Parts and Specification Information
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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.
Item | Part Number | Part Description | Qty | Specification | Approximate Weight | |
272-3410 Cooling Ar, 272-3421 Cooling Ar, 272-3408 Air Lines Gp, 288-2624 Air Lines Gp, 375-2497 Heat Shield Gp, 272-3248 Sensor Wiring Gp, 379-8150 Sensor Mounting Gp, or 383-1160 Sensor Mounting Gp, 272-3355 Handrail Gp | ||||||
1 | 285-4173 | Cooling Ar | 1 | |
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2 | 4S-8033 | Secondary Bar Pin | 2 | |||
3 | 3B-4640 | Cotter Pin | 2 | |||
4 | 198-4782 | Hard Washer | 14 | |||
5 | 7X-2489 | Bolt | 14 | |||
6 | 5P-1076 | Hard Washer | 10 | |||
7 | 8T-4956 | Bolt | 6 | |||
8 | 278-2481 | Tube As | 1 | |
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9 | 278-2479 | Tube As | 1 | |
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10 | 278-2482 | Tube As | 1 | |
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11 | 278-2480 | Tube As | 1 | |
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12 | 8T-4121 | Hard Washer | 100 | |||
13 | 8T-4136 | Bolt | 100 | |||
14 | 376-0665 | Plate | 4 | |||
15 | 204-8000 | Cable Tie Mounting | 30 | |||
16 | 161-9926 | Pressure Sensor Gp | 4 | Tighten to |
||
17 | 204-2281 | Cable Strap | 40 | |||
18 | 130-5300 | Clip | 4 | |||
19 | 277-7045 | Sensor Harness As | 2 | |||
20 | 9X-0262 | Adapter | 4 | |||
21 | 3J-7354 | O-Ring Seal | 4 | Apply Tooling (A) | ||
22 | 305-9237 | Sensor Harness As | 2 | |||
23 | 8T-4195 | Bolt | 27 | |||
24 | 7X-7729 | Washer | 64 | |||
25 | 291-1444 | Plate | 8 | |||
26 | 8T-4244 | Nut | 22 | |||
27 | 8T-4223 | Hard Washer | 32 | |||
27A | 8T-4184 | Bolt | 2 | |||
28 | 242-0810 | Clamp | 2 | |||
29 | 242-9806 | Clamp As | 2 | |||
30 | 8T-4133 | Nut | 4 | |||
31 | 8T-4910 | Bolt | 2 | |||
32 | 233-6699 | Rod As | 2 | |||
33 | 201-1378 | Spacer | 4 | |||
34 | 8T-5041 | Bolt | 2 | |||
34A | 8T-4178 | Bolt | 2 | |||
35 | 291-1442 | Clamp As | 2 | |||
36 | 291-1412 | Clamp As | 2 | |||
37 | 6V-7744 | Locknut | 12 | |||
38 | 291-1443 | Plate | 2 | |||
39 | 8X-3635 | Strip | 2 | |||
40 | 9X-6605 | U-Bolt | 2 | |||
41 | 366-8500 | Hose | 4 | |||
42 | 5T-6459 | Elbow | 4 | |||
43 | 251-0039 | T Bolt Clamp | 16 | Tighten to |
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44 | 219-0313 | T Bolt Clamp | 16 | Tighten to |
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45 | 445-8068 | Tube As | 2 | |||
46 | 248-0102 | U-Bolt | 2 | |||
47 | 8T-4224 | Hard Washer | 4 | |||
48 | 5C-7261 | Nut | 4 | |||
49 | 281-6798 | Handrail As | 1 | |
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50 | 288-2534 | Handrail As | 1 | |
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51 | 445-8067 | Handrail As | 1 | |||
52 | 146-3287 | Special Bolt | 2 | |||
52A | 9X-2133 | Hose | 2 | |||
53 | 449-5464 | Gate As | 1 | |||
54 | 290-7167 | Handrail As | 1 | |||
55 | 8T-4195 | Bolt | 2 | |||
56 | 279-9496 | Handrail As | 1 | |||
57 | 5p-7468 | Clip | 6 | |||
58 | 8T-7087 | Grommet | 6 | |||
59 | 5P-7469 | Clip | 6 | |||
60 | 115-3580 | Plate | 1 | |||
61 | 8T-4183 | Bolt | 6 | |||
62 | 352-5028 | Heat Shield As | 1 | |||
63 | 372-3117 | Angle As | 2 | |||
64 | 371-5839 | Baffle | 1 | |||
65 | 352-5031 | Heat Shield As | 1 | |||
66 | 393-5257 | Baffle | 1 | |||
67 | 5P-4115 | Hard Washer | 8 | |||
68 | 6V-7357 | Bolt | 8 | |||
69 | 501-6480 | Plate As | 2 | |||
70 | 484-0774 | Plate As | 6 | |||
71 | 355-6155 | Plate | 2 | |||
72 | 227-5327 | Clip | 6 | |||
73 | 484-0743 | Baffle | 2 | |||
74 | 278-1598 | Plate | 2 | |||
74A | 198-4777 | Hard Washer | 8 | |||
75 | 8T-4222 | Plated Washer | 16 | |||
76 | 375-4079 | Expansion Tank As | 1 | |
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77 | 8T-4186 | Bolt | 16 | |||
78 | 286-5260 | Tube | 2 | |||
79 | 135-6261 | T Bolt Clamp | 16 | Tighten to |
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80 | 366-8500 | Hose | 4 | |||
81A | 8T-4194 | Bolt | 8 | |||
82 | 198-4778 | Hard Washer | 8 | |||
83 | 329-3555 | Half Clip | 8 | |||
84 | 355-1735 | Bracket | 4 | |||
85 | 8T-4956 | Bolt | 8 | |||
86 | 128-2477 | Spacer | 8 | |||
89 | 336-6684 | Camera Gp | 1 | |||
90 | 8T-6466 | Bolt | 3 | |||
91 | 305-3748 | Plate As | 1 | |||
92 | 9X-8256 | Washer | 2 | |||
93 | 312-4475 | Bracket | 1 | |||
94 | 344-5675 | Nut | 10 | |||
96 | 348-8145 | Bracket | 1 | |||
97 | 347-7917 | Object Detection Box Gp | 4 | |||
98 | 8T-4195 | Bolt | 8 | |||
99 | 380-4489 | Plate | 4 | |||
100 | 458-2204 | Bracket As | 4 | |||
101 | 379-8128 | Sensor Mounting Gp | 1 | |||
102 | 8T-4183 | Bolt | 8 | |||
103 | 198-4778 | Hard Washer | 8 | |||
104 | 380-8404 | Sensor Harness As | 2 | |||
105 | 383-1162 | Sensor Mount As | 1 | |||
106 | 368-9816 | Sensor Harness As | 1 | |||
107 | 226-0087 | T Bolt Clamp | 4 | Tighten to |
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108 | 217-4192 | Hose | 1 | |||
109 | 220-4126 | Clamp | 4 | |||
110 | 444-9740 | Hose | 1 | |||
111 | 232-4901 | Clamp | 4 | Tighten to |
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112 | 465-1317 | Hose | 1 | |||
113 | 465-0338 | Tube As | 1 | |||
114 | 230-3671 | T Bolt Clamp | 4 | Tighten to |
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115 | 217-4195 | Hose | 1 | |||
116 | 328-9072 | Tube As | 1 | |||
117 | 328-9073 | Tube As | 1 | |||
118 | - | Bracket Sub-Assembly | 1 | |||
119 | 135-6261 | T- Bolt Clamp | 8 | Tighten to |
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120 | 294-7373 | Hose | 2 | Assembled with |
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121 | 328-9086 | Tube As | 1 | |||
122 | 328-9075 | Tube As | 1 | |||
123 | 212-6932 | T- Bolt Clamp | 8 | Tighten to |
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124 | 334-3674 | Hose | 4 | Assembled with |
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125 | 371-5943 | V-Band Clamp | 4 | Tighten to |
Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 5P-3975 | Rubber Lubricant | - |
B | 439-3941 | Link Bracket As | 2 |
C | 189-0410 | Shackle As | 2 |
D | 386-6034 | Link Bracket As | 1 |
439-3940 | Bracket As | 1 | |
E | 477-3139 | Eyebolt As | 2 |
Start By:
- Install the left-hand walkway
NOTICE |
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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. |
Note: All protective shipping covers, caps, and plugs are to be removed, unless otherwise specified. The components are to be inspected and cleaned, if necessary.
Note: Clean all mounting and contact surfaces free of wax, dirt, debris, paint, and grease. Chase all unprotected threaded holes with an appropriately sized tap.
Note: Unless otherwise specified, all fasteners are to be tightened to Standard Torque values. Refer to the Torque Specification tables at the beginning of this document for the correct standard torque values for Inch and Metric fasteners.
Note: Hoses and harnesses are to be routed to allow the most clearance and largest bend radius possible to eliminate hose rub and harness strain. Harnesses should be routed with enough slack and secured to provide adequate strain relief.
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. |
- If shipped in an Engine-Out configuration, the front module must be removed and the engine installed first. Refer to Disassembly and Assembly, KENR8384, "Front Module - Remove and Install" to remove the front module. Refer to Disassembly and Assembly, KENR8384, "Engine and Torque Converter - Remove and Install" to install the engine.
- Apply Tooling (A) onto two O-ring seals (21). Install two O-ring seals (21) onto one adapter (20). Install one adapter (20) and one pressure sensor group (16) onto tube assembly (8). Tighten one pressure sensor group (16) to a torque of
10 ± 2 N·m (89 ± 18 lb in) Show/hide tableIllustration 23 g03832157 (8) 278-2481 Tube As
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(14) 376-0665 Plate
(15) 204-8000 Cable Tie Mounting
(17) 204-2281 Cable Strap
(19) 277-7045 Sensor Harness As - Install one harness assembly (19), five mounts (15), five cable straps (17), one bracket (14), seven hard washers (12), and seven bolts (13) onto tube assembly (8).
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Illustration 24 g03832163 (8) 278-2481 Tube As
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(16) 161-9926 Pressure Sensor Gp
(17) 204-2281 Cable Strap
(18) 130-5300 Clip - Install one cable strap (17) onto pressure sensor group (16). Install one clip (18), one hard washer (13), and one bolt (12) onto tube assembly (8). Remove one plug (A).
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Illustration 25 g03832261 (16) 161-9926 Pressure Sensor Gp
(19) 277-7045 Sensor Harness As - Connect harness assembly (19) to pressure sensor group (16).
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Illustration 26 g03832169 (10) 278-2482 Tube As
(16) 161-9926 Pressure Sensor Gp
(20) 9X-0262 Adapter
(21) 3J-7354 O-Ring Seal
(A) 5P-3975 Rubber Lubricant - Apply Tooling (A) onto two O-ring seals (21). Install two O-ring seals (21) onto one adapter (20). Install one adapter (20) and one pressure sensor group (16) onto tube assembly (10). Tighten one pressure sensor group (16) to a torque of
10 ± 2 N·m (89 ± 18 lb in) .Show/hide tableIllustration 27 g03832300 (10) 278-2482 Tube As
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(14) 376-0665 Plate
(15) 204-8000 Cable Tie Mounting
(17) 204-2281 Cable Strap
(22) 305-9237 Sensor Harness As - Install one harness assembly (22), six mounts (15), six cable straps (17), one bracket (14), seven hard washers (12), and seven bolts (13) onto tube assembly (10).
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Illustration 28 g03832301 (10) 278-2482 Tube As
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(16) 161-9926 Pressure Sensor Gp
(17) 204-2281 Cable Strap
(18) 130-5300 Clip - Install one cable strap (17) onto pressure sensor group (16). Install one clip (18), one hard washer (13), and one bolt (12) onto tube assembly (10). Remove one plug (A).
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Illustration 29 g03832302 (16) 161-9926 Pressure Sensor Gp
(22) 305-9237 Sensor Harness As - Connect harness assembly (22) to pressure sensor group (16).
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Illustration 30 g03832319 (8) 278-2481 Tube As
(10) 278-2482 Tube As
(42) 5T-6459 Elbow
(43) 251-0039 Clamp - Install two elbows (42) and eight T-bolt clamp assemblies (43) onto tube assembly (8) and tube assembly (10).
Note: Do not tighten the T-bolt clamp assemblies to a final torque now.
Show/hide tableIllustration 31 g03832325 (8) 278-2481 Tube As
(10) 278-2482 Tube As
(41) 366-8500 Hose
(44) 219-0313 T Bolt Clamp - Install two hoses (41) and eight T bolt clamps (44) onto tube assembly (8) and tube assembly (10).
Note: Do not tighten the T-bolt clamp assemblies to a final torque now.
Show/hide tableIllustration 32 g03832333 Show/hide tableIllustration 33 g03832658 VIEW A-A
(26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(28) 242-0810 Clamp
(29) 242-9806 Clamp As
(32) 233-6699 Rod As
(33) 201-1378 Spacer
(34) 8T-5041 Bolt - Install one clamp (28), one clamp assembly (29), one spacer (33), one rod assembly (32), two hard washers (27), one bolt (34), and one nut (26) onto tube assembly (8).
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Illustration 34 g03832358 (23) 8T-4195 Bolt
(24) 7X-7729 Washer
(25) 291-1444 Plate
(30) 8T-4133 Nut
(34A) 8T-4178 Bolt
(35) 291-1442 Clamp As
(36) 291-1412 Clamp As
(38) 291-1443 Plate - Install one clamp assembly (35), one clamp assembly (36), two hard washers (24), one bolt (34A) and one nut (30) onto tube assembly (8). Install two plates (25), two hard washers (24), two bolts (23) onto clamp assembly (35) and clamp assembly (36). Install one plate (38), four hard washers (24), two bolts (23), and two nuts (30) onto two plates (25).
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Illustration 35 g06121607 Show/hide tableIllustration 36 g06015376 Show/hide tableIllustration 37 g06121635 (10) 278-2482 Tube As
(41) 366-8500 Hose
(42) 5T-6459 Elbow
(43) 251-0039 T Bolt Clamp
(44) 219-0313 T Bolt Clamp - Use a suitable lifting device to position tube assembly (10). The weight of tube assembly (8) is approximately
30 kg (65 lb) . Connect one elbow (42) and one hose (41). Tighten four T bolt clamps (43) and four T bolt clamps (44) to a torque of10 ± 2 N·m (89 ± 18 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
Show/hide tableIllustration 38 g06121680 Show/hide tableIllustration 39 g06015387 Show/hide tableIllustration 40 g06121691 (8) 278-2481 Tube As
(41) 366-8500 Hose
(42) 5T-6459 Elbow
(43) 251-0039 T Bolt Clamp
(44) 219-0313 T Bolt Clamp - Use a suitable lifting device to position tube assembly (8). The weight of tube assembly (8) is approximately
30 kg (65 lb) . Connect one elbow (42) and one hose (41). Tighten four T bolt clamps (43) and four T bolt clamps (44) to a torque of10 ± 2 N·m (89 ± 18 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
Show/hide tableIllustration 41 g06015654 Show/hide tableIllustration 42 g06015630 VIEW B-B
(26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(31) 8T-4910 Bolt
(32) 233-6699 Rod As
(33) 201-1378 Spacer - Position rod assembly (32). Install one spacer (33), two hard washers (27), one bolt (31), and one nut (26).
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Illustration 43 g03832545 (24) 7X-7729 Washer
(37) 6V-7744 Locknut
(39) 8X-3635 Strip
(40) 9X-6605 U-Bolt - Install one strip (39), one U-bolt (40). two hard washers (24), and two lock nuts (37).
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Illustration 44 g06117989 Right-Hand Side
(19) 277-7045 Sensor Harness As
(22) 305-9237 Sensor Harness As - Connect harness assembly (19) and harness assembly (22) to the right-hand side chassis harness.
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Illustration 45 g06118021 Left-Hand Side
(19) 277-7045 Sensor Harness As
(22) 305-9237 Sensor Harness As - Connect harness assembly (19) and harness assembly (22) to the left-hand side chassis harness.
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Illustration 46 g06118056 Left-Hand side
(9) 278-2479
(11) 278-2480 - Repeat Step 1 through 18 for tube assembly (9) and tube assembly (11) on the left-hand side of the truck.
- Once the air lines are installed, refer to Testing and Adjusting , KENR8371 , "Air Inlet System - Test and Inspect" to test the system.
Illustration 22 | g03832149 |
(8) 278-2481 Tube As
(16) 161-9926 Pressure Sensor Gp (20) 9X-0262 Adapter (21) 3J-7354 O-Ring Seal |
- Use Tooling (E) and a suitable lifting device to install expansion tank (76) onto the radiator module. The weight of expansion tank (76) is approximately
170 kg (375 lb) . Install eight hard washers (24) and eight bolts (77).Show/hide tableIllustration 48 g06118156 (126) 8T-4191 Bolt
(127) 8T-4121 Hard Washer
(128) 443-0300 Cover - Remove four bolts (126), four hard washers (127), and one cover (128). Retain the hardware.
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Illustration 49 g06118269 (17) 204-2281 Cable Strap
(129) 465-0619 Front Harness As
(130) 111-4012 Grommet
(B) 443-4613 Service Center Wiring Gp
(C) 430-9449 Coolant Level Sensor Gp - Route harness assembly (129) through grommet (130). Connect harness connector (A) to service center wiring group (B). Connect harness connector (C) to coolant level sensor (D). Install one cable strap (17).
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Illustration 50 g06118277 (126) 8T-4191 Bolt
(127) 8T-4121 Hard Washer
(128) 443-0300 Cover - Install one cover (128), four hard washers (127), and four bolts (126).
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Illustration 51 g06118283 (132) 451-7287 Hose As or 452-6617 Hose As
(133) 1P-3709 Rectangular Seal
(134) 8T-4910 Bolt
(135) 8T-4223 Hard Washer
(136) 367-2360 Tube As - Connect hose assembly (132). Install D-ring seal (133) onto tube assembly (136). Install four hard washers (134) and four bolts (135).
Illustration 47 | g06123249 |
(24) 7X-7729 Washer
(76) 375-4079 Expansion Tank As (77) 8T-4186 Bolt (E) 477-3139 Eyebolt As |
- Install two handrail assemblies (45).
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Illustration 53 g03832840 Show/hide tableIllustration 54 g03832856 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(49) 281-6798 Handrail As - Use a suitable lifting device to position handrail assembly (49). The weight of handrail assembly (49) is approximately
28 kg (61 lb) . Install twelve hard washers (12) and twelve bolts (13).Show/hide tableIllustration 55 g03832841 Show/hide tableIllustration 56 g03832856 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(50) 288-2534 Handrail As - Use a suitable lifting device to position handrail assembly (50). The weight of handrail assembly (50) is approximately
15 kg (33 lb) . Install eight hard washers (12) and eight bolts (13).Show/hide tableIllustration 57 g03832899 (6) 5P-1076 Hard Washer
(26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(57) 5p-7468 Clip
(58) 8T-7087 Grommet
(59) 5P-7469 Clip
(60) 115-3580 Plate
(61) 8T-4183 Bolt - Install two clips (57), two grommets (58), two clips (59), and one plate (60). Install two hard washers (6), two hard washers (27), two bolts (61), and two nuts (26).
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Illustration 58 g03832857 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(46) 248-0102 U-Bolt
(47) 8T-4224 Hard Washer
(48) 5C-7261 Nut
(51) 445-8067 Handrail As
(54) 290-7167 Handrail As
(55) 8T-4195 Bolt - Position handrail assembly (51). Install eight hard washers (12) and eight bolts (13). Install one U-bolt (46), two washers (47), and two nuts (48).
- Position handrail assembly (54). Install eight hard washers (12) and eight bolts (13). Install one U-bolt (46), two washers (47), and two nuts (48). Install two hard washers (12) and two bolts (55).
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Illustration 59 g03832888 (52) 146-3287 Special Bolt
(52A) 9X-2133 Hose
(53) 449-5464 Gate As - Position gate assembly (53). Install two hoses (52A) and two shoulder bolts (52).
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Illustration 60 g03888732 (6) 5P-1076 Hard Washer
(26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(27A) 8T-4184 Bolt
(57) 5P-7468 Clip
(58) 8T-7087 Grommet
(59) 5P-7469 Clip - Install four clips (57), four grommets (58), four clips (59). Install two washers (6), two hard washers (27), two bolts (27A), and two nuts (26).
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Illustration 61 g06018382 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(56) 279-9496 Handrail As - Use a suitable lifting device to install handrail assembly (56). The weight of handrail assembly (56) is approximately
32 kg (70 lb) . Install ten hard washers (12) and ten bolts (13).
Illustration 52 | g03832839 |
(45) 445-8068 Tube As |
NOTICE |
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In the following procedure, do not apply the final torque to a fastener until all parts have been loosely assembled in the correct positions. |
Note: Loosely assemble the parts. All parts should be loose from the turbocharger outlets to the after cooler. Align the tube assemblies and hoses, and install all hardware. After the overall alignment is ensured, all hardware can be tightened. The parts must be correctly installed from the turbochargers to the ATTAC. Then, apply the final torque values to the fasteners.
- Loosen two T- bolt clamps (137) and remove two protective shipping covers Retain the hardware.
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Illustration 63 g06121834 (23) 8T-4195 Bolt
(74A) 198-4777 Hard Washer
(118) Bracket As - Install bracket assembly (118). Install eight hard washers (74A) and eight bolts (23).
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Illustration 64 g06122082 (118) Bracket As
(139) 8T-4183 Bolt
(140) 198-4778 Hard Washer
(141) 8T-4223 Hard Washer
(142) 8T-4244 Nut
(143) 329-3555 Half Clip - Remove four bolts (139), four hard washers (140), four hard washers (141), four nuts (142), and two clips (143) from bracket assembly (118). Retain the hardware.
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Illustration 65 g06122103 Show/hide tableIllustration 66 g06122114 (116) 328-9072 Tube As
(117) 328-9073 Tube As
(137) 342-1323 T- Bolt Clamp - Position tube assembly (116) and tube assembly (117).
- Tighten two T- bolt clamps (137) to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) .Note: The connecting hoses should be assembled with
10 mm (0.4 inch) axial compression.Show/hide tableIllustration 67 g06122177 (139) 8T-4183 Bolt
(140) 198-4778 Hard Washer
(141) 8T-4223 Hard Washer
(142) 8T-4244 Nut
(143) 329-3555 Half Clip - Install two clips (143), four nuts (142), four hard washers (141), four hard washers (140), and four bolts (139).
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Illustration 68 g06122187 (61) 8T-4183 Bolt
(82) 198-4778 Hard Washer
(83) 329-3555 Half Clip - Install four clips (83), four hard washers (82), and four bolts (61)
Illustration 62 | g06121732 |
(137) 342-1323 T- Bolt Clamp |
- Remove two bolts (144) from camera group (89). Retain the hardware.
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Illustration 70 g06122297 (89) 336-6684 Camera Gp
(91) 305-3748 Plate As
(92) 9X-8256 Washer
(144) 3T-0849 Bolt - Install camera group (89) onto plate assembly (91). Install two washers (92) and two bolts (144).
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Illustration 71 g06122304 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(15) 204-8000 Cable Tie Mounting
(17) 204-2281 Cable Strap
(90) 8T-6466 Bolt
(93) 312-4475 Bracket
(94) 344-5675 Nut
(145) Camera Group and Bracket Subassembly - Install camera group and bracket assembly (145) onto bracket (93). Install six hard washers (12), three bolts (90), and three nuts (94). Install one mount (15), two hard washers (12), one bolt (13), and one nut (94). Install one cable strap (17).
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Illustration 72 g06122315 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(94) 344-5675 Nut
(96) 348-8145 Bracket
(146) Camera Group and Bracket Subassembly - Install camera group and bracket subassembly (146) onto bracket (96). Install eight hard washers (12), four bolts (13), and four nuts (94).
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Illustration 73 g06122318 (147) 8T-4186 Bolt
(148) 7X-7729 Washer
(149) 204-8000 Cable Tie Mounting
(150) 283-0657 Cable As - Remove one bolt (147) and one hard washer (148). Position mount (149) and coaxial cable assembly (150) out of the way. Retain the hardware.
- Remove cap (151) from coaxial cable assembly (150).
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Illustration 74 g06122320 (12) 8T-4121 Hard Washer
(23) 8T-4195 Bolt
(147) 8T-4186 Bolt
(148) 7X-7729 Washer
(149) 204-8000 Cable Tie Mounting
(150) 283-0657 Cable As
(152) Camera Group and Bracket subassembly - Install camera group and bracket subassembly (152). Install three hard washers (12) and three bolts (23). Position coaxial cable assembly (150) and mount (149). Install one hard washer (148) and one bolt (147). Connect coaxial cable assembly (150) to camera group and bracket subassembly (152).
Illustration 69 | g06122285 |
(89) 336-6684 Camera Gp
(144) 3T-0849 Bolt |
Note: In the following procedure, the connecting hoses can be pre-assembled onto either the tubes on the front module side or the tubes on the engine side for ease of assembly.
- Remove twelve bolts (153), twelve hard washers (154), two plates (155), and one baffle (156). Retain the hardware.
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Illustration 76 g06122329 - Remove one T- bolt clamp assembly (157) and one shipping cover (158) from the after cooler.
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Illustration 77 g06123946 (79) 135-6261 Clamp
(80) 366-8500 Hose - Install one hose (80) and four clamps (79).
- Repeat Step 1 and Step 2 for the opposite side of the front module.
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Illustration 78 g06118592 (160) 8T-4956 Bolt
(161) 8T-4223 Hard Washer
(162) 248-3104 Flange
(163) 129-1609 O-Ring Seal - Remove four bolts (160), four hard washers (161), two flanges (162), and one O-ring seal (163). Retain the hardware.
- Remove four shipping covers (159).
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Illustration 79 g06122426 (164) 8T-4194 Bolt
(165) 8T-4223 Hard Washer
(166) 1P-5767 Half Flange
(167) 235-2475 Rectangular Seal - Remove eight bolts (164), sixteen hard washers (165), four flanges (166), two D-ring seals (167), eight nuts (168), and two covers (169). Retain the hardware.
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Illustration 80 g06122844 - Remove one shipping cover (170). Remove one protective cap (171). Remove four bolts (172), two covers (173), and two gaskets (174).
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Illustration 81 g06122916 - Remove one T- bolt clamp assembly (175), one shipping cover (176), and one cap (177).
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Illustration 82 g06117184 - Clean the front module mounting surfaces free of wax, dirt, debris, paint, and grease.
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Illustration 83 g06123003 Right-Hand Side
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(62) 352-5028 Heat Shield As
(63) 372-3117 Angle As
(64) 371-5839 Baffle - Install one angle assembly (63), two hard washers (12), and two bolts (13). Install one heat shield assembly (62), one baffle (64), five hard washers (12), and five bolts (13).
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Illustration 84 g06122999 Left-Hand Side
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(63) 372-3117 Angle As
(65) 352-5031 Heat Shield As
(66) 393-5257 Baffle - Install one angle assembly (63), two hard washers (12), and two bolts (13). Install one heat shield assembly (65), one baffle (66), five hard washers (12), and five bolts (13).
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Illustration 85 g06117103 Right-Hand Side
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(70) 484-0774 Plate Assembly - Install three gusset assemblies (70), six hard washers (12), and six bolts (13).
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Illustration 86 g06117098 Left-Hand Side
(12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(70) 484-0774 Plate Assembly - Install three plate assemblies (70), six hard washers (12), and six bolts (13).
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Illustration 87 g06123385 Left-Hand Side
(23) 8T-4185 Bolt
(67) 5P-4115 Hard Washer
(68) 6V-7357 Bolt
(69) 501-6480 Plate As
(71) 355-6155 Plate
(72) 227-5327 Clip
(73) 484-0743 Baffle
(74) 278-1598 Plate
(75) 8T-4222 Plated Washer
(94) 344-5675 Nut - Position one baffle (73) and install one plate assembly (69), one plate (71), three plates (72), one plate (74), four hard washers (67), four bolts (68), eight hard washers (75), seven bolts (23), and one nut (94).
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Illustration 88 g06123413 Right-Hand Side
(23) 8T-4185 Bolt
(67) 5P-4115 Hard Washer
(68) 6V-7357 Bolt
(69) 501-6480 Plate As
(71) 355-6155 Plate
(72) 227-5327 Clip
(73) 484-0743 Baffle
(74) 278-1598 Plate
(75) 8T-4222 Plated Washer
(94) 344-5675 Nut - Position one baffle (73) and install one plate assembly (69), one plate (71), three plates (72), one plate (74), four hard washers (67), four bolts (68), eight hard washers (75), seven bolts (23), and one nut (94).
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Illustration 89 g06123933 - Remove one T- bolt clamp assembly (178) and one shipping cover (179).
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Illustration 90 g06123936 (79) 135-6261 Clamp
(80) 366-8500 Hose - Install one hose (80) and four clamps (79).
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Illustration 91 g06122921 (180) 127-2170 Screw
(181) 290-4689 Plate - Remove ten screws (180) and one cover (181). Retain the hardware.
- Repeat Step 2 through Step 19 for the opposite side of the front module.
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Illustration 92 g06120535 (1) 285-4173 Cooling Ar - Attach Tooling (B), Tooling (C), Tooling (D), and a suitable lifting device onto cooling arrangement (1) at the specified lifting locations.
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Illustration 93 g06120645 (1) 285-4173 Cooling Ar - Use Tooling (B), Tooling (C), Tooling (D), and the suitable lifting device to lift and level cooling arrangement (1). Position cooling arrangement (1) onto the truck chassis. The weight of cooling arrangement (1) is approximately
6545 kg (14430 lb) .Show/hide tableIllustration 94 g06014574 Right-Hand Side
(4) 198-4782 Hard Washer
(5) 7X-2489 Bolt - Install seven hard washers (4) and seven bolts (5). Tighten bolts (5) to a torque of
800 ± 100 N·m (590 ± 74 lb ft) .Show/hide tableIllustration 95 g06014582 Left-Hand Side
(4) 198-4782 Hard Washer
(5) 7X-2489 Bolt - Install seven hard washers (4) and seven bolts (5). Tighten bolts (5) to a torque of
800 ± 100 N·m (590 ± 74 lb ft) .Show/hide tableIllustration 96 g06014598 Left-Hand Side
(6) 5P-1076 Hard Washer
(7) 8T-4956 Bolt - Install three hard washers (6) and three bolts (7). Tighten bolts (7) to a torque of
100 ± 20 N·m (74 ± 15 lb ft) .Show/hide tableIllustration 97 g06014609 Right-Hand Side
(6) 5P-1076 Hard Washer
(7) 8T-4956 Bolt - Install three hard washers (6) and three bolts (7). Tighten bolts (7) to a torque of
100 ± 20 N·m (74 ± 15 lb ft) .Show/hide tableIllustration 98 g06122924 Right-Hand Side
(2) 4S-8033 Secondary Bar Pin
(3) 3B-4640 Cotter Pin
(182) 221-0751 LinkShow/hide tableIllustration 99 g06122929 Left-Hand Side
(2) 4S-8033 Secondary Bar Pin
(3) 3B-4640 Cotter Pin
(183) 221-0751 Link - Position link assembly (182). Install one pin (2) and one cotter pin (3).
- Position link assembly (183). Install one pin (2) and one cotter pin (3).
- Adjust link assembly (182) and link assembly (183) as needed to align the cooling module vertically.
Note: The link assemblies are used for aligning the front module with the hood panels.
Show/hide tableIllustration 100 g06122934 (180) 127-2170 Screw
(181) 290-4689 Plate - Install one cover (180) and ten bolts (181) . Repeat this step for the opposite side of the front module.
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Illustration 101 g06123477 (27) 8T-4223 Hard Washer
(84) 355-1735 Bracket
(85) 8T-4956 Bolt - Install two brackets (84), four hard washers (27), and four bolts (85).
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Illustration 102 g06124199 (78) 286-5260 Tube
(79) 135-6261 Clamp - Install tube (78). Tighten eight T bolt clamp assemblies (79) to a torque of to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
Show/hide tableIllustration 103 g06123906 Show/hide tableIllustration 104 g06123960 (26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(73) 8T-4910 Bolt
(74) 198-4778 Hard Washer
(86) 128-2477 Spacer
(75) 329-3555 Half Clip - Install four clips (75), four spacers (86), four hard washers (74), four bolts (73), four hard washers (27), and four nuts (26).
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Illustration 105 g06124217 (153) 8T-4195 Bolt
(154) 8T-4121 Hard Washer
(155) 308-6629 Plate
(156) 308-6625 Baffle - Install one baffle (156), two plates (155), twelve hard washers (154), twelve bolts (153).
- Repeat Step 31 through Step 34 for the opposite side of the front module.
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Illustration 106 g06124233 (164) 8T-4194 Bolt
(165) 8T-4223 Hard Washer
(166) 1P-5767 Half Flange
(167) 235-2475 Rectangular Seal
(184) 423-5682 Hose As
(185) 423-5683 Hose As - Install one rectangular seal (167) on hose assembly (184) and one rectangular seal (167) on hose assembly (185). Position hose assembly (184) and hose assembly (185) onto the hydraulic fan make-up valve. Install four half-flanges (166), eight hard washers (165), and eight bolts (164).
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Illustration 107 g06124236 Right-Hand Side
(186) 338-0036 Hose As - Connect hose assembly (186).
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Illustration 108 g06124241 Left-Hand Side
(187) 459-2590 Hose As - Connect hose assembly (187).
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Illustration 109 g06124242 From Service Center
(188) 342-2790 Hose As - Connect hose assembly (188) from the service center to the radiator.
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Illustration 110 g06119514 (109) 220-4126 Clamp
(110) 444-9740 Hose
(111) 232-4901 Clamp
(112) 465-1317 Hose
(113) 465-0338 Tube As
(114) 230-3671 T Bolt Clamp
(115) 217-4195 Hose - Install one hose (112), one hose (110), one hose (115), four T-bolt clamps (111), four T-bolt clamps (109), and T-bolt clamps (114) onto tube assembly (113).
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Illustration 111 g06119527 (113) 465-0338 Tube As
(148) 8T-4956 Bolt
(149) 8T-4223 Hard Washer
(150) 248-3104 Flange
(152) 129-1609 O-Ring Seal - Install one O-ring seal (152) onto tube assembly (113). Install one tube assembly (113), two flanges (150), four hard washers (149), and four bolts (148).
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Illustration 112 g06119536 (109) 220-4126 Clamp
(111) 232-4901 Clamp
(189) 392-5045 Hose As - Tighten four T-bolt clamps (109) and four T-bolt clamps (111) to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) . Connect hose assembly (189).Show/hide tableIllustration 113 g06119549 (114) 230-3671 T Bolt Clamp - Tighten four T-bolt clamps (114) to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
Show/hide tableIllustration 114 g06119388 (190) 370-4297 Hose As - Connect hose assembly (190).
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Illustration 115 g06119397 (107) 226-0087 T Bolt Clamp
(108) 217-4192 Hose - Install one hose (108) and four T-bolt clamps (107). Tighten four T-bolt clamps (107) to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
Show/hide tableIllustration 116 g06117066 (193) 452-6617 Hose As
(194) 338-0052 Hose As - Connect hose assembly (193) and hose assembly (194) to the expansion tank.
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Illustration 117 g06117085 (195) 274-4477 Cable As
(196) 500-1819 Chassis Harness As
(197) 470-1567 Hose As
(198) 471-7944 Hose As - Connect one coaxial cable assembly (195), one hose assembly (198), one hose assembly (197), and one harness assembly (196).
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Illustration 118 g06120715 (119) 135-6261 Clamp
(120) 294-7373 Hose
(123) 212-6932 T Bolt Clamp
(124) 334-3674 Hose
(125) 371-5943 V Band Clamp - Install two hoses (120) and eight T-bolt clamps (119). Install four hoses (124), four V-band clamps (125), an eight T-bolt clamps (123).
Note: Do not tighten the V-band clamps or T-bolt clamps to a final torque now.
Show/hide tableIllustration 119 g06120737 (26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(81A) 8T-4194 Bolt
(82) 198-4778 Hard Washer
(83) 329-3555 Half Clip
(121) 328-9086 Tube As
(122) 328-9075 Tube As - Install one tube assembly (121), one tube assembly (122), eight half-clips (83), eight hard washers (27), eight hard washers (82), eight bolts (81A), and eight nuts (26), loosely.
Note: Do not tighten the hardware to a final torque now.
Show/hide tableIllustration 120 g06120753 Show/hide tableIllustration 121 g06120758 (26) 8T-4244 Nut
(27) 8T-4223 Hard Washer
(81A) 8T-4194 Bolt
(82) 198-4778 Hard Washer
(83) 329-3555 Half Clip
(119) 135-6261 Clamp
(120) 294-7373 Hose
(123) 212-6932 T Bolt Clamp
(124) 334-3674 Hose
(125) 371-5943 V Band ClampShow/hide tableNOTICE Check the alignment of the hoses at the outlet to the turbo chargers and the inlets to the ATTAC. The center lines of the hoses and the tube assemblies must align.
- Tighten eight T-bolt clamps (119), eight T-bolt clamps (123), and four V-band clamps (125) to a torque of
7.5 ± 1 N·m (66.4 ± 8.9 lb in) .Note: The T-bolt clamps should be orientated 180° apart.
- Tighten eight half-clips (83), eight hard washers (27), eight hard washers (82), eight bolts (81A), and eight nuts (26).
Note: For hoses (120) and (124) to work correctly, the center lines of the tube assemblies and the hoses must lineup within
12.7 mm (0.50 inch) .
Illustration 75 | g06122326 |
(153) 8T-4195 Bolt
(154) 8T-4121 Hard Washer (155) 308-6629 Plate (156) 308-6625 Baffle |
Weld Specifications | |||
Weld | Type | Size | Penetration |
W1 | Fillet | |
|
W2 | Fillet | |
|
W3 | Fillet | |
|
W4 | Fillet | |
Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding.
- Refer to Illustration 122 to install the eight plates next to the two plate assemblies and the ROPS tube. Mark the location of the plates on the tube assembly. Remove the eight plates. Clean the area of the eight plates. Install the eight plates. Paint the plates and the weld areas.
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Illustration 123 g03878885 Show/hide tableIllustration 124 g03879003 (W3) 3 mm (0.12 inch) 25 x 50 mm (1.0 x 2.0 inch)
(W4)3 mm (0.12 inch) 25 x 50 mm (1.0 x 2.0 inch) - Ensure that the hoses are properly installed. Ensure that the bolts on the brackets and clamps are correctly tightened for both banks. Use the information in Illustration 123 and Illustration 124 to weld the brackets to the plate assemblies for both banks.
Note: Weld only in the positions shown. Do not weld the bracket to the tube assemblies for the ATTAC.
Illustration 122 | g06124581 |
Parts not shown for clarity (199) 465-8083 Plate (200) 465-8084 Plate (W1) (W2) |
Installation of the Cat® Detect Object Detection
Note: The information that is contained in this Special Instruction guides the user in the installation of the Caterpillar Integrated Object Detection System for Off-Highway Trucks.
Note: Do not perform any of the procedures until you have read the information in this publication.
Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.
Note: Do not perform any of the procedures until you have read the information in this publication.
Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.
NOTICE |
---|
The radar boxes contain sensors and lights. Use caution while installing. |
- Use the following steps if installing the 379-8150 Sensor Mounting Gp
- Install one sensor mounting group (101), four hard washers (103), and four bolts (102).
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Illustration 126 g06124143 (24) 7X-7729 Washer
(37) 6V-7744 Locknut
(77) 8T-4186 Bolt
(100) 458-2204 Bracket As - Install two bracket assemblies (100), sixteen hard washers (24), eight bolts (77), and eight lock nuts (37).
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Illustration 127 g06124135 (24) 7X-7729 Washer
(97) 347-7917 Object Detection Box Gp
(98) 8T-4195 Bolt
(99) 380-4489 Plate - Install two object detection box groups (97), two plates (99), four hard washers (24), and four bolts (98).
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Illustration 128 g03867071 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(15) 204-8000 Cable Tie Mounting
(18) 130-5300 Clip
(23) 8T-4195 Bolt - Install three mounts (15), three hard washers (12), and three bolts (23). Install one clip (18), one hard washer (12), and one bolt (13).
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Illustration 129 g06124131 (17) 204-2281 Cable Strap
(104) 380-8404 Sensor Harness As - Install one harness assembly (104) and five cable straps (17).
Show/hide tableIllustration 125 g06124170 (101) 379-8128 Sensor Mounting Gp
(102) 8T-4183 Bolt
(103) 198-4778 Hard Washer - Install one sensor mounting group (101), four hard washers (103), and four bolts (102).
Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.
NOTICE |
---|
The radar boxes contain sensors and lights. Use caution while installing. |
- Use the following steps if installing the 383-1160 Sensor Mounting Gp
- Install one bracket assembly (105), four hard washers (1103), and four bolts (102).
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Illustration 131 g06124111 (24) 7X-7729 Washer
(37) 6V-7744 Locknut
(77) 8T-4186 Bolt
(100) 458-2204 Bracket As - Install two bracket assemblies (100), sixteen hard washers (24), eight bolts (77), and eight lock nuts (37).
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Illustration 132 g06124101 (24) 7X-7729 Washer
(97) 347-7917 Object Detection Box Gp
(98) 8T-4195 Bolt
(99) 380-4489 Plate - Install two object detection box groups (97), two plates (99), four hard washers (24), and four bolts (98).
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Illustration 133 g03886551 (12) 8T-4121 Hard Washer
(13) 8T-4136 Bolt
(15) 204-8000 Cable Tie Mounting
(18) 130-5300 Clip
(23) 8T-4195 Bolt - Install five mounts (15), five hard washers (12), and five bolts (23). Install one clip (18), one hard washer (12), and one bolt (13).
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Illustration 134 g06124096 (17) 204-2281 Cable Strap
(104) 380-8404 Sensor Harness As
(106) 368-9816 Sensor Harness As - Install one harness assembly (104), one harness assembly (106), and seven cable straps (17).
Show/hide tableIllustration 130 g06124114 (105) 383-1162 Sensor Mount As
(102) 8T-4183 Bolt
(103) 198-4778 Hard Washer - Install one bracket assembly (105), four hard washers (1103), and four bolts (102).
Radar and Camera adjustment and calibration
- After the truck has been assembled and the body has been installed, the camera and radars must be adjusted and calibrated. Refer to Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust" or Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust"for the correct procedures.