Installation of the Access Platform on the 16M Motor Grader REHS7164

12/6/23, 4:28 PM SIS 2.
Installation of the Access Platform on the 16M Motor Grader {7253} (REHS7164-05)
SMCS - 7253 i09729213

Motor Grader
16M (S/N: B9H1-UP; R9H1-UP)
PSP
202 -0005
Revision History:
19: 3/12/0 A09A

Table 1
Revision Summary of Changes
05
04
Updated Illustration 6.
2
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Note information on Section "Left Fender Handrails"
Introduction
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Reference: Disassembly and Assembly, KEBR6019, "Service Brake (Wheel Spindle) - Remove"
Cat
Reference: Special Instructions, REHS1841 , "General Welding Procedures"
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This instruction will cover the installation of a catwalk type platform on the machines that are listed
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above. This platform will provide operators an easier and safer way to get into the machine as well
c.
perform common maintenance. This procedure requires an extensive list of parts and welding on
the Rollover Protective Structure (ROPS).
Note: The platform and fenders outlined in this instruction are not compatible with the L-5 tires. The
larger tires can interfere with the fenders and the platform in certain machine positions.
https://sis2.cat.com/#/print-preview/service/987df57a-6fe3-4597-93c2-fece4a459057 1/94
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Illustration 1 g03383949
View of installed platform
Safety Section
Personal injury or death can result from fumes, gases and

ultraviolet rays from the weld arc.
Welding can cause fumes, burn skin and produce ultraviolet

rays.
Keep your head out of the fumes. Use ventilation, exhaust at the
arc, or both, to keep fumes and gases from your breathing area.
Wear eye, ear and body protection before working.
Protect yourself and others; read and understand this warning.

Fumes and gases can be dangerous to your health. Ultraviolet
rays from the weld arc can injure eyes and burn skin. Electric
shock can cause death.
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Read and understand the manufacturer's instructions and your

employer's safety practices. Do not touch live electrical parts.
Do not operate or work on this machine unless you have read

and understand the instructions and warnings in the Operation
and Maintenance Manual. 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.
Personal injury or death can result from improper

troubleshooting and repair procedures.
The following troubleshooting and repair procedures should

only be performed by qualified personnel familiar with this
equipment.
Required Parts
The following table shows the high-level group part numbers that will be used in this installation, and
which kits will be needed for the machine you are working on. More detailed parts breakdown tables
are in the appropriate sections of this instruction.
Table 2
S/N:B9H616-
S/N:B9H1- S/N:B9H582- UP; S/N:R9H558- S/N:R9H830-
Machine S/N
581 615 S/N:R9H1- 829 UP
557
Kit Part Kit
Number Description
Platforms,
Handrails,
Fenders,
399-0278 x x x x x
Steps, and
Installation
Components
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Right-Hand
399-0280 x
Walkway
Engine
Enclosure
Rear, Right-
399-0281 Hand Access x x
Door, and
Access
Panels
Engine
Enclosure
Rear, Left-
399-0282 Hand Access x x
Door, and
Access
Panels
Engine
Enclosure
Front, Left-
399-0284 Hand Access x x x
Door, and
Access
Panels
Updated
Light
399-0285 Package for x x x x
Fabricated
Doors
Updated
Light
399-0286 Package for x
Stamped
Doors
Sound
399-0283 Suppression Optional Optional Optional Optional Optional
Components
Welding Details
Reference: Refer to Special Instructions, REHS1841 , "General Welding Procedures" for additional
welding instructions.
Shielded Metal Arc Welding

The Shielded Metal Arc Welding (SMAW) process may be used with the E7018 (ANSI/AWS A5.1)
welding electrode. The weld that will be deposited by these electrodes will have the following
mechanical properties.
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Table 3
Tensile strength 480 MPa (69600 psi)

Yield strength 400 MPa (58000 psi)
Elongation 22%
Impact toughness 27 N·m (20 lb ft)
These low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F) when the
electrodes are not being used. Scrap the electrodes if the electrodes get damp.
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due
to the manufacturer of the welding electrode.
The following chart relates to the electrode diameter and approximate current settings for welding.
Table 4
Diameter Current
3.2 mm (0.1260 inch) 70-140
4 mm (0.16 inch) 110-180
4.8 mm (0.19 inch) 190-270
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass.
Weld all joints from the bottom upward. The number of weld passes will depend on the width of the
weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the
weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a
fine pad. No sharp edges are acceptable.
Flux Cored Arc Welding

The Flux Cored Arc Welding (FCAW) process may be used with the E71T-1 (AWS A5.20) welding
electrode. The FCAW process may also be used with shielding gas. The weld that will be deposited
by these electrodes will have the following mechanical properties.
Table 5
Tensile strength 480 MPa (69600 psi)

Yield strength 400 MPa (58000 psi)
Elongation 22%
Impact toughness 27 N·m (20 lb ft)
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due
to the manufacturer of the welding electrode.
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For a 1.1 mm (0.045 inch) electrode, the typical welding parameters should be the following.
Table 6
Wire Feed Speed Voltage Approximate Amperage

MIN 175 Inches Per Minute. 22-24 130
MID 350 Inches Per Minute. 26-28 210
MAX 425 Inches Per Minute. 29-31 275
For a 1.3 mm (0.052 inch) electrode, the typical welding parameters should be the following.
Table 7
Wire Feed Speed Voltage Approximate Amperage
MIN 200 Inches Per Minute. 22-24 185
MID 300 Inches Per Minute. 25-27 245
MAX 425 Inches Per Minute. 28-30 295
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass.
Weld all joints from the bottom upward. The number of weld passes will depend on the width of the
weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the
weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a
fine pad. No sharp edges are acceptable. Clean all weld surfaces after rework and apply paint as
needed.
Table 8
Weld Specifications
W1 8 mm (0.31 inch) triple pass fillet weld
W2 8 mm (0.31 inch) square groove weld
Note: All vertical welds will be welded with a vertical up technique.
Sub-Assembly of the Major Components

Some of the components will need to be assembled before installation to the machine. This section
will cover the major subassembly procedures for the affected parts.
Ladder Assembly
This section will cover the subassembly of the main access ladder. The ladder will be installed on
the machine in a later section.
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Table 9
Required Parts
Item Part Number Description Quantity
1 336-8441 Plate As 1
2 337-3323 Plate As 1
3 198-4778 Hard Washer 8
4 238-0251 Screw 4
5 7X-7729 Screw 2
6 8T-4121 Hard Washer 4
7 8T-4136 Bolt 2
8 8T-4194 Bolt 7
9 8T-4910 Bolt 1
10 8C-4663 Handle 1
11 125-6857 Rod End 1
12 178-2593 Bumper 2
13 296-6677 Wear Pad 2
14 336-8456 Tread 1
15 352-1066 Ladder As 1
16 352-1070 Ladder As 1
17 354-0101 Handrail As 1
18 354-1204 Lever As 1
19 362-3496 Latch As 1
20 362-3497 Striker 1
21 366-0673 Plate As 1
22 366-1513 Plate As 1
23 366-2103 Pin As 1
24 366-2313 Spacer 2
25 366-2382 Nylon Washer 2
26 366-2384 Bearing 2
27 367-8620 Cable 1
28 381-9342 Plate As 1
29 090-8661 Pin 2
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31 221-8058 Special Bolt 2

32 2N-3948 Spacer 2
33 300-1710 Washer 2
34 3B-4617 Cotter Pin 2
35 5C-7261 Nut 2
36 5P-8246 Hard Washer 4
37 6C-3678 Rivet 11
38 6V-7357 Bolt 4
39 6V-8181 Full Nut 1
40 7X-0517 Hard Washer 2
42 7X-2554 Bolt 1
44 8T-4139 Bolt 4
45 8T-4183 Bolt 4
46 8T-4189 Bolt 3
48 9X-8256 Washer 4
49 255-4126 Film 65 cm (25.5 inch)
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1. Begin with ladder assembly (15). Install two sets of bumpers (12) and nuts (35). Install two sets
of wear pads (13), washers (33), and rivets (37).
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Illustration 3 r In
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2. Install ladder assembly (15) to plate assembly (21). Use four bolts (45) and four washers (3).
3. Rivet tread (14) to plate assembly (21). Use nine rivets (37).
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4. Install plate assembly (2) to the ladder. Use two screws (4), washers (6), bolts (7), and washers
(5).
5. Install plate assembly (1) to the ladder. Use four bolts (8) and washers (3). Use two bolts (7),
and washers (5).
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6. Install plate assembly (22) to the ladder. Pin assembly (23) supports the plate, which is flanked
by two spacers (24). Install striker (20) onto plate assembly (22). Use two bolts (46) and
washers (47). Secure the pin assembly (23) with a single bolt (46).
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7. Thread cable (27) into plate assembly (28) until 9 ± 1 mm (0.35 ± 0.04 inch) stick out of the top
of the plate assembly. Pull cable (28) out from the side of the lever assembly and attach the
cable to the latch assembly (19) trip lever. Loosely attach the latch assembly (19) to the lever
assembly (18). Use four bolts (38) and washers (48).
8. Install nut (39) onto rod end (11). Install rod end (11) into the lever (18). Orient as shown, lock
the rod end into position with the nut.
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9. Install ladder assembly (16) to the ladder. Use two pins (29), four washers (36), and two pins
(34).
10. Install the assembled lever assembly (18) to the ladder. Use two bolts (31), nylon washers (25),
washers (41) and bearings (26).
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11. Secure the lower end of the lever to ladder assembly (16). Use a bolt (42), two washers (40),
and two spacers (32). Raise the ladder so that the striker (20) that was installed in Step 6
contacts the latch assembly (19).
12. Tighten the latch assembly (19). Adjust both bumpers on the upper ladder assembly so they
contact the lower assembly. Adjust the cable assembly threads so the cable is taut. Apply
Loctite 242 to the plate assembly (28) threads and install handle (10).
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13. Install the handrail (17) to the ladder. Use four bolts (44) and washers (43).
14. Apply three pieces of film (49) to the ladder assembly. Two pieces will be 279 mm (11 inch) and
one piece will be 127 mm (5 inch). The two long pieces will wrap around the lever (18) and the
shorter piece applies to the plate (22) as shown.
Left-Hand Platform
The left and right platforms are much easier to assemble at ground level and then install as a single
or two smaller components. The following parts list will outline what is needed to assemble these
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platforms.
Note: When assembling these platforms at ground level, do not tighten down the bolts fully. Some
play in all bolted joints will be required for final fit up to the machine.
Table 10
Left Side Platform
1 336-7468 Walkway As 1
2 336-7477 Support As 1
3 336-7473 Support As 1
5 8T-4183 Bolt 9
6 336-7475 Plate As 1
7 336-7476 Plate As 1
8 336-7469 Walkway As 1
9 336-7470 Walkway As 1
10 336-7480 Bracket As 1
11 113-9305 Hinge 1
12 275-0572 Latch As 1
13 8T-4195 Bolt 5
14 7X-7729 Washer 5
15 344-3785 Latch Cam 1
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1. Assemble the front of the left platform first. Attach the two supports (2) and (3) to the catwalk
(1). Use four bolts (4) and washers (5).
2. Assemble the catwalk section (8) to the support plates (6) and (7) and to the bracket (10). Use
five bolts (5), five washers (4).
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Illustration 19
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3. Assemble smaller catwalk section (9). Install the hinge assembly (11) to the bracket (10). Use
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two bolts (13) and two washers (14). Install the cam (15) to the latch assembly. Install the latch
assembly (12) to the catwalk (9). Install the catwalk (9) to the hinge (11), Use three bolts (13)
and three washers (14). erp
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Note: The five bolts that go into the hinge may be tightened fully as they will not affect the
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alignment of the platform on the machine.
Right-hand platform c.
The left and right platforms are much easier to assemble at ground level and then install as a single
or two smaller components. The following parts list will outline what is needed to assemble these
platforms.
Note: When assembling these platforms at ground level, do not tighten down the bolts fully. Some
play in all bolted joints will be required for final fit up to the machine.
Table 11
Right Side Platform
1 336-7467 Walkway As 1
2 368-7618 Support As 1
3 336-7474 Support As 1
5 8T-4183 Bolt 9
6 336-7475 Plate As 1
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7 336-7476 Plate As 1
8 336-7466 Walkway As 1
9 368-1323 Bracket As 1
1. Assemble the right front platform first. Attach the two supports (2) and (3) to the catwalk (1).
Use four bolts (5) and four washers (4).
2. Assemble the two support plates (6) and (7) and the bracket (9) to the catwalk (8). Use five
bolts (5) and five washers (4).
Modification of Frame and Component Removal

The ROPS support will need to have mount blocks removed and new ones installed. The cab will
need the exterior door handles removed. The rear enclosure will have holes drilled for wiring. And
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some of the grab irons will be removed from the rear enclosure. This section will cover all of these
changes.
Air Conditioning Modifications

Table 12
Required Parts
1 328-8446 Tube As 1
Note: If your machine is equipped with an accumulator that has brazed connections, it will be
necessary to replace the existing accumulator with a new 274-5909 Refrigerant Accumulator and a
328-8448 Tube As.
A tube in the air conditioning system will need to be replaced before proceeding. The new tube
provides the needed clearance for the new walkway supports.
1. Remove the guards below the ROPS. Remove the air conditioner group (A) from below the
cab. Refer to Disassembly and Assembly, SENR5664 , "All Products Air Conditioning and
Heating R134a for All Caterpillar Machines".
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2. Remove existing tube and install the new tube (1). Replace o-rings if needed.
3. Reinstall the air conditioner group to the machine.

Note: It will be easier to install the mounting blocks in the following sections if the air
conditioning system is not installed. You may wait to reinstall the air conditioning group until
after the mounting blocks are installed.
Mounting Blocks for the New Platform

This section will cover the installation of the mounting blocks for the platform and associated
hardware. There are nine blocks to weld on the left side of the machine and seven on the right side.
All mounting blocks near the new blocks must be removed before the new ones can be welded in
place.
Note: When removing the existing mount blocks, do not gouge into the parent material.
Note: Two blocks that are not covered in this section will be located and welded to the machine
after the front platforms have been fitted to the machine.
Table 13
Mounting Blocks
1 337-7518 Block 4
2 368-2078 Block 2
3 382-8958 Block 2
4 382-8957 Plate 4
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5 368-2428 Plate 2
6 9R-2672 Threaded Boss 1
1. Begin by removing the guards on either side of the steering valve and the top cover on the
steering valve.
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View of prepared weld area
2. Prepare each surface for welding. Be sure that each area is clear of dirt, paint, oil, and other
materials.
(1) Block
(2) Block
(3) Block
(B) 97.5 mm (3.8 inch)
(C) 40 mm (1.5 inch)
(D) 90.6 mm (3.6 inch)
(E) 174.8 mm (6.9 inch)
(F) 55 mm (2.2 inch)
(G) 45.7 mm (1.8 inch)
(H) 21.9 mm (0.9 inch)
(J) 25 mm (1 inch)
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(4) Bar
(K) 81.5 mm (3.2 inch)
(L) 34.88 mm (1.4 inch)
(4) Bar
(M) 49.5 mm (1.9 inch)
(N) 34.88 mm (1.4 inch)
3. Lay out the area for the new mounting blocks. Refer to Illustrations 27 through 29 for the
correct locations. Five blocks will be welded to each side of the machine. Both the left and right
side will use the same locations.
Note: Your machine may already be equipped with one or more of the mounting blocks.
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4. Weld blocks (1), (2), and (3), and (4) into position (W1). Do the same for the other side of the
machine. Blocks (4) will be welded to both the front and rear of the called out ROPS support.
Take care to note the different measurements. Do not weld in dimension (J).
Note: Your machine may already be equipped with one or more of the mounting blocks.
5. Prepare the rear of the frame on the machine left side for the new mounting blocks. Be sure
that the area is clear of dirt, paint, oil, and other materials.
(5) Plate
(P) 72.5 mm (2.9 inch)
(Q) 89.5 mm (3.5 inch)
(R) 35.8 mm (1.4 inch)
(S) 15 mm (0.6 inch)
6. Lay out the area for the new mounting blocks. Refer to Illustration 31 for the correct locations.
Two blocks will be welded to the left-hand side of the machine on the rear frame.
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Illustration 32 Cat g02748920
(5) Plate
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7. Weld the plates (5) to the frame (W1). Do not weld in dimension (S).
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(6) Boss
(T) 1161 ± 5 mm (45.7 ± 0.2 inch)
(U) 693 ± 5 mm (27.3 ± 0.2 inch)
8. Weld boss (6) to the left side of the front frame. Refer to illustration for clarification.
Modifications to the Tandem

The tandem on the left side of the machine may need to be modified before the platform is installed.
If the machine you are working on has the vertical plates on top, they must be removed or trimmed.
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Mounting blocks for the fenders will also need to be welded to the tandems.
Table 14
Required Parts
1 421-4119 Plate 4
2 421-4125 Plate 4
3 421-4118 Plate 2
4 421-4127 Step As 1
5 421-4126 Step As 1
6 421-4128 Step 2
7 421-4120 Bracket 2
9 8T-4136 Bolt 8
1. Begin by removing the wheel spindles from the tandems. Refer to Disassembly and Assembly,
KEBR6019, "Service Brake (Wheel Spindle) - Remove"
View of removed plates
2. Use a torch or other cutting tool to remove the vertical plates on top of the tandem, if equipped.
Be sure that you do not cut into the parent material of the tandem.
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3. Remove the existing bracket from the forward section of both tandems. Use the carbon arc
gouging process to remove the brackets. Take care not to gouge into the parent material of the
tandem. Clean the prepared the area for the new brackets (7).
(A) 107 mm (4.2 inch)
(B) 12 mm (0.47 inch)
4. Locate brackets (7) on each tandem. Refer to Illustration 35 for clarification.
5. Weld two brackets (7) to the tandems, (W1) and (W2).
6. Removed the existing center block from the top of both tandems. Use the carbon arc gouging
process to remove the blocks. Take care not to gouge into the parent material of the tandem.
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(C) 404.5 mm (16 inch)
7. Locate plates (3) on each tandem. The side edge of each plate will be flush with the edge of the
tandem. Refer to Illustration 36 for clarification.
8. Weld plates (3) to the tandems on three sides, (W1).
9. Remove the existing block from both tandems above the access cover or spill port at the center
of the tandem. Use the carbon arc gouging process to remove the blocks. Take care not to
gouge into the parent material of the tandem.
(2) Plate
(D) 96 mm (3.8 inch)
(E) 126 mm (5 inch)
(F) 230 mm (9 inch)
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(1) Plate
(G) 198 mm (7.8 inch)
(H) 302 mm (11.9 inch)
(J) 30 mm (1.2 inch)
10. Locate four plates (1) and (2) on the side of each tandem. Refer to Illustrations 37 and 38 for
clarification.
11. Weld eight plates to the tandems, (W1).
12. Scribe a mark on the tandem 42 mm (1.7 inch) above the existing rear step on each tandem.
Remove the rear step from each tandem. Use the carbon arc gouging process to remove the
steps. Take care not to gouge into the parent material of the tandem. The replacement step will
be installed, along with the fenders in a later section.
Rear Enclosure Modifications

The rear engine enclosure will have a few holes drilled and the removal of a few grab handles. The
enclosure doors will also be replaced. This section will cover all the modifications that are needed.
You may also need to weld on three weld links for later use.
Newer machines already have the modifications done to the enclosure.
Table 15
Required Parts
1(1) 7T-1099 Link 4
2 8T-3490 Weld Nut 2
3 8T-4133 Nut 2
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5 336-8110 Access Door As(2) 1
6 336-8302 Panel(2) 1
7 321-4351 Access Door As(2) 1
8 321-5665 Panel(2) 1
9 384-1875 Access Door As(3) 11
10 384-1877 (3)
1
11 321-6974 Access Door As(3) 1
12 321-5666 Panel(3) 1
13 326-0610 Latch As 4
(1) May not be needed
(2) Left-hand side
(3) Right-hand side
(A) 138.5 mm (5.5 inch)
(B) 46.7 mm (1.8 inch)
(C) 81 mm (3.2 inch)
(D) 32.5 mm (1.3 inch)
(E) 13.8 mm (0.5 inch) Diameter hole
(F) 19 mm (0.75 inch) Diameter hole
1. Drill two holes in to the top of the hood enclosure closest to the cab. Refer to Illustration 39 for
clarification. Weld a weld nut (2) to inside the enclosure under hole (E). If the enclosure is not
removed, hole (F) may be drilled in an alternate location. You may also use a standard nut (3)
and washer (4) if installing a weldnut is not practical.
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(G) 580 mm (22.8 inch)
(H) 66.1 mm (2.6 inch)
(J) 51.4 mm (2 inch)
(K) 62.5 mm (2.5 inch)
(E) 13.8 mm (0.5 inch) Diameter hole
(F) 19 mm (0.75 inch) Diameter hole
2. Drill two holes in to the top of the hood enclosure at the rear of the machine. Refer to Illustration
40 for clarification. Weld a weld nut (2) to inside the enclosure under hole (E). You may also
use a standard nut (3) and washer (4) if installing a weldnut is not practical.
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(L) 40 mm (1.6 inch)
(M) 7.7 mm (0.3 inch)
(N) 30.2 mm (1.2 inch) diameter hole
3. Drill a hole in the left panel of the enclosure, at ground level. Refer to Illustration 41 for
clarification.
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4. Remove the grab handles from the left-hand side of the enclosure. The rear enclosure should
not have any more grab handles than what is shown in Illustration 42. Some of these grab
handles cannot be removed without removing the enclosure. It is acceptable to leave those
handles in place until other maintenance requires removal of the enclosure.
View of the left front enclosure door, looking up
5. Check to see if there are four weld links (1) in place on the top rail of the enclosure, just inside
the front left door. If the machine you are working on does not have these links, you will have to
install them.
In the above illustration, the weld links are highlighted red. The machine forward most link shall
be next to the bolt as show near callout (1). The next two links shall be 348 ± 6 mm
(14 ± 0.25 inch) apart. The rear most link shall be 190 ± 6 mm (7.5 ± 0.25 inch) from the third
link.
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6. Remove the four doors and four lower panels from the enclosure. Retain all the hardware.
7. Install four latches (13) to access doors (5), (7), (9), and (11). Use the included hardware to
secure the latches to the access doors.
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8. Install access doors (5) and (7) to the enclosure. It will be necessary to relocate the door latch
catches on the enclosure. Remove and reweld the catches to the correct position. Use the new
doors to locate the catches in the correct position. Reuse the existing hinges. Install panels (6)
and (8) to the enclosure. Reuse the hardware saved from Step 3.
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9. Install access doors (9) and (11) to the enclosure. Reuse the existing hinges. Install panels (10)
and (12) to the enclosure. Reuse the hardware saved from Step 3.
Installation of the Exterior Wiring Group

This section will cover the installation of the platform wiring group. The routing of the harness is very
important if these instructions are not followed exactly, the harness may not be long enough to
reach the needed connectors. The harness may also be damaged from machine operation.
Table 16
Required Parts
1 334-5109 Lighting Harness As 1
4 7K-1181 Cable Strap 25
5 272-6641 Flood Lamp Gp 2
7 346-3624 Plate As 1
8 346-3625 Plate As 1
9 352-1598 Bracket 2
12 130-5300 Clip 1
13 2G-1133 Grommet 1
16 4D-9517 Clip 4
17 4P-8134 Clip 1
18 5P-8439 Grommet 4
19 6H-4005 Grommet 1
21 8T-4136 Bolt 2
22 8T-4137 Bolt 6
12/6/23, 4:28 PM SIS 2.0
1. Begin at the rear of the machine. It will be necessary to remove the fan guard. Push
approximately two feet of the harness (1) through the new hole in the left rear enclosure. Install
grommet (13) to the end of the harness (1). Install the grommet (19) in the new hole in the left
rear enclosure.
View from the rear of the machine
2. Route the harness inside the enclosure as shown in Illustration 48. Use the clip (17), use the
existing bolt and washer at this location. Use three new clips (16), use the existing bolts and
washers at this location. Use six cable straps (4) along the route, use the ladder clips at the
12/6/23, 4:28 PM SIS 2.0
called out locations. Remove and unplug the ground level shut-off switch. Keep the switch and
all related hardware for use in a later section.
View from right side of enclosure
3. Connect the harness (1) to the machine harness for the kill switch. Refer to Illustration 49.
4. Install the harness (2). Pull approximately six inches through each hole (A). Install two
grommets (18). Install a clip (12) at the called out location. Use existing bolt and washer to
install the clip. Use ten cable straps (4) at each weld link.
12/6/23, 4:28 PM SIS 2.0
5. Install the two flood lamps (5) to the enclosure. Use the holes with weld nuts that were installed
in the previous sections. Use two brackets (9), two bolts (22), and two washers (20). Plug the
harness (2) into each flood lamp (5).
6. Install harness (3). Begin with the ground loop at location (B). Use existing hardware. Connect
harness (3) to harness (1) at location (C). Connect harness (3) to harness (2) at location (D).
Use three cable straps (4).
12/6/23, 4:28 PM SIS 2.0
7. Route the forward section of the harness (3) as shown. Follow the main electrical harness
through the hitch. Use existing clamps on the main harness to secure the new harness (3).
8. Finish routing the new harness (3) through the hitch. Route the harness (3) as shown to the
back of the cab. Use six cable straps (4) to secure the new harness near the called out
location.
9. Leave the plug at the end of the new harness near the rear access plate at the rear of the cab
for later use.
12/6/23, 4:28 PM SIS 2.0
Installation of Internal Wiring Group

Table 17
Required Parts
1 383-7542 Harness 1
2 261-4907 Rocker Switch 1
Exterior view of plate
12/6/23, 4:28 PM SIS 2.0
Interior view of plate
1. Begin by removing the plate (A) that is shown in Illustration 55. This plate must have the four
machine screws (B) removed from inside the cab before it can be pressed out. Illustration 56
shows the view from inside the cab.
Note: Keep screws (B) for later use.
2. Install harness (1) to the cab at the same location as Step 1. Use the four screws (B) to attach
the connector to the cab.
3. Plug the harness that was routed to the rear of the cab in the previous section into the harness
(1).
12/6/23, 4:28 PM SIS 2.0
PSP
202 -0005
3
19: /12/0 A09A
2
RE 7:58- 6
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023 4
Illustration 58 Cat g02776598
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4. Route the new harness (1) through the cab. The new harness will reach the right-hand switch
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panel and the fuse block near the operator's left foot.
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Note: The headliner not to be removed to complete the routing of this harness. However, the
radio may be removed to facilitate the installation.
c.
5. Locate an empty slot in the right-hand switch panel and install the switch (2) for the platform
lights. Insert the plug on the new harness (1) into the rear of the switch (2).
12/6/23, 4:28 PM SIS 2.0
6. Use three cable straps (3) on the new harness (1) at the right rear pillar of the cab.
Bottom view of fuse block
7. Route the last leg of the new harness (1) behind the cabin recirculation filter and below the
cabin air filter. Connected the terminal of the new harness (1) to the rear of the fuse block. The
12/6/23, 4:28 PM SIS 2.0
terminal will be installed on the machine right side fuse block (C), as it lays in the installed
position.
8. Reassembly any cab trim pieces that were removed.
Hydraulic Line Changes

There is one change to the hydraulic system that will need to be made before the platform can be
installed.
Newer machines may already have these changes made.
Table 18
Required Parts
1 352-1620 Tube As 1
2 9M-8406 Clip 1
3 8T-4137 Bolt 1
1. Replace the existing tube at the shown location with a new tube (1). Secure the tube to the
machine with a new clip (2), new bolt (3), and a new washer (4).
Autolube Grease Line Changes

12/6/23, 4:28 PM SIS 2.0
If the machine is equipped with the Autolube system, the grease lines at the front left of the rear
frame will need to be reworked before the rest of this instruction is completed.
Table 19
Required Parts
1 3V-3612 Block 1
2 9R-7799 Boss 1
3 3B-6552 Pipe Elbow 1
1. Remove the existing grease lines from the existing components (A) on the frame. Retain all
hardware for later use.
12/6/23, 4:28 PM SIS 2.0
(1) Block
(2) Boss
(B) 62 ± 5 mm (2.4 ± 0.2 inch)
(C) 235 ± 5 mm (9.3 ± 0.2 inch)
(D) 311.7 ± 5 mm (12 ± 0.2 inch)
(E) 204.4 ± 5 mm (8 ± 0.2 inch)
2. Weld (W1) the new boss (2) and block (1) onto the frame.
3. Install the new elbow (3) to the block (1) as shown in Illustration 65. Reuse all the hoses and
mounting hardware. Connect the hoses to the block (1) and use boss (2) to affix the hose to the
machine.
12/6/23, 4:28 PM SIS 2.0
Fender and Walkway Installation

This section will cover the installation of the fenders and walkway platforms on both sides of the
machine. The following parts will be required to complete the installation.
Table 20
Required Parts for Fender Install
1 271-5390 Handrail 1
2 329-8845 Plate As 1
3 329-8847 Plate As 1
4 421-4126 Step As 1
5 421-4127 Step As 1
6 388-9328 Plate As 1
7 399-0701 Support 2
8 417-6867 Plate As 2
9 417-6870 Plate As 2
10 417-6873 Plate As 2
11 417-6875 Plate As 2
12 417-6910 Plate As 2
13 417-6917 Channel As 2
14 418-1350 Plate As 1
15 418-1351 Plate As 1
16 420-8665 Platform Support 2
17 421-7354 Plate As 1
18 422-1299 Shim 56
19 422-1300 Shim 48
20 338-9729 Plate As 1
21 338-9732 Plate As 1
22 176-5311 Locknut 8
23 198-4780 Hard Washer 28
24 198-4781 Hard Washer 48
26 7X-2556 Bolt 8
12/6/23, 4:28 PM SIS 2.0
27 7X-2563 Bolt 16
28 7X-7729 Washer 42
29 8T-4133 Nut 4
30 8T-4136 Bolt 34
31 8T-4139 Bolt 10
32 8T-4175 Bolt 4
33 8T-4193 Bolt 16
34 8T-4195 Bolt 4
36 8T-5460 Bolt 16
37 8T-6430 Bolt 16
38 8T-6868 Bolt 2
39 8T-8549 Locknut 1
40 9X-8257 Washer 8
41 421-4128 Step 2(1)
42 8T-4121 Hard Washer 8(1)
43 8T-4136 Bolt 8(1)
44 337-3332 Tread 1
45 337-3331 Tread 1
46 136-8794 Rivet 16
(1) Carryover from the "Modifications to the Tandem" section
Table 21
Required Parts for Walkway Install
Item
Part Number Description Quantity
47+2
47 336-8055 Bracket As 1
48 336-8059 Bracket As 2
49 423-0294 Support As 1
50 336-8100 Plate As 1
51 423-0291 Plate As 1
52 344-7702 Bracket As 2
53 344-7707 Bracket 1
54 344-7712 Bracket As 1
12/6/23, 4:28 PM SIS 2.0
55 344-7713 Bracket As 1
56 344-7714 Bracket As 1
57 423-0292 Plate As 1
59 1S-4305 Spacer 10
60 238-0251 Screw 21
62 8T-4136 Bolt 29
63 8T-4195 Bolt 6
64 8T-4956 Bolt 10
65 6V-7744 Locknut 2
Note: It may assist assembly to leave all bolts finger tight until the entire fender has been
assembled.
1. Install bracket assemblies (42), (46), (41), and (43). Use 10 bolts (58) and washers (53) on the
upright brackets. Use two bolts (57) and two washers (52) on the support bracket.
12/6/23, 4:28 PM SIS 2.0
2. Install two brackets (48) and (49). Use two bolts (57) and washers (55).
3. Install two plate assemblies (44) and (51). Use 21 bolts (56), 22 washers (55), and one bolt
(57). Use a washer (55) and a locknut (59) on the backside of bolt (57).
12/6/23, 4:28 PM SIS 2.0
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023 4
4. Beginning with the left tandem, install four plate assemblies (8), (9), (10), and (12). Use eight
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bolts (36), four bolts (27), and 12 washers (24).
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5. Install plate assembly (11). Use eight bolts (37), four bolts (27), and twelve washers (24).
12/6/23, 4:28 PM SIS 2.0
6. Install channel (13) to the plate assembly (11). Shims (18) are installed between the channel
and the plate assembly. It will be necessary to adjust the number of shims installed to ensure
that the front and rear fender halves are level with each other. Use eight bolts (33) and eight
washers (23) to secure the channel.
7. Install the support (7) to the front of the tandem. Use four bolts (26) four washers (23), four
washers (40), and four locknuts (22). Install a plate assembly (6) to the support. Use a bolt (30)
and a washer (28).
12/6/23, 4:28 PM SIS 2.0
8. Install the support assembly (16) to the rear support step (4) from the "Modifications to the
Tandem" section. Secure the support assembly with two bolts (32) and two washers (23). you
will use the support assembly and the fender to assist locating the step.
9. Install the left rear half of the fender group (21). Secure the fender to the channel (13) and the
support (16) with three bolts (30), three washers (28), a bolt (31), three washers (35), a bolt
(38), and a locknut (39).
12/6/23, 4:28 PM SIS 2.0
(A) 12 mm (0.5 inch)
10. Locate step assembly (4) on the left tandem. The top of the step assembly will fall in line with
the scribe mark made in the "Modifications to the Tandem" section. Make sure that the fender is
level. Refer to Illustration 75 for clarification.
11. Weld step (4) to the left tandem, (W1).
12. Secure step (41) to the step assembly (4). Use four washers (42) and four bolts (43) on the
step.
12/6/23, 4:28 PM SIS 2.0
13. Rivet tread (44) to the fender (21). Use twelve rivets (46).
14. Install front fender group (20). Secure the fender group to the channel (13) and the support (7)
with three bolts (31), three washers (35), three bolts (30), and three washers (28).
12/6/23, 4:28 PM SIS 2.0
15. Rivet tread (45) to the fender (20). Use four rivets (46).
16. Secure the already installed plate assembly (6) to the underside of the front half of the fender.
Secure the plate with bolt (30) and washers (28).
12/6/23, 4:28 PM SIS 2.0
Note: The factory walkway has been removed from some of the following illustrations for
improved clarity.
17. Moving onto the right tandem, install four plate assemblies (8), (9), (10), and (13). Use eight
bolts (36), four bolts (27), and 12 washers (24).
18. Install plate assembly (11). Use eight bolts (37), four bolts (27), and twelve washers (24).
12/6/23, 4:28 PM SIS 2.0
19. Install channel (13) to the plate assembly (11). Shims (18) are installed between the channel
and the plate assembly. It will be necessary to adjust the number of shims installed to ensure
that the front and rear fender halves are level with each other. Use eight bolts (33) and eight
washers (23) to secure the channel.
20. Install the support (7) to the front of the tandem. Use four bolts (26), four washers (23), four
washers (40), and four locknuts (22). Install a plate assembly (6) to the support. Use a bolt (30)
and a washer (28).
12/6/23, 4:28 PM SIS 2.0
PSP
202 -0005
19: 3 / 1 A 0
2 2 / 0 9 A
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023 4
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21. Install the support assembly (16) to the rear support step (5) from the "Modifications to the
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Tandem" section. Secure the support assembly with two bolts (32) and two washers (23). You
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will use the support assembly and the fender to assist locating the step.
c.
22. Install the rear half of the fender (15). Use five bolts (30), five washers (29), two bolts (31), and
two washers (35). Install a plate (5) onto the fender. Use two bolts (34), four washers (28), and
two nuts (29).
12/6/23, 4:28 PM SIS 2.0
(A) 12 mm (0.5 inch)
23. Locate step assembly (5) on the left tandem. The top of the step assembly will fall in line with
the scribe mark made in the "Modifications to the Tandem" section. Make sure that the fender is
level. Refer to Illustration 87 for clarification.
24. Weld step (5) to the left tandem, (W1).
25. Secure step (41) to the step assembly (5). Use four washers (42) and four bolts (43) on the
step.
12/6/23, 4:28 PM SIS 2.0
26. Install handrail (1) onto the right rear fender. Two washers (25) install on the top of the fender. A
bolt (31) and an additional washer (25) secure the top of the handrail from the underside of the
fender. A bolt (38) and a washer (35) secure the bottom of the handrail from the underside of
the fender.
27. Install the front half of the fender (14). Use five bolts (30), five washers (29), three bolts (31),
and three washers (35). Install a plate (4) to the fender. Use two bolts (34) four washers (28)
and two nuts (29).
12/6/23, 4:28 PM SIS 2.0
28. Secure the already installed plate assembly (17) to the underside of the front half of the fender.
Secure the plate with bolt (30) and washers (28).
29. Install two plates (2) and (3) to the fenders and existing walkway. Use 14 bolts (30) and
washers (28).
12/6/23, 4:28 PM SIS 2.0
30. Install the plate assembly (45). Use four bolts (57) and washers (55).
31. Install two brackets (47) and (50). These brackets will secure the platform to the fenders. Use
eight bolts (56) and washers (55).
Rear Ladder Installation

This section will cover the installation of the access ladder.
Table 22
12/6/23, 4:28 PM SIS 2.0
Required Parts for Ladder Install

58 346-0026 Ladder Gp(1) 1
59 336-8441 Plate As 1
60 8T-4194 Bolt 7
61 8T-4910 Bolt 1
62 238-0251 Screw 2
63 8T-4137 Bolt 4
64 8T-4136 Bolt 2
67 346-3625 Plate As 1
68 346-3624 Plate As 1
69 2G-1133 Grommet 1
70 4D-9517 Clip 1
71 276-2332 Toggle Switch 1
72 320-2690 Film 1
73 353-4515 Toggle Switch Gp 1
74 109-0361 Film 1
75 3E-5169 Switch Guard 1
(1) Parts that were subassembled at the beginning of this instruction
Note: It may be necessary to install all mounting hardware loose to align all the mounting holes. Be
sure to tighten all fasteners to standard torques.
12/6/23, 4:28 PM SIS 2.0
1. Install the plate (59) to the left rear of the machine. Use three bolts (60), one bolt (61), and four
washers (65).
2. Install the sub assembled ladder (58) to the plate (59). Use four bolts (60) and four washers
(65). Use two screws (62) and two washers (66) on the top of the ladder.
12/6/23, 4:28 PM SIS 2.0
3. Install the plate (68) to the ladder. Use two bolts (64) and two washers (66). Push the wire
harness through the hole as shown.
4. Install the light switch (71), the ground level kill switch (73), switch guard (75), and grommet
(69).
5. Install the two films for the light switch (72) and ground level kill switch (74).
12/6/23, 4:28 PM SIS 2.0
6. Install the plate (67) to cover the switches. Use four bolts (63) and four washers (66). Install a
clip (70) around the harness at shown location. Use cable straps (76) as needed to secure the
harness to the weld links on the ladder assembly.
Installation of the Cab Platform

This section will cover the install of the platforms that were pre-assembled earlier in this instruction.
Table 23
Required Parts
1 N/A Cable Strap N/A
5 8T-4184 Bolt 24
7 8T-4183 Bolt 12
8 343-4088 Bracket 2
9 8T-7338 Bolt 20
10 267-8821 Washer 20
11 368-0753 Bracket As 2
12 368-0752 Bracket As 2
12/6/23, 4:28 PM SIS 2.0
13 8T-6868 Bolt 8
15 336-7481 Plate As 1
16 424-3605 Plate As 1
17 198-4778 Hard Washer
PSP 3
202 -0005
18 311-8300 Boss 3
19 8T-5041 Bolt 3
20 337-7519 Block 3
19: /12/0 A09A 2
21
22
278-0674
214-9186
Plate
Button 2
RE 7:58- 6
2
4
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© 2 716 3:00
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Note: It may be necessary to install all mounting hardware loose to align all the mounting holes. Be
sure to tighten all fasteners to standard torques.
023 4
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View of plate on inside the cab, to the right of the operator seat
1. Remove the door hold open latches from the outside of the cab. On inside the cab, install two
plates (21) with buttons (22) to cover the holes left from removing the latches. Use black 3M
window weld sealant to attack the plates to the cab.
12/6/23, 4:28 PM SIS 2.0

2. Install the assembled left front platform (2) to the machine. Use eight bolts (5) and eight
washers (6). Install the bracket (8) to the machine. Use four bolts (7) and four washers (6).
3. Install the two brackets (11) and (12) to the machine. Use eight bolts (9) and eight washers
(10).
12/6/23, 4:28 PM SIS 2.0

4. Install the assembled left rear platform. Use four bolts (13), four washers (14), four bolts (5),
and four washers (6).
5. Repeat Steps 2 through 4 on the right side of the machine.
6. Assemble plates (15) and (16). Use three bolts (19), washers (17), and bosses (18).
Note: This assembly will be referred to as support (15).
12/6/23, 4:28 PM SIS 2.0

7. Install the support (15) to the left and right front platforms. Use four bolts (7) and four washers
(6).
8. Use the support (15) to locate two blocks (20) on both sides of the machine. Use two bolts (9)
and two washers (10) to mount the blocks. Weld (W1) as shown. It may be necessary to
remove the support (15) to gain access to the weld area. Reinstall the support (15) after the
weld process is complete.
Installation of the Handrails

12/6/23, 4:28 PM SIS 2.0
This section will cover the installation of the handrails to the machine. This section will be split up
into three parts for the different sections of the handrails.
Left Fender Handrails

Table 24
Required Parts
3 115-3580 Plate 2
4 337-3347 Bracket As 1
5 382-3037 Plate As 1
6 382-3039 Plate As 1
8 5P-7468 Clip 4
9 5P-7469 Clip 4
10 6V-1874 Grommet 4
12 7X-7729 Washer 12
13 8T-4139 Bolt 5
14 8T-4183 Bolt 6
15 8T-4195 Bolt 4
16 8T-4196 Bolt 8
18 8T-4244 Nut 4
19 8T-6868 Bolt 1
12/6/23, 4:28 PM SIS 2.0
1. Install the bracket (4) to the left fender. Use four bolts (16) and four washers (12).
2. Install plates (5) and (6) to the rear of the left fender. Take note of the orientation of the holes in
the plates in Illustration 108. Use four bolts (13) and four washers (7).
12/6/23, 4:28 PM SIS 2.0

3. Install the rear handrail (2). Use four bolts (15), four washers (12), two bolts (14), two washers
(7), one bolt (19), one bolt (13), and two washers (11).
Note: Holes will need to be drilled on plate assembly (if required), to mount the handrail
hardware.
4. Install the forward handrail (1) on the left fender. Use four bolts (16) and four washers (12).
Note: Holes will need to be drilled on plate assembly (if required), to mount the handrail
hardware.
12/6/23, 4:28 PM SIS 2.0

5. Install two sets of two clips (8) and (9), two grommets (10), one plate (3), two nuts (18), two
bolts (14), and four washers (17).
Left Platform Handrails

Table 25
Required Parts
2 8T-4184 Bolt 2
5 8T-4183 Bolt 8
6 8T-4139 Bolt 18
8 115-3580 Plate 2
9 5P-7469 Clip 4
10 5P-7468 Clip 4
12 8T-4244 Nut 4
13 368-1438 Plate 1
12/6/23, 4:28 PM SIS 2.0
PSP
202 -0005
19: 3/12/0 A09A
2
RE 7:58- 6
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© 2 S716 03:00
023 4
Cat
erp
illa
1. Install the new handrail (1). Use two bolts (2) and two washers (3). Use two bolts (5), four bolts
(6), six washers (4), and a plate (13).
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c.
2. Install the new handrail (7). Use two bolts (5), two washers (3), 14 bolts (6) and 14 washers (4).
12/6/23, 4:28 PM SIS 2.0

3. Install two sets of clamps to the handrails (1) and (7). Use two clips (9), two clips (10), two
grommets (11), a plate (8), two bolts (5), four washers (4), and two nuts (12) on each set.
Right Platform Handrails and Ladder

Table 26
Required Parts
2 8T-4139 Bolt 22
6 8T-4183 Bolt 6
8 115-3580 Plate 2
9 5P-7468 Clip 4
10 5P-7469 Clip 4
12 8T-4244 Nut 4
13 336-7433 Ladder As 1
14 300-4511 Latch Gp 2
12/6/23, 4:28 PM SIS 2.0
15 248-0102 U-Bolt 4
17 6V-9189 Locknut 8
18 3E-8349 Seal 304 mm (12 inch)
19 345-8534 Special Bolt 2
20 129-3180 Locknut 2
21 7E-0031 Washer 2
22 8D-5054 Hard Washer 6
1. Install the right-hand platform rear handrail (1). Use ten bolts (2) and ten washers (3).
12/6/23, 4:28 PM SIS 2.0
2. Install the two handrails (4) and (5) to the right platform. Use 12 bolts (2), 12 washers (3), two
bolts (6), and two washers (7).
3. Install two sets of clamps to the handrails (1) and (5). Use two clips (9), two clips (10), two
grommets (11), a plate (8), two bolts (6), four washers (3), and two nuts (12) on each set.
4. Install the ladder (13) to the left platform. Use two bolts (19), six washers (22), two washers
(21), and two lock nuts (20). Make sure that the ladder is oriented so that the stop blocks on the
12/6/23, 4:28 PM SIS 2.0
ladder contact the platform when the ladder is in the down position. Tighten the lock nuts (20)
so there are three exposed threads showing.

5. Install two set of latches (14) to the handrails, on either side of the ladder. Use a latch (14), two
u-bolts (15), four locknuts (17), and four washers (16) on each set. Install the latches so that
the ladder will drop freely from the latch when they are pulled. Also install approximately 75 mm
(3 inch) of seal (18) to the ladder, on each side, to prevent metal to metal contact with the
handrails. Cut the seal on each side of the latter so that each side has two pieces. Do not install
the tape spanning the bend on the ladder.
Installation of New Door Handles, Rear View Mirrors,

and Door Stops
Installation of the New Door Handles
This section will cover the installation of the new door handles for the cab doors. Refer to the correct
parts table for the kind of cab you have, either fabricated or stamped.
Table 27
Required Parts for Stamped Doors
1 357-9188 Plate 2
2 9X-2043 Screw 6
3 397-4828 Bracket 1
12/6/23, 4:28 PM SIS 2.0
4 362-3499 Plate 2
5 362-3503 Plate 2
6 362-3502 Bushing 4
7 147-5530 Lip Type Seal 2
8 384-5369 Bracket 1
9 205-5149 Flat Head Screw 4
10 384-5376 Shaft Assembly(1) 1
11 384-5371 Washer 4
12 6V-4422 Spring Pin 2
13 362-3505 Pedal As 1
14 384-5372 Spring 2
15 6V-7636 Spring Pin Assembly 2
16 397-4827 Bracket 1
17 362-3501 Shaft Assembly(2) 1
18 362-3500 Pedal Assembly 1
19 384-5366 Bracket 1
20 384-5377 Connecting Link 2
(1) RH
(2) LH
12/6/23, 4:28 PM SIS 2.0
1. Begin with the left-hand door. Stack the door lever parts against the door as shown in
Illustration 120. The door will be sandwiched at location (A).
2. Inside the cab, install spring (14) connecting link (20), and pin assembly (15).
3. Adjust the door mechanism so that the foot pedal is parallel with the bottom of the door. Install
spring pin (12) into the pedal assembly.
12/6/23, 4:28 PM SIS 2.0

4. Install the cover plate (1) to inside the door. Use three screws (2) to secure the plate (1).
5. Repeat Steps 1 through 4 on the opposite side of the machine. Note some parts are left and
right side specific.
Table 28
Required Parts for Fabricated Doors
20 397-4828 Bracket 1
21 362-3499 Plate 2
22 362-3502 Bushing 4
23 147-5530 Lip Type Seal 2
24 385-3456 Bracket 1
25 362-3503 Plate 2
26 205-5149 Flat Head Screw 4
27 384-5371 Washer 4
28 390-4000 Spacer 2
29 385-3538 Cover 1
30 385-3460 Shaft As(1) 1
31 362-3505 Pedal As 1
32 6V-4422 Spring Pin 2
33 384-5372 Spring 2
12/6/23, 4:28 PM SIS 2.0
34 9X-2046 Screw 6
35 6V-7636 Spring Pin Assembly 2
36 397-4827 Bracket 1
37 385-3454 Bracket 1
38 385-3537 Cover 1
39 385-3459 Shaft As(2) 1
40 362-3500 Pedal Assembly 1
41 385-3457 Connecting Link 2
(1) RH
(2) Left-hand
1. Begin with the left-hand door. Stack the door lever parts against the door as shown in
Illustration 124. The door will be sandwiched at location (A).
12/6/23, 4:28 PM SIS 2.0
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19: 3/12/0 A09A
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© 2 S716 03:00
023 4
2. Inside the cab, install spring (33), connecting link (41), and pin assembly (35).
Cat
erp
illa
r In
c.
3. Adjust the door mechanism so that the foot pedal is parallel with the bottom of the door. Install
spring pin (32) into the pedal assembly.
12/6/23, 4:28 PM SIS 2.0

4. Install the cover plate (38) to inside the door. Use three screws (34) to secure cover plate (38).
5. Repeat Steps 1 through 4 on the opposite side of the machine. Note some parts are left and
right side specific.
Installation of the Rear View Mirrors

Table 29
Required Parts
1 259-4758 Mirror As 2
2 381-7991 Tube As 1
3 381-7999 Tube As 1
4 2K-3019 Hose Clamp 8
5 4K-5824 Boss 4
6 5M-2894 Hard Washer 8
7 7Y-5262 U-Bolt 4
8 8T-0389 Locknut 12
10 8T-4182 Bolt 4
12/6/23, 4:28 PM SIS 2.0
1. Install the tube (3) to the left side platform. Use two u-bolts (7), four washers (9), six locknuts
(8), four clamps (4), four washers (6), two bolts (10), and two bosses (5).
2. Install the mirror (1) to the tube. Tighten the screws on the rear of the mirror.
3. Repeat Steps 1 through 2 on the right side of the machine, using tube (2).
12/6/23, 4:28 PM SIS 2.0

View of harness routing
4. If the machine you are working on has the optional headed mirrors, the wiring harness for the
heated mirrors will need to be extended. Use the Caterpillar electrical connection kit to build
two, two wire harnesses. Be sure to measure the exact length. Use plastic conduit to sheathe
the wire harness extension. Route the harness extension as shown in Illustration 130. Use
cable straps (11) as needed to secure the extended wire harness.
Installation of Door Stops

Table 30
Required Parts
1 336-8436 Block 2
2 7X-2393 Conical Bumper 4
3 8T-4189 Bolt 4
5 5C-7261 Nut 2
12/6/23, 4:28 PM SIS 2.0
1. Install the block (1) to the lower front platform. Use two bolts (3) and two washers (4). Install a
bumper (2) into the block.
2. Install a bumper (2) into the handrail shown in Illustration 132. Use a nut (5) to set the correct
depth so that both bumpers contact the door at the same time.
3. Repeat Steps 1 through 2 on the opposite side of the machine.
Installation of the New A/C Cover Group

12/6/23, 4:28 PM SIS 2.0
Table 31
Required Parts
1 367-3254 Cover As 1
2 367-3256 Cover As 1
3 367-3260 Support As 2
4 385-6755 Cover 1
5 385-6754 Cover 1
6 385-6753 Cover 1
7 385-6752 Cover 1
8 370-1722 Bracket As 1
9 370-1597 Bracket As 1
10 8T-4137 Bolt 39
11 7X-7729 Washer 32
14 370-2197 Bracket As 1
15 8T-4179 Bolt 1
12/6/23, 4:28 PM SIS 2.0
1. Install the support (3), bracket (8), and cover (6) to the left side of the machine. Use four bolts
(10), four washers (11), one bolt (15), and one washer (12).
2. Install a new cover (1). Use nine bolts (10) and nine washers (11).
3. Install the cover (4). Use five bolts (10) and five washers (11).
4. Repeat Steps 1 through 3 on the right side of the machine with the repaining parts in Table 32.
Also install a bracket (14) to the boss that was installed to the frame earlier in the instruction.
12/6/23, 4:28 PM SIS 2.0
Use a bolt (10) and washer (11) to install the bracket.
Relocation of the Tandem Lights

Table 32
Required Parts
1 288-5530 Bracket 2
2 8T-4136 Bolt 4
4 130-5300 Clip 2
The existing lights for the tandems will need to be relocated from the A/C cover to one of the
supports for the walkway.
1. Install a new bracket (1) to the forward edge of the support for the left walkway. Use two bolts
(2) and two washers (3).
12/6/23, 4:28 PM SIS 2.0
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Cat
erp
2. Install the existing light fixture (A) to the new bracket (1). Use the existing hardware for the light
illa
to secure a clip (4) between the bracket (1) and the light. Connect the existing wire harness for
the light, secure the connector to the clip (4).
r In
3. Repeat Steps 1 through 2 on the opposite side of the machine.c.
PSP-0005A09A
2023/12/06
18:50:48-03:00
i04558485
© 2023 Caterpillar Inc.

Installation of the Access Platform on the 16M Motor Grader REHS7164

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Installation of the Access Platform on the 16M Motor Grader REHS7164

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12/6/23, 4:28 PM SIS 2.

SMCS - 7253 i09729213

19: 3/12/0 A09A

Personal injury or death can result from fumes, gases and

Welding can cause fumes, burn skin and produce ultraviolet

Protect yourself and others; read and understand this warning.

Read and understand the manufacturer's instructions and your

Do not operate or work on this machine unless you have read

Personal injury or death can result from improper

The following troubleshooting and repair procedures should

Shielded Metal Arc Welding

Tensile strength 480 MPa (69600 psi)

Flux Cored Arc Welding

Tensile strength 480 MPa (69600 psi)

Wire Feed Speed Voltage Approximate Amperage

Note: All vertical welds will be welded with a vertical up technique.

Sub-Assembly of the Major Components

31 221-8058 Special Bolt 2

Modification of Frame and Component Removal

Air Conditioning Modifications

3. Reinstall the air conditioner group to the machine.

Mounting Blocks for the New Platform

Modifications to the Tandem

4. Locate brackets (7) on each tandem. Refer to Illustration 35 for clarification.

5. Weld two brackets (7) to the tandems, (W1) and (W2).

8. Weld plates (3) to the tandems on three sides, (W1).

11. Weld eight plates to the tandems, (W1).

Rear Enclosure Modifications

Newer machines already have the modifications done to the enclosure.

4 7X-0605 Hard Washer 2

Installation of the Exterior Wiring Group

Installation of Internal Wiring Group

Hydraulic Line Changes

Newer machines may already have these changes made.

Autolube Grease Line Changes

Fender and Walkway Installation

11. Weld step (4) to the left tandem, (W1).

24. Weld step (5) to the left tandem, (W1).

Rear Ladder Installation

Required Parts for Ladder Install

Installation of the Cab Platform

Illustration 100 g03375739

Illustration 101 g02781854

Illustration 102 g02781899

Illustration 103 g02781936

5. Repeat Steps 2 through 4 on the right side of the machine.

Illustration 104 g03374620

Illustration 105 g02781956

Illustration 106 g03374609

Installation of the Handrails

Left Fender Handrails

Illustration 107 g02793863

Illustration 108 g02793866

Illustration 109 g02793871

Illustration 110 g02793885

Illustration 111 g02794368

Left Platform Handrails

Illustration 113 g02794478

Illustration 114 g02794947

Right Platform Handrails and Ladder

Illustration 115 g02795183

Illustration 116 g02795199

Illustration 117 g02795208

Illustration 118 g02795269