Seat Mounted Control Bracket Needs To Be Replaced On Certain 980G Wheel Loaders And 824G, 825G And 826G Compactors Caterpillar

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 Caterpillar product analyst.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3947" as the Part Number, "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 "PI3947" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

Termination Date

Problem

The seat mounted control bracket needs to be replaced on certain 980G Wheel Loaders and 824G, 825G and 826G Compactors. The three bolts that attach the 1166527 Control Bracket to the upper slide plate were incorrectly tightened during assembly. The bracket was redesigned to improve the seat belt mounting.

Affected Product
Model & Identification Number

824G (4SN1-321)

825G (6RN1-280)

826G (7LN1-178)

980G (9CM1-376 2KR1-552 )

Parts Needed

1 - 1A4350 Bolt

5 - 7U4898 Screw

1 - 7X0321 Bolt

1 - 7X0589 Washer - Hard

2 - 7X1387 Washer

2 - 8Y5947 Fastener

1 - 1338523 Spacer

1 - 1387518 Bracket

1 - 1419750 Bracket Assembly

4 - 1431288 Locknut

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

NOTE: This is a 3.5-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

Parts Disposition

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

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

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

This document explains the procedure to replace the operator-seat right hand armrest bracket that ties the controls and the armrest to the seat, and to install a new front support strap on the bracket. The machines that need these new brackets are the 98OG wheel loaders, and 824, 825 and 826 compactors.

I. Parts to be replaced:

II. Step-by-step instructions:

NOTE: Use the seat fore/aft, recliner forward/backward, armrest up/down and armrest fore/aft adjustments to allow, access to the hardware (nuts and bolts).

1. Remove 1275478 and 1275479 right-hand armrest covers, refer to Illustration 1. Illustration 1 shows a perspective representation of the seat without the cushions. The bracket that needs to be replaced is also indicated by the part number 1166527.

2. Remove the four 6V7731 seat mount bolts shown in Illustration 1. This allows the seat to be moved and positioned inside the cab so as to provide enough room to remove the seat upper from its suspension.

3. Remove the 4F4879 front stopper bolt () on the 1247125 upper housing of the 1197027 seat suspension. The 4F4879 front stopper bolt is shown in Illustration 1.

4. Remove the two 6V9327 screws on the 4E9173 upper-slide shaft as indicated in Illustration 2. Note that the screw head is on the outside for the screw at the rear and is on the inside for the screw at the front.

5. Slide the 4E9173 upper-slide shaft out of the 4E6523 casting bolted to the seat. Be sure to collect the 9U3926 rubber dampers (shown in Illustration 2) that may fall when the shaft is removed from the casting.

NOTE: The implement controls box may need to be removed from the bracket assembly 1269578 to have the shaft removed from the front. Illustration 2.

Illustration 1

Illustration 2

6. Hold and let the rest of the mechanism fall to the sides gradually until it can be removed from the 4E9173 Lower Side Shaft (refer to Illustration 3). Place the controls along with the mechanism on the cab floor.

7. Remove the 4E6523 Aluminum casting Illustration 3 from the 1166527 Bracket (Illustration 1) mounted to the seat. The four 8T4136 (M1O) bolts that need to be removed are shown in Illustration 3.

Illustration 3

8. Remove the bottom seat cushion (labeled (4) in Illustration 4 from the seat pan, Use a screwdriver to pry the cushion out of the pan as shown in Illustration 4.

9. Lift the seat fore/aft slide handle and slide the seat upper out of its suspension and turn it upside down. The seat upper may have to be taken out of the cab for the bracket rework if the cab does not have enough room to place the seat upside down on top of the seat suspension.

10. Remove the three 7U4898 () Screws and 5V1498 Locknuts that bolt the 1166527 Seat mount Control Bracket to the 8Y5929 Seat Slide Plate and also the 7X0321 ) pivot bolt shown in Illustration 5. While removing the three locknuts, be sure to hold on to the screw and loosen the locknut. Loosening the screw can cause its head to break off. Use the seat back reclining mechanism to allow access to the nuts.

Illustration 4

Illustration 5

11. Replace the 1166527 Bracket with the new 1419750 Bracket Assembly, the 5V1498 Flange Locknuts with the 1431288 Flange Locknut, the 1338523 Spacer with the new 1338523 Spacer and the 7X0546 Washer with the thicker 7X0589 Washer. Refer to Illustration 5 for the configuration of these parts.

NOTE: The washer between the 1338523 and 1166527 is not there anymore in the new configuration.

Assemble the 1419750 Bracket to the seat with a new 7X0321 Pivot Bolt: Align the seat back pan to the threaded hole in the tube welded to the seat pan to be able to insert and thread the pivot bolt in its location. Locate the bracket on the slide plate with the three sets of 7U4898 Screws and 1431288 Locknuts.

12. Tighten the 7X0321 () pivot bolt to a dynamic torque of 70± 15 N·m (51.6 ± 11 lb-ft) and a static torque of 4O N·m (29.5 lb/ft). Tighten the three 1431288 Locknuts to a dynamic torque of 5O ± 10 N·m (37 ± 7.5 lb/ft) and a static torque of 27 N.m (20 1b/ft). Remember to hold the screw and tighten the nut and NOT vice versa.

13. Remove the 1337345 Seat Belt Buckle Assembly from the 1166527 Bracket and assemble it to the new 1419750 Bracket as shown in Illustration 6 (a dynamic assembly torque of 70 ± 15 N·m (51.6 ± 11 lb/ft) and a static inspection torque of 55 N·m (40.5 lb/ft)). Use the new 1A4350 Bolt () to assemble the belt buckle to the bracket. Refer to Illustration 6 for the configuration of this assembly.

The belt buckle has two bolts on them. The shorter one to hold the buckle assembly together and the longer one to mount the buckle to the bracket. The longer mounting bolt is the one that needs to be removed. Some of the later models may have a seat belt buckle that has only one bolt on it, in which case this may not be a concern.

Illustration 6

14. Assemble the 1387518 Strap bracket to the 1419750 bracket (refer to Illustration 7). The 1387518 Strap Bracket has its one end squared and the other rounded. Use a 7U4898 (3/8) bolt and a 7X1387 Washer to locate the square end of the 1387518 Bracket on the 1419750 Bracket. Do not tighten the 7U4898 Bolt yet. Adjust the 1387518 Bracket until it mates with a flat surface on the seat pan as shown in the Illustration. Hold the bracket in that position and drill a 12 mm diameter hole on the seat pan using the hole provided on the 1387518 Bracket as a pilot hole. Use a 7U4898 bolt and a 7X1387 Washer on the inside and a 1431288 Flange Locknut on the outside of the pan to bolt the 1387518 Bracket to the pan. Tighten the bolts to a dynamic assembly torque of 5O± 10 N·m (37 ± 7.5 1b/ft) and a static inspection torque of 27 N·m (120 lb/ft).

Illustration 7

Illustration 8

15. Replace the plastic 8Y5947 Christmas Tree Fasteners on the seat pan to allow re-assembly of the seat cushion to the pan. While holding down the seat tilt plate (labeled (6) in Illustration (9)) by hand, remove the two cotter pins (labeled as (5) in Illustration 8). Slowly release the spring force against seat tilt plate. Pull up the seat cushion tilt adjustment lever (labeled as (8) in Illustration 9), and remove the seat tilt plate (6).

Use a screwdriver to remove the 8Y5947 Christmas-Tree Fasteners and replace them with the new ones provided.

Assemble the seat tilt plate back to the seat pan.

There is spring force against the seat tilt plate (6). When the cotter pins (5) are removed and the lever is raised, the spring force will be released. To prevent possible personal injury, retain seat tilt plate (6) by hand when cotter pins (5) are being removed. Remove the two cotter pins (5) and slowly release the spring force against the seat tilt plate by hand.

16. Assemble the seat cushion back to the seat pan. Make sure that the christmas-tree fasteners line up with the hole on the bottom side of the cushion before pressing it against the pan.

Illustration 9

17. Assemble the rest of the components at their respective locations. Assemble the 4E6523 Casting to the new 1419750 Bracket using the four 8T4130 Bolts and tighten to a standard dynamic torque of 55 ± 10 N·m (40.5 ± 7.5 lb/ft) and a static inspection torque of 31 N·m (23 lb/ft) as shown in Illustration 4.

Assemble the seat upper on its seat suspension by sliding, it on the rails (Caution not to knock any of the four slide pucks on the slide rail off while assembling the seat back to the suspension). Install the 4F4879 Front Stopper Bolt on the suspension. Make sure that the seat fore/aft mechanism works fine by trying to lock the seat at various positions.

Mount the control console and armrest mechanism back to the seat and assemble the 4E9173 Upper-Slide Shaft to the mechanism with a standard dynamic torque of 47 ± 9 N·m (35 ± 7 lb/ft) and a static inspection torque of 38 N·m (28 lb/ft). Install the two 6V9327 Screws that hold the upper-slide shaft in its place (Dynamic assembly torque of 12 ± 3 N·m (9 ± 2.2 lb/ft) and static inspection torque of 9 N·m (7 lb/ft)). Make sure that the armrest fore/aft mechanism works fine.

Assemble the 1275478 and 1275479 Covers back to where it belonged and mount the seat back to the cab with the four 6V7731 Bolts (a dynamic assembly torque of 55 ± 10 N·m (40.5 ± 7.5 lb/ft) and a static inspection torque of 45 N·m (33 lb/ft)) as was shown in Illustration 1.