Technical Station 6 - Wiring loom, control console, throttle cable
The control console is sub-assembled on a bench alongside Station 6 with the control unit mounted into its frame, the control fascia is then attached to the top of the frame and the wiring loom and
fuses boxes attached to the various switches and joystick. The throttle cable is then run to the back to be connected to the engine. Note that the control console cover is left off after installation.
This is because, at a later date in the test procedures, the technician may have to gain access to the controller for remedial work. It is much easier with the cover off!
Control unit sub-assembly
Mounted on chassis with wiring loom attached
Station 7 - Radiator, oil cooler sub-assembly and fitting
Fitting the cooling system begins with the sub-assembly of the radiator and oil cooler on the workbench alongside this
station. Once assembled, this is then fitted to the chassis, the bug screen inserted, the protective outer casing and
radiator hoses attached. The final job at this station is to attach the air filter.
Rear wiring loom showing alternator and starting motor
The radiator and oil cooler being assembled
Lifting the assembled cooling system onto the machine
The cooling system installed complete with air filter
Station 8 - Fuel and hydraulic tanks, fuel line, major flexible hoses to main pumps
The fuel and hydraulic tanks on the GP400 look like a one-piece unit, but they comprise of two separate tanks that appear as one. These are assembled on a
jig beside the production line, bolted to a base plate and the fuel pump, fuel filter and rigid fuel lines fixed into position.
Once assembled, it is lifted and bolted into position on hinges on the chassis. Finally, the flexible hydraulic hoses are fitted to the hydraulic tank.
Fuel tank in its basic stage
Fuel tank with integrated hydraulic oil tank
The completed unit with fuel pump and filter visible
120 PC JUNE/JULY 2013
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