Required Tools and Supplies | ||
Part Number | Part Description | Qty |
- | Canes with an individual capacity of |
2 |
- | Lift truck with a capacity of |
1 |
- | Portable air compressor with a capacity of |
1 |
- | Lifting equipment for personnel with a weight capacity of |
1 |
- | 110 V Generator | 1 |
- | Stepladder that is |
1 |
- | Stepladder that is |
1 |
- | Suitable Cribbing
|
18 |
- | Suitable Cribbing
|
1 |
- | Suitable Cribbing
|
28 |
- | Suitable Cribbing
|
24 |
- | Suitable Cribbing
|
8 |
- | Suitable Cribbing
|
2 |
193-5474 | Shackle As | 4 |
189-0409 | Shackle As | 1 |
451-9248 | Pin positioner for linkage pin installation | 1 |
8T-3087 | Hand Tap (M10X1.5) | 1 |
4C-4967 | Tap (M20X2.5) | 1 |
4C-4970 | Tap (M36X4) | 1 |
- | Loctite C5-A Copper Anti-Seize Lubricant | - |
- | Loctite Graphite-50 Anti-Seize Lubricant | - |
- | Loctite 271 | - |
460-0955 | Fixture As | 1 |
441-8318 | Pin As | 1 |
457-6114 | Cable As | 1 |
422-5477 | Lifting Eye Assembly | 4 |
422-5476 | Lifting Eye Assembly | 4 |
- | Spreader Bar |
1 |
Required tools and supplies to perform the field assembly.
The required tools and supplies should be present before assembly. If the required tools and supplies are not present, assembly will be more difficult and more time will be necessary to complete the assembly.
Reference: Service Magazine, SEPD0531, 3, July 2000, "Fabric Slings and Protective Sleeves Are Available for Lifting Truck Bodies"
Reference: Special Instruction, SMHS7867, "Use of 6V-4040 Inflation Group"
Reference: Operation and Maintenance Manual, SEBU5898, "Cold Weather Recommendations for Caterpillar Machine"
Site Layout, Shipping Weights, and Unloading of Major Components
Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below. |
Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
Choose a flat, drained area for assembly. The area should have the following dimensions:
Note: Do not open the bags of hardware. The bags of hardware are marked for easy identification and for orderly use.
Illustration 1 | g03584156 |
Item | Description | Approximate Weight |
1 | Crate 1 contains Unpinned Assembly Kit | |
2 | Crate 2 contains Front Axle Kit | |
3 | Crate 3 contains Rear Axle Kit | |
4 | Crate 4A contains Standard Fuel Tank Kit | |
Crate 4B contains 24 Hour Fuel Tank Kit | ||
Crate 4C contains Standard Fuel Tank Kit and Optional Oil Renew System Components | |
|
Crate 4D contains 24 Hour Fuel Tank Kit and Optional Oil Renew System Components | ||
5 | Crate 5A contains Hydraulic Components | |
Crate 5B contains Hydraulic Components | |
|
6 | Crate 6A contains Electrical Components | |
Crate 6B contains Electrical Components | ||
7 | Crate 7A contains Hardware | |
Crate 7B contains Hardware | ||
8 | Crate 8A contains Access Groups | |
Crate 8B contains Access Groups | |
|
9 | Crate 9 contains Guards and Walkway Kit | |
10 | Crate 10 contains Rollover Protective Structure Hardware, Cab Hardware, Linkage Position Sensor, and Films | |
11 | Crate 11A contains Links (High Lift) | |
Crate 11B contains Links (Standard Lift) | ||
12 | Crate 12 contains Pins | |
13 | Crate 13 contains Pins | |
14 | Crate 14A contains Engine Installation Kit | |
Crate 14B contains Engine Installation Kit | ||
Crate 14C contains Engine Installation Kit | |
|
Crate 14D contains Engine Installation Kit | ||
15 | Crate 15 contains Engine Installation Kit | |
16 | Hood Pallet | |
17 | Guardrail Pallet 1 | |
Guardrail Pallet 2 | |
|
Guardrail Pallet 3 | |
|
18 | Walkway Pallet | |
19 | Bumper Pallet | |
20 | Cooling System Package | |
21 | Stairway Pallet | |
22 | Rear Frame | |
23 | Rear Oscillating Axle | |
24 | Loader Frame | |
25 | Front Fixed Axle | |
26 | Tire | |
27 | Left, Right, and Center Platform Pallet | |
28 | Left Hand Tilt Cylinder | |
Right Hand Tilt Cylinder | |
|
29 | Fuel Tank Pallet | |
30 | Loader Arms (Standard Lift) | |
Loader Arms (High Lift) | |
|
31 | Bucket | |
32 | Cab Pallet | |
33 | Roll Over Protective Structure (ROPS) Pallet | |
Illustration 2 | g03604965 |
(S) (T) (W) (X) (Y) (Z) |
- Use a suitable crane and a suitable lifting device to position rear oscillating axle (22). The weight of rear oscillating axle (22) is approximately
23206 kg (51160 lb) . Position rear oscillating axle in the center of the assembly area.Leave the axle on the shipping supports, until the axle is installed on the rear frame.
Show/hide tableIllustration 4 g03605382 (A) 193-5474 Shackle As
(-) Suitable Cribbing (2438 mm (96 inch) Length X305 mm (12 inch) Width X305 mm (12 inch) Height)
(-) Suitable Cribbing (610 mm (24 inch) Length X305 mm (12 inch) Width X305 mm (12 inch) Height)
(-) Suitable Cribbing (610 mm (24 inch) Length X305 mm (12 inch) Width X152 mm (6 inch) Height)
(W)1575 mm (62 inch)
(X)1981 mm (78 inch)
(Z)5410 mm (213 inch)
(23) Rear FrameNote: The suitable cribbing is stacked alternately.
- Use the suitable cribbing to support the rear frame (23). Position the suitable cribbing in the front and in the back of rear oscillating axle. Use suitable cribbing to obtain a Dimension (W) for the front of rear frame (23). Dimension (W) is
1575 mm (62 inch) . Use suitable cribbing to obtain a Dimension (X) for the rear of rear frame (23). Dimension (X) is1981 mm (78 inch) . Space the suitable cribbing for the rear frame to Dimension (Z). Dimension (Z) is5410 mm (213 inch) . - Use two suitable cranes, suitable lifting devices, and four of Tooling (A) to position rear frame (23). Use one suitable crane, suitable lifting devices, and two of Tooling (A) to lift the front of rear frame (23). Use one suitable crane, suitable lifting devices, and two of Tooling (A) to lift the rear of rear frame (23). The weight of rear frame (23) is approximately
44379 kg (97840 lb) . Remove the shipping supports from rear frame (23) and position rear frame (23) onto the suitable cribbing over the rear axle.Show/hide tableIllustration 5 g03605383 (A) 193-5474 Shackle As
(-) Suitable Cribbing (2438 mm (96 inch) Length X305 mm (12 inch) Width X305 mm (12 inch) Height)
(-) Suitable Cribbing (610 mm (24 inch) Length X305 mm (12 inch) Width X305 mm (12 inch) Height)
(-) Suitable Cribbing (610 mm (24 inch) Length X305 mm (12 inch) Width X152 mm (6 inch) Height)
(S)1473 mm (58 inch)
(T)152 mm (6 inch)
(Y)2667 mm (105 inch)
(24) Loader FrameNote: The suitable cribbing is stacked alternately.
- Use the suitable cribbing to support the loader frame (24). Position the suitable cribbing in front of the rear frame. Use suitable cribbing to obtain a Dimension (S) for the front of loader frame (24). Dimension (S) is
1473 mm (58 inch) . Use suitable cribbing to obtain a Dimension (T) for the rear of loader frame (24). Dimension (T) is152 mm (6 inch) . Space the suitable cribbing for the loader frame to Dimension (Y). Dimension (Y) is2667 mm (105 inch) . - Use two suitable cranes, suitable lifting devices, and four of Tooling (A) to position loader frame (24). Use one suitable crane, suitable lifting devices, and two of Tooling (A) to lift the front of loader frame (24). Use one suitable crane, suitable lifting devices, and two of Tooling (A) to lift the rear of loader frame (24). The weight of loader frame (24) is approximately
28495 kg (62820 lb) . Remove the shipping supports from loader frame (24) and position rear frame (24) in front of the rear frame.Note: Align the hitch of loader frame (24) with the hitch of the rear frame.
Show/hide tableIllustration 6 g03614438 (25) Front Fixed Axle - Use a suitable crane and a suitable lifting device to position front fixed axle (25). The weight of front fixed axle (22) is approximately
22235 kg (49020 lb) . Position front fixed axle (25) in the front of the loader frame. - As the rest of the components are unloaded, place the components near the rear frame and loader frame. Leave space to allow movement of the cranes. Refer to Illustration 1 for the placement of components, crates, and pallets. Refer to Table 2 for the approximate weights of components, crates, and pallets.
Illustration 3 | g03605381 |
(22) Rear Oscillating Axle |
Illustration 7 | g06013137 |
Cycle time is calculated based on the Caterpillar Production System methodology consisting of value-added and non-values added elements. The cycle times provided in this document are intended to reflect the lowest and most repeatable time validated during the time studies of this value stream.
Cycle times are provided as a reference and should be considered for planning or continuous improvement purposes only.
Cycle Times | ||
Assembly Procedure | Approximate Time | Recommended Number of People |
Assembly Preparation | ||
Loader Frame to Rear Frame - Connect | ||
Oscillating Axle (Rear) - Install | ||
Fixed Axle (Front) - Install | ||
Drive Shaft (Rear) - Install | ||
Drive Shaft (Center) - Install | ||
Fuel Tank - Install | ||
Tire and Rim - Install | ||
Lift Arms and Linkage - Install | ||
Cooling System Package - Install | ||
Battery and Wiring - Install | ||
Wiring (Heater) - Install | ||
Bypass Valve (Fan) - Install | ||
Bumper - Install | ||
Stairway (Powered) - Install | ||
Step - Install | ||
Bumper Lines and Wiring - Connect | ||
Cooling System Package Lines and Wiring - Connect | ||
Platform (Left Hand) - Assemble | ||
Platform (Left Hand) - Install | ||
Platform (Right Hand) - Assemble | ||
Platform (Right Hand) - Install | ||
Stairway - Install | ||
Steering Neutralizer Valve - Install | ||
Cab - Install | ||
Rollover Protective Structure (ROPS) - Assemble | ||
Rollover Protective Structure (ROPS) - Install | ||
Platform (Center) - Install | ||
Hood - Install | ||
Grill - Install | ||
Walkway (Front) - Install | ||
Automatic Lubrication - Install | ||
Tilt Cylinder - Install | ||
Loader Frame to Rear Frame Lines and Wiring - Connect | ||
Modification Group - Install | ||
Machine Starting Procedure | ||
Lift Cylinder - Connect | ||
Tilt Cylinder - Connect | ||
Steering Cylinder - Connect | ||
Position Sensor (Lift, Tilt) - Install | ||
Bucket - Install | ||
Monitor - Install | ||
Bottom Guard - Install | ||
Wheel Chock - Install | ||
Mirror - Install | ||
Films - Install |