Installation Procedure for the 992K Tier 4, LRC, and Tier 2 Large Wheel Loaders and 854K Tier 4, LRC, and Tier 2 Large Wheel Dozers Powered Access System (PAS) {1408, 7254, 7255, 7256} Caterpillar

Wheel Dozer

854K (S/N: 2211-UP; KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)

Wheel Loader

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)

Reference: REHS1841Special Instruction, "General Welding Procedures"

Introduction

This Special Instructions contains the procedure for installing the Power Access System (PAS) on the 992K Large Wheel Loaders and 854K Large Wheel Dozers.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Show/hide table

Do not operate or work on this machine or work tool unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals and Owner's Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Show/hide table

Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside.

Show/hide table

Shock/Electrocution Hazard! Do not work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

Show/hide table

Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Machine Preparation

1. Move the machine to a smooth, level surface that will support the weight of the machine.

2. Turn off the engine at the start switch and attach a Lock out Tag out warning tag to the controls of the machine.

3. Turn the battery disconnect switch to the OFF position.

4. Release any pressure left in the hydraulic system.

5. Refer to the Operations and Maintenance Manual and the Disassembly and Assembly Manual specific to your machine for any additional information.

Illustration 1	g06325104
Before and after Powered Access System (PAS) 489-6336 Handrail and Stairway Kit and 489-0883 Handrail and Stairway Kit

Required Parts

992K Tier 2 and 854K Tier 2 Unique Installation Instructions - Electrical - H4C and 221

Show/hide table

Illustration 2	g06365567
(A) 325 mm (12.80 inch) (B) 325 mm (12.80 inch) (C) 95.3 mm (3.75 inch) (D) 177 mm (7.00 inch) (22) 4E-0019 Boss

1. Weld three bosses (22) to the bumper and frame assembly.
   Show/hide table

   Illustration 3	g06079328
   (E) 155.5 mm (6.12 inch) (F) 160 mm (6.30 inch) (22) 4E-0019 Boss

2. Weld one boss (22) to the bumper and frame.
   Show/hide table

   Illustration 4	g06116467
   (G) 100 mm (3.94 inch) (H) 100 mm (3.94 inch) (J) 50 mm (1.97 inch) (K) 35 mm (1.38 inch)

3. Cut out the engine enclosure guard where the harness enters in the engine bay.
   Show/hide table

   Illustration 5	g06079426
   (L) 179.50 mm (7.06 inch) (M) 409.00 mm (16.10 inch) (N) 372.00 mm (14.65 inch) (P) 22.00 mm (0.87 inch) (2) 125-9738 Block (31) 8T-3851 Weld Boss

4. Weld two weld bosses (31) and one block (2) to the cross-member.
   Show/hide table

   Illustration 6	g06079436
   (Q) 62.00 mm (2.44 inch) (R) 277.50 mm (10.92518 inch) (S) 420.00 mm (16.54 inch) (22) 4E-0019 Boss

5. Weld one boss (22) to the cross member, to right side of the frame 62 mm (2.44 inch) (Q) from under side of cross member, and 277.5 mm (10.93 inch) (R) from front face of cross member and the second boss (22) 420 mm (16.54 inch) (S) in line with first boss.
   Show/hide table

   Illustration 7	g06374883
   (T) 3.5 mm (0.14 inch) (U) 12.5 mm (0.50 inch) (V) 9.5 mm (0.37 inch) (9) 308-3527 Toggle Switch (12) 367-3594 Film

6. Drill pattern as shown to mount switch (9) to the bumper service center. Move smaller hole to be below bigger hole for proper switch movement. After installing switch assembly (9), apply film (12).
   Show/hide table

   Illustration 8	g06079446
   (3) 130-5300 Clip (9) 308-3527 Toggle Switch (15) 366-1395 Switch Harness As (25) 6B-6205 Spacer (32) 8T-4121 Hard Washer (37) 8T-6466 Bolt

7. Install bumper service panel toggle switch (9), clip (3), spacer (25), hard washer (32), and bolt (37).
   Show/hide table

   Illustration 9	g06079466
   (41) Rear panel (42) Lower radiator grill

8. Remove rear panel (41) over the service panel and lower radiator grill (42) for Switch Harness As (15) to be strapped to the bumper harness.
   Show/hide table

   Illustration 10	g06079566
   (15) 366-1395 Switch Harness As (40) 9X-6772 Cable Strap

9. Install Switch Harness As (15) into the rear bumper service panel using Cable Strap (40). Secure the Switch harness assembly (15) to the bumper harness and the radiator harness.
   Show/hide table

   Illustration 11	g06365569
   (20) 371-6273 Power Harness As (27) 7S-8920 Clip (28) 7S-8921 Clip (32) 8T-4121 Hard Washer (33) 8T-4136 Bolt (35) 8T-4192 Bolt (36) 8T-4223 Hard Washer

10. Continue installing Power Harness As (20) as shown above.
    Show/hide table

    Illustration 12	g06079655
    (1) 124-3019 Bracket As. (8) 200-6345 Mount-Swivel (23) 4P-7581 Clip-Ladder (32) 8T-4121 Washer-Hard (33) 8T-4136 Bolt (40) 9X-6722 Strap

11. Continue installing Power Harness As (20) as shown above.
    Show/hide table

    Illustration 13	g06079659
    (6) 192-5017 Bracket As (23) 4P-7581 Clip (32) 8T-4121 Hard Washer (34) 8T-4137 Bolt (40) 9X-6772 Cable Strap

12. Continue installing Power Harness As (20) as shown above.
    Show/hide table

    Illustration 14	g06105523
    (3) 130-5300 Clip (5) 171-2215 Circuit Breaker As (17) 366-5092 Plate (18) 367-3594 Film (23) 4P-7581 Clip (32) 8T-4121 Hard Washer (34) 8T-4137 Bolt (40) 9X-6772 Cable Strap

13. Install 366-5092 Plate (17) and 171-2215 Circuit Breaker As (5). Apply 367-3594 Film (18) to font side of circuit breaker.
    Show/hide table

    Illustration 15	g06079663
    (7) 1S-0994 Clip (13) 366-1393 Cable As (16) 366-4569 Platform Harness As (20) 371-6273 Power Harness As (23) 4P-7581 Clip (32) 8T-4121 Hard Washer (34) 8T-4137 Bolt (38) 8W-8909 Sleeve (40) 9X-6772 Cable Strap

14. Install 366-4569 Platform Harness As (16), 371-6273 Power Harness As (20), and 366-1393 Cable As (13).
    Show/hide table

    Illustration 16	g06079664
    (4) 132-5789 Clip (16) 366-4569 Platform Harness As (40) 9X-6772 Cable Strap

15. Secure 366-4569 Platform Harness As (16) with 132-5789 Clip (4) and secure with 9X-6772 Cable Strap (40).
    Show/hide table

    Illustration 17	g06079665
    (16) 366-4569 Platform Harness As (40) 9X-6772 Cable Strap

16. Using 9X-6772 Cable Strap (40), secure 366-4569 Platform Harness As (16) to the main machine harness.
    Show/hide table

    Illustration 18	g06079667
    (16) 366-4569 Platform Harness As

17. Finish securing 366-4569 Platform Harness As (16) all the way to the engine bay enclosure, at the front of the platform.
    Show/hide table

    Illustration 19	g06079669
    (16) 366-4569 Platform Harness As

18. Route the 366-4569 Platform Harness As (16) through the front hood panel at the same location as the stairway light harness. Remove material as needed to fit.
    Show/hide table

    Illustration 20	g06079674
    (16) 366-4569 Platform Harness As (40) 9X-6772 Cable Strap

19. Secure 366-4569 Platform Harness As (16), using 9X-6772 Cable Strap (40), to the handrail reaching up to the switch location.
    Show/hide table

    Illustration 21	g06097268
    (3) 130-5300 Clip (9) 308-3527 Toggle Switch (11) 363-8233 Box (12) 365-2287 Film (23) 4P-7581 Clip (29) 8S-0023 Clip (30) 8S-0024 Clip (32) 8T-4121 Hard Washer (33) 8T-4136 Bolt (40) 9X-6772 Cable Strap

20. Install 363-8233 Box (11) and 308-3527 Toggle Switch (9). Secure to handrail using 8S-0023 Clip (29) and 8S-0024 Clip (30).
    Show/hide table

    Illustration 22	g06079686
    (43) C7 connector

21. In the engine bay, extract wire from Pin 11 on C7 (43) and insert into Pin 1 on 155-2269 Connector Plug As. Extract wire from Pin 10 on C7 (43) and insert into Pin 2 on 155-2269 Connector Plug As.

    Plug the four terminal wires on 371-4195 Control Harness As (19), into the connector C7 (43) in the locations indicated in Table 5.

    Note: After extracting wires from positions 10 and 11 on R-C7, insert the wire into GT-C3.

    Show/hide table

    Table 5

    371-4195 Control Harness As	Connector R-C7
    C903-BU(Blue)	Pin 12
    M904-OR(Orange)	Pin 27
    164-WH(White)	Pin 11
    202-BK(Black)	Pin 10

    Show/hide table

    Illustration 23	g06079687

22. In the engine bay, insert wire C903-BU(Blue)into Pin 12 of M-C7 and Pin 9 of M-C4.

    Insert wire M904-OR(Orange)into Pin 27 of M-C7 and Pin 31 of M-C4.

992K Tier 2 and 854K Tier 2 Unique Installation Instructions - Light Structure - H4C and 221

Show/hide table

Illustration 24	g06079688
(1) Handrail (2) Top cover (3) Steps

1. Remove handrail (1), two top covers (2), and the steps (3) that are mounted to the bumper.
   Show/hide table

   Illustration 25	g06079689
   (4) Handrail assembly (5) Upper LH stairs

2. Remove handrail assembly (4), to allow the removal of the upper left-hand stairs (5).
   Show/hide table

   Illustration 26	g06079690
   (6) Block

3. Remove blocks (6) from the bumper by grinding the welds off the blocks.
   Show/hide table

   Illustration 27	g06079691
   (A) 579 mm (22.80 inch) (B) 180 mm (7.10 inch) (C) 435 mm (17.13 inch)

4. Prepare bumper side plate surface for welding by removing paint and scale from area.
   Show/hide table

   Illustration 28	g06079805
   (8) 375-4072 Plate (9) 131-8072 Block (D) 35 mm (1.40 inch) (E) 45 mm (1.80 inch) (F) 6 mm (0.24 inch) (W1) Fillet weld 10 mm (0.40 inch)

5. Prepare plate assembly (8), prior to welding to the bumper.

   Weld two 131-8072 Block (9) onto 375-4072 Plate (8). Weld on three edges of blocks (9) with fillet weld (W1).

   Show/hide table

   Illustration 29	g06101011
   (9) 131-8072 Block (11) 375-3870 Plate (G) 6 mm (0.24 inch) (H) 39.3 mm (1.55 inch) (J) 198 mm (7.80 inch) (W1) Fillet weld 10 mm (0.40 inch)

6. Prepare 375-3870 Plate (11) prior to welding to the bumper.

   Weld two 131-8072 Block (9) onto plate (11). Weld on three edges of blocks (9) with fillet weld (W1).

   Show/hide table

   Illustration 30	g06079821
   (8) 375-4072 Plate (11) 375-3870 Plate (K) 121 mm (4.80 inch) (L) 56 mm (2.20 inch) (W1) Fillet weld 10 mm (0.40 inch)

7. Weld 375-4072 Plate (8) and 375-3870 Plate (11) to bumper using fillet weld (W1).
   Show/hide table

   Illustration 31	g06101519
   (12) 375-3867 Plate (M) 180 mm (7.10 inch) (N) 115 mm (4.53 inch) (W1) Fillet weld 10 mm (0.40 inch)

8. Weld 375-3867 Plate (12) to bumper using fillet weld (W1) on three sides.
   Show/hide table

   Illustration 32	g06364164
   (13) 481-3227 Bar (14) 481-3228 Bar (P) 179 mm (7.05 inch) (P2) 179.5 mm (7.07 inch) (R) 811 mm (32.00 inch) (S) 78 mm (3.10 inch) (W1) Fillet weld 10 mm (0.40 inch)

9. Weld 481-3227 Bar (13) and 481-3228 Bar (14) using fillet weld all around each plate.
   Show/hide table

   Illustration 33	g06079822
   (15) 480-4174 Plate (16) 4I-5228 Plate (W1) 10 mm (0.40 inch)

10. Weld three 4I-5228 Plate (16) to the bumper side with fillet welds (W1), using 480-4174 Plate (15) as a template.
    Show/hide table

    Illustration 34	g06101916
    (16) 133-8652 Block (T) 53 mm (2.10 inch) (U) 355 mm (14.00 inch) (V) 440 mm (17.30 inch) (X) 525 mm (20.70 inch) (W1) Fillet weld 10 mm (0.40 inch)

11. Weld three 133-8652 Block (16) to the bottom plate with fillet weld (W1). See following steps for exact weld locations and procedures.
    Show/hide table

    Illustration 35	g06102093
    (16) 133-8652 Block (W1) 10 mm (0.40 inch) Fillet weld

12. Weld outer two plates on all edges (W1).
    Show/hide table

    Illustration 36	g06102099
    (16) 133-8652 Block (W1) 10 mm (0.40 inch) Fillet weld

13. Weld center plate on the two shorter edges (W1).
    Show/hide table

    Illustration 37	g06079916
    (2) Top cover (Y) 477 mm (18.80 inch) (Z) 124 mm (4.90 inch)

14. Rework top cover (2) as shown, by trimming return flange to avoid interference with the Powered Access Stairway.
    Show/hide table

    Illustration 38	g06102570
    (2) Top cover (AA) 35 mm (1.38 inch) (AB) 15 mm (0.60 inch) (AC) 10 mm (0.40 inch)

15. Using same cover (2) as the previous step, trim return flange to avoid interference with the Powered Access Stairway.
    Show/hide table

    Illustration 39	g06103231
    (18) 15.5 mm (0.6 inch) Hole (AD) 530 mm (20.87 inch) (AE) 105 mm (4.10 inch) (AF) 37 mm (1.46 inch) (AG) 128 mm (5.05 inch) (AH) 135 mm (5.30 inch) (AJ) 420 mm (16.50 inch)

16. After trimming the first cover, add four holes with the diameter of 15.5 mm (0.6 inch) on top of cover.

    Note: Ignore the tread hole if new hole is on top of tread.

    Show/hide table

    Illustration 40	g06103281
    (2) Top cover (AK) 124 mm (4.90 inch) (AL) 124 mm (4.90 inch) (AM) 10 mm (0.40 inch) (AN) 21 mm (0.83 inch) (AP) 23 mm (0.91 inch)

17. Rework the next top cover (2) as shown, by trimming return flange to avoid interference with the Powered Access Stairway.
    Show/hide table

    Illustration 41	g06079962
    (19) Plate

18. Install plate (19).
    Show/hide table

    Illustration 42	g06079967
    (2) Top cover

19. Reinstall reworked top cover (2).
    Show/hide table

    Illustration 43	g06079689
    (4) Handrails (5) Upper LH stairway

20. Reinstall stairs (5) and handrails (4).

992K/854K Unique Installation Instructions - Electrical - 880, ZMX, KK2, RM2, KK4, RM5, 854K H8M, H9K, KK3, RM3, KK6, and RM6

Illustration 44	g03176678

1. Install the 366-1424 Harness As (1) to the frame. Route through the cross member and follow the battery lines connecting the right and left side of the machine. Start on the right side of the machine. Connect one end to the open connector on top of the frame rail behind the inlet grill and under the sound floor. Secure the other end of the harness to the existing mount by using one 132-5789 Clip (3) and one 7K-1181 Cable Strap (2).
   Show/hide table

   Illustration 45	g03176681

2. Continue with the harness installation. Use two 352-3964 Clips (4) and two 7K-1181 Cable Straps (2) to connect to the existing bolts that the current battery cables are using. This area can be accessed through the bottom cutouts in the cross member.
   Show/hide table

   Illustration 46	g03176704

3. Open the cover for the left side battery compartment. Continue with the harness installation by using three 132-5789 Clips (3) and three 7K-1181 Cable Straps (2) to connect to the existing cable mounting location
   Show/hide table

   Illustration 47	g03176707

4. Remove the small cover on the outside wall of the left side battery compartment.

5. Install the 171-2215 Circuit Breaker As (11) to the panel using two 8F-1434 Lockwashers (12) and two 113-8373 Screws (13).

6. Apply the 367-3594 Film (10) to the breaker. Refer to the Illustration that is above this step.
   Show/hide table

   Illustration 48	g03176711

7. Install 366-1425 Solenoid Harness As (9) to the battery compartment and bumper so that the tube is covered as shown above.

8. Use 7S-8920 Clip (14) and 7S-8921 Clip (15), 9Y-2700 Spacer (16), 8T-4121 Hard Washer (6), and 8T-5005 Bolt (17) to connect to the battery compartment.

9. Use the 7S-8920 Clip (14) and 7S-8921 Clip (15), 8T-4121 Hard Washer (6), and 8T-4136 Bolt (7) to connect to the bumper. The ends of the cable will be connected later.
   Show/hide table

   Illustration 49	g03176725

10. Connect the power end of the cable assembly to the bottom stud of the breaker (A). Secure the boot to the cable using one 7K-1181 Cable Strap (2).

11. Connect the 366-1422 Cable As (8) to the top stud of the breaker (B). Connect the other end to the stud (C) sharing the power cable from the battery. Use a tie strap (2) to secure the boot to the cable on the end connected to the breaker.

12. Connect the harness (1) to the 366-1425 Solenoid Harness As (9) and clip to the boss using a 130-5300 Clip (5), 8T-4121 Hard Washer (6), and 8T-4136 Bolt (7).

13. Use a tie strap (2) to connect the cable to the welded link on the bumper within the battery compartment.
    Show/hide table

    Illustration 50	g03176735

14. Install 341-5895 Strap (20) to the bumper below the installed harness assembly using 8T-4192 Bolt (23) and 8T-4223 Hard Washer (21). The other end will be install later.

992K/854K Unique Installation Instructions - Install Platform Switch and Harness - 880, ZMX, KK2, RM2, KK4, RM5, 854K H8M, H9K, KK3, RM3, KK6, and RM6

Show/hide table

Illustration 51	g06014811

1. Install the 365-2287 Film (98) onto the 363-8233 Box (99) so that opening in the box assembly is facing downward.

2. Install the 308-3527 Toggle Switch (96) into the hole of the box (99) along with the 249-5492 Switch Guard (97). Secure with the attached fastener.

3. Secure the harness from the switch to the box using the clip (102), cable strap (95), clip (90), hard washer (92), and bolt (91).

4. Attach the box (99) to the guardrail on the machine. Attach at the top of the stairway on the left side of the machine. Install so that the box is located above the opening in the platform for the harness. Use two 8S-0023 Clips (100) and two 8S-0024 Clips (101), 8T-4121 Hard Washers (92) and 8T-4136 Bolts (93) to secure to the guardrail.
   Show/hide table

   Illustration 52	g03178070

5. Tie strap the harness from the box (99) to the vertical post of the guardrail. Also, connect to the harness (89) that comes through the opening in the platform.

992K/854K Unique Installation Instructions - Install Bumper Switch - 880, ZMX, KK2, RM2, KK4, RM5, 854K H8M, H9K, KK3, RM3, KK6, and RM6

Show/hide table

Illustration 53	g03177118

1. Remove the top cover of the bumper above the electrical panel at the rear.

2. Install 308-3527 Toggle Switch (24) into the drawbar panel group by removing the plastic plug at the top of the panel first.

3. Install 365-2287 Film (25) around hole.

4. Insert switch (24) into opening and secure using attached nut and ensure 249-5492 Switch Guard (26) is assembled with switch.

5. Connect harness to bumper harness.

992K/854K Tier 4 Unique Installation Instructions - Block - 880, ZMX, KK2, RM2, KK4, RM5, 854K H8M, H9K, KK3, RM3, KK6, and RM6

Show/hide table

Illustration 54	g06327854
Battery compartment (50) 561-7516 Enclosure (51) 9C-7863 Block (A) 28 mm (1.10 inch) (B) 56 mm (2.20 inch) (W) Fillet weld

1. Prepare enclosure (50) plate surface on the upper right side for welding by removing paint and scale from area.

2. Weld block (51) to the battery compartment enclosure (50) as shown above with fillet weld (W) around the block.

992K/854K Common Installation Instructions

Install Enclosure to Drawbar

Show/hide table

Illustration 55	g06208707
(30) 364-7965 Platform Gp (31) 198-4780 Hard Washer (32) 8T-4140 Bolt (XX) 442-8916 Crank

1. Remove the large front cover to the 364-7965 Platform Gp (30) to gain access to the mounting locations of the platform. Also remove the side cover to expose the electrical connections.

2. Install 364-7965 Platform Gp (30) to the drawbar using nine 198-4780 Hard Washers (31) and nine 8T-4140 Bolts (32).

3. Tighten all bolts to specification.

4. Make sure to apply grease to the zerk fittings on the shaft bearings located outside the enclosure. Apply grease to the zerk on both ends of the cylinder.
   Show/hide table

   Illustration 56	g06012881
   (2) 7K-1181 Cable Strap (6) 8T-4121 Hard Washer (7) 8T-4136 Bolt (9) 366-1425 Solenoid Harness As (18) 204-2281 Cable Strap (19) 204-8000 Cable Tie Mounting (20) 341-5895 Strap (33) 8T-4192 Bolt (34) 8T-4223 Hard Washer (35) 4P-7581 Clip

5. Attach solenoid harness assembly (9) and the ground strap (20) to the platform using two Bolts (33) and two Hard Washers (34).

6. The harness can be connected to the platform (30) using the Cable Tie Mounting (19), Cable Strap (18), Clip (35), Cable Strap (2), Hard Washer (6), and Bolt (7).

7. Install remaining harness connection as shown in the above illustration.

   Note: Inspect Crank (XX), the LEFT side seen in Illustration 55 should be a cast surface. If the surface is machined and marked with part number, reposition the Crank 180°. Contact DSN for further assistance.

8. The side cover can then be reinstalled.

Preparation for Stairway Installation

Show/hide table

Illustration 57	g06004401

1. Attach plate (160) to stairway assembly (159) using two washers (155), two hard washers (152), two locknuts (154), and two bolts (151).
   Show/hide table

   Illustration 58	g06015318

2. Attach plate (157) to stairway assembly (159) using six washers (155), six hard washers (152), six locknuts (154), and six bolts (151).
   Show/hide table

   Illustration 59	g06015328

3. Attach plate (158) to stairway assembly (159) using twelve hard washers (156) and twelve bolts (153).
   Show/hide table

   Illustration 60	g06015338

4. Attach two blocks (161) to stairway assembly (159) using four washers (162) and four bolts (163) on each side.
   Show/hide table

   Illustration 61	g06015346

   Show/hide table

   Illustration 62	g06015356

5. Attach block (164) to stairway assembly (159) using four washers (165) and four bolts (166).

Sub Assembly for the Hub Assembly

Illustration 63	g06015368

Install Stairway

Show/hide table

Illustration 64	g06325085

1. Install the stairway group (36). Attach a lifting device to the appropriate step in order for the stairway to hang at about 45 degrees.

2. Line up large hole on the stairway with the shaft on the platform and slide the hub assembly (37) onto the splined shaft. Apply anti-seize onto the splines before assembly.

3. Ensure that the groove in the splined shaft is horizontal and facing towards the drawbar. With this shaft orientation the stairway should be at about 45 degrees.

4. Fasten the stairway group (36) and hub assembly (37) to platform using sixteen bolts (39) and sixteen hard washers (38).

5. Tighten bolts to specification.
   Show/hide table

   Illustration 65	g06208588
   Cutaway for clarity.

6. Use washers (54), (55), and/or (56) under the retention washer (53) as needed to shim the area between the shaft and the retention washer (53). Ensure that washers are level with hub flange as shown in the image above.

7. Install plugs (57) into the center of the hub on both sides.

Install Fast Fill Extension

Show/hide table

Illustration 66	g06328307

1. Remove fast fill in components from the outside of the drawbar before installing the extension system.

2. Install the tube assembly (67) to fuel tank using two half flanges (66) and four bolts (68). Ensure that o-ring seal (69) is in place between tube and tank.

3. Tighten bolts to specifications.

4. Connect the mounting block assembly (70) to the tube assembly (67). Use the same o-ring seal (69), flanges (66), and bolts (68) used to connect to the tank side.

5. Tighten bolts to specifications.

6. Connect the fast fill fuel adapter (71) to the block assembly (70). Attach the dust cap (72) to the receiver.

7. Attach the bracket assembly (75) to the block assembly (70) using two bolts (74), four hard washers (73), and two hex nuts (65).

   Note: There should be no holes overhanging the block assembly on the stairway side.

8. Tighten all bolts to specifications.

Install Bottom Guard

Show/hide table

Illustration 67	g06013309

1. Install the guard assembly (27) to the three blocks on the bottom of the drawbar using six bolts (29) and six washers (28).

2. Tighten bolts to specifications.

Install Side Guard

Show/hide table

Illustration 68	g06328531

1. Install the guard assembly (76) to the drawbar using six bolts (78) with six washers (77) on the right side of the fill bracket assembly (75) and two bolts (121) with two washers (120) on the left side.

2. The fast fill bracket assembly (75) can be attached to the side guard using two bolts (80) with two hard washers (79).

   Note: The bracket assembly should attach to the guard assembly using the provided holes.

Install Handrails

Show/hide table

Illustration 69	g06324669
Handrail assembly for 489-0883 Handrail and Stairway Kit

Show/hide table

Illustration 70	g06374463
Handrail assembly for 489-6336 Handrail and Stairway Kit

1. If assembling 489-0883 Handrail and Stairway Kit, attach handrail assembly (133) using two bolts (135) and two hard washers (137). Do not apply final torque. Refer to Illustration 69.

   If assembling 489-6336 Handrail and Stairway Kit, attach handrail assembly (133A) using two bolts (135) and two hard washers (137) with two bosses (133B). Do not apply final torque. Refer to Illustration 70.

   Show/hide table

   Illustration 71	g06324672

2. Attach handrail assembly (134) using two bolts (136) with two hard washers (137). Do not apply final torque.
   Show/hide table

   Illustration 72	g06324607

3. Attach handrail group (132) and handrail group (131) using two quad ring seal (139), one bushing (138), and one bolt (140) on each side of the stairway.

4. Apply grease on seal (139) before assembly.
   Show/hide table

   Illustration 73	g06324489

5. Attach two handrails (130) and two handrails (129) using two bushings (141), two seal quad rings (142), one washer (143), and one screw (144) on eight joints.

   Note: Apply Loctite 243 Blue on screws (144).

6. Apply grease on quad ring seals (142) before assembly.

7. Tighten all bolts to specifications.

Install Rubber Guards and Pin

Show/hide table

Illustration 74	g06374527

1. Install flap (83) and flap (84) to the side guard using four bolts (86) and hard washer (85).

2. Install (87) to both sides of the stairway using a spacer (88), hard washer (85), and bolt (86).

3. Install pin assembly (81) to the top of the side guard and retain using pin assembly (82).

Fill Hydraulic System and Purge Air

Illustration 75	g06324190
(P) Fill port (S) Sight gauge

Fill the hydraulic system with the designated oil based on the ambient temperatures that the machine will be operating in. Refer to Table that follows for a quick reference guide. Additional information can be found in the OMM for the machine. The fill port (P) is located above the side cover and the level can be monitored through the sight gage (S) hole in the side cover.

Once, the sight gage shows acceptable level the system cycle the system a few times to purge the air out of the cylinder and reservoir. After cycling a few times the hydraulic system, check fluid levels and refill as needed.

Software

• The Powered Access System software enables the visual and audible warnings for the operator. If the stairway is not in the full upright position with the latch fully extended when the machine parking brake is disengaged, the warning will engage.

• To enable the software, go to the transmission ECM and turn on the Powered Access feature.

• Test the warning system by leaving the stairway lowered and disengage the parking brake. An audible and visual alarm should trigger.

Switch Status - Check Procedure

Introduction

The following machine check will check the distance between the position switch and the crank for the powered access stairway.

Check Preparation

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

2. Move the transmission control to the NEUTRAL position.

3. Activate the parking brakes. Stop the engine.

4. 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.

5. Place wheel chocks in front of the wheels and behind the wheels.

6. Make sure that the transmission is in the NEUTRAL position.

7. Make sure that all air pressure and oil pressure is released before any fittings, hoses, or components are worked on.

Check Procedure

1. Ensure that ladder is pinned in the upright position.
   Show/hide table

   Illustration 76	g06384664
   (1) Cover

2. Remove cover (1) from behind the stairway. Retain all the existing hardware.
   Show/hide table

   Illustration 77	g06372825
   (A) Crank (B) Sensor

3. A light on the back of the sensor (B) should turn on once the sensor is triggered by the crank (B).

   Note: An incorrect distance could prevent the locking pin from extending and result in false stairway down alarms.

4. If the distance is not correct, adjust sensor (B) accordingly.

5. Secure the cover (1) to the powered stairway panel.

6. The large FRONT cover can be installed.