is for glass to
glass joints. Adhesive will be fully dry in 24 hours.
Sealant (3) should be used when a slow cure time is needed. Adhesive will be fully dry in 4 to 6
hours at 24 C (75 F) with 50% humidity to 75% humidity. Increased temperature and humidity
will greatly decrease adhesive dry time.
Adhesive (4) should be used when a faster cure time is required. Adhesive will be fully dry in 1 to
2 hours at 24 C (75 F) with 50% humidity to 75% humidity. Increased temperature and humidity
will greatly decrease adhesive dry time.
SIKA Activator Primer (5) must be used with SIKA Tack-Plus Booster Adhesive (4) .
SIKA 206 G & P Primer (6) should be used with item (3) or SIKA 206 G & P Primer (6) should
be used with item (4) for glass that does not have a ceramic coating (fretting).
SIKA 215 Primer (9) should be used when you are bonding to ABS, PVC, and EPDM.
SIKA 209 Primer (10) should be used when you are bonding to a polycarbonate.

Procedure for Replacing the Windows


Refer to the previous chart for a listing of tools and adhesives in order to install the window.
Remove any components that may interfere with the removal of the window. This process will aid
in the removal and installation of the seals and the adhesives.

Removal of the Existing Silicone Joint

Illustration 1

g00681473

1. Start a cut at the top edge of the silicone strip that bonds the two windows. Use the utility
knife in order to initiate the cut.

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Illustration 2

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g00681478

2. Cut a piece of 121-9777 Wire that is approximately 91.4 cm (36 inch) long. Install one end
of the wire into the 121-9780 Handle . Insert the other end of the wire through the hole in
the silicone strip that was previously cut. Install this end of the wire into the other handle.

Illustration 3

g00681497

(1) Silicone strip


(2) Wire
(3) Handle

3. Pull back and forth on each of the handles (3). The wire (2) will cut through the silicone
strip (1). Cut the silicone strip for the entire length of the window. Remove the wire from
the window when the silicone seal is cut.

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Illustration 4

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g00681535

4. Use the utility knife in order to remove the silicone seal, as shown. Clean the remainder of
the silicone with the 9U-6917 Cleaner .

Removing the Glass

Illustration 5

g00681569

1. Start a cut at the left edge of the urethane adhesive that bonds the window to the cab. Use
the utility knife in order to initiate the cut.

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Illustration 6

Illustration 7

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g00681607

g01475227

(A) 2.5 .5 mm (0.10 0.02 inch)


(4) Old seal
(5) Cab

2. Insert the wire and attach the handles. Make sure that you leave 2 mm (0.08 inch) to 3 mm
(0.1 inch) (A) of the old seal (4) on the cab (5). Use the wire in order to cut the urethane
adhesive. Pull the wire back and forth in order to cut the urethane.
3. Remove the handles and the wire after the urethane adhesive has been cut. Attach the
holders to the glass and remove the glass from the cab. Use the utility knife in order to level
the remaining urethane adhesive on the cab. The urethane surface should be consistent.
Check the area of the cab door or window that will be bonded for any excess weld or weld
splatter. The area should be free from any weld splatter. Remove the weld from the area for
bonding so that the weld is flush with the surface for bonding. For the weld that is excessive
on the Rollover Protection Structure (ROPS), contact engineering through Dealer Solution
Network (DSN) for instructions to rework. Areas that are not flush with the surface will
cause extra stress on the glass. The extra stress on the glass may cause the glass to break.
4. Apply the appropriate primer and paint to any scratches that may have been caused by
removing the window or preparing the bonded surface. This procedure will prevent rust
from starting. Rust will cause water leaks at the seals.

Installation of Single Glass Pane (Tempered Glass, Laminated Glass or


Polycarbonate Glass)

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Illustration 8

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g01475233

(6) 25.4 mm (1.00 inch) Exposed area


(7) Glass

Note: For faster dry times, preheat 175-2935 Polyurethane Sealant in 175-2936 Oven
(Adhesive) for 1 hour prior to repair.
1. Lay the new glass on a flat work area. The new glass may have a ceramic fretting around
the border. This surface should face Upward. Some glass does not have the ceramic fretting
around the edge. Use tape in order to cover the inside area of the glass (7). Installer should
leave a 25.4 mm (1 inch) area (6) exposed around the edge of the glass.
2. Clean the exposed area of the glass by using glass cleaner. Apply the 175-2934 Activator to
the glass surface with the fretting. The activator could also be applied to the point of contact
between the adhesive and the glass. Wait for 5 seconds and wipe the glass by using a lint
free cloth. Apply one coat of 121-3911 Primer to the exposed area of the glass.

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Note: Do not apply more than two coats of the 121-3911 Primer . Problems with the
adhesive may occur if you apply more than two coats of primer. Wait between 30 seconds
and 30 minutes before you apply the urethane adhesive.
3. Clean the sheet metal of the cab with 9U-6917 Cleaner . Apply the 175-2934 Activator
primer to the cleaned area of the cab. Wait for 15 minutes in order to allow the primer to
dry. Do not touch the primer.

Illustration 9

g00681931

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Illustration 10

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g01473898

(7) Glass
(8) Adhesive
(9) 110-7524 Button
(10) Sheet metal

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Illustration 11

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g01473899

(7) Glass
(8) Adhesive
(9) 110-7524 Button
(10) Sheet metal

4. Make sure that the new glass will fit the opening for the window. 110-7524 Buttons (9) are
placed around the opening for the window in order to allow you to maintain a uniform
thickness of the adhesive. The 110-7524 Buttons (9) may also be used in order to hold the
glass off the steel locating tabs. The 110-7524 Buttons (9) may also be used in order to hold
the glass off the sheet metal on the cab. Refer to Illustration 10 and Illustration 11. Use a
caulking gun in order to apply an even layer of adhesive around the sheet metal or around
the edge of the glass. Cutting a groove into the tip of the caulking gun will help in the even
application of the adhesive. Refer to Illustration 9.
5. Apply a layer of adhesive approximately 6 mm (0.24 inch) in height. The adhesive should
be approximately 3 mm (0.12 inch) from the outer edge of the window.
Note: The window must be installed within 15 minutes after the adhesive is applied.
6. Install the glass. Use the holders in order to install the glass. Make sure that no adhesive
contacts the interior of the cab or area of the sheet metal that is not primed. Press the glass
onto the adhesive. Align the window evenly with the opening on all sides. Apply firm
pressure and even pressure when you are pressing the glass. Hold the glass in position by

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using several pieces of tape. Leave the tape in position for 2 hours in order for the adhesive
to cure.
7. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the
sheet metal and from the glass. Follow the recommendations from the manufacturer of the
adhesive.
Note: Avoid slamming the door of the cab for 24 hours. The excessive air pressure in the
cab could loosen the window. The pressure could also cause potential water leaks.

Installation of Multiple Glass Panes (Tempered Glass and Laminated Glass)


Applies to Medium Wheel Loaders

Illustration 12

g01475233

(6) 25.4 mm (1.00 inch) Exposed area

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(7) Glass

1. Lay the new glass on a flat work area. The new glass may have a ceramic fretting around
the border. This surface should face Upward. Some glass does not have the ceramic fretting
around the edge. Use tape in order to cover the inside area of the glass (7). Installer should
leave a 25.4 mm (1 inch) area (6) exposed around the edge of the glass.
2. Clean the exposed area of the glass by using glass cleaner. Apply the 175-2934 Activator to
the glass surface with the fretting. The activator could also be applied to the point of contact
between the adhesive and the glass. Wait for 5 seconds and wipe the glass by using a lint
free cloth. Apply one coat of 121-3911 Primer to the exposed area of the glass.
Note: Do not apply more than two coats of the 121-3911 Primer . Problems with the
adhesive may occur if you apply more than two coats of primer. Wait between 30 seconds
and 30 minutes before you apply the urethane adhesive.
3. Clean the sheet metal of the cab with 9U-6917 Cleaner . Apply the 175-2934 Activator
primer to the cleaned area of the cab. Wait for 15 minutes in order to allow the primer to
dry. Do not touch the primer.
4. Ensure that the glass will fit into the opening for the window.

Illustration 13

g01474097

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(7) Glass
(8) Adhesive
(10) Sheet metal
(11) 7X-2634 Seal

5. Install the 7X-2634 Seal (11) onto the sheet metal. Align the edge of the seal with the edge
of the sheet metal opening.
6. Use a caulking gun in order to apply an even bead of 175-2935 Sealant around the 7X-2634
Seal (11). The bead of adhesive should be 9.5 mm (0.37 inch) tall and 5.0 mm (0.20 inch)
wide.
Note: The multiple panes of glass must be installed within 15 minutes after the
adhesive is applied.
7. Install the center pane first so that the pane can be centered in the opening. Leave a 5 mm
(0.20 inch) gap between the windows. Press on the glass with a firm and even pressure. Use
several pieces of tape in order to hold the glass in position. Leave the tape in position for 2
hours in order for the adhesive to cure.
8. Install the side panes. Leave a 5 mm (0.20 inch) gap between the windows. Press on the
glass with a firm and even pressure. Use several pieces of tape in order to hold the glass in
position. Leave the tape in position for 2 hours in order for the adhesive to cure.
9. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the
sheet metal and from the glass. Follow the recommendations from the manufacturer of the
adhesive.
Note: Avoid slamming the door of the cab for 24 hours. The excessive air pressure in the
cab could loosen the window. The pressure could also cause potential water leaks.
10. Allow the adhesive to cure for a minimum of 45 minutes before bonding the joint between
the windows.

Bond the Joint Between the Side Window and the Center
Window
1. Clean the surface of the glass by using glass cleaner. Allow the cleaner to dry. Wipe the
glass by using a lint free cloth.

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Illustration 14

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g00682092

Top view of the windows


(1) Front window. (2) Tape. (3) Tape. (4) Silicone. (5) Side window.
(A) 4 1 mm (0.15 0.04 inch)
(B) 37.5 mm (1.5 inch)

2. Apply a piece of tape that is (3) 76.2 mm (3 inch) wide across the inside of the glass seam.
Approximately 38.1 mm (1.5 inch) (B) of tape should be on each piece of glass. See
illustration 14.
3. Apply a piece of tape that is (2) 25.4 mm (1 inch) wide to each piece of glass. This tape
should be on the outside of the cab. The tape should be approximately 4 1 mm (0.15
0.04 inch) (A) from the seam. See illustration 14.
4. Use the caulking gun in order to apply 119-0781 Adhesive or 8T-9014 Silicone Sealant (4).
The adhesive or silicone should be applied from the outside of the glass. The tape (3) that
was applied earlier will prevent the silicone from entering the inside of the cab. The silicone
(4) should completely fill the glass seam. See illustration 14.

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Illustration 15

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g00682156

5. Remove any excess silicone from the seam by using a clean cloth. The seam of silicone
should be smooth and level with the glass, as shown. Immediately remove the tape from the
outside of the glass. The tape should be removed within 1 to 2 minutes after the application
of the silicone.
Note: Remove only the outside tape. The tape on the inside of the glass should be left in
place for 24 hours. The silicone should not tear when the tape is removed.

Installing the Polycarbonate Window


1. The mounting surface must be milled down 0.5 mm (0.02 inch) around the edge of the
window. This procedure is necessary for a good adhesion. This area is 25.4 mm (1 inch)
wide around the border of the window.
2. Lay the window on a flat work area. The milled area should be facing Upward. Remove the
plastic covering from the surface of the window. Clean the milled surface with the 9U-6917
Cleaner in order to remove any dirt and oil from the window.
3. Cover the inside of the window. Leave the milled area exposed. Apply the 166-1358 Primer
to the milled area of the window. Apply one coat of primer to the milled area of the
window. Allow the primer to dry from 30 seconds to 30 minutes.
4. Clean the sheet metal of the cab with 9U-6917 Cleaner . Apply the 175-2934 Activator
primer to the edge of the opening for the window. Allow the primer to dry for 15 minutes.
Apply the adhesive on the window or on the sheet metal of the cab. Install the window
within 15 minutes.

Installing Custom Glass

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Illustration 16

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g00750897

Typical Chemically Tempered Laminated Glass


(A) Protective Fiberglass Tape
(B) Bonded area on cab
(C) Glass
(D) Glass
(E) PVB

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Illustration 17

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g00750892

Typical Thermo-pane Laminated Glass


(A) Bonded area on cab
(B) Spacer Bar
(C) Air Space
(D) Glass
(E) Glass

1. Install any of the following custom glass products. Use the required adhesives that are
specified in Table 2.
Chemically Tempered Laminated Glass Windows
Thermo-pane Laminated Glass
2. When you install chemically tempered laminated glass, apply protective fiberglass tape to
the following areas.
Each side of the glass
Edge of the glass

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3. The fiberglass tape must be left on the glass. The fiberglass tape must be painted to a black
color before you install the glass. Refer to Illustration 12.
4. Determine the side of the glass that will be bonded to the cab. Lay the glass on a flat work
area.
5. Clean the fiberglass tape with 9U-6917 Cleaner Primer . Wait for 5 seconds and wipe this
area with a lint free cloth. Apply one coat of 175-2934 Activator .
6. Clean the sheet metal of the cab with 9U-6917 Cleaner Primer . Wait for 5 seconds and
wipe this area by using a lint free cloth. Wait for 15 minutes in order to allow the primer to
dry. Do not touch the primer.

Illustration 18

g00681931

7. Make sure that the new glass will fit the opening for the window. Buttons may be placed
around the opening for the window. This procedure will allow you to maintain a uniform
thickness of the adhesive. Use a caulking gun in order to apply an even layer of adhesive
around the sheet metal or around the edge of the glass. Cutting a groove into the tip of the
caulking gun will help in the even application of the adhesive.
8. Apply a layer of adhesive approximately 6 mm (0.24 inch) in height. The adhesive should
be approximately 3 mm (0.12 inch) from the outer edge of the window.
Note: The window must be installed within 15 minutes after the adhesive is applied.
9. Install the glass. Use the holders in order to install the glass. Make sure that no adhesive
contacts the interior of the cab or area of the sheet metal that is not primed. Press the glass
onto the adhesive. Apply firm pressure and even pressure when you are pressing the glass.
Hold the glass in position by using several pieces of tape. Leave the tape in position for 2
hours in order for the adhesive to cure.

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10. Remove any excessive adhesive. Use the cleaner in order to remove any adhesive from the
sheet metal and from the glass. Follow the recommendations from the manufacturer of the
adhesive.
Note: Avoid slamming the door of the cab for 24 hours. The excessive air pressure in the
cab could loosen the window. The pressure could also cause potential water leaks.
Copyright 1993 - 2011 Caterpillar Inc.

Tue Sep 6 08:29:52 EST 2011

All Rights Reserved.


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