Procedure to Install the Working at Heights Retrofit Kit on the 785C and 785D Off-Highway Trucks{0635, 0679, 5057, 6922, 7051, 7255, 7256, 7509} Caterpillar

Off-Highway Truck:

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)

785D (S/N: MSY1-UP)

Introduction

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceSpecial Instruction, REHS5097, "Instructions to Register the Retrofit"

The following procedure includes the instructions needed to install the Working at Heights Retrofit Kit on the 785C and 785D. The Working at Heights Retrofit Kit contains the parts needed for the 785C and 785D to be safely serviced at heights.

There are three kits related to Working at Heights that must be installed for the retrofit:

• 464-2539 Service Platform Gp

• 464-2540 Handrail Gp

• 437-8751 Handhold Gp

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death.

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Falling Hazard. May cause personal injury or death. Always attach safety lanyard to appropriate fixing point.

Required Parts

Prepare the Machine

Note: 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.

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 P position.

3. Fully raise the truck body and install the truck body retaining cable. Move the hoist control to the FLOAT position until the cable is tight, then move the hoist control to the HOLD position.

   Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)"

4. Stop the engine.

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

Note: Customers/Installers should use a suitable manlift or approved portable type access platform to assist in the installation.

Fabrication Procedure

464-2539 Service Platform Gp

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

Fabrication to the Frame

Fabrication to the Left-Hand Rail Assembly

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Illustration 1	g03727093
View of the left-hand side of the frame (1) 9C-8710 Block

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Illustration 2	g03727094
View of the left-hand side of the frame (1) 9C-8710 Block (AA) 224 ± 3 mm (8.819 ± 0.118 inch) (AB) 212 ± 3 mm (8.346 ± 0.118 inch) (AC) 497 ± 3 mm (19.567 ± 0.118 inch) (AD) 285 ± 3 mm (11.220 ± 0.118 inch) (AE) 495.5 ± 3 mm (19.508 ± 0.118 inch) (AF) 157 ± 3 mm (6.181 ± 0.118 inch) Four places

1. Locate the position of blocks (1) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position blocks (1) correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Right-Hand Rail Assembly

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Illustration 3	g03727130
View of the right-hand side of the frame (1) 9C-8710 Block

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Illustration 4	g03727129
View of the right-hand side of the frame (1) 9C-8710 Block (AA) 216 ± 3 mm (8.504 ± 0.118 inch) (AB) 203 ± 3 mm (7.992 ± 0.118 inch) (AC) 631.5 ± 3 mm (24.862 ± 0.118 inch) (AD) 265 ± 3 mm (10.433 ± 0.118 inch) (AE) 496.5 ± 3 mm (19.547 ± 0.118 inch) (AF) 157 ± 3 mm (6.181 ± 0.118 inch) Four places

1. Locate the position of blocks (1) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position blocks (1) correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Beam and Support Assembly

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Illustration 5	g03727144
View of the rear of the beam and support assembly (2) 5T-6229 Block Used on the 785C not needed for the 785D (3) 141-9002 Plate

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Illustration 6	g03727148
Rear view of the beam and support assembly (2) 5T-6229 Block (3) 141-9002 Plate (AA) 1242 ± 3 mm (48.897 ± 0.118 inch) (AB) 140 ± 3 mm (5.512 ± 0.118 inch) (AC) 926 ± 3 mm (36.457 ± 0.118 inch) (AD) 189 ± 3 mm (7.441 ± 0.118 inch) (AE) 474 ± 3 mm (18.661 ± 0.118 inch) (AF) 140 ± 3 mm (5.512 ± 0.118 inch) (AG) 94 ± 3 mm (3.701 ± 0.118 inch) Two places (AH) 170 ± 3 mm (6.693 ± 0.118 inch) Two places (AJ) 132.5 ± 3 mm (5.216 ± 0.118 inch) Four places

1. Locate the position of blocks (2) and plates (3) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position blocks (2) and plates (3) correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks and the plates onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Center Tube Assembly

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Illustration 7	g03727159
View of the top of the center tube assembly (4) 434-0931 Bracket As

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Illustration 8	g03727162
View of the top of the center tube assembly (4) 434-0931 Bracket As (AA) 38 ± 3 mm (1.496 ± 0.118 inch)

1. Locate the position of bracket assembly (4) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position bracket assembly (4) correctly. The handrail should be in as vertical position as possible.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the bracket assembly onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Left-Hand Support Assembly

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Illustration 9	g03727189
View of the rear of the left-hand support assembly (5) 8X-5942 Block

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Illustration 10	g03727190
View of the rear of the left-hand support assembly (5) 8X-5942 Block (AA) 158 ± 3 mm (6.220 ± 0.118 inch) (AB) 248 ± 3 mm (9.763 ± 0.118 inch) (AC) 273 ± 3 mm (10.748 ± 0.118 inch) Two places

1. Locate the position of blocks (5) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position blocks (5) correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Right-Hans Support Assembly

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Illustration 11	g03727201
View of the rear of the right-hand support assembly (6) 337-0146 Block

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Illustration 12	g03727202
View of the rear of the right-hand support assembly (6) 337-0146 Block (AA) 187 ± 3 mm (7.362 ± 0.118 inch) Two places (AB) 205 ± 3 mm (8.071 ± 0.118 inch) (AC) 151 ± 3 mm (5.945 ± 0.118 inch)

1. Locate the position of blocks (6) onto the frame.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position blocks (6) correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the frame and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks onto the frame

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Fuel Tank

Refer to Special Instruction, REHS1841, "General Welding Procedures" before welding on any fuel tank.

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Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

Do Not Weld an Empty Fuel Tank.

Fabrication to a 2040 L (540 US gal) Fuel Tank

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Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

Do Not Weld an Empty Fuel Tank.

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Illustration 13	g03727145
View of a 2040 L (540 US gal) fuel tank (7) 440-2419 Block (8) 423-1697 Block (9) 8X-5963 Block (10) 8Y-3795 Boss

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Illustration 14	g03728058
View of the rear of the 2040 L (540 US gal) fuel tank (7) 440-2419 Block (8) 423-1697 Block (AA) 85 ± 3 mm (3.346 ± 0.118 inch) (AB) 90 ± 3 mm (3.543 ± 0.118 inch) (AC) 1111 ± 3 mm (43.740 ± 0.118 inch) (AD) 137 ± 3 mm (5.394 ± 0.118 inch)

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Illustration 15	g03728059
View of the left-hand side of the 2040 L (540 US gal) fuel tank (9) 8X-5963 Block (AE) 90 ± 2 mm (3.543 ± 0.079 inch) Two places (AF) 1070.3 ± 2 mm (42.138 ± 0.079 inch) (AG) 101.7 ± 2 mm (4.004 ± 0.079 inch)

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Illustration 16	g03728060
View of the front of the 2040 L (540 US gal) fuel tank (7) 440-2419 Block (8) 423-1697 Block (AH) 85 ± 3 mm (3.346 ± 0.118 inch) (AJ) 90 ± 3 mm (3.543 ± 0.118 inch) (AK) 147 ± 3 mm (5.787 ± 0.118 inch) (AL) 1121 ± 3 mm (44.134 ± 0.118 inch)

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Illustration 17	g03728061
View of the top of the 2040 L (540 US gal) fuel tank (10) 8Y-3795 Boss (AM) 60 ± 2 mm (2.362 ± 0.07874 inch) (AN) 100.4 ± 2 mm (3.953 ± 0.07874 inch)

1. Locate the position of blocks (7), blocks (8), blocks (9), and boss (10) onto the 2040 L (540 US gal) fuel tank.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position the blocks and boss correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the fuel tank and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks and boss onto the fuel tank

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to a 2725 L (720 US gal) Fuel Tank

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Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

Do Not Weld an Empty Fuel Tank.

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Illustration 18	g03727850
View of a 2725 L (720 US gal) fuel tank (7) 440-2419 Block (9) 8X-5963 Block (10) 8Y-3795 Boss

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Illustration 19	g03728063
View of the rear of the 2725 L (720 US gal) fuel tank (7) 440-2419 Block (9) 8X-5963 Block (AA) 90 ± 2 mm (3.543 ± 0.079 inch) Three places (AB) 1468 ± 2 mm (57.795 ± 0.079 inch) (AC) 966.4 ± 2 mm (38.047 ± 0.079 inch) (AD) 808 ± 2 mm (31.811 ± 0.079 inch) (AE) 169.5 ± 2 mm (6.673 ± 0.079 inch) (AF) 85 ± 2 mm (3.346 ± 0.079 inch)

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Illustration 20	g03728064
View of the left-hand side of the 2725 L (720 US gal) fuel tank (9) 8X-5963 Block (AG) 90 ± 2 mm (3.543 ± 0.079 inch) Two places (AH) 1075 ± 2 mm (42.323 ± 0.079 inch) (AJ) 105 ± 2 mm (4.134 ± 0.079 inch)

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Illustration 21	g03728065
View of the front of the 2725 L (720 US gal) fuel tank (7) 440-2419 Block (9) 8X-5963 Block (AK) 85 ± 2 mm (3.346 ± 0.079 inch) (AL) 169.5 ± 2 mm (6.673 ± 0.079 inch) (AM) 808 ± 2 mm (31.811 ± 0.079 inch) (AN) 966.4 ± 2 mm (38.047 ± 0.079 inch) (AP) 1468 ± 2 mm (57.795 ± 0.079 inch) (AR) 90 ± 2 mm (3.543 ± 0.079 inch) Three places

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Illustration 22	g03728066
View of the top of the 2725 L (720 US gal) fuel tank (10) 8Y-3795 Boss (AS) 60 ± 2 mm (2.362 ± 0.079 inch) (AT) 100.4 ± 2 mm (3.953 ± 0.079 inch)

1. Locate the position of blocks (7), blocks (9), and boss (10) onto the 2725 L (720 US gal) fuel tank.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position the blocks and boss correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the fuel tank and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks and boss onto the fuel tank

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Fabrication to the Hydraulic Tank

Refer to Special Instruction, REHS1841, "General Welding Procedures" before welding on any hydraulic tank.

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Personal injury or death can result from an explosion. Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force. Do not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions such as filling the tank with either carbon dioxide or water.

Do Not Weld on a Closed Hydraulic Tank.

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Illustration 23	g03728187
View of the hydraulic tank (9) 8X-5963 Block (11) 391-0635 Block

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Illustration 24	g03728188
View of the rear of the hydraulic tank (11) 391-0635 Block (AA) 79.4 ± 2 mm (3.126 ± 0.079 inch) Two places (AB) 96 ± 2 mm (3.779 ± 0.079 inch) (AC) 597.5 ± 2 mm (23.524 ± 0.079 inch)

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Illustration 25	g03728189
View of the right-hand side of the hydraulic tank (9) 8X-5963 Block (AD) 60.7 ± 2 mm (2.390 ± 0.079 inch) (AE) 791.7 ± 2 mm (31.169 ± 0.079 inch)

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Illustration 26	g03728190
View of the rear of the hydraulic tank (11) 391-0635 Block (AF) 79.4 ± 2 mm (3.126 ± 0.079 inch) Three places (AG) 625.7 ± 2 mm (24.634 ± 0.079 inch) (AH) 524.1 ± 2 mm (20.634 ± 0.079 inch) (AJ) 124.2 ± 2 mm (4.890 ± 0.079 inch)

1. Locate the position of blocks (11) and block (9) onto the hydraulic tank.

   Note: The handrail assemblies and bracket assemblies should be assembled to help position the blocks correctly.

   Note: Remove any hardware or machine components that may interfere with the welding.

2. Clean the hydraulic tank and the areas to be welding. Remove all paint, dirt, oil, or debris.

   Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" before performing any welding on the machine.

3. Weld the blocks boss onto the hydraulic tank

   Note: Weld using mild steel, low hydrogen welding filler metals. Controlled heating cycles may or may not be required to control heat affected zone microstructure. The electrodes may also be used on hardenable steels and low alloy steels where "under-matched" weld deposits are allowed or preferred.

Installation Procedure

Install the 464-2539 Service Platform Gp

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Illustration 27	g03727095
View of the top of the hood group of the 785C (1) 9D-4721 Rail As (2) 8W-7381 Block (3) 8T-2502 Bolt (4) 8T-4896 Hard Washer

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Illustration 28	g03740719
Dimensions for welding on blocks (if needed) (AA) 612.50 mm (24.11 inch) (BB) 844 mm (33.23 inch) (CC) 167 mm (6.57 inch)

1. Secure rail assembly (1) to the top of the rear hood assembly by using four bolts (3), four hard washers (4), and two blocks (2) .

   Note: This step is only applicable for 785C machines.

   Note: Weld blocks (2) using the dimensions in Illustration 28 as needed. Bolt rail assembly (1) to existing weld nuts if present.

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Illustration 29	g03727097
View of the rear of the beam and support assembly of the 785C (3) 8T-2502 Bolt (4) 8T-4896 Hard Washer (5) 423-1720 Ladder As

2. Secure ladder assembly (5) to the beam and support assembly by using 10 bolts (3) and 10 hard washers (4) .

   Note: This step is only applicable for 785C machines.

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Illustration 30	g03728277
(3) 8T-2502 Bolt (6) 420-4489 Guard As (7) 5P-1075 Hard Washer

3. Secure guard assembly (6) to the center tube by using five bolts (3) and five hard washers (7) .

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Illustration 31	g03728826
(8) 366-5780 Platform (9) 2B-0947 Bolt (10) 5P-8245 Hard Washer (11) 1A-2029 Bolt (12) 9L-9132 Washer

4. Secure platform (8) to the top of the transmission by using four bolts (11) and four washers (12) .

   Secure platform (8) to the front of the torque converter by using four bolts (9) and four hard washers (10) .

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Illustration 32	g03728865
(3) 8T-2502 Bolt (7) 5P-1075 Hard Washer (13) 420-4491 Guard As

5. Secure guard assembly (13) to the center tube assembly by using five bolts (3) and five hard washers (7) .

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Illustration 33	g03728868
(11) 1A-2029 Bolt (14) 438-3273 Guard As (15) 2S-6160 Hard Washer

6. Secure guard assembly (14) to the transmission by using two bolts (11) and two hard washers (15) .

   Note: No hardware is used to secure guard assembly (14) to the right-hand side at this time.

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Illustration 34	g03729154
(16) 434-0980 Hose As (17) 9M-7958 Hose Clamp (18) 5P-2369 Clip (19) 8T-4137 Bolt (20) 8T-4121 Hard Washer

7. Connect the coupler for hose assembly (16) to the elbow on the breather. Secure the other end of hose assembly (16) to the vent on the top of the fuel tank by using hose clamp (17).

8. Secure hose assembly (16) to the top of the fuel tank by using clip (18), bolt (19), and hard washer (20) .

Assemble the Mounting Bracket Groups for the Handhold Assemblies

Note: After assembly, the 437-8759 Mounting Bracket Gp and the 437-8769 Bracket Mounting Gp will be mounting to the machine.

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Illustration 35	g03729183
View of the 437-8759 Mounting Bracket Gp (right-hand) (1) 437-8761 Plate As (2) 312-9076 Anchor (3) 8T-4138 Bolt (4) 8T-4205 Hard Washer (5) 5C-2890 Nut (6) 9M-3835 Rubber Latch (7) 2M-5795 Clevis Pin (8) 5P-4115 Hard Washer (9) 3B-4607 Cotter Pin (10) 418-7343 Rubber Block (11) 8T-4186 Bolt (12) 8T-4121 Hard Washer (13) 1V-6645 Spacer (14) 8T-4133 Nut (15) 9M-3837 Catch Bracket (16) 8T-4137 Bolt

1. Secure two anchors (2) to plate assembly (1) by using four bolts (3), eight hard washers (4), and four nuts (5) .

   Secure two rubber latches (6) to anchors (2) by using two clevis pins (7), two hard washers (8), and two cotter pins (9) .

2. Secure two rubber blocks (10) to non-hinged portion of plate assembly (1) by using four bolts (11), four hard washers (12), and four spacers (13) .

   Secure two rubber blocks (10) to the hinged portion of plate assembly (1) by using four bolts (11), eight hard washers (12), four spacers (13), and four nuts (14) .

3. Secure two catch brackets (15) to plate assembly (1) by using four bolts (16) and four hard washers (12) .

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Illustration 36	g03729235
View of the 437-8769 Bracket Mounting Gp (left-hand) (2) 312-9076 Anchor (3) 8T-4138 Bolt (4) 8T-4205 Hard Washer (5) 5C-2890 Nut (6) 9M-3835 Rubber Latch (7) 2M-5795 Clevis Pin (8) 5P-4115 Hard Washer (9) 3B-4607 Cotter Pin (10) 418-7343 Rubber Block (11) 8T-4186 Bolt (12) 8T-4121 Hard Washer (13) 1V-6645 Spacer (14) 8T-4133 Nut (15) 9M-3837 Catch Bracket (16) 8T-4137 Bolt (17) 437-8771 Plate As

4. Secure two anchors (2) to plate assembly (17) by using four bolts (3), eight hard washers (4), and four nuts (5) .

   Secure two rubber latches (6) to anchors (2) by using two clevis pins (7), two hard washers (8), and two cotter pins (9) .

5. Secure two rubber blocks (10) to non-hinged portion of plate assembly (17) by using four bolts (11), four hard washers (12), and four spacers (13) .

   Secure two rubber blocks (10) to the hinged portion of plate assembly (17) by using four bolts (11), eight hard washers (12), four spacers (13), and four nuts (14) .

6. Secure two catch brackets (15) to plate assembly (17) by using four bolts (16) and four hard washers (12) .

Install the 437-8751 Handhold Gp

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Illustration 37	g03729233
(1) 437-8759 Mounting Bracket Gp (2) 437-8769 Bracket Mounting Gp (3) 8T-4183 Bolt (4) 7X-3391 Hard Washer

1. Secure mounting bracket group (1) and bracket mounting group (2) to the rear of the beam assembly by using eight bolts (3) and eight hard washers (4) .

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Illustration 38	g03729284
(1) 437-8759 Mounting Bracket Gp (2) 437-8769 Bracket Mounting Gp (5) 391-1754 Handhold As

2. To store handhold assemblies (5), secure five handhold assemblies (5) to mounting bracket group (1) and bracket mounting group (2) .

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Illustration 39	g03729322
View with a 2040 L (540 US gal) fuel tank (6) 8T-4956 Bolt (7) 8T-4223 Hard Washer (8) 421-1395 Bracket As (9) 423-1694 Bracket As (10) 391-0636 Bracket As (11) 8T-4195 Bolt (12) 8T-4121 Hard Washer (13) 420-7425 Plate (14) 421-1400 Bracket As (15) 8T-4186 Bolt (16) 7X-7729 Washer (17) 437-8774 Mount

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Illustration 40	g03729295
View with a 2725 L (720 US gal) fuel tank (6) 8T-4956 Bolt (7) 8T-4223 Hard Washer (8) 421-1395 Bracket As (9) 423-1694 Bracket As (10) 391-0636 Bracket As (11) 8T-4195 Bolt (12) 8T-4121 Hard Washer (13) 420-7425 Plate (14) 421-1400 Bracket As (15) 8T-4186 Bolt (16) 7X-7729 Washer (17) 437-8774 Mount

3. Secure bracket assemblies (8), bracket assemblies (9), bracket assemblies (10), plates (13), bracket assemblies (14), and mounts (17) by using bolts (6), hard washers (7), bolts (11), hard washers (12), bolts (15), and washers (16) .

   The following quantities are needed for a 2040 L (540 US gal) fuel tank:

   • 44 bolts (6)

   • 44 hard washers (7)

   • Eight bracket assemblies (8)

   • Two bracket assemblies (9)

   • Eight bracket assemblies (10)

   • Four bolts (11)

   • Four hard washers (12)

   • Two plates (13)

   • One bracket assembly (14)

   • Four bolts (15)

   • Four washers (16)

   • Two mounts (17)

   The following quantities are needed for a 2725 L (720 US gal) fuel tank:

   • 52 bolts (6)

   • 52 hard washers (7)

   • Eight bracket assemblies (8)

   • Two bracket assemblies (9)

   • 12 bracket assemblies (10)

   • Four bolts (11)

   • Four hard washers (12)

   • Two plates (13)

   • One bracket assembly (14)

   • Four bolts (15)

   • Four washers (16)

   • Two mounts (17)

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Illustration 41	g03729347
(7) 8T-4223 Hard Washer (18) 8T-4139 Bolt (19) 391-0614 Bracket As (20) 391-0621 Bracket As

4. Secure three bracket assemblies (19) and bracket assemblies (20) by using 16 bolts (18) and 16 hard washers (7) .

Install the 464-2540 Handrail Gp

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Illustration 42	g03729351
View with a 2040 L (540 US gal) fuel tank (1) 416-4489 Guardrail Gp (2) 391-0630 Guardrail Gp (3) 391-0628 Handrail Gp (4) 391-0639 Handrail As (5) 391-1754 Handhold As

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Illustration 43	g03729629
View with a 2725 L (720 US gal) fuel tank (1) 416-4489 Guardrail Gp (2) 391-0630 Guardrail Gp (3) 391-0628 Handrail Gp (4) 391-0639 Handrail As (5) 391-1754 Handhold As

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NOTICE
All handrail assemblies and guardrail assemblies must be removed from the brackets before the body is lowered.

1. Install handhold assemblies (5), guardrail groups (1), guardrail groups (2), handrail groups (3), and handrail assemblies (4) onto the available bracket assemblies.

   Refer to Illustration 42 and Illustration 43 for the locations based on the size of the fuel tank.

   When the handrail assemblies and guardrails assemblies are in use, insert the handrail assemblies and guardrail assemblies into the available brackets.

   Note: The bracket assemblies may require slight adjustments for easy installation and removal of the handrail assemblies.

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 9.

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

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   Table 9

   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 9 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".