PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SEAT SUSPENSION ON CERTAIN 770, 773F, 775F, 777F, 777G, 793D, 793F, 795F AC, 797F OFF-HIGHWAY TRUCKS AND 966K, 980K WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SEAT SUSPENSION ON CERTAIN 770, 773F, 775F, 777F, 777G, 793D, 793F, 795F AC, 797F OFF-HIGHWAY TRUCKS AND 966K, 980K WHEEL LOADERS

Usage:

REBE7970-01

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19Jul2012

(Revised 29Aug2013)

U-385

A-307

D-335

O-354

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SEAT SUSPENSION ON CERTAIN 770, 773F, 775F, 777F, 777G, 793D, 793F, 795F AC, 797F OFF-HIGHWAY TRUCKS AND 966K, 980K WHEEL LOADERS
7324		PI10898

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10898" 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 "PI10898" 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 19Jul2012 Service Letter. Changes have been made to Affected Product.

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PROBLEM

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A group of certain seat suspensions had quality issues where the existing seat suspension can fail causing the seat to tilt forward which may cause the operator to lose control of the machine and, in conjunction with other factors and circumstances, create a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
770	BZZ00637
773F	EED01220-01221, 1223, 1226-1228, 1230-1231, 1234
775F	DLS01217-01219, 1221-1229, 1278
777F	JRP01725, 2485-2486, 2489, 2492, 2494-2496, 2499-2502, 2508
777G	TNM00101
793D	FDB00304, 357-358, 473-474, 982
793F	SSP00129
795F AC	ERM00153-00154
797F	LAJ00209

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*****Group 2*****
793D	FDB00983

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*****Group 3*****
966K	PBG00282 TFS00145
980K	GTZ00130, 132, 135 W7K00300, 323

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1737035	BLOCK KIT-SLIDER
1	3556681	SUSPENSION GP -J
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	1737035	BLOCK KIT-SLIDER
1	3621774	SUSPENSION GP -E
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	1737035	BLOCK KIT-SLIDER
1	3482409	SUSPENSION GP -J
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

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Replace the former seat suspension with an improved seat suspension.

Reference the appropriate machine service manual for the specific removal and install procedure for the seat suspension.

In addition, a generic seat suspension removal and installation procedure is in the attached Rework Procedure to assist in accomplishing this work.

Once the new seat suspension is installed, use RENR2165 to adjust the seat and seat suspension.

Please record the Machine Serial Number and the old Seat Serial Number. Refer to Image1.11.1 in the Rework Procedure for the location of the Seat Serial Number.

Please document the Machine Serial Number and the old Seat Serial Number in the claims report.

Refer to the Parts Disposition for the old seat suspension.

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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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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 1.0-hour job for Group 1

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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 1.0-hour job for Group 2

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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 1.0-hour job for Group 3

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PARTS DISPOSITION

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***** NACD *****
Hold all Seat Suspensions for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip. Include the closed work order paperwork, Machine Serial Number and the Seat Serial Number.

***** EAME, LACD, and APD *****
Hold all Seat Suspensions for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip. Include the closed work order paperwork, Machine Serial Number and the Seat Serial Number.

If a Parts Return Request (PRR) is not issued to you within 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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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 REPLACING THE SEAT SUSPENSION ON CERTAIN 770, 773F, 775F, 777F, 777G, 793D, 793F, 795F AC, 797F OFF-HIGHWAY TRUCKS AND CERTAIN 966K, 980K WHEEL LOADERS

MODELS INVOLVED - 770, 773F, 775F, 777F, 777G, 793D, 793F, 795F AC, 797F, 966K, 980K

Dear Caterpillar Product Owner:

The Seat Suspension needs to be replaced on the products listed below. The existing Seat Suspension can fail causing the seat to tilt forward which may cause the operator to lose control of the machine and, in conjunction with other factors and circumstances, create a risk of 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 19Jul2012 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 19Jul2012 Service Letter

Rework Procedure

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Caterpillar Optimized Seat System (COSS) Seat - Removal from the Cab

Image1.1.1

Removal Procedure

1. Disconnect seat harnesses (1) and (2), as equipped.

Image1.2.1

2. Remove bolt (3)

Image1.3.1

3. Slide seat (4) forward off of suspension (5) and remove the seat (4) from the cab. The slide blocks will not be reused.

Image1.4.1

4. Remove four bolts (6).

5. Remove suspension (5) from the cab.

Image1.5.1

Installation Procedure

1. Place suspension (5) in cab.

2. Install four bolts (6).

Image1.6.1

3. Install four new slide blocks (7).

Image1.7.1

4. Position seat (4) on suspension (5), then slide seat (4) rearward onto the suspension (5).

Image1.8.1

5. Install bolt (3).

Image1.9.1

6. Connect seat harnesses (1) and (2), as equipped.

7. Adjust the seat and seat suspension for proper operation according to RENR2165.

8. Please record the Machine Serial Number and the Seat Serial Number. Refer to Image1.11.1 for the location of the Seat Serial Number. For an example, see Image1.11.2.

With a "paint pen" or equivalent, write the Machine Serial Number and the Seat Serial Number on the old seat suspension.

Please document the Machine Serial Number and the old Seat Serial Number in the claims report.

9. Retain the removed seat suspension. Refer to the Parts Disposition.