Procedure to Retrofit the Power Access Stairway to the 789C Off-Highway Truck {1408, 7253, 7254, 7960} Caterpillar

Off-Highway Truck/Tractor

789C (S/N: 2BW1-UP)

Introduction

This Special Instruction provides the installation of the power stairway.

Illustration 1	g02730735
View of the Power Access Stairway (PAS)

Illustration 2	g02730736
View of the truck prior to the PAS

Weights of Major Components

Illustration 3	g02730741

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure your safety and safety of others if a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

2. Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.

3. Move the transmission control to the PARK position.

4. Activate the parking brakes. Stop the engine and remove the ignition key.
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   Illustration 4	g02730742

5. Turn the ground level shut off to the OFF position and lock out the machine.
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   Illustration 5	g02730744

6. Disconnect the battery.

7. Place blocks in front of the wheels and behind the wheels.

Required Parts List

Remove the Existing Walkway

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Illustration 6	g02730738

1. Use a suitable lifting device to remove the existing walkway and ladder assembly (A) that would be located on the bottom of the stairway. Refer to Table 1 in order to view the weights.

2. Use a suitable lifting device to remove the existing handrails (B) that would be located on the bottom of the stairway.

3. Retain the clips and grommet (C) for later use.
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   Illustration 7	g02730747

4. Remove the existing mud flap (D) and bracket (E). Retain metal strips (F) and hardware for later use.
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   Illustration 8	g02730748

5. Remove the existing mud flap bracket (G).
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   Illustration 9	g02730749
   (1) 285-4267 Bracket As (H) 94 mm (3.70 inch)

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   Illustration 10	g02730751
   Rear view of the bracket (1) 285-4267 Bracket As (W1) 6 mm (0.24 inch) flare bevel weld

6. Position the new mud flap bracket (1). Refer to Illustration 9 and Illustration 10 to view the installation of bracket (1).
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   Illustration 11	g02730932

7. Remove covers (J). Retain hardware that was removed.

Preparation and Welding

1. Remove lower screen (K). Retain hardware that was removed.
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   Illustration 12	g02730971

2. Remove the existing mounting blocks (L).
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   Illustration 13	g02730983
   RH view (M) 580 mm (23 inch) (N) 10 mm (0.40 inch)

3. Remove the paint and scale from the area shown.
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   Illustration 14	g02731004
   (P) 238 mm (9..5 inch) (R) 98 mm (4.0 inch) (S) 50 mm (2.0 inch)

4. Remove paint and scale from area shown.
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   Illustration 15	g02731042
   (T) 32 mm (1.25 inch) (U) 63 mm (2.5 inch) (V) 50 mm (2.0 inch)

5. Remove paint and scale from area shown.
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   Illustration 16	g02731055
   (W) 32 mm (1.25 inch) (X) 20 mm (0.75 inch)

6. Scribe a line on the frame as shown.
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   Illustration 17	g02731092
   (2) 363-8771 Plate As (W2) 6 mm (0.24inch) fillet weld (W3) 4 mm (0.16 inch) fillet weld

7. Align plate assembly (2) on the frame as shown in Illustration 16.

8. Weld plate assembly (2) to the frame.
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   Illustration 18	g02731219
   (3) 8X-4712 Boss (P) 238 mm (9..5 inch) (R) 98 mm (4.0 inch) (W4) 3 mm (0.12 inch) fillet weld all around

9. Weld boss (3) to the frame.
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   Illustration 19	g02731259
   (4) 9R-2613 Weld Boss (T) 32 mm (1.25 inch) (U) 63 mm (2.5 inch) (W4) 3 mm (0.12 inch) fillet weld all around

10. Weld boss (4) to the frame.
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    Illustration 20	g02731288
    View of bumper (5) 5G-8480 Lug (Y) 25 mm (1.0 inch) (Z) 95 mm (3.75 inch) (AA) 204 mm (8.0 inch) (W4) 3 mm (0.12 inch) fillet weld all around

11. Prepare the frame in the locations shown.
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    Illustration 21	g02731324
    (5) 5G-8480 Lug (W4) 3 mm (0.12 inch) fillet weld all around

12. Weld lug (5) to frame.
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    Illustration 22	g02731341
    (4) 9R-2613 Weld Boss (AB) 271 mm (10.5 inch) (AC) 122 mm (5.0 inch) (W4) 3 mm (0.12 inch) fillet weld all around

13. Prepare the frame in the locations shown.

14. Weld boss (4) to frame.

Prepare Platform Group for Install

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Illustration 23	g02480617
(1) 360-4900 Platform Gp (2) 7T-9575 Cable As

1. Remove lid (A) from platform (1) and prepare the cable assembly (2) for installation.
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   Illustration 24	g02480716
   (2) 7T-9575 Cable As

2. Remove hardware (B) from cable assembly (2). Retain hardware (B) for later use.
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   Illustration 25	g02480742
   (1) 360-4900 Platform Gp (2) 7T-9575 Cable As (3) 5D-7635 Grommet

3. Install grommet (3) on platform group (1) and insert one end of cable assembly (2) through grommet (3).
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   Illustration 26	g02480839

4. Install cable assembly (2) in platform (1).

5. Install nut (E) and washer (F) on to cable (2).

   Note: Do not tighten nut (E).

6. Thread cable assembly (2) through loop (D).

7. Install nut (E) and washer (F) on to cable (2).

   Note: Do not tighten nut (E).

8. Thread cable assembly (2) into valve assembly (C).
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   Illustration 27	g02480845

9. Fully extend control arm (G) on valve group (C) in the direction shown in Illustration 27. Tighten nut (E).

Install the Platform Group

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Illustration 28	g02320875
(1) 360-4900 Platform Gp (2) 7X-0345 Bolt (3) 198-4780 Hard Washer

1. Use a suitable lifting device in order to install platform group (1). Secure platform group (1) with eight bolts (2) and eight washers (3). The approximate weight for the platform group (1) is 220 kg (485 lb).
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   Illustration 29	g02322413
   (4) 328-1191 Plate As (5) 8T-4183 Bolt (6) 198-4778 Hard Washer

2. Install plate assembly (4) with 12 bolts (5) and 12 washers (6).
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   Illustration 30	g02793877
   (1) 360-4900 Platform Gp (7) 328-1141 Stairway As (8) 328-1178 Hub (9) 8T-4182 Bolt (10) 198-4777 Hard Washer

3. Use a suitable lifting device in order to install stairway assembly (7) to platform group (1). Secure stairway assembly (7) with two hubs (8), 16 bolts (9) and 16 washers (10). The approximate weight of stairway assembly (7) is 110 kg (243 lb).
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   Illustration 31	g02732068
   (11) 363-8760 Handrail As (12) 8T-2502 Bolt (13) 8T-4896 Hard Washer

4. Install handrail assembly (11) with eight bolts (13) and eight washers (14).
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   Illustration 32	g06301654
   (1) 360-4900 Platform Gp (Powered Stairway) (14) 481-7869 Pipe As (15) 481-7865 Pipe As

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   Illustration 33	g06301662
   View of area (A) ( 1) 360-4900 Platform Gp (Powered Stairway) (14) 481-7869 Pipe As (15) 481-7865 Pipe As (18) 8T-4186 Bolt (19) 8T-7934 Hard Washer (19A) 466-9260 Plate

5. Install pipe assembly (14) and tube assembly (15) with 16 bolts (18) 16 hard washers (19), and four plates (19A).
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   Illustration 34	g06301683
   (16) 480-1163 Pipe As (17) 480-1154 Pipe As (18) 8T-4186 Bolt (19) 8T-7934 Hard Washer (20) 336-7068 Block (20A) 4W-2754 Quad Ring Seal (21) 489-2792 Bushing (22) 354-0501 Bushing (23) 7X-2565 Bolt

6. Assemble the lower handrails as shown in Illustration 34.

7. Install pipe assembly (16) and pipe assembly (17) with eight bolts (18) and eight washers (19).
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   Illustration 35	g06301696
   (14) 481-7869 Pipe As (15) 481-7865 Pipe As (16) 480-1163 Pipe As (17) 480-1154 Pipe As (24) 480-1165 Pipe As (25) 480-1157 Pipe As

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   Illustration 36	g06301717
   View of area (A) ( 15) 481-7865 Pipe As (25) 480-1157 Pipe As (27) 9X-2041 Screw (28) 8T-4222 Plated Washer (28A) 4W-0435 Quad Ring Seal (29) 457-0270 Bushing

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   Illustration 37	g06301726
   View of area (B) ( 17) 480-1154 Pipe As (25) 480-1157 Pipe As (27) 9X-2041 Screw (28) 8T-4222 Plated Washer (28A) 4W-0435 Quad Ring Seal (29) 457-0270 Bushing

8. Install lower pipe assemblies (24), and the lower pipe assemblies (25) with four screws (27), four washers (28), eight quad ring seals (28A), and eight bushings (29).
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   Illustration 38	g06301742
   Upper pipe assemblies (14) 481-7869 Pipe As (15) 481-7865 Pipe As (16) 480-1163 Pipe As (17) 480-1154 Pipe As (24) 480-1165 Pipe As (25) 480-1157 Pipe As (27) 9X-2041 Screw (28) 8T-4222 Plated Washer (28A) 4W-0435 Quad Ring Seal (29) 457-0270 Bushing

9. Install upper pipe assemblies (24), and the upper pipe assemblies (25) with four screws (27), four washers (28), eight quad ring seals (28A), and eight bushings (29).
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   Illustration 39	g02793890
   (34) 8T-4183 Bolt (35) 5P-1076 Hard Washer (36) 8T-4244 Nut (37) 115-3580 Plate (38) 5P-7469 Clip (39) 5P-7468 Clip (40) 6V-1874 Grommet

10. Secure handrail (14) and handrail (15) to handrails (11) with clips (38), clips (39), grommet (40), bolts (34), washers (35), nuts (36), and plate (37).

Install the Platform Wiring Group

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Illustration 40	g02793907
(1) 306-7213 Plate (5) 308-3527 Toggle Switch (6) 266-7268 Switch Guard (9) 319-7543 Film (31) 2D-0388 Grommet

1. Assemble the upper switch assembly by installing toggle switch (5), switch guard (36), and film (38) to plate (1).
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   Illustration 41	g02795298
   View of the upper switch assembly (1) 306-7213 Plate (2) 248-0102 U-Bolt (3) 5C-7261 Nut (4) 8T-4224 Hard Washer (10) 130-5300 Clip (32) 149-9129 Clip

2. Install plate (1) to the handrail with two U-bolts (2), four washers (4) and four nuts (3). Use clip (39) with the lower U-bolt (2).

3. Secure the wire harness with clip (40) with the existing hardware.
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   Illustration 42	g02735350
   (11) 358-0429 Switch Harness As (12) 7K-1181 Cable Strap (13) 147-0385 Clip

4. Connect harness (11) to the upper switch assembly and route harness assembly (11) as shown in Illustration 42.

5. Secure harness (11) with three cable straps (12) and two clips (13).
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   Illustration 43	g02735356
   (11) 358-0429 Switch Harness As (14) 033-8248 Clip (15) 8T-4195 Bolt (16) 8T-4121 Hard Washer (17) 8T-0389 Locknut (18) 310-7300 Clip

6. Drill two holes that are 11 mm (0.43 inch) in the locations shown. Secure harness (11) with two clips (14), two bolts (15), four washers (16) and two nuts (17).

7. Secure harness (11) with clip (18) with existing hardware.
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   Illustration 44	g02735376
   (10) 130-5300 Clip (11) 358-0429 Switch Harness As (14) 033-8248 Clip (15) 8T-4195 Bolt (16) 8T-4121 Hard Washer (17) 8T-0389 Locknut (A) 325 mm (13.0 inch)

8. Drill eight holes that are 11 mm (0.43 inch), in the stairway in the locations as shown.

9. Secure harness (11) with eight clips (14), eight bolts (15), 16 washers (16), and eight nuts (17).
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   Illustration 45	g02735391
   View of the lower switch assembly on the front left corner

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   Illustration 46	g02735392
   (10) 130-5300 Clip (16) 8T-4121 Hard Washer (18) 8T-4137 Bolt

10. Install the lower switch assembly in the location shown using two bolts (18), two washers (16) and one clip (10).
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    Illustration 47	g02735394
    (2) 248-0102 U-Bolt (7) 8T-4224 Hard Washer (8) 5C-7261 Nut (13) 147-0385 Clip (16) 8T-4121 Hard Washer (18) 8T-4137 Bolt (19) 2W-6818 Knob (20) 9S-1354 Nut (21) 347-2423 Plate (22) 319-6496 Film (23) 7T-9575 Cable As (24) 8T-4133 Nut (25) 5P-7469 Clip (26) 5P-7468 Clip (27) 8T-7087 Grommet (28) 167-9579 Strip (29) 8T-4183 Bolt (30) 8T-4244 Nut

11. Install plate (21) to the handrail with two U-bolts (2), four washers (7), and four nuts (8).

12. Install film (22) to plate (21).

13. Install cable assembly (23) to plate (21) using nut (20) and knob (19).

14. Secure cable assembly (23) using clip (13), bolt (18), washer (16) and nut (24).

15. Secure cable assembly (23) with clip (25), clip (26), grommet (27), strip (28), bolt (29), washer (16), and nut (30).

Routing Cables, Installing Cover, Bracket, and Mud Flaps

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Illustration 48	g02736924
(1) 6Y-6584 Ground Strap (2) 8T-4179 Bolt (3) 8T-4223 Hard Washer

1. Install ground strap (1) with two bolts (2) and two washers (3).
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   Illustration 49	g02737037
   (4) 363-9128 Cable As (5) 8M-2773 Clip (6) 8T-4185 Bolt (7) 8T-4121 Hard Washer (8) 363-8784 Switch Harness As (9) 6K-8178 Clip (10) 8T-4137 Bolt

2. Secure cable assembly (4) with clip (5), bolt (6) and washer (7).

3. Secure harness assembly (8) with clip (9), bolt (6) and washer (7).

4. Install cable assembly (4) with bolt (10) and washer (7).
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   Illustration 50	g02737278
   (4) 363-9128 Cable As (8) 363-8784 Switch Harness As (9) 6K-8178 Clip (11) 1S-0994 Clip

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   Illustration 51	g02737339
   (7) 8T-4121 Hard Washer (9) 6K-8178 Clip (10) 8T-4137 Bolt (11) 1S-0994 Clip

5. Secure cable assembly (4) and harness assembly (8) with clip (11) and clip (9) in three locations.

   Note: The clips will be located 12.7 mm (0.50 inch) above the block shown.

   Note: The clips will be bolted in place at a later time.

   Note: Ensure that the cable assembly and the harness assembly do not rub on the bumper.

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   Illustration 52	g02737318

6. Cut a slot in the cowl that is 50 mm (2.0 inch) by 60 mm (2.4 inch).
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   Illustration 53	g02737356
   (7) 8T-4121 Hard Washer (12) 363-8764 Bracket As (13) 6V-7732 Bolt (14) 362-0227 Cover (15) 8T-4189 Bolt (16) 8T-4224 Hard Washer

7. Install bracket assembly (12) with two bolts (13) and two washers (7).

8. Install cover (14) with four bolts (15) and four washers (16).
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   Illustration 54	g02737517
   (18) 285-4238 Plate (A) 184 mm (7.25 inch) (B) 595 mm (23.505 inch)

9. Cut plate (18) into lengths shown.
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   Illustration 55	g02737459
   (17) 363-9118 Mud Deflector (18) 285-4238 Plate (19) 8T-9056 Bolt (20) 8T-4896 Hard Washer

10. Reinstall the strips and hardware that was removed.

11. Install mud flap (17) with strip (18), bolts (19) and washers (20).
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    Illustration 56	g02737556
    (C) 375 mm (14.76375 inch) (D) 375 mm (14.76375 inch)

12. Cut strip (F) to lengths shown. Strip (F) was retained from the removal of the existing platform.

13. Reinstall the strips with hardware that was removed.
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    Illustration 57	g02737558
    (4) 363-9128 Cable As (8) 363-8784 Switch Harness As (9) 6K-8178 Clip (11) 1S-0994 Clip

14. Secure cable assembly (4) and harness assembly (8) with clip (11), clip (9), bolts (10), and washers (7) in three locations. Refer to Illustration 50 and Illustration 51 to view the clips mounting to strip (E).

    Note: Strip (E) was reused and modified from the previous mud flap.

15. Install strip (E) with bolts (F) and washers (G). The hardware was retained earlier in the mud flap removal process.
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    Illustration 58	g02738661
    (18) 285-4238 Plate (19) 8T-9056 Bolt (20) 8T-4896 Hard Washer

16. Install plate (18) with bolt (19) and washer (20). Plate (18) was modified in a Step 9. Refer to Illustration 54 to view plate (18).
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    Illustration 59	g02741520
    (4) 363-9128 Cable As (7) 8T-4121 Hard Washer (8) 363-8784 Switch Harness As (9) 6K-8178 Clip (10) 8T-4137 Bolt (11) 1S-0994 Clip (21) 5T-9135 Hose As (22) 130-5300 Clip (23) 7K-1181 Cable Strap

17. Drill a 35 mm (1.38 inch) hole in the cover.

18. Install grommet (21) in the hole.

19. Route harness assembly (8) through grommet (21).

20. Secure cable assembly (4) and harness assembly (8) with clip (9), clip (11) bolt (10) and washer (7).

21. Connect harness assembly (8) to the harness that was previously installed.

22. Secure harness (8) with clip (9) and clip (22).

23. Secure harness assembly (8) with cable strap (23).

24. Route harness assembly (8) as shown.
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    Illustration 60	g02742077
    (8) 363-8784 Switch Harness As (9) 6K-8178 Clip

25. Secure harness assembly (8) with five clips (9).
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    Illustration 61	g02742098
    (8) 363-8784 Switch Harness As (9) 6K-8178 Clip (23) 7K-1181 Cable Strap

26. Secure harness assembly (8) with clip (9) and existing hardware. Use cable straps (23) to secure harness assembly (8) as needed.
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    Illustration 62	g02742203
    (8) 363-8784 Switch Harness As (24) 363-9127 Platform Harness As

27. Connect harness assembly (8) to harness assembly (24).
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    Illustration 63	g02745856
    (4) 363-9128 Cable As (6) 8T-4185 Bolt (7) 8T-4121 Hard Washer (9) 6K-8178 Clip (11) 1S-0994 Clip (20) 8T-4896 Hard Washer (24) 363-9127 Platform Harness As (25) 032-3237 Spacer (26) 7X-0289 Bolt

28. Secure harness assembly (24) and cable assembly (4) with clip (9) and clip (11) and the existing hardware.

29. Secure harness assembly (24) and cable assembly (4) with clip (9), clip (11), spacer (25), bolt (26) and washer (20).

30. Secure harness assembly (24) and cable assembly (4) with clip (9), clip (11), spacer (25), bolt (7) and washer (7).
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    Illustration 64	g02746280
    (9) 6K-8178 Clip 6K-8178 Clip (11) 1S-0994 Clip (20) 8T-4896 Hard Washer (25) 032-3237 Spacer (26) 7X-0289 Bolt

31. Secure harness assembly (24) and cable assembly (4) with clip (9), clip (11), spacer (25), bolt (26) and washer (20).

32. Secure harness assembly (24) and cable assembly (4) with clip (9), clip (11) and the existing hardware.
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    Illustration 65	g02746300
    (4) 363-9128 Cable As (5) 8M-2773 Clip (9) 6K-8178 Clip (24) 363-9127 Platform Harness As

33. Secure harness (24) and cable (4) with clips (5), clips (9) and existing hardware.
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    Illustration 66	g02746447
    (23) 7K-1181 Cable Strap (24) 363-9127 Platform Harness As

34. Use cable straps (23) as needed in order to secure harness (24).
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    Illustration 67	g02746697
    (24) 363-9127 Platform Harness As (27) 5P-4295 Clip

35. Secure harness (24) with clip (27).
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    Illustration 68	g02746816
    (9) 6K-8178 Clip (23) 7K-1181 Cable Strap (24) 363-9127 Platform Harness As

36. Secure harness (24) with clip (9) and cable strap (23).

37. Connect harness (24) to the existing cab harness.
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    Illustration 69	g02747141
    (4) 363-9128 Cable As (5) 8M-2773 Clip (20) 8T-4896 Hard Washer (25) 032-3237 Spacer (26) 7X-0289 Bolt

38. Secure cable assembly (4) with three clips (5) and existing hardware.

39. Secure cable assembly (4) with clip (5), spacer (25), bolt (26) and washer (20).
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    Illustration 70	g02747181

40. Add an opening in the battery box.

41. Route cable assembly (4) as shown.

42. Secure cable assembly (4) with clip (5), bolt (10), washer (7) and block (29).

43. Secure cable assembly (4) with clip (5), bolt (10), washer (7) and boss (30).

44. Remove the existing cover.

45. Install cover (28).
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    Illustration 71	g02747909

46. Reinstall covers (J).

47. Reinstall lower screen (K).
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    Illustration 72	g02747912

48. Turn on the ground level shutdown.

Install the Cab Wiring

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Illustration 73	g02496297

1. Remove rear cover assembly (A).
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   Illustration 74	g02496317

2. Remove wiper assembly (B).

3. Remove front plate assembly (C).
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   Illustration 75	g02496338

4. Remove bottom covers (D).
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   Illustration 76	g02496500

5. Install circuit breaker assembly (1) with four screws (2). Tighten four screws (2) to a torque value of 1.2 ± 0.1 N·m (10.6 ± 0.9 lb in).
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   Illustration 77	g02730394
   Rear view of cab.

6. Route cab harness (3) as shown in Illustration 77. Secure cab harness (3) using cable straps (4) as needed.
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   Illustration 78	g02498078

7. Connect the BK(Black)wire with the ring terminal to the ground stud.
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   Illustration 79	g02496576

8. Disconnect the two 40 pin connectors of the upper "IBC Controller" (E).
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   Illustration 80	g02497077
   (3A) Indicates pink wire in location 34 (3B) Indicates white wire in location 34 (E1) Indicates J2 (E2) Indicates J1

9. Install sockets of cab harness assembly (3) into the "IBC Control Connectors" as shown.
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   Illustration 81	g02497098

10. Reconnect the two 40 pin connectors of the upper "IBC Controller" (E).
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    Illustration 82	g02498620
    Rear view of cab. (F) Indicates the OR(Orange)wire (G) Indicates the RD(Red)wire

11. Connect the wire terminals to the breakers as shown in Illustration 82.

12. Connect the wire terminals to the main relay as shown in Illustration 82.
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    Illustration 83	g02730391
    Front view of cab.

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    Illustration 84	g02730388
    Bottom view of cab.

13. Continue routing cab harness (3) as shown in Illustration 83 to the front of the cab, along the main harness. Use cable straps (4) as needed.

    Note: Leave all the cable straps (4) loose.

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    Illustration 85	g03110599

14. Push the connector on cab harness (A) through the existing hole in the bottom of the cab as shown in Illustration 85.

15. Attach cab harness (3) to the harness assembly (8).

16. Connect harness assembly (8) to 363-9127 Platform Harness As (A) that was installed earlier.

17. Connect harness assembly (8) to relay control group (9).

18. Secure harness assembly (8) with the existing hardware and one clip (13).
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    Illustration 86	g03110618

19. Route harness assembly (8) towards the rear of the cab.
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    Illustration 87	g03110697

20. Connect harness assembly (8) in the shown location in the rear of the cab.
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    Illustration 88	g03110704

21. Position relay control group (9) in an appropriate location but still able to be plugged into harness assembly (8).

22. Secure relay control group (9) using two bolts (10) four washers (11) and two nuts (12).

    Note: Pilot holes will need to be drilled to mount relay control group (9).

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    Illustration 89	g03110702

23. Secure harness assembly (8) using cable straps (20).
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    Illustration 90	g02730383
    Front view of cab.

24. Continue routing cab harness (3) as shown to the front of the cab along the main harness. Use cable straps (4) as needed.
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    Illustration 91	g02499518

25. Remove instrument panel (H) from dash.
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    Illustration 92	g02499556

26. Remove the existing film (J) from instrument panel (H).
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    Illustration 93	g02730378

27. Install LED lamp (5) into dash harness assembly (6).
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    Illustration 94	g02730377

28. Install dash harness assembly (6) into instrument panel (H).
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    Illustration 95	g02730374

29. Route dash harness assembly (6) along the existing harness. Use cable straps (4) as needed.
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    Illustration 96	g02730370

30. Install the new film (7) to instrument panel (H).
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    Illustration 97	g02500676

31. Reinstall instrument panel (H).
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    Illustration 98	g02730369
    Front view of cab.

32. Connect cab harness assembly (3) and harness assembly (6).

33. Tighten all cable straps (4).
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    Illustration 99	g02496297

34. Reinstall rear cover assembly (A).
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    Illustration 100	g02496317

35. Reinstall wiper assembly (B).

36. Reinstall front plate assembly (C).
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    Illustration 101	g02496338

37. Reinstall bottom covers (D).

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 8.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 8

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number(1)
   Removed Component Serial Number(1)
   Installed Component Part Number(2)
   Installed Component Serial Number(3)

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   (1)	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   (2)	Record the highest level retrofit kit, arrangement, or group part number.
   (3)	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 8 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".