Assembly Preparation (UENR2889-07)

SMCS - 7000, 7960 i08111727

General Tools PIP

Table 1 -
202 1091
Tool Part
Number 3
Part Description

15: 10/0 092

/ 3 Qty

A
B
1U-5545
6V-9093
0
UE 8:04+ 7
Combination Wrench Set 6 mm to 19 mm
Combination Wrench 13 mm
1
1
C
D
6V-9094
6V-9095
N
© 2 R28 00:00
Combination Wrench 14 mm
Combination Wrench 15 mm
1
1
E 6V-9096 023 89 Combination Wrench 16 mm 1
F 6V-9097
Cat Combination Wrench 17 mm 1
G 6V-9098
erp
Combination Wrench 18 mm 1
H 6V-9099 illa
Combination Wrench 19 mm 1
I 6V-9100 rI
Combination Wrench 20 mm
nc. 1
J 6V-9101 Combination Wrench 21 mm 1
K 6V-9102 Combination Wrench 22 mm 1
L 6V-9103 Combination Wrench 24 mm 1
M 6V-9104 Combination Wrench 30 mm 1
N 214-7215 Combination Wrench 25 mm 1
P 214-7216 Combination Wrench 27 mm 1
Q 214-7222 Combination Wrench 32 mm 1
R 214-7223 Combination Wrench 36 mm 1
S 386-3332 Combination Wrench 41 mm 1
T 9U-5130 Combination Wrench 46 mm 1
U 4C-9600 Combination Wrench Set 11 Piece 3/8 - 1 inch 1
V 4C-9592 Combination Wrench 3/8'" 1
W 4C-9593 Combination Wrench 7/16" 1
X 4C-9594 Combination Wrench 1/2" 1
Y 4C-9595 Combination Wrench 9/16" 1
Z 4C-9596 Combination Wrench 5/8" 1
AA 4C-9597 Combination Wrench 11/16" 1
AB 4C-9598 Combination Wrench 3/4" 1
AC 4C-9599 Combination Wrench 13/16" 1
AD 4C-9601 Combination Wrench 7/8" 1
AE 4C-9602 Combination Wrench 15/16" 1
AF 4C-9603 Combination Wrench 1" 1
AG 8H-8516 Combination Wrench 1-1/6" 1
AH 8H-8517 Combination Wrench 1-1/8" 1
AI 8H-8518 Combination Wrench 1-1/4" 1
AJ 8H-8520 Combination Wrench 1-3/8" 1
AK 386-3274 Combination Wrench 1-7/16" 1
AL 8H-8424 Combination Wrench 1-1/2" 1
AM 8H-8423 Combination Wrench 1-5/8" 1
AN 386-3274 Combination Wrench 1-11/16" 1
AP 386-3275 Combination Wrench 1-3/4" 1
AQ 386-3277 Combination Wrench 1-7/8" 1
AR 386-3281 Combination Wrench 2" 1
AS 386-3278 Combination Wrench 2-1/4" 1
AT 386-3279 Combination Wrench 2-3/16" 1
AU 200-1928 Fractional Allen Head Wrench Set, 13 Piece 0.05 to 3/8 inch 1
AV 200-1929 Metric Allen Head Wrench Set 9 Piece 1.5 to 10 mm 1
AW 293-3026 Metric Ball End Allen Head Wrench Set, 13 Piece 1.5 to 10 mm 1
AX U1-7568 Hex Key Wrench 12 mm 1
AY U1-7569 Hex Key Wrench 14 mm 1
AZ U1-7570 Hex Key Wrench 17 mm 1
BA U1-7571 Hex Key Wrench 19 mm 1
BB U1-7581 Standard Allen Head Wrench 3/8" 1
BC U1-7582 Standard Allen Head Wrench 7/16" 1
BD U1-7583 Standard Allen Head Wrench 1/2" 1
BE U1-7585 Standard Allen Head Wrench 5/8" 1
BF 214-7322 Wrench Adjustable 0 to 24 mm 1
BG 214-7323 Wrench Adjustable 0 to 29 mm 1
BH 214-7330 Wrench Adjustable 0 to 33 mm 1
BI 214-7332 Wrench Adjustable 0 to 42 mm 1
BJ 386-3324 Open End Wrench 17 mm 1
BK 386-3325 Open End Wrench 19 mm 1
BL 386-3326 Open End Wrench 22 mm 1
BM 386-3327 Open End Wrench 24 mm 1
BN 386-3328 Open End Wrench 27 mm 1
BP 386-3329 Open End Wrench 30 mm 1
BQ 386-3330 Open End Wrench 32 mm 1
BR 386-3331 Open End Wrench 36 mm 1
BS 386-3333 Open End Wrench 46 mm 1
BT 4C-4065 Open End Wrench 55 mm 2
BU 4C-6964 Pipe Wrench 14" 1
Metric Hex Driver Socket 9 Piece Set 4, 5, 6,7, 8, 10. 3/8 Drive. 12,
BV 194-3585 1
14, 17, mm 1/2 Drive.
BW 194-3546 Hex Driver 3/8 Drive 10 mm Socket 1
BX 194-3547 Hex Driver 1/2 Drive 12 mm Socket 1
BY 194-3548 Hex Driver 1/2 Drive 14 mm Socket 1
BZ 194-3549 Hex Driver 1/2 Drive 17 mm Socket 1
CA 4C-9819 1/2" Drive Swivel Joint 1
CB 8H-8559 1/2" Square Drive 250 mm Extension 1
CC 9S-1732 1/2" Square Drive 125 mm Extension 1
CD 214-7320 1/2" Drive 1/2" Allen Head Socket 1
CE 214-7328 1/2" Drive 5/8" Allen Head Socket 1
CF 386-3336 1/2" Drive 3/4" Allen Head Socket 1
CG 386-3339 1/2" Drive 7/8" Allen Head Socket 1
CH 199-6156 Socket Set 13 Piece 12pt 1/2" Drive 12 to 24 mm 1
CI 213-6926 1/2" Square Drive 6pt 10 mm Socket 1
CJ 213-6927 1/2" Square Drive 6pt 11 mm Socket 1
CK 213-6928 1/2" Square Drive 6pt 12 mm Socket 1
CL 213-6929 1/2" Square Drive 6pt 13 mm Socket 1
CM 213-6930 1/2" Square Drive 6pt 14 mm Socket 1
CN 213-6932 1/2" Square Drive 6pt 15 mm Socket 1
CP 213-6933 1/2" Square Drive 6pt 16 mm Socket 1
CQ 213-6934 1/2" Square Drive 6pt 17 mm Socket 1
CR 213-6935 1/2" Square Drive 6pt 18 mm Socket 1
CS 213-6936 1/2" Square Drive 6pt 19 mm Socket 1
CT 213-6924 1/2" Square Drive 6pt 20 mm Socket 1
CU 213-6937 1/2" Square Drive 6pt 21 mm Socket 1
CV 6V-9116 1/2" Square Drive 6pt 22 mm Socket 1
CW 199-6154 1/2" Square Drive 6pt 24 mm Socket 1
CX 214-6506 1/2" Square 3/8" Drive Socket 1
CY 214-6500 1/2" Square 7/16" Drive Socket 1
CZ 214-6501 1/2" Square 1/2" Drive Socket 1
DA 214-6503 1/2" Square 9/16" Drive Socket 1
DB 214-6504 1/2" Square 5/8" Drive Socket 1
DC 214-6506 1/2" Square 11/16" Drive Socket 1
DD 214-6507 1/2" Square 3/4" Drive Socket 1
DE 214-6509 1/2" Square 13/16" Drive Socket 1
DF 214-6510 1/2" Square 7/8" Drive Socket 1
DG 214-6511 1/2" Square 15/16" Drive Socket 1
DH 214-6512 1/2" Square 1" Drive Socket 1
DI 214-6513 1/2" Square 1-1/16" Drive Socket 1
DJ 5P-3534 3/4" Drive Swivel Joint 1
DK 5P-3588 3/4" to 1" Adaptor Socket Drive 1
DL 8H-8548 3/4 Square Drive 200 mm Extension 1
DM 386-3341 3/4" Drive 3/4" Allen Head Socket 1
DN 386-3342 3/4" Drive 5/8" Allen Head Socket 1
DP 386-3343 3/4" Drive 7/8" Allen Head Socket 1
Impact Socket Set 24 Piece 3/4" Drive 6 Point (17, 19, 21, 22, 23, 24,
DQ 9U-6547 1
26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 38, 41, 42, 43, 46, 50)
DR 9U-6529 24 mm Impact Socket 3/4" Drive 1
DS 9U-6533 30 mm Impact Socket 3/4" Drive 1
DT 9U-6539 36 mm Impact Socket 3/4" Drive 1
DU 9U-6545 46 mm Impact Socket 3/4" Drive 1
DV 8H-8531 15/16" Impact Socket 3/4" Drive 1
DW 261-8570 Adaptor Socket Drive 1" Female to 1-1/2" Male 1
DX 9S-4028 Impact Extension 1" Drive x 5 1/4" Length 1
DY 5S-6076 Drive Extension 1" Drive x 8" Length 1
DZ 386-3260 Drive Extension 1" Drive x 3" Length 1
EA 386-3261 30 mm Impact Socket 1" Drive 1
EB 9U-5089 36 mm Socket 1" Drive - Wheel Nut 1
EC 4C-6724 46 mm Impact Socket 1" Drive 1
ED 4C-8217 55 mm Impact Socket 1" Drive 1
EE 136-5189 55 mm Impact Socket 1-1/2" Drive 1
EF 386-3226 2-3/8 Impact Socket 1-1/2" Drive 1
EG 386-3252 1-13/16" Impact Socket 1-1/2" Drive 1
EH 156-0927 Air Gun 1
EI 1U-7592 Pry Bar 24" 1
EJ 4C-5647 Pry Bar 54" 1
EK 4C-5742 Pry Bar 46" 1
EL 1U-9366 Tape Measure 1
EM 383-8887 Metric Feeler Gauge 1
EN 1U-9915 Wire Brush 1
EP 223-1697 Double Faced Sledge 9.52 Lb. 1
EQ 245-9823 Sledge Hammer 1
ER 8H-8577 Hammer - 2 Lb. Ball and Peen 1
ES 227-3799 Chisel 1
ET 1F-1159 Center Punch 1
EU 236-1169 Pliers 1
EV 316-0703 Pliers Locking 1
EW 257-9140 Multimeter 1
EX 263-9067 Flat File 1
EY 263-9069 Half Round File 1
EZ 8H-8580 Scraper 2
FA 185-3630 Filter Strap Wrench 1
FB 4C-6922 Caulk Gun 1
FC 5P-7414 Seal Pick Kit 1
FD 222-3050 Air Impact Gun 1/2" Drive 1
FE 222-3053 Air Impact Gun 3/4" Drive 1
FF 222-3054 Air Impact Gun 1" Drive 1
FG 222-3074 Die Grinder 1
FH 231-0039 Air Hose 3/8" 50 Ft. 1
FI 288-2512 HD Angle Grinder 1
FJ 4C-4510 Air Hose 1/2" 50 Ft. 1
FK 384-8910 Hydraulic Torque Wrench 3/4" Drive 1
FL 385-3995 Hydraulic Pump 115 VAC 1
FM 385-3996 Hydraulic Pump 208 / 240 VAC 50 / 60 Hz 1
FN 385-7874 Hydraulic Torque Wrench 1" Drive 1
FP 385-8467 Drive Unit 1
FQ 385-8481 2-3/16" Tool Cassette 1
FR 385-8578 Hydraulic Torque Wrench 1-1/2" Drive 1
FS 9U-5020 Hand Torque Wrench 3/8" Drive 1
FT 9U-5006 Hand Torque Wrench 1/2" Drive 1
FU 9U-5007 Hand Torque Wrench 3/4" Drive 1
FV 189-0408 Shackle - Lifting 2.0 Ton 4
FW 189-0409 Shackle - Lifting 3.5 Ton 4
FX 189-0410 Shackle - Lifting 4.75 Ton 4
FY 189-0412 Shackle - Lifting 9.5 Ton 4
FZ 385-3599 Shackle - Lifting 25 Ton 8
GA 1U-8221 Sling - Lifting 1" x 3' 4
GB 1U-8223 Sling - Lifting 1" x 6" 4
GC 1U-8225 Sling - Lifting 1" x 8" 2
GD 1U-8240 Sling - Lifting 2" x 4' 2
GE 1U-8256 Sling - Lifting 2" x 6' 2
GF 1U-8258 Sling - Lifting 2" x 10' 4
GG 1U-8261 Sling - Lifting 3" x 12' 2
GH 384-9657 Lifting Eye Bolts m10 4
GI 384-9658 Lifting Eye Bolts m12 4
GJ 384-9659 Lifting Eye Bolts m14 4
GK 384-9660 Lifting Eye Bolts m16 4
GL 384-9661 Lifting Eye Bolts m20 4
GM 384-9662 Lifting Eye Bolts m24 4
GN 384-9663 Lifting Eye Bolts m30 2
GP 384-9664 Lifting Eye Bolts m36 2
GQ 384-9665 Lifting Eye Bolts m48 1
GR 384-9666 Lifting Eye Bolts m64 1
GS 138-7573 Lifting Link - 3/8" 4
GT 138-7575 Lifting Link - 1/2" 4
GU 138-7574 Lifting Link -3/4" 4
GV 241-3790 Lifting Link -7/8" 4
GW 138-7576 Lifting Link -1-1/4" 4
GX 386-6031 Chain Lever Hoist 10 Ft. 1500 Lb. 2
GY 386-6033 Chain Lever Hoist 10 Ft. 3000 Lb. 2
GZ 386-6035 Chain Lever Hoist 10 Ft. 6000 Lb. 2
HA 386-6036 Chain Lever Hoist 5 Ft. 12000 Lb. 1
HB 1U-5718 Vacuum Pump 1
HC 6D-7726 Hose Assembly 1
HD 9U-6600 Hand Pump 1
HE 116-1859 Elbow 2
HF 8S-7169 Adaptor - STR 2
HG 127-5588 Adaptor - STR 2
HH 7X-7934 Adaptor 2
HI 7X-2441 Adaptor 2
HJ 270-1528 Kit - ORing 1
HK 270-1533 Kit - ORing 1
HL 270-1537 Kit - ORing 1
HM 349-4203 Infrared Thermometer 1
HN 384-1386 Magnetic Thermometer 1
HP 175-5507 Accumulator Fitting 1
HQ 152-2023 Fitting 1
HR 9U-6741 Adaptor Assembly 1
HS 8T-3081 Tap Metric M6 X 1 1
HT 8T-3083 Tap Metric M8 X 1.25 1
HU 8T-3087 Tap Metric M10 X 1.5 1
HV 8T-3091 Tap Metric M12 X 1.75 1
HW 4C-4965 Tap Metric M14 X 2 1
HX 8T-3096 Tap Metric M16 X 2 1
HY 4C-4967 Tap Metric M20 X 2.5 1
HZ 4C-4968 Tap Metric M24 X 3 1
IA Tap Metric M30 X 2 1
IB 4C-4969 Tap Metric M30 X 3.5 1
IC 4C-4970 Tap Metric M36 X 4 1
ID 9U-6503 Tap Metric M48 X 5 1
IE 9U-6902 Tap Metric M64 X 6 1
IF - STW Controller Flash Cables 1
IG - Communication Adaptor 1
IH - Pressure Gauge Set 1
II 198-4240 Indicator 1
IJ 198-4239 Sensor 2
IK 198-4236 Cable DPI 2
IL 8T-5115 Hose Assembly 4
IM 8T-5114 Adaptor Assembly 4
IN 6V-3965 Adaptor - STR 4
IP 3J-1907 Seal O-Ring 4
IQ 5P-4162 Contact Point 1
IR 5P-7262 Contact Point 1
 IS 7H-1942 Indicator 1
IT 8S-2329 Magnetic Base 1
IU 4C-9297 Test Strip 1
IV 4C-9301 Coolant Tester
IW 9S-9273 Engine Oil Refill Adaptor
IX 108-5453 Hydraulic Oil Refill Adaptor
IY 108-5455 Coolant Water Refill Adaptor
IZ 4C-6716 Grease Refill Adaptor
JA 310-5744 Oil Bottle Kit
JB 267-6535 CAT Wipers
JC 422-6704 20W Hydraulic Oil
JD 263-1030 4' Ladder
JE 263-1031 8' Ladder
JF 157-2276 Drain Shovel
JG 157-2268 Square Shovel
JH 4C-4205 CAT Yellow Primer
JI 4C-4200 CAT Yellow Spray Paint
JJ 4C-4198 CAT Black Paint
JK 245-5836 Oil Sorbent Pads
JL 243-1875 Extension Cords 50 Ft.
JM 7K-1181 Cable Ties 3/8" X 12"
JN 6K-8066 Cable Ties 3/16" X 12"
JP 175-3700 Service Kit
JQ 1U-5804 Crimp Tool
JR 262-9305 Tarp Strap

Table 2
Required Tools
Part Number Description
123-6700 Laser Infrared Thermometer Gp
137-7715 Regulator
138-7573 Link Bracket
138-7574 Link Bracket
138-7575 Link Bracket
138-7576 Link Bracket
163-6455 Link Bracket
 164-4035 Shackle As
189-0408 Shackle As
189-0409 Shackle As
189-0410 Shackle As
189-0411 Shackle As
189-0412 Shackle As
189-0863 Shackle As
191-3538 Plug Tap (M24)
193-5474 Shackle As
4C-4967 Tap (M20)
4C-4968 Tap (M24)
4C-4969 Tap (M30)
4C-4970 Tap (M36)
4C-6723 Socket (36 mm)
4C-6724 Socket (46 mm)
4C-9748 Socket (55 mm)
5P-8622 Shackle As
8T-3081 Tap (M6)
8T-3083 Tap (M8)
8T-3087 Tap (M10)
8T-3091 Tap (M12)
8T-3096 Tap (M16)
9U-5794 Tap (M20)
9U-6503 Tap (M48)
9U-6533 Socket (30 mm)
9U-6539 Socket (36 mm)
9U-6545 Socket (46 mm)
9U-6571 Socket (56 mm)
9U-6577 Socket (65 mm)
9U-6901 Tap (M42)
9U-6902 Tap (M64)

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.
Pin Tools
Table 3
Required Tools
Part Number Description
4C-9544 Pin Driver Cap (M48)
9U-6758 Pin Driver Cap (M64)

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.

Required Supplies
Table 4
Required Tools and Supplies
Part
Part Description Qty
Number
Twenty two barrels 208 L (55 US gal) of hydraulic oil. Refer to Service
- 22
Manual, SEBU6250 , "Caterpillar Machine Lubricant Recommendations".
One barrel 208 L (55 US gal) of transmission / drive train oil. Refer to
- Service Manual, SEBU6250 , "Caterpillar Machine Lubricant 1
Recommendations".
Two barrels 180 kg (397 lb) of grease for the central lubrication system.
- Refer to Service Manual, SEBU6250 , "Caterpillar Machine Lubricant 2
Recommendations".
Portable air compressor. The air compressor should have enough capacity
- to operate two 25.4 mm (1 inch) impact wrenches. The air compressor 1
should have a minimum capacity of 185 cfm.
- Stepladder that is 1.83 m (6 ft) tall. 2
- Stepladder that are 3.66 m (12 ft) tall. 2
Suitable Cribbing
- 406 mm (16 inch) Length X 203 mm (8 inch) Width X 102 mm (4 inch) 30
Height
- Several cables, lifting straps, and chains that have adequate lifting capacity -

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.
Use approved cables, chains, and lifting devices to lift the components. Refer to the
manufacturer's literature to determine the application when you select the items that follow:
cable, chain, and lifting devices. When you lift a component, the lift angle is critical.

Required Tools
Table 5
Required Tools and Supplies
Part
Part Description Qty
Number
Crane or a suitable lifting device with a lifting capacity of 150000 kg
- 2
(330700 lb).
- Cat 1055 Telehandler or equivalent 1
- Off-road forklift track with at least 25 ton load capacity (optional) 1
- Power supply with 230/400 VAC (for cold weather use only) 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.

The cranes must be equipped with the following load-bearing rigging material in the proper
length and quantity:

chains

ropes (steel and plastic)

belts

The necessary length depends on the angle of the welded transport lugs of the individual
modules. The rigging material must match the lugs.

Shipping Weights

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.

Table 6
Dimensions and Weights
Component Gross Weight Length (cm) Width (cm) Height (cm)
(kg) /
Net Weight
(kg)
31700 kg
Upper Carriage W/ (69886 lb) / 770 cm 410 cm 363 cm
Hydraulic Tank 31600 kg (303 inch) (161 inch) (143 inch)
(69666 lb)
30500 kg
Track Roller Assembly (67241 lb) / 755 cm 200 cm 200 cm
(Right) 30000 kg (297 inch) (79 inch) (79 inch)
(66139 lb)
30500 kg
Track Roller Assembly (67241 lb) / 755 cm 200 cm 200 cm
(Left) 30000 kg (297 inch) (79 inch) (79 inch)
(66139 lb)
18800 kg
(41447 lb) / 380 cm 340 cm 161 cm
Carbody Arrangement
18600 kg (150 inch) (134 inch) (63 inch)
(41006 lb)
17150 kg
(37810 lb) / 745 cm 250 cm 348 cm
Power Module Arrangement
16250 kg (293 inch) (98 inch) (137 inch)
(35825 lb)
3440 kg
Cab Riser Arrangement (7584 lb) / 266 cm 224 cm 244 cm
(Crate) 2810 kg (105 inch) (88 inch) (96 inch)
(6195 lb)
2760 kg
Fuel Tank Arrangement (6085 lb) / 246 cm 164 cm 256 cm
(Crate) 2240 kg (97 inch) (65 inch) (101 inch)
(4938 lb)
 4700 kg
Operators Cab Arrangement (10362 lb) / 400 cm 276 cm 318 cm
(Crate) 3375 kg (157 inch) (109 inch) (125 inch)
(7441 lb)
12000 kg
(26455 lb) / 546 mm 236 cm 215 cm
Stick Arrangement
12000 kg (21 inch) (93 inch) (85 inch)
(26455 lb)
12914 kg
(28470 lb) / 345 cm 325 cm 280 cm
Bucket Arrangement
12779 kg (136 inch) (128 inch) (110 inch)
(28173 lb)
22100 kg
(48722 lb) / 940 cm 250 cm 380 cm
Boom Arrangement
22100 kg (370 inch) (98 inch) (150 inch)
(48722 lb)
5700 kg
Boom Cylinder Arrangement (12566 lb) / 484 cm 121 cm 105 cm
x 2 (Pallet) 5250 kg (191 inch) (48 inch) (41 inch)
(11574 lb)
4670 kg
Stick Cylinder Arrangement (10296 lb) / 450 cm 111 cm 105 cm
x 2 (Pallet) 4300 kg (177 inch) (44 inch) (41 inch)
(9480 lb)
25800 kg
(56879 lb) / 620 cm 149 cm 105 cm
Counterweight
25800 kg (244 inch) (58 inch) (41 inch)
(56879 lb)
2430 kg
Swing Drive Arrangement x (5357 lb) / 162 mm 110 cm 210 cm
2 (Crate) 1950 kg (6 inch) (43 inch) (83 inch)
(4299 lb)
2855 kg
Right Hand Platform (6294 lb) / 450 cm 222 cm 164 cm
Arrangement (Crate) 1600 kg (177 inch) (87 inch) (65 inch)
(3527 lb)
2420 kg
Left Hand Platform (5335 lb) / 440 cm 212 cm 154 cm
Arrangement (Crate) 1600 kg (173 inch) (83 inch) (61 inch)
(3527 lb)
1170 kg
Boarding Ladder (2579 lb) / 476 cm 175 cm 150 cm
Arrangement (Crate) 630 kg (187 inch) (69 inch) (59 inch)
(1389 lb)
1720 kg
Box of Parts (Bolts / (3792 lb) / 262 cm 140 cm 148 cm
Hardware) 1400 kg (103 inch) (55 inch) (58 inch)
(3086 lb)
Box of Parts (Hoses) 790 kg 280 cm 175 cm 100 cm
(1742 lb) / (110 inch) (69 inch) (39 inch)
 385 kg (849 lb)
640 kg
280 cm 150 cm 150 cm
Box of Parts (Handrails) (1411 lb) /
(110 inch) (59 inch) (59 inch)
225 kg (496 lb)
790 kg
Box of Parts (Exhaust (1742 lb) / 240 cm 210 cm 112 cm
Cover) 530 kg (94 inch) (83 inch) (44 inch)
(1168 lb)
915 kg
(2017 lb) / 220 cm 60 cm 80 cm
Box of Parts (Bucket Pin)
730 kg (86 inch) (23 inch) (31 inch)
(1609 lb)

Site Layout
Choose a flat, drained area for assembly. The area should be 60 m (197 ft) long and 60 m
(197 ft) wide, of which 25 m (82 ft) by 25 m (82 ft) located in the center of the area must be level
ground with a 1 percent maximum variation.

The surface must have a load capacity of at least 22 N/cm2.

The complete assembly site must be clean, dry, flat, and solid. A flat surface is absolutely
necessary to correctly align the components during assembly.

Note: The 6020B Excavator components may be arranged in several ways. This arrangement
will minimize the movements of the cranes and the arrangement will simplify the assembly.
Illustration 1 g03779476
(A) 40 foot container (suggested)
(B) 20 to 40 foot container (optional)
(1) Carbody
(2) Left-hand track roller
(3) Right-hand track roller
(4) Chassis arrangement
(5) Power module
(6) Counterweight
(7) Boom
(8) Cylinders
(9) Stick
(10) Right-hand walkway
(11) Bucket
(12) Cab
(13) Cab module
(14) Swing drive groups
(15) Fuel tank
(16) Hydraulic tank (if delivered separately)
(17) Grease station (if delivered separately)
(18) Hoses box
(19) Bolts box
(20) Electrical parts
(21) Fluids
(22) Miscellaneous boxes
(23) Miscellaneous boxes

Note: Each site for the assembly is different. Each site will require a unique layout to assemble
the components. With proper planning, the cost of keeping the cranes and the crew at the site
can be minimized.
Flow Chart
Provide a flow chart if you have one available.
Illustration 2 g03866097

Illustration 3 g03866203

Cycle Times
Cycle times are calculated based on the Caterpillar Production System methodology consisting
of value-added and non-value 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. Procedures indicated as "Options" may be factory installed. All time
approximations are calculated flowing the suggested assembly flow order and include time to
locate parts, tools, and prepare surfaces unless otherwise indicated. Deviation from this
suggested assembly order may increase the difficulty and time to complete certain assembly
tasks. Personnel recommendations may include a crane signal person where applicable.

Table 7
Cycle Times
Approximate Recommended Equipment /
Assembly Procedure
Time Number of People
Unload Machine / Parts 8 hrs 2 Cranes - 4 Technicians
Prepare Carbody and Crawler
5 hrs 3 Technicians
Frames
LH Track Roller Frame - Install 3 hrs 1 Crane - 3 Technicians
RH Track Roller Frame - Install 3 hrs 1 Crane - 3 Technicians
Travel Motor Lines - Connect 2 hrs 1 Technician
Belly Plate (Option) - Install 3 hrs 1 Crane - 2 Technicians
Rock Guards (Option) - Install 3 hrs 1 Telehandler - 2 Technicians
Prepare Main Frame Surfaces 10 hrs 3 Technicians
Fuel Tank W/ Handrail - Install 5 hr 1 Crane - 3 Technician
LH Walkway - Install 3 hrs 1 Crane - 2 Technicians
Boarding Ladder - Install 3 hrs 1 Crane - 2 Technicians
Boarding Ladder Lines - Connect 1 hr 1 Technician
Fuel Tank Platform W/ Handrail -
2 hr 1 Crane - 1 Technician
Install
Cab Riser Walkway W/ Handrail -
2.5 hrs 1 Telehandler - 2 Technician
Install
Grease Platform Handrail - Install 1 hr 1 Crane - 1 Technician
RH Walkway W/ Handrail - Install 5 hrs 1 Crane - 3 Technicians
Upper Chassis W/ Fuel Tank, Ladder,
10 hrs 2 Cranes - 4 Technicians
RH Walkway - Install
Swing Drives - Install 5 hrs 1 Crane - 3 Technicians
Rotary Swivel Lines - Connect 3 Hours 1 Technician
Swing Drive Lines - Connect 4 Hours 2 Technicians
Grease Scrapers (Option) - Install 1 Hour 1 Technician
Power Module - Install 5 Hours 2 Cranes - 4 Technicians
Power Module Lines - Connect 4 Hours 2 Technicians
Engine Fan Lines - Connect 1.5 Hours 1 Technician
Oil Cooling System Lines - Connect 4 Hours 1 Technician
Center Walkway W/ Handrail - Install 2 Hours 1 Crane - 2 Technicians
Exhaust Hoods - Install 3 Hours 1 Crane - 2 Technicians
Cold Weather Group (Option) - Install 6 Hours 2 Technicians
Boom and Stick Cylinders - Install (On 1 Crane - 1 Aerial Lift - 1
7 Hours
Boom) Telehandler - 3 Technicians
LH Boom Walkway W/ Handrail -
3 Hours 1 Crane - 2 Technicians
Install
Boom Worklights (Option) - Install 1 Hour 1 Technician
2 Cranes - 1 Telehandler - 4
Boom - Install 6 Hours
Technicians
2 Cranes - 1 Aerial Lift - 1
Stick - Install 5 Hours
Telehandler - 4 Technicians
RH Boom Walkway W/ Handrail -
2 Hours 1 Crane - 1 Technician
Install
Boom Cylinders to Mainframe - 1 Crane - 1 Aerial Lift - 2
4 Hours
Connect Technicians
Boom Lines - Connect 8 Hours 1 Aerial Lift - 2 Technicians
Stick Lines - Connect 3 Hours 1 Aerial Lift - 2 Technicians
Counterweight W/ Handrail - Install 6 Hours 1 Crane - 3 Technicians
Cab Walkway W/ Handrail and Ladder
6 Hours 1 Crane - 2 Technicians
- Install
Cab Riser - Install 3 Hours 1 Crane - 3 Technicians
Cab Staircase W/ Handrail - Install 2 Hours 1 Crane - 2 Technicians
1 Crane - 1 Aerial Lift - 4
Operators Cab - Install 6 Hours
Technicians
Lighting Group - Install 2 Hours 1 Technician
Electrical Harness Group - Install 8 Hours 1 Aerial Lift - 2 Technicians
HVAC Lines - Connect 4 Hours 1 Technician
Mirrors - Install 1 Hour 1 Technician
Camera System (Option) - Install 4 Hours 2 Technicians
Fluids - Fill 8 Hours 1 Telehandler - 2 Technicians
Start Machine 2 Hours 2 Technicians
Cycle Machine / Top Off Fluids 2 Hours 1 Telehandler - 2 Technicians
Bucket - Install 3 Hours 1 Telehandler - 3 Technicians
Calibrate and Commission Machine 10 Hours 2 Technicians

Preparation of Modules for Assembly

Before assembly of each module, prepare the contact surfaces of the main frame and the
relevant module according to the following instructions.

If the preparation work is completed before assembly of the module, apply a protective oil film to
the contact surfaces immediately after preparation and cover the bore threads with a plastic cap.

Prepare the modules and other components in the following steps:

1. Remove all packaging and the transport protection material only directly before the
installation of the components in the relevant module. If you do not install the components
immediately, do not remove the packaging.
Note: Longer periods without protection can damage or contaminate assembly surfaces.

Take special care when removing the protective film from the cylinder pins. Even the
smallest damage to the pin surface can cause destruction of the pins and bearing bushing in
the long term.

2. Check all parts and transport containers for damage caused during transportation.
Document all damage as evidence for the transport insurance company in case of a
complaint. Provide this documentation with photos of the damaged parts.

3. Prepare all hardware and check for the correct quantities. If necessary, oil the bolts.
 4. Before preparation of the contact surfaces under the relevant module, place the modules on
an adequately stable base. Do not lift the modules with the crane to reach the contact
surfaces.

5. Immediately before assembly, clean the module contact surfaces of paint, dirt, grease, rust,
and oil using an appropriate solvent. The surfaces must be metallic blank after cleaning.

6. Apply Loctite 518 to machined surfaces before installing. Where sealant is used, full torque
of the mating joint must be performed within 24 hours. If this cannot be done, postpone
installation until the following day.

7. Check and trim all threaded bores. After trimming clean out the thread bores with
compressed air.

8. To achieve the correct tension of the fixing bolts with the defined torque value, ensure that
all threaded bores are in optimum state.

9. If the assembly cannot take place immediately after cleaning the contact surfaces, protect
the surface from corrosion. Remove the protection material before assembly so that the
contact surfaces are dry, clean, and metallic blank. If there is corrosion, completely remove
the corrosion.

10. To avoid contamination during assembly, ensure that the surfaces around and over the
assembly surfaces are clean.

11. Before assembly, clean the bearings and pins from oil. Spray the bearings and pin with
assembly spray.

12. Grease all bushes and pins before fitting. Secure all pins as soon as they have been fitted.

13. If you have to remove individual components for the assembly, reinsert the removed bolts in
their threaded holes. This will ensure that the bolts are not lost and dirt will be kept from
entering the threaded holes.

During the modules preparation, items that are required only for transportation, such as covers,
blanking plates, and transport nuts are left over. Store these parts in a secure place, so that the
parts can be reused if required.

PIP-10913092
2023/10/07
15:07:25+00:00
i06007190
© 2023 Caterpillar Inc.