USSC LLC 4 ONE LLC FIELD MODIFICATION INSTRUCTIONS

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1 1 OF 15 C 1. PURPOSE: Installation instructions to install 78 degree shoulder belt retractors.. SCOPE: Effects the 3 point bolt on brackets, the old style suspensions and also the current suspensions. 3. PROCEDURE: 3.1. Bolt on brackets types: (BRACKET 3PT/BOLT-ON/EXT/VOY). This external mounted bracket is used on all back frames that measure mounting foot width (BRACKET 3PT/BOLT-ON/EXT/MRE). This external mounted bracket is used on all back frames that measure mounting foot width (BRACKET 3PT/BOLT-ON/EXT/CONSO). This external mounted bracket is used on all back frames that measure mounting foot width (SUSPENSION ASSY/913/AIR/3PT) (SUSPENSION ASSY/AIR/3-PT/500LB) 3.. Tools and materials required: Ratchet with 5/8 and 1/ sockets 3... # phillips screw driver Red loctite #71 or permanent thread locker equal /16 drill bit and drill used with P/N (TEMPLATE/78 DEGREE BOLT- ON BRACKETS) Center punch and hammer 3.3. Identification process: Verify type of suspension being used, and the type of back mounted to the suspension. The 78/90 shoulder belt is to be mounted at a 78 degree angle to the horizon. The different types of mounts are identified and shown later in this document.

2 OF 15 C IDENTIFYING A VOYAGER BACK: If the seat contains a bolt-on 3 point bracket, identify the 3 point shoulder belt orientation. All bolt-on brackets are used when there are no welded brackets used on the suspensions, so verify that the suspension has welded on shoulder belt brackets. Also, identify whether the back frame has snap-on knobs, or screw on knobs. Sometimes the Voyager back frame uses a plastic mounted foot cover, see figure 1when the bolt on 3 point bracket is not used. SNAP-ON KNOB IDENTIFIER (VOYAGER STYLE BACK FRAME) FOOT COVER IDENTIFIER (NOT USED IF 3 POINT BOLT-ON BRACKET IS BEING USED) WELDED SHOULDER MOUNT BRACKET ( SUSPENSION SHOWN) Figure 1 (shown with no 3 point bolt-on brackets)

3 3 OF 15 C Shown in figure, is the current style of the 3 point bolt-on bracket that is used with the Voyager (VOY) back frame. Part number (BRACKET 3PT/BOLT- ON/EXT/VOY). This back frame is identified by the use of the snap on knobs. When using the following bolt on 3 point bracket, the suspension would not have a welded on bracket. Welded on brackets are shown later in The 3 point bolt-on bracket mount would have the belt clocked or angled also shown in figure.this mounting bracket measures in width when measured from inside of the mounting feet.

4 4 OF 15 C 1 VOYAGER BACK FRAME STYLE 3 POINT BOLT ON BRACKET 78 DEGREE MOUNT SHOULDER BELT SCREWHEX HD\7/16-0X1\G WASHER FLAT\PLATED\7/16\GR BRACKET 3 PT/BOLT-ON/EXT/VOY ITEM QTY PART NUMBER DESCRIPTION Angled mounting of shoulder belt to Voyager 3point bolt on bracket Figure No three point style bolt-on brackets are required when the suspensions are using welded on brackets which are needed to accommodate the 3 point shoulder belt. These welded on brackets are shown below in figures 3, 4, and figure 5.

5 5 OF 15 C ( ) 78 clocking angle shown Figure 3 ` Figure 4 (Early ) 90 clocking angle shown Current angled Left hand shoulder mount location ( ) Both 78 and 90 clocking angle shown Figure On suspensions, the welded on shoulder mount belt bracket (Figure 3) were only used on the left side of the suspension. Then eventually used on both sides of suspension. Early suspensions (Figure 4) used welded on brackets located on both left hand and right hand sides. These brackets have the holes in vertical alignment and were used for 90/90 or non-angled shoulder belts. See figure 1 for 78/90 belt relocation kits. 90/90 or vertical mounted belts are no longer available.

6 6 OF 15 C Current suspensions have the belt shoulder mount belt bracket (as shown in figure 5) located on both the left and right hand sides IDENTIFYING A MRE BACK: Shown below is the MRE back frame which is identified by the use of screw on knob and no plastic foot covers. The mounting feet are narrow as compared to the CONSO back frame shown later in Figure 8. SCREW-ON KNOB IDENTIFIER (MRE STYLE) NARROW MOUNT FOOT (MRE STYLE) Figure 6

7 7 OF 15 C If no welded on brackets are identified the use of part number (BRACKET 3PT/BOLT-ON/EXT/MRE) is needed to mount the 3 point shoulder belt onto the MRE back. See figure 7. 1 MRE BACK FRAME STYLE 3 POINT BOLT ON BRACKET 78 DEGREE MOUNT SHOULDER BELT SCREWHEX HD\7/16-0X1\G WASHER FLAT\PLATED\7/16\GR BRACKET 3 PT/BOLT-ON/EXT/MRE ITEM QTY PART NUMBER DESCRIPTION Figure 7

8 8 OF 15 C IDENTIFICATION OF A CONSO BACK: The back frame is identified by the use of a screw on knob, and no plastic foot covers. The mounting feet are wide as compared to the MRE back frame shown in figure 6. SCREW-ON KNOB IDENTIFIER (CONSO STYLE BACK FRAME) WIDE MOUNT FOOT USED ON (CONSO STYLE BACK FRAME) Figure 8 WELDED SHOULDER MOUNT BRACKET ( ) SUSPENSION SHOWN)

9 9 OF 15 C If no welded on brackets are identified the use of part number (BRACKET 3PT/BOLT-ON/EXT/CONSO) is needed to mount the 3 point shoulder belt onto the CONSO back. See figure 9. 1 CONSOBACK FRAME STYLE 3 POINT BOLT ON BRACKET 78 DEGREE MOUNT 3 SHOULDER BELT SCREWHEX HD\7/16-0X1\G WASHER FLAT\PLATED\7/16\GR BRACKET 3 PT/BOLT-ON/EXT/CONSO ITEM QTY PART NUMBER DESCRIPTION

10 10 OF 15 C Figure Installation process of the 3 point bolt-on bracket when no welded on brackets are present and the lap belt is using belt spacers as shown in figure Remove foot cover screws and covers if present, remove the back frame mounting hardware, belt receptor and belt retractor. Then install the 3 point bolt-on bracket NOTES: - THREAD LOCKER AND ADHESIVE: - BACK FRAME HARDWARE, BELT HARDWARE (PERMANENT - RED-71OR EQUAL) 5 1 SEE INDENTIFICATION BRACKET 3 PT/BOLT-ON/EXT/ SCREWHEX HD\7/16-0X SCREWHEX HD/7/16-0X1.5" WASHER FLAT\PLATED\7/16\GR SPACER\BELT\1/" IDx1" ODx5/8" ITEM QTY PART NUMBER DESCRIPTION Figure 10

11 11 OF 15 C Install back frame, 3 point bolt-on bracket, and lap belt components using new mounting hardware as shown in figure Add flat washers and permanent thread locker onto screw threads Tighten screws with 5/8 socket and ratchet, while holding the lap belt components on a 60 degree angle to the floor Installation process of the 3 point bolt-on bracket when no welded on brackets are present (lap belt using dual sense alignment bracket (P/N 3300N05-XX) Remove foot cover screws and covers if present, remove the back frame attaching hardware, remove dual sense alignment bracket, belt receptor and belt retractor. Then install back frame, and the 3 point bolt-on bracket Use new mounting hardware (Refer to FMI for installation of dual sense lap belt) To install 78 degree or clocked shoulder belt as shown in figure degree mount location CONSOBACK FRAME STYLE 3 POINT BOLT ON BRACKET 78 DEGREE MOUNT 3 SHOULDER BELT Figure SCREWHEX HD\7/16-0X1\G Align pin of shoulder WASHER belt FLAT\PLATED\7/16\GR8 retractor to small upper angled hole. The hole located 1 degrees 1 1 from vertical must BRACKET be used 3 PT/BOLT-ON/EXT/CONSO for the proper function of the belt. This alignment can be verified ITEM QTY PART NUMBER DESCRIPTION

12 1 OF 15 C with the use of (TEMPLATE/78 DEGREE BOLT-ON BRACKETS) P/N shown in section Add washer and permanent thread locker to screw Tighten screw with 5/8 socket and ratchet Installation process of the 78 degree retractor onto the early suspensions having the vertical alignment weld on bracket. (See figure 4 on page 4) A kit is available to mount the 78 degree retractor. Part number (KIT/3- POINT/BELT REPOSITION). For left hand or driver s side orientation see figure 1.

13 13 OF 15 C PLATE--3PT WITH VERTICAL HOLE MOUNT (SUSPENSION HIDDEN FOR CLARITY) 1 FOR LEFT HAND USE FOR RIGHT HAND USE SCREWHEX HD\7/16-0X1.5\GR WASHER FLAT\PLATED\7/16\GR BRKT WELD/SHLDR/78-90 BELT/SUSP MNT ITEM QTY PART NUMBER DESCRIPTION Figure Align centered pin of item #1clocking bracket into the weld on bracket upper hole Add item # flat washer in between clocking bracket and the shoulder belt retractor For left hand application (driver side), align pin of the shoulder belt retractor into the left side hole of the clocking bracket as shown in figure 10. This hole will clock the belt retractor to 1 degrees from vertical For right hand application (passenger side), align pin of the shoulder belt retractor using the right side hole of the clocking bracket. (As noted in figure 1) Add washer and permanent thread locker onto screw Tighten screw with 5/8 socket and ratchet Early bolt-on brackets modification for current 78 degree retractor mounting using template.

14 14 OF 15 C A template P/N (TEMPLATE/78 DEGREE BOLT-ON BRACKETS) can be provided and used to modify the early revision bolt-on brackets that were used with the older mounted shoulder belts. EXISTINGHOLE VERTICAL TO THE LARGE MOUNT HOLE ALIGN HOLE (SMALL ALIGNMENT HOLE) DRILL USING5/16" DRILL BIT (FOR LEFT HAND SIDE SHOULDER BELT) TEMPLATE ALIGN HOLE (LARGE MOUNT HOLE) Figure Lay template onto the surface of the bolt-on bracket Align the large hole on the template to the larger mount hole on the bolt-on bracket Align the smaller hole on the template to the small alignment hole on the bolt-on bracket. This hole should be vertical to the larger mount hole. If this hole is not vertical to the large mount hole, then align the bottom edge of the template to the bottom edge of the bolt-on bracket Next, determine shoulder belt mount location. See figure 13 for left hand mount. Opposite side small alignment hole applies for the use of right hand mount shoulder belts Use a center punch and hammer and mark the appropriate location into the surface of the bolt-on bracket. Then remove template Verify that no other existing holes are near the center punched area needed to drill a 5/16 diameter hole If an existing hole is within this area it will have to be welded then ground flush. Then repeat steps 3.8. through

15 15 OF 15 C Use a drill with 5/16 diameter drill bit and drill through center punched marked location.