Usage:
The Assembly Procedures and Specifications charts offer many advantages to the serviceman who assembles engines, transmissions and torque converters.
Each chart is a separate reference publication for a specific component. Each chart has two sides. One side shows the correct sequence to follow for the installation of parts. The other side shows the specifications (torque, critical dimensions, etc.) that are needed during the assembly of the component. The parts, tools and any special equipment needed to assemble the engine, transmission or torque converter are also given in the charts.
A check of the chart before the start of the assembly work tells the serviceman what parts, tools and equipment will be needed to assemble the specific component. Each chart has all of the information a serviceman needs during normal assembly procedures.
When the chart is in the specialized work area it is not necessary for a serviceman to stop work and go to a central library to look up other publications. The ability to work with no interruptions (stops) makes it easier to get high quality repairs since delays can increase the percentage of errors that make much of the redo-work necessary.
The chart shown here stays with the engine for fast and easy reference of service information until the assembly is complete.
The Assembly Procedures and Specifications Charts can be used as a work plan. This is a big advantage when two servicemen work together on the assembly of one component and/or when servicemen on different shifts work on the same component.
The charts improve communication between servicemen on different shifts. If each assembly step is checked off as it is completed, the servicemen on the next shift can quickly see what work has been completed and what work is still to be done. This decreases the possibility of an important step not being done, especially an inspection function.
The Assembly Procedures and Specifications Charts can also be used as efficient guides for the disassembly of the basic component.
During disassembly the serviceman can check the chart to see in what step each subassembly and parts (such as hardware) will be used. He then makes a separation of the parts (and components) according to the sequence in which they will be needed.
Groups of charts are hung in different areas of the service shop. Servicemen use the chart nearest to their work for reference.
It takes much less time to do the work if the parts are put in groups together as they will be used in the assembly process.
Each chart is a separate publication and has its own form number. When a chart needs revision, a new one takes the place of the out-of-date one. This makes it easy to give the serviceman the most current information. When a revision is made to a chart, a "C" is added to show what was changed.
The charts are designed to be used and kept in the assembly work area. For this reason they are printed on soil-resistant and tear-resistant paper. Oil and dirt can be easily cleaned off the charts.
Dealers that use the Assembly Procedures and Specifications Charts regularly have developed several different methods for the storage of the charts where they are needed. The illustrations give you ways to use the charts. Remember that for easy reference the charts must be available for use in the specialized service work area.
There are many transmission and torque converter charts. For this reason some dealers put the charts between pieces of Plexiglas (a type of plastic) with the titles of the charts on the side for easy reference. The charts are kept on a shelf in the specialized transmission area.
These charts are laminated (put between thin layers of material) in plastic and can be hung on a beam.
Other dealers put the charts between two pieces of glass or plastic and put them in wooden frames. For storage the charts are kept on a shelf. Chart titles are painted on the side of the frame.
Thompson Tractor Co., Inc., in Birmingham, Alabama, U.S.A., laminates (puts between thin layers of material) the charts in plastic. The plastic cover on the charts makes them easy to clean and prevents excessive wear. Copies of the charts are hung in the specialized rebuild areas. The servicemen go to the charts to find information they need during the assembly procedure.
Hewitt Equipment Limited in Montreal, Canada puts each chart between two pieces of Plexiglas (plastic) in a wooden frame. The title of each chart is written on the side of the frame. The charts are kept on a shelf. When work begins on a component, the correct chart is given to the serviceman. The chart stays with the component until the work is complete.
Some dealers put the charts in frames with hinges so the charts can be moved back and forth. This lets the serviceman read both sides of the charts easily. Each chart is put between two pieces of Plexiglas.
Darr Equipment Co. in Dallas, Texas, U.S.A. has another method for the use of the Assembly Procedures and Specifications Charts. The charts for engines are put between two pieces of Plexiglas and hung with hinges so they can be read from either side (see Illustration). This method is used only in the engine shop. A different method is used in the specialized transmission area because of the large number of transmission charts. Instead of being hung vertically, the charts are kept on a shelf with the title of each chart on the side.
The chart that follows gives the form number and component of available charts as of June, 1978. The cost of each chart is $0.75 (U.S.). Order them on a standard Miscellaneous Material order form.
Replacement of out-of-date charts is important. The PUBLICATIONS LIST microfiche in the Service Information Retrieval System will always have a current list of the available charts. As of this date, this information can be found on Fiche 9, Grid G3. This fiche and grid location can change in the future, so always check the Insert "Caterpillar Publications List, Index to Microfiche" under Special Publications. When this information is needed one person in the service department can keep the charts up-to-date if a record is kept of all charts in the shop. A comparison of this record to the Publications List microfiche will tell whether your shop has all current Assembly Procedures and Specifications charts.