994K Large Wheel Loader Field Assembly Manual Caterpillar

Required Tools and Supplies

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

Show/hide table

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.

Show/hide table

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: 24 m (78 ft) long by 24 m (78 ft) wide.

Note: Do not open the bags of hardware. The bags of hardware are marked for easy identification and for orderly use.

Illustration 1	g03584156

Illustration 2	g03604965
(S) 1473 mm (58 inch) (T) 152 mm (6 inch) (W) 1575 mm (62 inch) (X) 1981 mm (78 inch) (Y) 2667 mm (105 inch) (Z) 5410 mm (213 inch)

Show/hide table

Illustration 3	g03605381
(22) Rear Oscillating Axle

1. 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 table

   Illustration 4	g03605382
   (A) 193-5474 Shackle As (-) Suitable Cribbing ( 2438 mm (96 inch) Length X 305 mm (12 inch) Width X 305 mm (12 inch) Height) (-) Suitable Cribbing ( 610 mm (24 inch) Length X 305 mm (12 inch) Width X 305 mm (12 inch) Height) (-) Suitable Cribbing ( 610 mm (24 inch) Length X 305 mm (12 inch) Width X 152 mm (6 inch) Height) (W) 1575 mm (62 inch) (X) 1981 mm (78 inch) (Z) 5410 mm (213 inch) (23) Rear Frame

   Note: The suitable cribbing is stacked alternately.

2. 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) is 1981 mm (78 inch). Space the suitable cribbing for the rear frame to Dimension (Z). Dimension (Z) is 5410 mm (213 inch).

3. 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 table

   Illustration 5	g03605383
   (A) 193-5474 Shackle As (-) Suitable Cribbing ( 2438 mm (96 inch) Length X 305 mm (12 inch) Width X 305 mm (12 inch) Height) (-) Suitable Cribbing ( 610 mm (24 inch) Length X 305 mm (12 inch) Width X 305 mm (12 inch) Height) (-) Suitable Cribbing ( 610 mm (24 inch) Length X 305 mm (12 inch) Width X 152 mm (6 inch) Height) (S) 1473 mm (58 inch) (T) 152 mm (6 inch) (Y) 2667 mm (105 inch) (24) Loader Frame

   Note: The suitable cribbing is stacked alternately.

4. 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) is 152 mm (6 inch). Space the suitable cribbing for the loader frame to Dimension (Y). Dimension (Y) is 2667 mm (105 inch).

5. 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 table

   Illustration 6	g03614438
   (25) Front Fixed Axle

6. 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.

7. 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.

Flow Chart

Illustration 7	g06013137

Cycle Times

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.