Parts and Specification Information
Note: Verifying 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 | |
462-7605 Truck Installation Ar | ||||||
1 | - | Walkway As | 1 | |
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2 | 8T-4223 | Hard Washer | 12 | |||
3 | 8T-4194 | Bolt | 26 | |||
4 | 8T-4121 | Hard Washer | 20 | |||
5 | 8T-4195 | Bolt | 35 | |||
6 | 445-9400 | Fender As | 1 | |||
7 | 306-7555 | Mud Deflector | 1 | |||
8 | 277-0736 | Air Cleaner Gp | 1 | |
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9 | 8T-4139 | Bolt | 16 | |||
10 | 5P-1076 | Hard Washer | 16 | |||
11 | 5N-7834 | Clamp As | 3 | |||
11A | 2M-0879 | O-Ring Seal | 3 | |||
12 | 2W-9069 | Precleaner Cup Assembly | 3 | |||
13 | 419-9172 | Air Filter Element As | 2 | |||
14 | 277-7838 | Air Filter Element As | 2 | |||
15 | 445-9368 | Plate As | 1 | |||
16 | 479-2171 | Bolt As | 7 | |||
17 | 479-2172 | Bolt As | 3 | |||
18 | 505-6225 | Plate As | 1 | |||
19 | 7X-2553 | Bolt | 2 | |||
20 | 198-4780 | Hard Washer | 2 | |||
21 | 8T-6868 | Bolt | 2 | |||
22 | 8T-4223 | Hard Washer | 6 | |||
23 | 7D-9969 | Support | 3 | |||
24 | 311-3276 | Tube As | 1 | |||
25 | 311-7058 | Mirror Gp | 1 | |||
26 | 383-8300 | Lever | 2 | |||
27 | 8T-4182 | Bolt | 2 | |||
28 | 384-7898 | Block | 2 | |||
29 | 8T-5005 | Bolt | 1 | |||
30 | 302-3908 | Spacer | 1 | |||
31 | 8T-4195 | Bolt | 6 | |||
32 | 426-5380 | Flood Lamp Gp | 1 | |||
33 | 204-8000 | Cable Tie Mounting | 6 | |||
34 | 204-2281 | Cable Strap | 19 | |||
35 | 9X-8256 | Washer | 2 | |||
36 | 336-6684 | Camera Gp | 1 | |||
37 | 288-4697 | Plate As | 1 | |||
38 | 347-7917 | Object Detection Box Gp | 1 | |||
39 | 372-9143 | Plate | 1 | |||
40 | 378-6997 | Bracket As | 1 | |||
41 | 5P-4116 | Hard Washer | 4 | |||
42 | 8T-4189 | Bolt | 4 | |||
43 | 7X-7729 | Washer | 4 | |||
44 | 265-9596 | Hard Washer | 4 | |||
45 | 380-4489 | Plate | 1 | |||
46 | 8T-4183 | Bolt | 2 | |||
47 | 198-4778 | Hard Washer | 16 | |||
48 | 378-7007 | Plate As | 1 | |||
49 | 360-5282 | Plate As | 1 | |||
50 | 8T-4192 | Bolt | 1 | |||
51 | 230-7732 | Cable Tie Mounting | 1 | |||
52 | 204-2281 | Cable Strap | 6 | |||
53 | 353-2835 | Mounting Bracket As | 1 | |||
54 | 8T-4178 | Bolt | 1 | |||
55 | 8T-4133 | Nut | 1 | |||
56 | 380-8415 | Lighting Harness As | 1 | |||
57 | 353-2833 | Flood Lamp Gp | 1 | |||
58 | 291-9266 | Catwalk As | 1 | |
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59 | 436-6141 | Guardrail As | 1 | |||
60 | 500-1338 | Cover | 1 | |||
61 | 500-1337 | Cover | 1 | |||
62 | 500-1334 | Plate As | 1 | |||
63 | 8T-4222 | Plated Washer | 12 | |||
64 | 479-2171 | Bolt As | 8 |
Start By:
- Install the right hand platform
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. |
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: 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 (mounting hardware), remove the slack from the harness assembly(s) and allow adequate strain relief.
- Remove and retain fourteen bolts (A) and fourteen washers (B) from walkway assembly (1).
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Illustration 2 g06221296 (6) 445-9400 Fender As
(A) 8T-4195 Bolt
(B) 8T-4121 Hard Washer - Use a suitable lifting device to position fender assembly (6) onto the walkway. Install fourteen washers (B) and fourteen bolts (A).
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Illustration 3 g06221299 (1) Walkway As
(6) 445-9400 Fender As
(C) 8T-4195 Bolt
(D) 8T-4222 Plated Washer - Remove and retain seventeen bolts (C) and seventeen washers (D) from fender assembly (6) and walkway assembly (1).
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Illustration 4 g06221300 (E) 479-2172 Bolt As
(F) 305-5571 Plate As - Remove and retain four bolt assemblies (E). Reposition plate assembly (F) so that the eight hole pattern is to the outside. Install four bolt assemblies (E).
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Illustration 5 g06221301 (7) 306-7555 Mud Deflector
(C) 8T-4195 Bolt
(D) 8T-4222 Plated Washer - Position mud deflector (7) onto the fender assembly and walkway assembly. Install seventeen washers (D) and seventeen bolts (C).
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Illustration 6 g06221303 (G) 479-2171 Bolt As
(H) 330-4316 Plate - If necessary, remove and retain seven bolt assemblies (G) and one plate (H).
Note: Removing plate (H) will allow more room to assemble the walkway over the air cleaner.
Show/hide tableIllustration 7 g06221305 (J) 306-7483 Brace - Connect two braces (J).
Note: Use the hardware that is included with the braces.
Show/hide tableIllustration 8 g06221308 (34) 204-2281 Cable Strap
(K) 422-6726 Lighting Harness As - Connect one harness assembly (K) and install twelve cable straps (34).
Illustration 1 | g06221294 |
(1) Walkway As
(A) 8T-4195 Bolt (B) 8T-4121 Hard Washer |
- Position mirror group (25) onto tube assembly (24). Install two blocks (28), two hard washers (22), two bolts (27), and two levers (26). Install three supports (23) onto tube assembly (24).
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Illustration 10 g06221312 (21) 8T-6868 Bolt
(22) 8T-4223 Hard Washer
(25) 311-7058 Mirror Gp - Install the mirror group (25) onto the handrail. Install three washers (22) and three bolts (21).
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Illustration 11 g06221317 (34) 204-2281 Cable Strap
(L) 422-6726 Lighting Harness As - Position harness assembly (L). Install cable strap (34).
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Illustration 12 g06357889 (4) 8T-4121 Hard Washer
(22) 8T-4223 Hard Washer
(50) 8T-4192 Bolt
(51) 230-7732 Cable Tie Mounting
(52) 204-2281 Cable Strap
(53) 353-2835 Mounting Bracket As
(54) 8T-4178 Bolt
(55) 8T-4133 Nut
(56) 380-8415 Lighting Harness As
(57) 426-5380 Flood Lamp Gp - Install one flood lamp group (57), one mounting bracket assembly (53), one bolt (54), one hard washer (4) and one nut (55). Install one harness assembly (56), one mount (50), one hard washer (22), one bolt (51), and six cable straps (52).
Illustration 9 | g03834922 |
(22) 8T-4223 Hard Washer
(23) 7D-9969 Support (24) 311-3276 Tube As (25) 311-7058 Mirror Gp (26) 383-8300 Lever (27) 8T-4182 Bolt (28) 384-7898 Block |
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.
- Remove two bolts (M) from camera group (36). Retain the hardware.
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Illustration 14 g06221321 (35) 9X-8256 Washer
(36) 336-6684 Camera Gp
(37) 288-4697 Plate As
(M) 3T-0849 Bolt - Install one camera group (36) onto plate assembly (37). Install two hard washers (35) and two bolts (M).
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Illustration 15 g06357603 (32) 426-5380 Flood Lamp Gp
(33) 204-8000 Cable Tie Mounting
(37) 288-4697 Plate As
(N) Nut
(P) 5C-7261 Nut - Install one mount (33) and one lamp group (32) onto plate assembly (37). Tighten nut (N) to a torque of
9 ± 1 N·m (80 ± 9 lb in) . Tighten nut (P) to a torque of25 ± 7 N·m (221 ± 62 lb in) .Show/hide tableIllustration 16 g06357637 Show/hide tableIllustration 17 g06357640 Detail A
(4) 8T-4121 Hard Washer
(17) 479-2172 Bolt As
(32) 426-5380 Flood Lamp Gp
(29) 8T-5005 Bolt
(30) 302-3908 Spacer
(33) 204-8000 Cable Tie Mounting - Position lamp group (32). Install three bolt assemblies (17). Install two cable tie mounts (33), spacer (30), washer (4), and bolt (29).
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Illustration 18 g06357651 (34) 204-2281 Cable Strap
(32) 336-6684 Camera Gp
(R) 528-7137 Lighting Harness As
(S) 283-0657 Cable As - Connect harness assembly (R) to lamp group (32). Install two cable straps (34).
- Connect coaxial cable (S) to camera group (32). Install cable strap (34).
Illustration 13 | g06221319 |
(36) 336-6684 Camera Gp
(M) 3T-0849 Bolt |
NOTICE |
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The radar boxes contain sensors and lights. Use caution while installing. |
- Remove and retain six bolts (T) and six hard washers (V).
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Illustration 20 g06357665 (49) 360-5282 Plate As
(T) 8T-4195 Bolt
(V) 8T-4121 Hard Washer - Position plate assembly (49) and install six hard washers (V) and six bolts (T).
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Illustration 21 g03835157 (3) 8T-4194 Bolt
(33) 204-8000 Cable Tie Mounting
(46) 8T-4183 Bolt
(47) 198-4778 Hard Washer
(48) 378-7007 Plate As - Position plate assembly (48) and install two mounts (33), four hard washers (47), two bolts (3), and two bolts (46).
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Illustration 22 g03835159 (31) 8T-4195 Bolt
(40) 378-6997 Bracket As
(43) 7X-7729 Washer - Position bracket assembly (40) and install two hard washers (43) and two bolts (31).
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Illustration 23 g03835093 Show/hide tableIllustration 24 g03835160 (31) 8T-4195 Bolt
(38) 347-7917 Object Detection Box Gp
(43) 7X-7729 Washer
(44) 265-9596 Hard Washer
(45) 380-4489 Plate - Position object detection box group (38) and install four hard washers (44), two hard washers (43), one plate (45), and four bolts (31).
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Illustration 25 g06357668 (33) 204-8000 Cable Tie Mounting
(34) 204-2281 Cable Strap
(39) 372-9143 Plate
(41) 5P-4116 Hard Washer
(42) 8T-4189 Bolt
(W) 528-7137 Lighting Harness As
(X) 479-2171 Bolt As - Install one cover (39), four hard washers (41), and four bolts (42). Install one mount (33) one bolt assembly (X). Connect harness assembly (W) and install three cable straps (34).
Illustration 19 | g06357663 |
(T) 8T-4195 Bolt
(V) 8T-4121 Hard Washer |
- Remove and retain two covers (Y) from air cleaner group (8).
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Illustration 27 g03835338 (8) 277-0736 Air Cleaner Gp
(13) 419-9172 Air Filter Element As
(14) 277-7838 Air Filter Element As - Install two air filter element assemblies (14) and two air filter element assemblies (13) into air cleaner group (8).
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Illustration 28 g06357672 (8) 277-0736 Air Cleaner Gp
(Y) 277-7836 Cover As - Install two covers (Y) onto air cleaner group (8).
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Illustration 29 g06357676 (AA) 8T-4193 Bolt
(AB) 9X-8257 Washer
(AC) 8T-4132 Nut
(Z) 338-0106 Brace - Remove bolt (AA), two washers (AB), and nut (AC) from two brace assemblies (Z).
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Illustration 30 g03835343 (8) 277-0736 Air Cleaner Gp - Attach a suitable lifting device onto air cleaner group (8). The weight of air cleaner group (8) is approximately
318 kg (700 lb) .Show/hide tableIllustration 31 g03835374 (11) 5N-7834 Clamp As
(11A) 2M-0879 O-Ring Seal
(12) 2W-9069 Precleaner Cup Assembly - Install three O-ring seals (11A), three clamp assemblies (11), and three precleaner cup assemblies (12).
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Illustration 32 g06357679 (AD) 8T-9393 Bolt - Remove and keep nine bolts (AD) and the washers.
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Illustration 33 g06220589 (5) 8T-4195 Bolt
(18) 444-5225 Plate As
(19) 7X-2553 Bolt
(20) 198-4780 Hard Washer
(60) 500-1338 Cover
(61) 500-1337 Cover
(62) 500-1334 Plate As
(63) 8T-4222 Plated Washer
(64) 479-2171 Bolt As - Install cover (60), cover (61), plate assembly (62), plate assembly (18), two hard washers (20), and two bolts (19), eight bolt assemblies (64), twelve plated washers (63), and twelve bolts (5).
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Illustration 34 g06357682 (AD) 8T-9393 Bolt - Install nine bolts (AD) and the washers.
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Illustration 35 g03835390 Show/hide tableIllustration 36 g03835488 Show/hide tableIllustration 37 g03835491 (8) 277-0736 Air Cleaner Gp
(9) 8T-4139 Bolt
(10) 5P-1076 Hard WasherShow/hide tableDo not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.
- Position air cleaner group (8) onto the truck frame. Install sixteen hard washers (10) and sixteen bolts (9).
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Illustration 38 g06357965 Outer Brace Show/hide tableIllustration 39 g06357685 Upper bracket
(AA) 8T-4193 Bolt
(AB) 9X-8257 Washer
(AC) 8T-4132 Nut
(Z) 338-0106 Brace - Position outer brace assembly (Z). Install two hard washers (AB), bolt (AA), and nut (AC).
Note: Tighten the hardware at both ends of the braces to a final torque.
Show/hide tableIllustration 40 g06357687 Inner Brace
(AA) 8T-4193 Bolt
(AB) 9X-8257 Washer
(AC) 8T-4132 Nut
(Z) 338-0106 Brace - Position inner brace assembly (Z). Install two hard washers (AB), bolt (AA), and nut (AC).
Note: Tighten the hardware at both ends of the braces to a final torque.
Illustration 26 | g06357673 |
(8) 277-0736 Air Cleaner Gp
(Y) 277-7836 Cover As |
- Remove and keep eight bolts (AE), eight washers (AF), and one plate (AG) from walkway assembly (1).
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Illustration 42 g06357691 (1) 272-3329 Walkway Gp, 281-6796 Handrail As, 272-3365 Signal Lighting Gp, 323-1360 Plate As, 305-5573 Plate As, 292-5686 Handrail As
(AH) 8T-4186 Bolt
(AJ) 8T-4121 Hard Washer
(AK) 8T-4136 Bolt
(AL) 8T-4121 Hard Washer
(AM) 8T-4133 Nut - Remove and keep six bolts (AH), six hard washers (AJ), two bolts (AK), four hard washers (AL), and two nuts (AM) from walkway assembly (1).
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Illustration 43 g06021456 Show/hide tableIllustration 44 g03836061 (1) Walkway As
(2) 8T-4223 Hard Washer
(3) 8T-4194 BoltShow/hide tableDo not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.
- Use a suitable lifting device to position walkway assembly (1) onto the truck frame. The weight of walkway assembly (1) is approximately
1633 kg (3600 lb) . - Install twelve hard washers (2) and twelve bolts (3).
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Illustration 45 g03836062 (4) 8T-4121 Hard Washer
(5) 8T-4195 BoltShow/hide tableDo not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.
- Install eighteen hard washers (4) and eighteen bolts (5).
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Illustration 46 g06221656 (15) 445-9368 Plate As
(16) 479-2171 Bolt As - Install one plate assembly (15), and seven bolt assemblies (16).
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Illustration 47 g06357701 Front Catwalk
(1) Walkway As
(AE) 9X-2040 Screw
(AF) 7X-7729 Washer
(AG) 294-8044 Platform - Install platform (AG), eight washers (AF), and eight screws (AE).
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Illustration 48 g06357694 Rear Catwalk
(58) 291-9266 Catwalk As
(AS) 8T-4136 Bolt
(AT) 8T-4121 Hard Washer
(AV) 295-1055 Plate - Remove and keep seven bolts (AS), seven hard washers (AT), and plate (AV) from catwalk assembly (58).
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Illustration 49 g06357695 (58) 291-9266 Catwalk As
(AW) 8T-4136 Bolt
(AX) 8T-4121 Hard Washer - Remove and keep twelve bolts (AW) and twelve hard washers (AX) from catwalk assembly (58).
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Illustration 50 g06357697 (58) 291-9266 Catwalk As
(59) 436-6141 Guardrail As
(AW) 8T-4136 Bolt
(AX) 8T-4121 Hard Washer - Position one guardrail assembly (59) onto catwalk assembly (58). Install twelve hard washers (AX) and twelve bolts (AW).
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Illustration 51 g06357730 (59) 436-6141 Guardrail As
(AY) 8T-4183 Bolt
(AZ) 5P-1076 Hard Washer
(BA) 8T-4244 Nut
(BB) 5P-7469 Clip
(BC) 5P-7468 Clip
(BD) 8T-7087 Grommet - Remove and keep two bolts (AY), four hard washers (AZ), two nuts (BA), two clips (BB), two clips (BC), and two grommets (BD) from guardrail assembly (59).
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Illustration 52 g03835748 Show/hide tableIllustration 53 g03836359 Show/hide tableIllustration 54 g06357699 (1) Walkway As
(3) 8T-4194 Bolt
(47) 198-4778 Hard Washer
(58) 291-9266 Catwalk As
(AH) 8T-4186 Bolt
(AJ) 8T-4121 Hard Washer - Use a suitable lifting device to position catwalk assembly (58) onto walkway assembly (1).
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Do not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.
- Install twelve hard washers (47) and twelve bolts (3). Install six hard washers (AJ) and six bolts (AH).
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Illustration 55 g06357700 Rear Catwalk
(AS) 8T-4136 Bolt
(AT) 8T-4121 Hard Washer
(AV) 295-1055 Plate - Install one plate (AV), seven hard washers (AT), and seven bolts (AS).
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Illustration 56 g06357728 (AK) 8T-4136 Bolt
(AL) 8T-4121 Hard Washer
(AM) 8T-4133 Nut - Install four hard washers (AL), four bolts (AK), and four nuts (AM).
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Illustration 57 g06357732 (59) 436-6141 Guardrail As
(AY) 8T-4183 Bolt
(AZ) 5P-1076 Hard Washer
(BA) 8T-4244 Nut
(BB) 5P-7469 Clip
(BC) 5P-7468 Clip
(BD) 8T-7087 Grommet - Install two grommets (BD), two clips (BC), two clips (BB), two nuts (BA), four hard washers (AZ), and two bolts (AY) to connect guardrail assembly (59).
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Illustration 58 g06357733 (X) 479-2171 Bolt As
(W) 272-3365 Signal Lighting Gp - Remove one bolt (X). Position harness assembly (W) out of the way.
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Illustration 59 g06357736 (G) 479-2171 Bolt As
(H) 330-4316 Plate
(W) 272-3365 Signal Lighting Gp
(X) 479-2171 Bolt As - Install one plate (H), seven bolt assemblies (G). Position harness assembly (W) and install one bolt (X).
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Illustration 60 g06221291 (63) 8T-4222 Plated Washer
(5) 8T-4195 Bolt - Install five plated washers (63) and five bolts (5).
Illustration 41 | g06357688 |
(1) 272-3329 Walkway Gp, 281-6796 Handrail As, 272-3365 Signal Lighting Gp, 323-1360 Plate As, 305-5573 Plate As, 292-5686 Handrail As
(AE) 9X-2040 Screw (AF) 7X-7729 Washer (AG) 294-8044 Platform |
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.