2023/04/07 Platform - Install - Superstructure (M0106718-06)

SMCS - 7253 i09804613

Table 1

PPI Summary of Changes 

-
202 0004
1  Added part number 8T-4182 Bolt 

6
2  Added instructions for handrail lighting group 442-3694. 

06: 3 / 0 2F0
3  Added part number 609-2520 Band Clamp and related torque information. 

0 5 / 1
M0 :44- 8
Updated for new content
7
4  Added detail for spring washers.
Added instruction for mounting caps. 

1 0
© 2 671 4:00 0
5  Added Command option assembly information. 
6  Added instruction and tooling for hoist rings and plug assemblies 

023 8
7  Added instruction to install turbocharger water lines. 

7  Cat
Removed 10 7X-7729 Washer and 10 8T-4136. Added 10 479-2171 bolt assemblies

e
for 279-9496 handrail group mounting. 

r
Parts and Specification Information pill
ar I
n c.
Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or
damaged parts can be ordered prior to assembly to avoid delays during assembly.

Table 2
Part Approximate
Item  Description  NHL  Qty  Specification 
Number  Weight 
15876 kg
551-8400
551- Platform Ar (35000 lb)
1  Common 1   
8410  Superstructure  Assembled
Ar 
Weight 
442-2542
442- Platform
2  Cap As  4    30 kg (66 lb) 
2820  Mounting
Gp 
3  8T-5361  Hard Washer    24     
4  8F-6124  Bolt    24     
442-2542
587- Platform Use as
5  Plate     
7587  Mounting required 
Gp 
6  7X-0515  Hard Washer    8     
201-
7  Bolt    8     
7354 
8  7X-0448  Nut    4     
9  7X-0515  Hard Washer    4     
591-0186
573-
10  Plate  Ladder 13     
9856 
Gp 
11  8T-4224  Hard Washer    52     
12  9X-2616  Screw    52     
13  7X-7729  Washer    36     
14  8T-4196  Bolt    10     
198-
15  Hard Washer    24     
4778 
16  8T-4194  Bolt    8     
591-0186
570-
17  Plate As  Ladder 1     
8490 
Gp 
591-0186
570-
18  Plate As  Ladder 1     
8491 
Gp 
591-0186
591- 171 kg
19  Stairway As  Ladder 1   
7456  (377 lb) 
Gp 
198-
20  Hard Washer    8     
4777 
21  8T-4185  Bolt    8     
22  7T-8331  Mount As    2     
7G-
23  Spacer    4     
8839 
24  8T-4648  Bolt    2     
25  6V-7687  Locknut    2     
591-0186
377-
26  Ladder As  Ladder 1     
2108 
Gp 
27  5P-1076  Hard Washer    11     
28  8T-4139  Bolt    14     
591-0186
361-
29  Channel As  Ladder 1     
0036 
Gp 
30  8T-4121  Hard Washer    103     
31  8T-4195  Bolt    14     
344-
32  Nut    33     
5675 
591-0186
331-
33  Plate  Ladder 1     
0157 
Gp 
34  8T-4183  Bolt    6     
329-
35  Nut    3     
3356 
568-8778
508- 170 kg
36  Water Tank  Water 1   
2525  (375 lb) 
Lines Gp 
37  8T-4186  Bolt    25     
38  5P-1935  Seal    1     
Rectangular
39  1P-3705    1     
Seal 
40  8T-4223  Hard Washer    30     
41  8T-4910  Bolt    16     
204-
42  Cable Strap    1     
2281 
445-
591-0186
43A 8068 1
Tube As  Ladder    
43B  361- 1 
Gp 
0032 
571-6270
281-
44  Handrail As  Handrail 1    28 kg (62 lb) 
6798 
Gp 
479-
45  Bolt As    56     
2171 
45A 7X-7729 Washer 571-6270
45B 8T-4136 Bolt Handrail      
45C  8T-4139  Bolt  Gp 
571-6270
288-
46  Handrail As  Handrail 1    15 kg (33 lb) 
2534 
Gp 
329-
47  Nut    13     
3356 
48  5P-7468  Clip    6     
49  8T-7087  Grommet    6     
50  5P-7469  Clip    6     
115-
51  Plate    3     
3580 
135-
52  Bolt As    8     
8578 
571-6270
445-
53  Handrail As  Handrail 1     
8067 
Gp 
571-6270
290-
54  Handrail As  Handrail 1     
7167 
Gp 
 248-
55  U-Bolt    4     
0102 
56  8T-4224  Hard Washer    8     
5C-
57  Nut    8     
7261 
571-6270
449-
58  Gate As  Handrail 1     
5464 
Gp 
146-
59  Special Bolt    2     
3287 
60  4E-1303  Spacer    2     
571-6270
279-
61  Handrail As  Handrail 1    32 kg (70 lb) 
9496 
Gp 
583-8867
Air
566-
62  Strap  Cleaner 4     
8719 
and
Mounting 
434-
63  Nut    2     
5654 
442-
64  Washer    2     
2672 
5H-
65  Bolt    2     
9707 
583-8867
Air
502-
66  Pipe Clamp  Cleaner 4     
7105 
and
Mounting 
583-8867
Air
502-
67  Pipe Clamp  Cleaner 4     
7104 
and
Mounting 
68  7X-7729  Washer    8     
533-
69  Bolt As    4     
4159 
70  6V-7744  Locknut    12     
71  8T-6466  Bolt    8     
583-8867
Air
233-
72  Clamp  Cleaner 8     
8485 
and
Mounting 
73  334- Reducer Hose  583-8867 4     
2545  Air
 Cleaner
and
Mounting 
583-8867
Air
323-
74  Clamp  Cleaner 8     
3315 
and
Mounting 
583-8867
Air
566-
75  Tube As  Cleaner 4     
8707 
and
Mounting 
583-8867
Air
560-
76  Elbow  Cleaner 4     
2104 
and
Mounting 
583-8867
Air
230-
77  Clamp  Cleaner 16     
2535 
and
Mounting 
573-4681
561- Air 200 kg
78  Duct As  1   
2164  Cooling (440 lb) 
Duct Gp 
573-4681
590- Air
79  Plate As  2     
0800  Cooling
Duct Gp 
593-2972
140- Chassis
80  Ground Strap  1     
0860  Wiring
Gp 
573-4681
387- Air
81  Air Filter  1     
7955  Cooling
Duct Gp 
82  8T-4136  Bolt    4     
573-4681
573- Air
83  Hose  1     
8155  Cooling
Duct Gp 
573-4681
Air
84  8T-4986  Hose Clamp  1     
Cooling
Duct Gp 
85  125- Clip  573-4681 4     
7131  Air
 Cooling
Duct Gp 
570-8497
366-
86  Hose  Air Lines 4     
8500 
Gp 
570-8497
135-
87  Clamp  Air Lines 16     
6261 
Gp 
570-8497
286-
88  Tube  Air Lines 2     
5260 
Gp 
570-8497
329-
89  Half Clip  Air Lines 8     
3555 
Gp 
570-8497
128-
90  Spacer  Air Lines 8     
2477 
Gp 
570-8497
570-
91  Tube As  Air Lines 2     
8494 
Gp 
570-8497
465-
92  Bellows As  Air Lines 2     
8082 
Gp 
570-8497
507-
93  Bellows As  Air Lines 2     
3849 
Gp 
570-8497
311-
94  Band Clamp  Air Lines 2     
9236 
Gp 
526-3890
319-
95  Strap  Electric 1     
7979 
Horn Gp 
526-3890
488-
96  Bolt As  Electric 2     
3974 
Horn Gp 
568-0125
574-
97  Hose As  Heater 2     
6467 
Lines Gp 
568-0125
432- Clamp
98  Heater 1     
3700  Assembly 
Lines Gp 
568-0125
3G-
99  Link  Heater 1     
4005 
Lines Gp 
5M-
100  Bolt    1     
3062 
101  6V-7359  Grommet    2     
102  5P-7465  Clip    2     
103  5P-7464  Clip    2     
104  8T-4176  Bolt    1     
348-
105  Spacer    1     
3428 
204-
106  Cable Strap    7     
2281 
107  9X-8250  Clip    3     
6D-
108  Clip    3     
4246 
4H-
109  Washer    3     
1225 
9M-
110  Clip    3     
8406 
204-
111  Cable Strap    21     
2281 
526-3890
424-
112  Plate As  Electric 1     
2375 
Horn Gp 
526-3890
424-
113  Block  Electric 1     
2324 
Horn Gp 
526-3890
424-
114  Block  Electric 1     
2323 
Horn Gp 
526-3890
424-
115  Block  Electric 1     
2318 
Horn Gp 
526-3890
424-
116  Block  Electric 1     
2335 
Horn Gp 
588-6546
424- Chassis
117  Block  1     
2341  Wiring
Gp 
526-3890
424-
118  Plate  Electric 1     
2373 
Horn Gp 
204- Cable Tie
119    2     
8000  Mounting 
133-
120  Spacer    1     
6934 
483-
121  Plate    1     
4287 
116-
122  Taperlock Stud    1     
3715 
123  9X-0262  Adapter    1     
 214-
124  O-Ring Seal    2     
7566 
161- Pressure
125    1     
9926  Sensor Gp 
565-
126  Pin    2     
5175 
565-
127  Pin Retainer    2     
5174 
479-
128  Bolt As         
2172 
442-2542
Platform
129  3E-9850  Bolt  2     
Mounting
Gp 
130  8T-4192  Bolt    1     
200- Mounting
131    5     
6345  Saddle 
5G-
132  Grommet    1     
3676 
133  8T-1890  Clip    1     
134  8T-1889  Clip    1     
135  3S-8664  Clip    1     
570-
136  Bracket    1     
7547 
135-
137  Bolt As    2     
8575 
604-
138  Bracket As    1     
4800 
570-
139  Bracket    1     
7596 
264-
140  Spacer    4     
8816 
570-
141  Exhaust Elbow    1     
1838 
570-
142  Exhaust Elbow    1     
1839 
149-
143  Washer    32     
4741 
268-
144  Bolt    16     
4770 
149-
145  Hex Nut    16     
0206 
134-
146  Gasket    2     
5641 
 524-
147  Bellows As    2     
8983 
Tighten to a torque of
65 ± 5 N·m (48 ± 4 lb ft)
with a maximum wrench
speed of 75 RPM. Strike
the band clamp three
times with a soft faced
mallet to seat the clamp.
The strike direction
should be radial to the
tube. If a hard faced
609- mallet is used, strike a
148  Band Clamp    2   
2520  piece of wood instead of
directly on the ball clamp.
The force of each strike is
approximately the same
as the force required to
drive a nail into soft wood.
Again, tighten to a torque
of 65 ± 5 N·m
(48 ± 4 lb ft) with a
maximum wrench speed
of 75 RPM. 
448-
149  Band Clamp    2     
0511 
560-
150  Tube As    1     
3645 
560-
151  Tube As    1     
3646 
572-
152  Insulation As    1     
2653 
572-
153  Insulation As    1     
2655 
338-
154  Plate As    1     
8490 
338-
155  Plate As    1     
8491 
Tighten nuts to
603-
156  Cable As    1  20 ± 2 N·m  
6995 
(177 ± 18 lb in) 
Tighten nuts to
603-
157  Cable As    1  20 ± 2 N·m  
6996 
(177 ± 18 lb in) 
Tighten nuts to
603-
158  Cable As    1  20 ± 2 N·m  
6997 
(177 ± 18 lb in) 
179- Belleville
159    48     
2021  Washer 
 593-
160  Plate As    1     
3010 
601-
161  Block    24     
7586 
593-
162  Plate    7     
3016 
488-
163  Bolt As    6     
3971 
424-
164  Plate    2     
2352 
593-
165  Spacer    12     
3011 
603-
166  Plate    2     
7003 
601-
167  Plate As    2     
6998 
603-
168  Plate    2     
7004 
169  8T-4178  Bolt    14     
593-
170  Plate As    1     
3017 
424-
171  Plate    5     
2373 
603-
172  Plate As    1     
6999 
173  8T-4178  Bolt    6     
564-1659
Electric
310-
174  Plate  Drive 3     
1703 
Wiring
Gp 
564-1659
Electric
601-
175  Block  Drive 3     
7582 
Wiring
Gp 
564-1659
Electric
601-
176  Block  Drive 3     
7583 
Wiring
Gp 
564-1659
Electric
312-
177  Clamp  Drive 1     
8913 
Wiring
Gp 
 564-1659
Electric
312-
178  Plate  Drive 2     
9093 
Wiring
Gp 
179  7X-0605  Hard Washer    2     
180  8T-4176  Bolt    1     
329-
181  Nut    1     
3356 
564-1659
Electric
182  8T-4182  Bolt  Drive 18     
Wiring
Gp 
442-3694
431- Flood
183  Mount  1     
8428  Lighting
Gp 
442-3694
533- Flood
184  Bolt As  1     
4159  Lighting
Gp 
442-3694
204- Flood
185  Cable Strap  15     
2281  Lighting
Gp 
442-3694
204- Cable Tie Flood
186  2     
8000  Mounting  Lighting
Gp 
442-3694
344- Flood
187  Nut  3     
5675  Lighting
Gp 
442-3694
535- Flood
188  Rocker Switch  1     
6196  Lighting
Gp 
442-3694
539- Flood Lamp Flood
189  3     
5525  Gp  Lighting
Gp 
442-3694
613- Flood
190  Harness As.  2     
9276  Lighting
Gp 
442-3694
Flood
191  5P-7468  Clip  2     
Lighting
Gp 
 442-3694
Flood
192  5P-7469  Clip  2     
Lighting
Gp 
442-3694
Flood
193  8T-4121  Hard Washer  7     
Lighting
Gp 
442-3694
Flood
194  8T-4182  Bolt  2     
Lighting
Gp 
442-3694
Flood
195  8T-7087  Grommet  2     
Lighting
Gp 
442-3694
Flood
196  9X-9365  Bracket  2     
Lighting
Gp 
442-2542
8C- Platform
197  Nut  2     
8722  Mounting
Gp 
619-9100
135-
198  Bolt As  Handrail 12     
8577 
Gp 
619-9100
199  9X-8257  Washer  Handrail 4     
Gp 
619-9100
200  8T-4779  Bolt  Handrail 4     
Gp 
619-9100
581-
201  Plate  Handrail 1     
2906 
Gp 
619-9100
533-
202  Bolt As  Handrail 6     
4159 
Gp 
619-9100
344-
203  Nut  Handrail 6     
5675 
Gp 
619-9100
292-
204  Plate  Handrail 2     
9302 
Gp 
619-9100
195-
205  Nut  Handrail 2     
3699 
Gp 
206  465- Plate  619-9100 1     
3206  Handrail
 Gp 
619-9100
581-
207  Plate  Handrail 1     
2905 
Gp 
619-9100
467-
208  Plate  Handrail 1     
9962 
Gp 
619-9100
623-
209  Plate  Handrail 1     
4583 
Gp 
619-9100
210  8T-4137  Bolt  Handrail 1     
Gp 
619-9100
193-
211  Bracket As  Handrail 1     
9131 
Gp 
619-9100
624-
212  Plate As  Handrail 1     
0402 
Gp 
619-9100
623-
213  Tube As  Handrail 1     
4573 
Gp 
419-
214  Plug As    3     
3248 
153-
215  Elbow As    2     
6237 
574-
216  Hose As    1     
0311 
592-
217  Hose As    1     
5326 
218  6V-1249  Grommet    7     
144-
219  Spacer    1     
8344 
220  5P-7465  Clip    7     
221  5P-7464  Clip    7     
222  8T-4896  Hard Washer    2     
223  8T-2501  Bolt    2     
442-
224  Washer    1     
2672 
434-
225  Nut    3     
5654 
574-
226  Bracket As    2     
0313 
227  8T-4223  Hard Washer    4     
228  8T-4139  Bolt    4     
 479-
229  Bolt As    1     
2172 
173-
230  Bracket As    1     
1583 
125-
231  Plate As    1     
8534 
533-
232  Bolt As    4     
4159 
576-
233  Plate    2     
4965 
234  8T-4121  Hard Washer    2     
235  6V-7744  Locknut    2     
236  8T-4896  Hard Washer    2     
237  8T-2501  Bolt    2     

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.

Dispose of all fluids according to local regulations and

mandates.

Observe the safe working load limits of all lifting and blocking
devices and keep a safe distance from suspended/blocked
loads. Personnel could be seriously injured or killed by falling
loads.

Personal injury or death can occur from heavy components

falling during removal or installation.

Properly support the component with a suitable lifting device

during removal or installation.
 Personal injury or death can result from improper lifting or
blocking.

When a hoist or jack is used to lift any part or component, stand

clear of the area. Be sure the hoist or jack has the correct
capacity to lift a component. Install blocks or stands before
performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all

surfaces where parts are to be installed.

Do not attempt to assemble this machine until you read and you
understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and
material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris,
paint, and grease.

Note: It is not required or recommended to remove the paint from the curved saddle mount or the
chassis platform tube mounting surface.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove
paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the
"General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps and mounting hardware, remove the slack from the harness
assemblies and allow adequate strain relief.

Note: Any tooling that is used for lifting the machine or for securing the machine in the raised
position should be used on a concrete surface capable of supporting the weight of the machine.

Installation Procedure
Table 3
 Required Tools 
Tool  Part Number  Part Description  Qty 
T1  439-3940  Bracket As  2 

PPI
T2  193-5474  Shackle  4 

202 -0004
T3  -  LOCTITE 243  - 
T4  -  LOCTITE Heavy-Duty Anti Seize  - 
T5  477-3139  Eyebolt As 

06: 3 / 0 6 2F0
2 

T6 
252-9971  Stud 

0 5 / 1
4 

M0 :44- 8
7
2M-5656 Nut  4 
T7  164-4033  Hoist Ring  3 

Start By: 1 0
© 2 671 4:00 0
023 8
a. Assemble the platform. Refer to Platform - Assemble  .

Cat
erp
illa
r In
c.

Illustration 1 g06442845
Shipping Support Beam
Typical Example
(T1) 439-3940 Bracket As
(A) 447-9191 Bracket As
(B) 7X-0448 Locknut
(C) 7X-0515 Hard Washer
(D) 201-7354 Bolt
(E) 221-0751 Link
(F) 4S-8033 Secondary Bar Pin
(G) 3B-4640 Cotter Pin
1. Attach Tooling (T1) and a suitable lifting device onto bracket assembly (A). The weight of
bracket assembly (A) is approximately 131 kg (289 lb).

2. Remove and keep eight locknuts (B), 16 washers (C), and eight bolts (D). Remove and keep
two cotter pins (G) and two secondary bar pins (F). Position two links (E) out of the way.
Remove and discard bracket assembly (A).

Illustration 2 g07558290
(T6) 252-9971 Stud 2M-5656 Nut
(2) 442-2820 Cap As
(3) 8T-5361 Hard Washer
(4) 8F-6124 Bolt
(5) 587-7587 Plate

Personal injury or death can occur from heavy components

falling during removal or installation.

Properly support the component with a suitable lifting device

during removal or installation.

3. Prior to installing the superstructure, four cap assemblies (2) can be loosely installed and
positioned out of the way. This will eliminate the need to lift them in place after the
superstructure has been assembled on the chassis.
4. Use two people to position cap assemblies (2). The weight of cap assembly (2) is approximately
30 kg (66 lb).

5. Retain cap assemblies (2) using Tooling (T6).

6. Use suitable O-rings to retain twenty bolts (4), twenty washers (3), and required shim plates (5).

7. It is not required or recommended to remove the paint from the curved saddle mount or the
chassis platform tube mounting surface.

Illustration 3 g07576521
Right-Hand Side
 Illustration 4 g07576524
Left-Hand Side
(T2) 193-5474 Shackle
(T7) 164-4033 Hoist Ring
(1) 551-8410 Platform Ar
8. Install three of Tooling (T7) at the designated lifting location. Attach four of Tooling (T2) and
suitable lifting devices onto platform arrangement (1). The assembled weight of platform
arrangement (1) is approximately 15876 kg (35000 lb).
Illustration 5 g06716029
Front View

Illustration 6 g06716037
Right-Hand Side View

Illustration 7 g06716057
 Illustration 8 g07069222
Right-Hand Side View
Chassis Platform Mounting
(1) 551-8410 Platform Ar
9. Use two suitable cranes to lift the platform at the four designated lifting points.

10. Once at a height to clear the front module and any obstruction, slowly move platform (1)
rearward over the chassis. Lower platform arrangement (1) onto the chassis platform mounting
on both sides. Position platform arrangement (1) so that the four saddle mounts are centered on
the mounting lugs and on each side of the location blocks on both sides of the chassis. Ensure
that the front face mounting holes line up with the vertical support beams on each side. Refer to
Illustration 7.
Illustration 9 g06316459

Illustration 10 g06727205
 Illustration 11 g06513090
View A-A
(2) 442-2820 Cap As
(3) 8T-5361 Hard Washer
(4) 8F-6124 Bolt
(5) 587-7587 Plate
11. Mark the location of each cap assembly (2) as installed for future service purposes. Apply
Tooling (T3) to twelve bolts (4). Use two people to install two cap assemblies (2), twelve
washers (3), and twelve bolts (4) hand tight until cap plate touches the tube. Repeat this step for
the opposite side. Equalize Gap (A) and Gap (B).

12. Measure Gap (A) and Gap (B). Subtract 4.7 mm (0.2 inch) from Gap (A) and Gap (B) to
establish the required shim thickness. Install plates (5).
Note: Use a minimum number of shims to ensure that the thin plate does not contact the thick
plate at Gap (C). Use an equal number of shims (5) at Gap (A) and Gap (B).

Note: Orientate plates (5) with the wide edge to the outside as shown.

Note: Cap assemblies (2) can be reused if the thin plate is flat within 0.76 mm (0.03 inch) and
the thick plate is flat within 0.25 mm (0.01 inch).
 Illustration 12 g06730791
View A-A
(E) 221-0751 Link
(F) 4S-8033 Secondary Bar Pin
(G) 3B-4640 Cotter Pin
(6) 7X-0515 Hard Washer
(7) 201-7354 Bolt
(8) 7X-0448 Nut
(9) 7X-0515 Hard Washer
13. Position link (E) and install secondary bar pin (F) and cotter pin (G). Install four washers (6), four
bolts (7), two washers (9), and two nuts (8). Repeat this step for the opposite side.

Stairway - Install

Illustration 13 g06730456
(10) 573-9856 Plate
(11) 8T-4224 Hard Washer
(12) 9X-2616 Screw
1. Install 13 plates (10), 52 washers (11), and 52 screws (12).

Illustration 14 g06726926
(13) 7X-7729 Washer
(14) 8T-4196 Bolt
(15) 198-4778 Hard Washer
(16) 8T-4194 Bolt
(17) 570-8490 Plate As
(18) 570-8491 Plate As

2. Install plate assembly (17), four washers (13), and four bolts (14).

3. Install plate assembly (18), four washers (15), and four bolts (16).

Illustration 15 g06726930
 Illustration 16 g06726936

Illustration 17 g06726937
(19) 591-7456 Stairway As
(20) 198-4777 Hard Washer
(21) 8T-4185 Bolt
(22) 7T-8331 Mount As
(23) 7G-8839 Spacer
(24) 8T-4648 Bolt
(25) 6V-7687 Locknut
4. use a suitable lifting device to install stairway assembly (19). The weight of stairway assembly
(19) is approximately 171 kg (377 lb).

5. Install two washers (20) and two bolts (21).

6. Install two mount assemblies (22), four spacers (23), two bolts (24), and two locknuts (25).
 Illustration 18 g06726951

Illustration 19 g06726950
(14) 8T-4196 Bolt
(20) 198-4777 Hard Washer
(26) 377-2108 Ladder As
(27) 5P-1076 Hard Washer
(28) 8T-4139 Bolt
(29) 361-0036 Channel As
(30) 8T-4121 Hard Washer
(31) 8T-4195 Bolt
(32) 344-5675 Nut
7. Use a suitable lifting device to install ladder assembly (26). The weight of ladder assembly (26)
is approximately 50 kg (110 lb).

8. Install six washers (27) and six bolts (28).

9. Install channel assembly (29), 16 washers (30), eight bolts (31), and eight nuts (32).
10. Install six washers (20) and six bolts (14).

Illustration 20 g06726953
(27) 5P-1076 Hard Washer
(30) 8T-4121 Hard Washer
(31) 8T-4195 Bolt
(32) 344-5675 Nut
(33) 331-0157 Plate
(34) 8T-4183 Bolt
(35) 329-3356 Nut

11. Install plate (33), two washers (27), two bolts (34), two nuts (35), two washers (30), two bolts
(31), and two nuts (32).

Expansion Tank - Install

Illustration 21 g07558283
(T5) 477-3139 Eyebolt As
(13) 7X-7729 Washer
(36) 508-2525 Water Tank
(37) 8T-4186 Bolt
1. Use Tooling (T5) and a suitable lifting device to install water tank (36) onto the radiator module.
The weight of water tank (36) is approximately 170 kg (375 lb). Install eight hard washers (13)
and eight bolts (37).

Illustration 22 g06727215
(H) 574-5347 Tube As
(J) 574-5296 Tube As
(38) 5P-1935 Rectangular Seal
(39) 1P-3705 Rectangular Seal
(40) 8T-4223 Hard Washer
(41) 8T-4910 Bolt

2. Install rectangular seal (38) onto tube assembly (H). Install rectangular seal (39) onto tube
assembly (J). Install eight washers (40) and eight bolts (41).

Illustration 23 g06727229
(K) 8T-4191 Bolt
(L) 8T-4121 Hard Washer
 (M) 443-0300 Cover
3. Remove and keep four bolts (K), four hard washers (L), and cover (M).

Illustration 24 g06727225
(N) 570-8852 Sensor Harness As
(42) 204-2281 Cable Strap

4. Connect sensor harness assembly (N). Install cable strap (42).

Illustration 25 g06727231
(K) 8T-4191 Bolt
(L) 8T-4121 Hard Washer
(M) 443-0300 Cover

5. Install cover (M), four hard washers (L), and four bolts (K).

Handrails Install
 PPI
-
202 0004
3
06: 05/1 2F0
/ 6
0
M0 7:44- 8
Illustration 26
(43A) 445-8068 Tube As
1 0
© 2 671 4:00 0
g07528392

(43B) 361-0032 Tube As

023 8
Cat
1. Install two tube assemblies (43A) and (43B).

erp
illa
rI nc.

Illustration 27 g07528410
(44) 281-6798 Handrail As
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt

2. Use a suitable lifting device to position handrail assembly (44). The weight of handrail assembly
(44) is approximately 28 kg (61 lb). Install twelve washers (45A) and twelve bolts (45B).
 Illustration 28 g07528453
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
(46) 288-2534 Handrail As
3. Use a suitable lifting device to position handrail assembly (46). The weight of handrail assembly
(46) is approximately 15 kg (33 lb). Install eight washers (45A) and eight bolts (45B).

Illustration 29 g06727343
(40) 8T-4223 Hard Washer
(47) 329-3356 Nut
(48) 5P-7468 Clip
(49) 8T-7087 Grommet
(50) 5P-7469 Clip
(51) 115-3580 Plate
(52) 135-8578 Bolt As

4. Install two clips (48), two grommets (49), two clips (50), and one plate (51). Install two hard
washers (40), two bolt assemblies (52), and two nuts (47).

Illustration 30 g07528480
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
(45C) 8T-4139 Bolt
(53) 445-8067 Handrail As
(54) 290-7167 Handrail As
(55) 248-0102 U-Bolt
(56) 8T-4224 Hard Washer
(57) 5C-7261 Nut
(128) 479-2172 Bolt As
5. Position handrail assembly (53). Install eight washers (45A) and eight bolts (45C). Install two U-
bolts (55), four washers (56), and four nuts (57).

6. Position handrail assembly (54). Install eight washers (45A) and eight bolts (45B). Install two U-
bolts (55), four washers (56), and four nuts (57). Install two bolt assemblies (128).

Illustration 31 g06727359
(58) 449-5464 Gate As
(59) 146-3287 Special Bolt
(60) 4E-1303 Spacer

7. Position gate assembly (58). Install two spacers (60) and two special bolts (59).

Illustration 32 g06730933
(40) 8T-4223 Hard Washer
(47) 329-3356 Nut
(48) 5P-7468 Clip
(49) 8T-7087 Grommet
(50) 5P-7469 Clip
(51) 115-3580 Plate
(52) 135-8578 Bolt As
 8. Install four clips (48), four grommets (49), four clips (50), and two plates (51). Install four
washers (40), four bolts assemblies (52), and four nuts (47).

Illustration 33 g07600287
(45) 479-2171 Bolt As
(61) 279-9496 Handrail As

9. Use a suitable lifting device to install handrail assembly (61). The weight of handrail assembly
(61) is approximately 32 kg (70 lb). Install ten bolt assemblies (45).

Handrails Install - Command Option

Illustration 34 g07528392
(43A) 445-8068 Tube As
(43B) 361-0032 Tube As

1. Install two tube assemblies (43A) and (43B).

 Illustration 35 g07528410
(44) 281-6798 Handrail As
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
2. Use a suitable lifting device to position handrail assembly (44). The weight of handrail assembly
(44) is approximately 28 kg (61 lb). Install twelve washers (45A) and twelve bolts (45B).

Illustration 36 g07528453
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
(46) 288-2534 Handrail As

3. Use a suitable lifting device to position handrail assembly (46). The weight of handrail assembly
(46) is approximately 15 kg (33 lb). Install eight washers (45A) and eight bolts (45B).

Illustration 37 g06727343
 (40) 8T-4223 Hard Washer
(47) 329-3356 Nut
(48) 5P-7468 Clip
(49) 8T-7087 Grommet
(50) 5P-7469 Clip
(51) 115-3580 Plate
(52) 135-8578 Bolt As
4. Install two clips (48), two grommets (49), two clips (50), and one plate (51). Install two hard
washers (40), two bolt assemblies (52), and two nuts (47).

Illustration 38 g07528480
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
(45C) 8T-4139 Bolt
(53) 445-8067 Handrail As
(54) 290-7167 Handrail As
(55) 248-0102 U-Bolt
(56) 8T-4224 Hard Washer
(57) 5C-7261 Nut
(128) 479-2172 Bolt As

5. Position handrail assembly (53). Install eight washers (45A) and eight bolts (45C). Install two U-
bolts (55), four washers (56), and four nuts (57).

6. Position handrail assembly (54). Install eight washers (45A) and eight bolts (45B). Install two U-
bolts (55), four washers (56), and four nuts (57). Install two bolt assemblies (128).

Illustration 39 g06727359
(58) 449-5464 Gate As
(59) 146-3287 Special Bolt
(60) 4E-1303 Spacer
7. Position gate assembly (58). Install two spacers (60) and two special bolts (59).

Illustration 40 g06730933
(40) 8T-4223 Hard Washer
(47) 329-3356 Nut
(48) 5P-7468 Clip
(49) 8T-7087 Grommet
(50) 5P-7469 Clip
(51) 115-3580 Plate
(52) 135-8578 Bolt As

8. Install four clips (48), four grommets (49), four clips (50), and two plates (51). Install four
washers (40), four bolts assemblies (52), and four nuts (47).

Illustration 41 g07527966
 Illustration 42 g07528500
(61) 580-1755 Handrail As Command Option
(198) 135-8577 Bolt As
9. Use a suitable lifting device to install handrail assembly (61). The weight of handrail assembly
(61) is approximately 195 kg (430 lb). Install twelve bolt assemblies (198).

Illustration 43 g07528504
(45) 479-2171 Bolt As
(199) 9X-8257 Washer
(200) 8T-4779 Bolt

10. Install two bolt assemblies (45) four washers (199) and four bolts (200).
 Illustration 44 g07528520
(45) 479-2171 Bolt As
(27) 5P-1076 Hard Washer
(41) 8T-4910 Bolt
11. Install two bolt assemblies (45) four washers (27) and four bolts (41).

Illustration 45 g07528891
(30) 8T-4121 Hard Washer
(55) 248-0102 U-Bolt
(201) 581-2906 Plate
(202) 533-4159 Bolt As
(203) 344-5675 Nut
(204) 292-9302 Plate
(205) 195-3699 Nut

12. Install plate (201), bolt assembly (202), washer (30), nut (203), U-bolt (55), plate (204), and two
nuts (205).
 Illustration 46 g07528894
(30) 8T-4121 Hard Washer
(45) 479-2171 Bolt As
(202) 533-4159 Bolt As
(203) 344-5675 Nut
(206) 465-3206 Plate
(207) 581-2905 Plate
13. Install plate (206), plate (207), two bolt assemblies (45), three bolt assemblies (202), three
washers (30), and three nuts (203).

Illustration 47 g07528900
(30) 8T-4121 Hard Washer
(202) 533-4159 Bolt As
(203) 344-5675 Nut
(208) 467-9962 Plate

14. Install plate (208), two bolt assemblies (202), two washers (30) and two nuts (203).
 Illustration 48 g07528903

Illustration 49 g07528905
(30) 8T-4121 Hard Washer
(45) 479-2171 Bolt As
(45A) 7X-7729 Washer
(45B) 8T-4136 Bolt
(209) 623-4583 Plate
(210) 8T-4137 Bolt
(211) 193-9131 Bracket As
(212) 624-0402 Plate As
15. Install plate (209), two washers (30), two bolts (210), and bracket assembly (211).

16. Install plate assembly (212), bolt assembly (45), washer (45A), and (45B)
 Illustration 50 g07528909
( 45) 479-2171 Bolt As
(213) 623-4573 Tube As
17. Install tube assembly (213) and four bolt assemblies (45).

Turbocharger - Connect
1. The following steps are optional. The air inlet to turbo charger connection tubes can be installed
before or after the platform has been assembled onto the truck. Use the following steps to install
the air inlet to turbo charger connection tubes If the platform has been installed.

Illustration 51 g06730563
(30) 8T-4121 Hard Washer
(62) 566-8719 Strap
(63) 434-5654 Nut
(64) 442-2672 Washer
(65) 5H-9707 Bolt
(66) 502-7105 Pipe Clamp
(67) 502-7104 Pipe Clamp
 (68) 7X-7729 Washer
(69) 533-4159 Bolt As
(70) 6V-7744 Locknut
(71) 8T-6466 Bolt

a. Install two straps (62), two nuts (63), two washers (64), and two bolts (65).

b. Install two pipe clamps (66), two pipe clamps (67), two washers (68), two bolt assemblies
(69), and two locknuts (70).

c. Install eight washers (30), four bolts (71), and four locknuts (70).

d. Prior to assembly, clean the airline pipes. Check all the new pipes for the protective caps.
Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris and rust
are found, clean inside the pipes until free of debris and rust.

e. Before installation, mark the hose overlap distance on all pipes.

f. During the pipe installation, leave the components loose to adjust the alignment of the
pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).

Illustration 52 g06730566
Front
(72) 233-8485 Clamp
(73) 334-2545 Reducer Hose
(74) 323-3315 Clamp
(75) 566-8707 Tube As
(76) 560-2104 Elbow
(77) 230-2535 Clamp

Improper assembly of parts that are spring loaded can cause

bodily injury.
 To prevent possible injury, follow the established assembly
procedure and wear protective equipment.

Note: Prior to assembly, clean the airline pipes. Check all the new pipes for the protective
caps. Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris
and rust are found, clean inside the pipes until free of debris and rust.

Note: Before installation, mark the hose overlap distance on all pipes.

Note: During the pipe installation, leave the components loose to adjust the alignment of
the pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).
g. Install four clamps (72), two reducer hoses (73) and four clamps (74).

h. Install two tube assemblies (75).

i. Install two elbows (76) and eight clamps (77).

j. Hose to tube connections use two T-bolt clamps on each end. Do not place clamp over the
bead on the tube. The recommended distance of 6.35 mm (0.25 inch) from the edge of the
clamp to the edge of the hose. The final torque for the 16 clamps 7.5 ± 1 N·m
(66.4 ± 9lb in).
Note: Position the T-bolt clamps at least 110 Degrees apart.

Note: Do not tighten the clamps to a final torque until the alignments are made.

Note: Several adjustments of the airlines tubes may be required.

Illustration 53 g06730592
 Illustration 54 g06730594
(28) 8T-4139 Bolt
(40) 8T-4223 Hard Washer
(78) 561-2164 Duct As
k. Use a suitable lifting device to install duct assembly (78). The weight of duct assembly (78)
is approximately 200 kg (440 lb).

l. Install eight washers (40) and eight bolts (28) to secure duct assembly (78).

Illustration 55 g06730596
(30) 8T-4121 Hard Washer
(37) 8T-4186 Bolt
(79) 590-0800 Plate As
2. Install two plates (79), 20 washers (30), and 20 bolts (37).
 Illustration 56 g06730598
(30) 8T-4121 Hard Washer
(37) 8T-4186 Bolt
(45) 479-2171 Bolt As
(80) 140-0860 Ground Strap
3. Install 20 washers (30), and 20 bolts (37).

4. Install ground strap (80) and two bolt assemblies (45).

Illustration 57 g06730599
(P) 8T-4986 Hose Clamp
(30) 8T-4121 Hard Washer
(81) 387-7955 Air Filter subassembly
(82) 8T-4136 Bolt

5. Install air filter subassembly (81), four washers (30), and four bolts (82).

6. Loosen hose clamp (P).

 PPI
202 -0004
06: 3 / 0 6 2F0
0 5 / 1
M0 7 : 44- 8
Illustration 58
1 0
© 2 671 4:00 0
g06730602
(P) 8T-4986 Hose Clamp
(83) 573-8155 Hose 023 8
(84) 8T-4986 Hose Clamp
Cat
7. Install hose (83) and hose clamp (84).

erp
8. Tighten hose clamp (P) and hose clamp (84).
illa
r In
c.

Illustration 59 g06730605
(31) 8T-4195 Bolt
(68) 7X-7729 Washer
(85) 125-7131 Clip

9. Install four clips (85), four washers (68), and four bolts (31).
 Illustration 60 g06730573
(30) 8T-4121 Hard Washer
(45) 479-2171 Bolt As
(62) 566-8719 Strap
(66) 502-7105 Pipe Clamp
(67) 502-7104 Pipe Clamp
(68) 7X-7729 Washer
(69) 533-4159 Bolt As
(70) 6V-7744 Locknut
(71) 8T-6466 Bolt
Note: Prior to assembly, clean the airline pipes. Check all the new pipes for the protective caps.
Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris and rust are
found, clean inside the pipes until free of debris and rust.

Note: Before installation, mark the hose overlap distance on all pipes.

Note: During the pipe installation, leave the components loose to adjust the alignment of the
pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).
10. Install two straps (62) and two bolt assemblies (45).

11. Install two pipe clamps (66), two pipe clamps (67), two washers (68), two bolt assemblies (69),
and two locknuts (70).

12. Install eight washers (30), four bolts (71), and four locknuts (70).
 Illustration 61 g06730568
Rear
(72) 233-8485 Clamp
(73) 334-2545 Reducer Hose
(74) 323-3315 Clamp
(75) 566-8707 Tube As
(76) 560-2104 Elbow
(77) 230-2535 Clamp

Improper assembly of parts that are spring loaded can cause

bodily injury.

To prevent possible injury, follow the established assembly

procedure and wear protective equipment.

13. Install four clamps (72), two reducer hoses (73) and four clamps (74).

14. Install two tube assemblies (75).

15. Install two elbows (76) and eight clamps (77).

16. Hose to tube connections use two T-bolt clamps on each end. Do not place clamp over the bead
on the tube. The recommended distance of 6.35 mm (0.25 inch) from the edge of the clamp to
the edge of the hose. The final torque for the 16 clamps 7.5 ± 1 N·m (66.4 ± 9lb in).
Note: Position the T-bolt clamps at least 110 Degrees apart.

Note: Do not tighten the clamps to a final torque until the alignments are made.

Note: Several adjustments of the airlines tubes may be required.

ATTAC - Connect
 Illustration 62 g06728108
(R) 8T-4121 Hard Washer
(S) 8T-4195 Bolt
(T) 308-6629 Plate
(V) 308-6625 Baffle

1. Remove and keep 12 bolts (S), 12 washers (R), two plates (T), and baffle (V).

Illustration 63 g06730609
(86) 366-8500 Hose
(87) 135-6261 Clamp
(88) 286-5260 Tube

2. Install two hoses (86), eight clamps (87), and tube (88).
 Illustration 64 g06730610
(15) 198-4778 Hard Washer
(40) 8T-4223 Hard Washer
(41) 8T-4910 Bolt
(47) 329-3356 Nut
(89) 329-3555 Half Clip
(90) 128-2477 Spacer
3. Install four half clips (89), four spacers (90), four washers (15), four washers (40), four bolts
(41), and four nuts (47).

Illustration 65 g06728113
(R) 8T-4121 Hard Washer
(S) 8T-4195 Bolt
(T) 308-6629 Plate
(V) 308-6625 Baffle

4. Install baffle (V), two plates (T), 12 washers (R), and 12 bolts (S).

5. Repeat Step 1 through Step 4 for the opposite side.

 Illustration 66 g06730612
(91) 570-8494 Tube As
(92) 465-8082 Bellows As

Improper assembly of parts that are spring loaded can cause

bodily injury.

To prevent possible injury, follow the established assembly

procedure and wear protective equipment.

6. Install two tube assemblies (91) onto bellows assemblies (92). Tighten the clamps of bellows
assemblies (92) to an initial torque of 8.5 ± 1 N·m (75.2 ± 9 lb in). Tap the clamp on the bottom
(next to the bolt), the left side, the right side, and then next to the bolt with a soft mallet. Tighten
to a final torque of 11.3 ± 1 N·m (100.0 ± 9 lb in)
 Illustration 67 g06730618
(15) 198-4778 Hard Washer
(16) 8T-4194 Bolt
(34) 8T-4183 Bolt
(47) 329-3356 Nut
(89) 329-3555 Half Clip
7. Install two half clips (89), eight washers (15), four bolts (16), and four nuts (47).

8. Install four half clips (89), four washers (15), and four bolts (34).

Illustration 68 g06730623
(93) 507-3849 Bellows As
(94) 311-9236 Band Clamp

Improper assembly of parts that are spring loaded can cause

bodily injury.

To prevent possible injury, follow the established assembly

procedure and wear protective equipment.

9. Install two bellows assemblies (93) and two band clamps (94). Tighten two bellows assemblies
(93) to a torque of 20 ± 3 N·m (177 ± 27 lb in) and two band clamps (94) to a torque of
17 ± 3 N·m (151 ± 27 lb in).

Platform Connect - Lines and wiring

 Illustration 69 g06728232
(W) 604-0637 Hose As
(X) 604-0638 Hose As
(Y) 604-0639 Hose As

1. Connect hose assembly (W), hose assembly (X), and hose assembly (Y).

Illustration 70 g06730624
(95) 319-7979 Strap
(96) 488-3974 Bolt As

2. Install strap (95) and two bolt assemblies (96).

Illustration 71 g06728279
Right Side Hose Connections
(Z) 604-0605 Hose As
(AA) 604-0608 Hose As
(AB) 604-0607 Hose As

Illustration 72 g06728280
Left Side Hose Connections
(AC) 604-0604 Hose As
(AD) 604-0606 Hose As
(AE) 604-0609 Hose As
 Illustration 73 g06728281
(Z) 604-0605 Hose As
(AA) 604-0608 Hose As
(AB) 604-0607 Hose As
(AC) 604-0604 Hose As
(AD) 604-0606 Hose As
(AE) 604-0609 Hose As
3. Connect hose assembly (Z), hose assembly (AA), hose assembly (AB), hose assembly (AC),
hose assembly (AD), and hose assembly (AE).

Illustration 74 g06730628
 Illustration 75 g06730634
(30) 8T-4121 Hard Washer
(40) 8T-4223 Hard Washer
(47) 329-3356 Nut
(97) 574-6467 Hose As
(98) 432-3700 Clamp
(99) 3G-4005 Link
(100) 5M-3062 Bolt
(101) 6V-7359 Grommet
(102) 5P-7465 Clip
(103) 5P-7464 Clip
(104) 8T-4176 Bolt
(105) 348-3428 Spacer
4. Connect two hose assemblies (97).

5. Install clamp assembly (98), link (99), washer (30), bolt (100), two grommets (101), two clips
(102), two clips (103), two washers (40), spacer (105), bolt (104), and nut (47).

Illustration 76 g06730635
(AF) 589-5484 Front Harness As
(106) 204-2281 Cable Strap
6. Connect front harness assembly (AF). Install cable strap (106).

Illustration 77 g06728568
(AG) 470-0405 Air Conditioner Lines Gp
(45) 479-2171 Bolt As

7. Position air conditioner lines group (AG) and install two bolt assemblies (45).

Illustration 78 g06730637
(30) 8T-4121 Hard Washer
(37) 8T-4186 Bolt
(107) 9X-8250 Clip
(108) 6D-4246 Clip
(109) 4H-1225 Washer
(110) 9M-8406 Clip

8. Install three clips (107), three clips (108), three washers (109), three clips (110), three washers
(30), and three bolts (37).
 Illustration 79 g06728596
Air Conditioner Lines
(AH) 580-1858 Hose As
(AJ) 580-1857 Hose As
9. Connect hose assembly (AH) and hose assembly (AJ).

Illustration 80 g06730638
(AK) 593-2985 Chassis Harness As
(106) 204-2281 Cable Strap

10. Connect harness assembly (AK) and install six cable straps (106).
 Illustration 81 g06729445
(AK) 593-2985 Chassis Harness As
(AL) 593-2984 Power Harness As
(AM) 604-3290 Sensor Harness As
(AN) 593-2985 Chassis Harness As
(AS) 593-2981 Power Harness As
11. Connect power harness assembly (AL), sensor harness assembly (M), chassis harness
assembly (AN), and power harness assembly (AS).

Illustration 82 g06729439
 Illustration 83 g06730656
(AL) 593-2984 Power Harness As
(AM) 604-3290 Sensor Harness As
(AN) 593-2985 Chassis Harness As
(AP) 283-0658 Cable As
(AR) 588-6550 Front Harness As
(AS) 593-2981 Power Harness As
(30) 8T-4121 Hard Washer
(32) 344-5675 Nut
(45) 479-2171 Bolt As
(111) 204-2281 Cable Strap
(112) 424-2375 Plate As
(113) 424-2324 Block
(114) 424-2323 Block
(115) 424-2318 Block
(116) 424-2335 Block
(117) 424-2341 Block
(118) 424-2373 Plate
(119) 204-8000 Cable Tie Mounting
(120) 133-6934 Spacer
(121) 483-4287 Plate
(122) 116-3715 Taperlock Stud
12. Install block (113) onto power harness assembly (AL), block (114) onto sensor harness
assembly (AM), block (115) onto chassis harness assembly (AN), block (116) onto chassis
harness assembly (AN), block (117) onto cable assembly (AP) and front harness assembly
(AR).

13. Install plate assembly (112), block (113), block (114), block (115), block (116), block (117), plate
(118), bolt assembly (45), taper lock stud (122), cable tie mount (119), spacer (120), washer
(30), plate (121), nut (32), and two cable straps (111) to secure power harness assembly (AS)
and chassis harness assembly (AN).
 PPI
-
202 0004
3
06: 05/1 2F0
/ 6
0
M0 7:44- 8
1 0
© 2 671 4:00 0
023 8
Cat
Illustration 84 g06730657
(111) 204-2281 Cable Strap
14. Install three cable straps (111).
erp
illa
rI nc.

Illustration 85 g06730661
(AS) 593-2981 Power Harness As
(111) 204-2281 Cable Strap
(123) 9X-0262 Adapter
(124) 214-7566 O-Ring Seal
(125) 161-9926 Pressure Sensor Gp

15. Install two O-ring seals (124) onto adapter (123). Install adapter (123) and pressure sensor
group (125). Connect pressure sensor group (125) to chassis harness assembly (AS). Install
cable strap (111).
 Illustration 86 g06730664

Illustration 87 g07528471
(W1) Tack Weld
(AT) 549-6284 Support As
(126) 565-5175 Pin
(127) 565-5174 Pin Retainer
(197) 8C-8722 Nut
(129) 3E-9850 Bolt
16. Position two support assemblies (AA). Install two pins (126), four pin retainers (127), two bolts
(129), and two nuts (197).
Note: Tack weld nuts (197) to bolts (129) after tightening.

Cab - Connect
 Illustration 88 g06729452
(AV) 4S-4465 Screw
(AW) 577-3580 Plate
(AX) 577-3510 Access Cover As

1. Remove and keep 16 screws (AV), plate (AW), and access cover assembly (AX).

Illustration 89 g06729453
(AY) 4S-4465 Screw
(AZ) 577-3580 Plate

2. Remove and keep ten screws (AY), plate (AZ).

 Illustration 90 g06730668
(BA) 588-6550 Front Harness As
(BB) 603-8542 Cable As
(BC) 580-1855 Hose As
(BD) 580-1856 Hose As
(111) 204-2281 Cable Strap
(128) 479-2172 Bolt As
(130) 8T-4192 Bolt
(131) 200-6345 Mounting Saddle
(132) 5G-3676 Grommet
(133) 8T-1890 Clip
(134) 8T-1889 Clip
3. Connect front harness assembly (BA) and cable assembly (BB). Install bolt (130). Connect hose
assembly (BC) and hose assembly (BD). Install grommet (132), clip (133), clip (134), and bolt
assembly (128). Install two mounting saddles (131) and two cable straps (111).

Illustration 91 g06729456
(BE) 283-0658 Cable As
(BF) 274-4477 Cable As
(BG) 274-4477 Cable As
(BH) 274-4478 Cable As
4. Connect cable assembly (BE), cable assembly (BF), cable assembly (BG), and cable assembly
(BH).

Illustration 92 g06729457
(BJ) 596-5075 Alarm Harness As
(BK) 593-2988 Chassis Harness As
(BL) 593-2988 Chassis Harness As
(BM) 593-2992 Front Chassis Harness As
(BN) 593-2991 Chassis Harness As

5. Connect alarm harness assembly (BJ), chassis harness assembly (BK), chassis harness
assembly (BL), front chassis harness assembly (BM), and chassis harness assembly (BN).

Illustration 93 g06730671
(BP) 589-5484 Front Harness As
(111) 204-2281 Cable Strap

6. Connect front harness assembly (BP). Install cable strap (111).

 Illustration 94 g06730673
(BJ) 596-5075 Alarm Harness As
(BK) 593-2988 Chassis Harness As
(BL) 593-2988 Chassis Harness As
(111) 204-2281 Cable Strap
(131) 200-6345 Mounting Saddle
7. Install two mounting saddles (131) and four cable straps (111) onto alarm harness assembly
(BJ) and chassis harness assembly (BK) (BL).

Illustration 95 g06730713
(BA) 588-6550 Front Harness As
(BB) 603-8542 Cable As
(BR) 9X-2133 Hose
(111) 204-2281 Cable Strap
(131) 200-6345 Mounting Saddle
(135) 3S-8664 Clip
8. Install mounting saddle (131) and two cable straps (111) onto front harness assembly (BA) and
cable assembly (BB). Install clip (135) to secure hose (BR).

Illustration 96 g06730708
(BJ) 596-5075 Alarm Harness As
(BK) 593-2988 Chassis Harness As
(BL) 593-2988 Chassis Harness As
(BM) 593-2992 Front Chassis Harness As
(BN) 593-2991 Chassis Harness As
(111) 204-2281 Cable Strap

9. Install four cable straps (111) onto alarm harness assembly (BJ), chassis harness assembly
(BK) (BL), front chassis harness assembly (BM), and chassis harness assembly (BN).

Illustration 97 g06730710
(BN) 593-2991 Chassis Harness As
(45) 479-2171 Bolt As
(111) 204-2281 Cable Strap
(119) 204-8000 Cable Tie Mounting
10. Connect chassis harness assembly (BN). Install cable tie mount (119), bolt assembly (45), and
two cable straps (111).

Illustration 98 g06729540

Illustration 99 g07490543
(BN) 593-2991 Chassis Harness As

11. Connect chassis harness assembly (BN).

 Illustration 100 g06729546
(AY) 4S-4465 Screw
(AZ) 577-3580 Plate
12. Install plate (AZ) and ten screws (AY).

Illustration 101 g06729544

(AV) 4S-4465 Screw
(AW) 577-3580 Plate
(AX) 577-3510 Access Cover As

13. Install access cover assembly (AX), plate (AW), and 16 (AV).

Exhaust - Install
 Illustration 102 g06730714
(27) 5P-1076 Hard Washer
(35) 329-3356 Nut
(52) 135-8578 Bolt As
(128) 479-2172 Bolt As
(136) 570-7547 Bracket
(137) 135-8575 Bolt As
(138) 604-4800 Bracket As
(139) 570-7596 Bracket

1. Install bracket (136) and two bolt assemblies (137). Install bracket assembly (138) and four bolt
assemblies (128). Install bracket (139), two bolt assemblies (52), washer (27), and nut (35).

Illustration 103 g06730715

(BS) Hanger Subassembly
(BT) Hanger Subassembly
(13) 7X-7729 Washer
(30) 8T-4121 Hard Washer
(21) 8T-4185 Bolt
(32) 344-5675 Nut
(140) 264-8816 Spacer
2. Install hanger subassembly (BS), four washers (13), two bolts (21), two washers (30), two
spacers (140), and two nuts (32).

3. Install four washers (30), two spacers (140), two bolts (21), and two nuts (32).

4. Install hanger subassembly (BT) four washers (30), two washers (13), two bolts (21), and two
nuts (32).

5. Install two washers (30), two washers (13), two spacers (134), two bolts (21), and two nuts (32).

Illustration 104 g06764130

(141) 570-1838 Elbow
(142) 570-1839 Elbow
(143) 149-4741 Washer
(144) 268-4770 Bolt
(145) 149-0206 Hex Nut
(146) 134-5641 Gasket

6. Install elbow (141), elbow (142), two gaskets (146), 32 washers (143), 16 bolts (144), and 16
hex nuts (145). Tighten 16 bolts (144) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
 Illustration 105 g06731126
(147) 524-8983 Bellows As
(148) 609-2520 Band Clamp
7. Position two band clamps (148) onto the exhaust elbows. Install two bellows assemblies (147).

Illustration 106 g06730718

(149) 448-0511 Band Clamp

8. Install two band clamps (149) onto the bellows.

 Illustration 107 g06729625
(BV) 6V-8188 Nut
(BW) 444-8827 Clamp Bar
9. Loosen four nuts (BV) and two clamp bars (BW).

Illustration 108 g06730720

 Illustration 109 g06730722

Illustration 110 g06440874

SECTION D-D
Slip Joint Engagement
(D2) 69 ± 9 mm (3 ± 0.4 inch)
(147) 524-8983 Bellows As
(148) 609-2520 Band Clamp
(149) 448-0511 Band Clamp
(150) 560-3645 Tube As
(151) 560-3646 Tube As
10. Install tube assembly (150) and tube assembly (151) onto two mufflers and into two bellows
assemblies (147) to Dimension (D2).
Note: The slip joint should slide smoothly with a minimum engagement of 40 mm (1.6 inch).

11. Tighten two band clamps (148) to a torque of 65 ± 5 N.m (48 ± 4 lb ft) with a maximum wrench
speed of 75 RPM.
Note: The specified torques are required for regulatory compliance.
12. Strike band clamps (148) three times with a soft faced mallet to seat band clamps (148). The
strike direction should be radial to the tube. If a hard faced mallet is used, strike a piece of wood
instead of directly on the band clamp. The force of each strike is approximately the same as the
force required to drive a nail into soft wood.
Note: The strike direction should be radial to the tube.

13. Again, tighten two band clamps (148) to a torque of 65 ± 5 N.m (48 ± 4 lb ft) with a maximum
wrench speed of 75 RPM.

14. Tighten two band clamps (149) to a torque of 45 ± 5 N·m (33 ± 4lb ft) with a maximum wrench
speed of 75 RPM.
Note: Reverify the engagement of the slip joint. Ensure that the band clamps cover the slots
completely.

Illustration 111 g06729628

(BV) 6V-8188 Nut
(BW) 444-8827 Clamp Bar

15. Tighten two clamp bars (BW) and four nuts (BV) to a torque of 60 ± 12 N·m (44 ± 9 lb ft).
 PPI
-
202 0004
3
06: 05/1 2F0
/ 6
0
M0 7:44- 8
1
© 2 0671 04:00
023 8
Illustration 112
Cat
g06729629

erp
16. Remove and discard eight cable straps (BX) and six alignment tools (BY).
Note: The alignment tools are provided with the bellows assemblies and must be removed.
illa
rI nc.

Illustration 113 g06730723

(152) 572-2653 Insulation As
(153) 572-2655 Insulation As

17. Install insulation assembly (152) and insulation assembly (153).

High-Voltage Cables - Install

 Illustration 114 g06729636
(BZ) 6V-2317 Bolt
(CA) 7X-0579 Hard Washer
(CB) 447-5090 Access Cover Gp and 447-5091 Access Cover Gp

1. Remove and keep 12 bolts (BZ), 12 washers (CA), and two access covers (CB).

Illustration 115 g06730724

(154) 338-8490 Plate As
(155) 338-8491 Plate As
(128) 479-2172 Bolt As

2. Install plate assembly (154), plate assembly (155), four bolt assemblies (128).
 Illustration 116 g06729641
(CC) 6V-5782 Bolt
(CD) 7H-3937 Lock washer
(CE) 8T-4224 Hard Washer
(CF) 580-6391 Plate
3. Remove and keep ten bolts (CC), ten lock washers (CD), ten washers (CE), and plate (CF).

Illustration 117 g06729642

(CG) 6V-5782 Bolt
(CH) 7H-3937 Lock washer
(CJ) 8T-4224 Hard Washer
(CK) 580-6390 Plate

4. If necessary, remove and keep ten bolts (CG), ten lock washers (CH), ten washers (CJ), and
plate (CK).
 Illustration 118 g06730727
(CL) 315-5391 Nut
(156) 603-6995 Power Cable
(157) 603-6996 Power Cable
(158) 603-6997 Power Cable
5. Remove and keep six nuts (CL) from both ends of power cable (156), power cable (157), and
power cable (158).

Illustration 119 g06730726

(CF) 580-6391 Plate
(CL) 315-5391 Nut
(156) 603-6995 Power Cable
(157) 603-6996 Power Cable
(158) 603-6997 Power Cable

6. Install plate (CF) and three nuts (CL) onto power cable (156), power cable (157), and power
cable (158).
Note: Green tape feature to be centered within the clamping components
Illustration 120 g06730728

Illustration 121 g06730729

 Illustration 122 g07488127
Spring Washer Orientation - Typical Example
DETAIL A
3 Places
(13) 7X-7729 Washer
(32) 344-5675 Nut
(37) 8T-4186 Bolt
(156) 603-6995 Power Cable
(157) 603-6996 Power Cable
(158) 603-6997 Power Cable
(159) 179-2021 Belleville Washer
7. Connect power cable (156), power cable (157), and power cable (158). Install six washers (13),
six belleville washers (159), six bolts (37), and six nuts (32).
Note: Note the orientation of both spring / lock washers to be on the same side of the
connection.

Illustration 123 g06729666

(CC) 6V-5782 Bolt
(CD) 7H-3937 Lock washer
(CE) 8T-4224 Hard Washer
 (CF) 580-6391 Plate
(CL) 315-5391 Nut
8. Position plate (CF) and three nuts (CL). Install ten lock washers (CD), ten washers (CE), and
ten bolts (CC). Tighten three nuts (CL) to a final torque of 20 ± 2 N·m (177 ± 18 lb in).

Illustration 124 g06729685

(CG) 6V-5782 Bolt
(CH) 7H-3937 Lock washer
(CJ) 8T-4224 Hard Washer
(CK) 580-6390 Plate

9. Install plate (CK), eight washers (CJ), eight lock washers (CH), and eight bolts (CG).

Illustration 125 g06730734

(13) 7X-7729 Washer
(128) 479-2172 Bolt As
(160) 593-3010 Plate As
(161) 601-7586 Block
(162) 593-3016 Plate
 (163) 488-3971 Bolt As
(164) 424-2352 Plate
(165) 593-3011 Spacer
(166) 603-7003 Plate
(167) 601-6998 Plate As
(168) 603-7004 Plate
(169) 8T-4178 Bolt
10. Install plate assembly (160), four bolt assemblies (128), three blocks (161), plate (162), and two
bolt assemblies (163).

11. Install plate (164), three blocks (161), two spacers (165), plate (166), plate assembly (167),
plate (168), two washers (13), two bolts (169), and two bolt assemblies (163).

Illustration 126 g06730740

(13) 7X-7729 Washer
(128) 479-2172 Bolt As
(161) 601-7586 Block
(162) 593-3016 Plate
(163) 488-3971 Bolt As
(164) 424-2352 Plate
(165) 593-3011 Spacer
(166) 603-7003 Plate
(167) 601-6998 Plate As
(168) 603-7004 Plate
(169) 8T-4178 Bolt
(170) 593-3017 Plate As
(171) 424-2373 Plate

12. Install plate (164), three blocks (161), two spacers (165), plate (166), plate assembly (167),
plate (168), two washers (13), two bolts (169), and two bolt assemblies (163).

13. Install plate assembly (170), four bolt assemblies (128), plate (171), three blocks (161), plate
(162), two washers (13), and two bolts (169).
 Illustration 127 g06730743
(128) 479-2172 Bolt As
(172) 603-6999 Plate As
14. Install plate assembly (172) and four bolt assemblies (128).

Illustration 128 g06730749

(13) 7X-7729 Washer
(161) 601-7586 Block
(162) 593-3016 Plate
(165) 593-3011 Spacer
(169) 8T-4178 Bolt
(171) 424-2373 Plate

15. Install plate (171), three blocks (161), two spacers (165), plate (162), two washers (13), and two
bolts (169).

16. Install plate (171), three blocks (161), two spacers (165), plate (162), two washers (13), and two
bolts (169).
 Illustration 129 g06730902
(13) 7X-7729 Washer
(32) 344-5675 Nut
(161) 601-7586 Block
(162) 593-3016 Plate
(165) 593-3011 Spacer
(169) 8T-4178 Bolt
(171) 424-2373 Plate
17. Install plate (171), three blocks (161), two spacers (165), plate (162), four washers (13), two
bolts (169), and two nuts (32).

18. Install plate (171), three blocks (161), two spacers (165), plate (162), four washers (13), two
bolts (169), and two nuts (32).

Illustration 130 g06730774

Generator HV Cables
(156) 603-6995 Power Cable "G1"
(157) 603-6996 Power Cable "G2"
(158) 603-6997 Power Cable "G3"
19. Route power cable (156) to Location "G1", power cable (157) to Location "G2", and power cable
(158) to Location "G3".

Illustration 131 g06730091

Traction Motor HV Cables
(CM) 601-7001 Cable As "M1"
(CN) 601-7002 Cable As "M2"
(CP) 601-7003 Cable As "M3"
(CR) 601-7004 Cable As "M4"
(CS) 601-7005 Cable As "M5"
(CT) 601-7006 Cable As "M6"

20. Route cable assembly (CM) to Location "M1", cable assembly (CN) to Location "M2", cable
assembly (CP) to Location "M3", cable assembly (CR) to Location "M4", cable assembly (CS) to
Location "M5", cable assembly (CT) to Location "M6".

Illustration 132 g06730841

 (13) 7X-7729 Washer
(173) 8T-4178 Bolt
(174) 310-1703 Plate
(175) 601-7582 Block
(176) 601-7583 Block
21. Install three blocks (175), three blocks (176), three plates (174), six washers (13), and six bolts
(173).

Illustration 133 g06730776

Illustration 134 g06748324

 Illustration 135 g07488124
(CM) 601-7001 Cable As
(CN) 601-7002 Cable As
(CP) 601-7003 Cable As
(CR) 601-7004 Cable As
(CS) 601-7005 Cable As
(CT) 601-7006 Cable As
(13) 7X-7729 Washer
(32) 344-5675 Nut
(156) 603-6995 Power Cable "G1"
(157) 603-6996 Power Cable "G2"
(158) 603-6997 Power Cable "G3"
(159) 179-2021 Belleville Washer
(182) 8T-4182 Bolt
22. Connect cable assembly (CM), cable assembly (CN), cable assembly (CP), cable assembly
(CR), cable assembly (CS), cable assembly (CT), power cable (156), power cable (157), power
cable (158).

23. Install four washers (13), four belleville washers (159), two bolts (182), and two nuts (32).
Repeat this step for nine terminal connections.
 Illustration 136 g06730850
(CL) 315-5391 Nut
(177) 312-8913 Clamp
(178) 312-9093 Plate
(179) 7X-0605 Hard Washer
(180) 8T-4176 Bolt
(181) 329-3356 Nut
24. Tighten nine nuts (CL) to a torque of 20 ± 2 N·m (177 ± 18 lb in).

25. Install clamp (177), two plates (178), two washers (179), bolt (180), and nut (181).

Illustration 137 g06729913

(BZ) 6V-2317 Bolt
(CA) 7X-0579 Hard Washer
(CB) 447-5090 Access Cover Gp and 447-5091 Access Cover Gp

26. Install two access covers (CB), 12 washers (CA), and 12 bolts (BZ).

Handrail Lights

Illustration 138 g06763725

(183) 8T-7087 Grommet
(184) 5P-7469 Clip
 (185) 5P-7468 Clip
(186) 8T-4182 Bolt
(187) 8T-4121 Hard Washer
(188) 9X-9365 Bracket
(189) 204-8000 Cable Tie Mounting
(190) 344-5675 Nut

1. Install grommet (183), clip (184), and clip (185).

2. Install bolt (186), washers (187), bracket (188), cable tie mounting (189), and nut (190).

Illustration 139 g06763759

(191) 539-5525 Flood Lamp Gp
Note: Final mounting installation tightens to 55 ± 10 N·m (41 ± 7 lb ft).

Note: Final vertical adjustment tightens to 28 ± 7 N·m (21 ± 5 lb ft).

3. Install flood lamp group (191).

Illustration 140 g06763988

(192) 345-7725 Screw
(193) 263-8153 Plate

4. Remove screws (192) and plate (193).

 Illustration 141 g06763992
(194) 613-9276 Harness As.
5. Install harness assembly (194).

Illustration 142 g06763995

(192) 345-7725 Screw
(193) 263-8153 Plate

6. Install plate (193) and screws (192).

Illustration 143 g06764014

(195) 204-2281 Cable Strap

7. Install cable straps (195).

 PPI
-
202 0004
3
06: 05/1 2F0
/ 6
Illustration 144
(183) 8T-7087 Grommet
(184) 5P-7469 Clip
0
M0 7:44- 8
g06764003

1
© 2 0671 04:00
(185) 5P-7468 Clip
(186) 8T-4182 Bolt
(187) 8T-4121 Hard Washer
(188) 9X-9365 Bracket

023 8
(189) 204-8000 Cable Tie Mounting
(190) 344-5675 Nut

Cat
8. Install grommet (183), clip (184), and clip (185).

erp
9. Install bolt (186), washers (187), bracket (188), cable tie mounting (189), and nut (190).

illa
rI nc.

Illustration 145 g06764006

(191) 539-5525 Flood Lamp Gp
Note: Final mounting installation tightens to 55 ± 10 N·m (41 ± 7 lb ft).

Note: Final vertical adjustment tightens to 28 ± 7 N·m (21 ± 5 lb ft).

10. Install flood lamp group (191).

 Illustration 146 g06764011
(195) 204-2281 Cable Strap
(196) 613-9276 Harness As.
11. Install harness assembly (196) and cable straps (195).

Lift Hardware - Remove

Illustration 147 g07576515

 Illustration 148 g07576518
(T2) 193-5474 Shackle
(T7) 164-4033 Hoist Ring
(214) 419-3248 Plug As

1. Remove four of Tooling (T2) and three of Tooling (T7).

2. Install three plug assemblies (214).

Note: Ensure the O-ring seals of the plug assemblies remain in place.

Water Lines (Turbocharger) - Install

Illustration 149 g07594667

(215) 153-6237 Elbow As
(216) 574-0311 Hose As
(217) 592-5326 Hose As

1. Install two elbow assemblies (215), hose assembly (216), and hose assembly (217).
 Illustration 150 g07594691
(218) 6V-1249 Grommet
(219) 144-8344 Spacer
(220) 5P-7465 Clip
(221) 5P-7464 Clip
(222) 8T-4896 Hard Washer
(223) 8T-2501 Bolt
(224) 442-2672 Washer
(225) 434-5654 Nut
2. Install grommet (218), spacer (219), clip (220), clip (221), washer (222), and bolt (223).

3. Install grommet (218), spacer (219), clip (220), clip (221), washer (224), nut (225), washer
(222), and bolt (223).

Illustration 151 g07594724

(216) 574-0311 Hose As

4. Connect hose assembly (216).

 Illustration 152 g07595148
(217) 592-5326 Hose As
5. Connect hose assembly (217).

Illustration 153 g07595053

(217) 592-5326 Hose As
(218) 6V-1249 Grommet
(220) 5P-7465 Clip
(221) 5P-7464 Clip
(226) 574-0313 Bracket As
(227) 8T-4223 Hard Washer
(228) 8T-4139 Bolt
(229) 479-2172 Bolt As

6. Install bracket assembly (226), two washers (227), two bolts (228), grommet (218), clip (220),
clip (221), and bolt assembly (229) to secure hose assembly (217).
 Illustration 154 g07595079
(217) 592-5326 Hose As
(218) 6V-1249 Grommet
(220) 5P-7465 Clip
(221) 5P-7464 Clip
(226) 574-0313 Bracket As
(227) 8T-4223 Hard Washer
(228) 8T-4139 Bolt
(229) 479-2172 Bolt As
(230) 173-1583 Bracket As
(231) 125-8534 Plate As
(232) 533-4159 Bolt As
7. Install bracket assembly (226), two washers (227), two bolts (228), grommet (218), clip (220),
clip (221), bolt assembly (229), bracket assembly (230), plate assembly (231), and two bolt
assemblies (232) to secure hose assembly (217).

Illustration 155 g07595111

(217) 592-5326 Hose As
(218) 6V-1249 Grommet
(220) 5P-7465 Clip
(221) 5P-7464 Clip
 (225) 434-5654 Nut
(232) 533-4159 Bolt As
(233) 576-4965 Plate
(234) 8T-4121 Hard Washer
(235) 6V-7744 Locknut
(236) 8T-4896 Hard Washer
(237) 8T-2501 Bolt
8. Install two plates (233), two washers (234), two bolts (235). and two locknuts (225) to secure
hose assemblies (217).

9. Install two grommets (218), two clips (220), two clips (221), two bolt assemblies (232), two
washers (236), two nuts (237) to secure hose assemblies (217).

PPI-000462F0
2023/05/18
06:06:49-04:00
i07797635
© 2023 Caterpillar Inc.