Assembly Procedure for the 789 X Body for Certain Off-Highway Trucks{7258, 7960} Caterpillar


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Assembly Procedure for the 789 X Body for Certain Off-Highway Trucks{7258, 7960} [REHS3718]
FRAME AND BODY
BODY GP-TRUCK
Assembly Procedure for the 789 X Body for Certain Off-Highway Trucks{7258, 7960}
1.1. Introduction
2.1. Parts List
3.1. Weights and Required Tools
4.1. Weld Specifications and Parameters
5.1. Welding Instructions
6.2. 400 Brinell Hardness Number or 450 Brinell Hardness Number Material
7.1. Specifications for Cables, Chains, and Lifting Devices
8.1. The Site for Assembly
9.1. Assembly Procedure
10.1. Installation of the Canopy Assembly and Guards
11.1. Installation of the Body Down Indicator
12.1. Miscellaneous
13.1. Liner Groups
14.1. Installation of the Rock Ejector Brackets
Off-Highway Truck/Tractor:
789C (S/N: 2BW1-UP)

Introduction

This Special Instruction contains the necessary procedures and information for assembling and welding the 789C X Body.

The shipping configuration of the X Body depends on the destination and the type of transportation that is available. In some cases, the X Body may be assembled differently from the factory.

Do not perform any procedures or order any parts until this publication is read thoroughly.

The recommended tools and equipment should be present during assembly. If the recommended tools or equipment are not present, assembly will be more difficult and more time will be necessary to complete the assembly.

A flat, smooth, drained area 25 m (80 ft) by 30 m (100 ft) is needed for the assembly.

Note: An enclosed structure is recommended for the assembly of the X Body. The dispersing of the shielding gases away from the welding area must be kept to a minimum.

------ WARNING! ------

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

----------------------

------ WARNING! ------

Make sure the lifting cables and other lifting devices are strong enough to support the machine.

----------------------

The assembly begins with the Center Body Assembly that is turned over. The Left Body Assembly and the Right Body Assembly are welded to the Center Body Assembly. The body assembly is turned over. The Canopy Assembly is installed.

Note: The serial number of the truck body is stamped on the edge of each section.

Parts List

Table 1
Required Parts for the 303-0600 X Truck Body    
Item     Qty     Part Number     Description    
1     1     303-0513     Center Body Assembly    
2     1     303-0515     Left Body Assembly    
3     1     303-0514     Right Body Assembly    
4     1     289-9530     Guard As    
1 289-9535     Guard As    
5     2     303-0517     Bracket As    
6     1     303-0516     Canopy Assembly    
7     2     303-0620     Plates    
8     2     303-0622     Plates    
9     1     288-1623     Left Transition Cap Plate    
10     1     288-1624     Right Transition Cap Plate    
11     6     -     Spacers    
12     14     7X-0851     Nuts    
13     14     8T-0674     Bolts    
14     1     196-6009     Plate    

Weights and Required Tools

The approximate weight of the truck body depends on the configuration of the truck body. Use one or two mobile cranes to lift the truck body.

Below are approximate weights of the truck body.

Table 2
Approximate Shipping Weights    
Description     Weight    
Center Body Assembly    
12061 kg (26600 lb)    
Left Body Assembly    
6993 kg (15450 lb)    
Right Body Assembly    
7036 kg (15515 lb)    
Canopy Assembly    
2146 kg (4735 lb)    

Note: The weights that are listed in this document are only approximate weights. Truck Bodies can vary in size and weight. Refer to the machine shipping order (MSO) that was shipped with the truck body for specific weights. Use the MSO in order to determine lifting requirements.

Table 3
Required Tools    
Qty     Tool Number     Description    
1     3S-6224     Electric Hydraulic Pump Gp    
1     1U-9367     Automatic Tape Measure    
1     164-3310     Infrared Thermometer    
1     1U-9204     Lever Puller Hoist    
As Required     4C-3761     C-Clamp    
As Required     4C-5647     Pry Bar    
As Required     -     Attachments for Electric Hydraulic Pump    
As Required     -     Wedges    
As Required     -     Sledge Hammer    
2     -     Preheating Equipment    
4     -     400 Amp Welder    
1     -     Hand Grinder    
4     -     Clevis
38 mm (1.5 inch)    
As Required     -     Cables
Chains
Hooks
Shackles    
1     -    
1.83 m (6 ft) Ladder    
1     -    
3.66 m (12 ft) Ladder    
1     -    
1.83 m (6 ft) Level    
1     -     Plumb Bob    
1     6V-6317     Bolt    
1     6V-5839     Washer    
1     138-7575     Link Bracket    

Two mobile cranes are necessary in order to lift the truck body.

Weld Specifications and Parameters

Note: Personal breathing protection should be worn by the welders. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator for respiratory protection.

All of the welders must be qualified in Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). All of the welders must be qualified in groove welding and fillet welding in the vertical position. Refer to the American National Standards Institute (ANSI)/American Welding Society (AWS) D1.1. Prior to welding, the process must have been used by the welders during the last six months. Welding qualifications must be documented and welding qualifications must be current.

The surrounding area must be a minimum temperature of 16 °C (60 °F) before welding and during welding.

The proper stick welding electrode for Shielded Metal Arc Welding (SMAW) is E7018 American National Standards Institute (ANSI)/American Welding Society (AWS) A5.1. The finished weld will have the following minimum mechanical properties:

  • 480 MPa (69600 psi) Tensile Strength

  • 400 MPa (58000 psi) Yield Strength

  • 22 percent elongation in 50 mm (2 inch)

  • 27 N·m (20 lb ft) at −29 °C (−20 °F) Impact Toughness

The "E7018" electrodes must be stored in an electrode oven at 121 °C (250 °F). Scrap the "E7018" electrodes or recondition the "E7018" electrodes if the "E7018" electrodes get damp. Recondition the "E7018" electrodes to the manufacturer's specifications. The following table is the electrode's current settings in relation to the electrode's diameters:

Table 4
Parameters for Welding    
Diameter     Amperage    

3 mm (.12 inch)    
70-140    

4 mm (.16 inch)    
110-180    

5 mm (.20 inch)    
190-270    

Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every weld pass. The width of the weld should not exceed two times the electrode diameter.

As an alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's shielding gases that are specified for inside welding. The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

  • 480 MPa (69600 psi) Tensile Strength

  • 400 MPa (58000 psi) Yield Strength

  • 22 percent elongation in 50 mm (2 inch)

  • 27 N·m (20 lb ft) at −29 °C (−20 °F) Impact Toughness

Use only flux cored welding electrodes that have been stored in undamaged packages that resist moisture or use only flux cored welding electrodes that have been stored in an oven at 120 °C (250 °F).

Welding parameters will vary due to the welding position and due to the manufacturer of the welding electrode. A 1.3 mm (0.051 inch) electrode diameter will typically have the following welding parameters:

Table 5
Parameters for Welding    
Wire Feed Rate     Voltage     Approximate Amperage    
Minimum 200 inches per minute     24     210    
Optimum 275 inches per minute     28     250    
Maximum 325 inches per minute     29     300    

Note: Use the manufacturer's recommended welding electrode parameter.

Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every weld pass. The width of the weld should not exceed two times the electrode diameter.

Refer to ""Welding Instructions" " for more welding guidelines.

Welding Instructions

The following materials are used in order to fabricate the X Body:

  • 400 Brinell hardness number

  • 450 Brinell hardness number

Before welding on the X Body, verify the materials that are used in order to fabricate your particular X Body. There are specific welding procedures for each material. Refer to the following procedures in order to weld the materials during the assembly of the truck body.

Note: When two or more different materials need to be welded together, use the procedure for the material that has the more stringent requirements.

400 Brinell Hardness Number or 450 Brinell Hardness Number Material

The following procedure covers the requirements for welding the assembly of the X Bodies that are fabricated with 400 Brinell hardness number material or 450 Brinell hardness number material. Refer to ""Welding Specifications and Parameters" " for qualifications, safety, and welding electrode parameters. Attach the welding ground cable directly to the body assembly. Protect all of the machined areas from sparks and spatter that are produced by welding, chipping, and grinding operations.

Proper preparation of the welding area must be conducted prior to welding. All weld joints and welding areas must be exceptionally clean. Clean the welding area with a grinder. Completely remove all paint, rust, scale, slag, dirt, moisture, grease, and so on, before welding.


NOTICE

400 Brinell hardness number and 450 Brinell hardness number are sensitive to hydrogen induced cracking. Cleanliness of the weld joints and of the consumables is of the utmost importance.


Tight fitup of the body assemblies is important. Ensure that every effort is made in order to minimize the gap spacing. Minimizing the gap spacing reduces the residual stresses.

In order to minimize the possibility of cracking, use large tack welds. The tack welds should have a maximum width of 8 mm (0.32 inch) and a length of 75 mm (3 inch).

A Tiger Torch can be used in order to preheat the material that is welded. Preheating is most critical during the tack welding procedure and during the welding of the root pass. Refer to Table 6 for the required preheat temperature of the weld area.

Table 6
Preheat Temperatures    
Combined Thickness of Material     Welding Preheat    

0 mm (0.0 inch) to
65 mm (2.6 inch)    

100 °C (212 °F)    

66 mm (2.6 inch) to
100 mm (3.9 inch)    

125 °C (257 °F)    
greater than
100 mm (3.9 inch)    

175 °C (350 °F)    

Ensure that the weld groove and 76 mm (3 inch) in each direction from the weld groove is preheated to the specified temperature. Verify the preheat temperature with a 164-3310 Infrared Thermometer or with a temperature stick.

The minimum interpass temperature should equal the preheat temperature. The maximum interpass temperature should not exceed 250 °C (480 °F).

Note: The above preheat and interpass temperatures are for mild restraint to moderate restraint. If clamping devices are utilized in order to reduce the gap spacing to less than 3 mm (0.12 inch), use the next higher preheat temperature, when possible. Additional stresses are offset by using the next higher preheat temperature.

Note: When the ambient temperature is below 0 °C (32 °F) the initial preheat temperature should be raised to 121 °C (250 °F). Preheat 76.0 mm (3.0 inch) inches in each direction from the weld joint. This will help avoid possible heat sink of the floorplates.

All welded areas need to be inspected. Hydrogen induced cracking normally occurs within 72 hours of welding. Allow the welded areas to cool for 48 hours to 72 hours prior to performing a visual inspection. If any welding areas are suspected of being cracked during the visual inspection, then use the dye penetrant process or the magnetic particle inspection process in order to inspect the welding areas. The welds shall be free from the following defects: cracks, porosity, undercut and incomplete fusion. All weld quality shall conform to American National Standards Institute (ANSI)/American Welding Society (AWS) D14.3.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weight's in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not AVSpare parts.




Illustration 1g00629745

Lift angles for lifting slings.

(A) The load capacity is 100% of the working load limit for the sling.

(B) The load capacity is 86% of the working load limit for the sling.

(C) The load capacity is 70% of the working load limit for the sling.

(D) The load capacity is 50% of the working load limit for the sling.

The Site for Assembly

The following photographs are of the shipping configuration.

The X Body will be delivered in four assemblies.

  • Center body assembly

  • Left body assembly

  • Right body assembly

  • Canopy assembly




Illustration 2g01412387



Illustration 3g01412388

View of the left and right body assemblies as the assemblies are shipped.

(2) Left body assembly

(3) Right body assembly




Illustration 4g01408085

View of the miscellaneous attachments that are tack welded to center body assembly (1) .

(1) Center body assembly

(4) Canopy rock guard

(5) Rock ejector brackets

Assembly Procedure




Illustration 5g01412402

Left side view

(1) Center body assembly that is positioned for assembly

  1. Use the lifting eyes that are provided and a suitable lifting device in order to position center body assembly (1) on a level surface. The approximate weight of center body assembly (1) is 12061 kg (26590 lb).



    Illustration 6g01412391

    View of the edges that need to be cleaned prior to assembly.




    Illustration 7g01384443

    This is a view of a rib joint on the center body assembly.




    Illustration 8g01404996

    View of the front transition plate and the front wall.

  1. Use a grinder in order to clean the welding areas of center body assembly (1). Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding. Refer to Illustration 6 through Illustration 8.

    Note: All of the welding areas on center body assembly (1) should now be cleaned.




    Illustration 9g01408878

    Top view of spacer (11) .

  1. Fabricate six spacers (11) with the following dimensions:

    (A) Length ... 50.8 mm (2 inch)

    (B) Width ... 25.4 mm (1 inch)

    (C) Thickness ... 6.0 mm (0.25 inch)

    Note: The spacers will be used to obtain the correct root opening of 6.0 mm (0.24 inch) between the center body assembly and the two side body assemblies.




    Illustration 10g01384589

    View of spacer (11) that is tack welded to left-hand side of center body assembly (1) .




    Illustration 11g01412392

    View of spacers (11) that are tack welded along the right side of the center body assembly.




    Illustration 12g01412393

    View of spacer (11) that is tack welded along the right side of the front wall of the center body assembly.

  1. Refer to Illustration 10 through Illustration 12 in order to position three spacers (11). Tack weld three spacers (11) to the right side of center body assembly (1). Repeat for the left side of center body assembly (1) .

    Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.




    Illustration 13g01280268

    View of the miscellaneous attachments that are tack welded to the center body assembly.

    (4) Canopy rock guard

    (5) Rock ejector brackets

  1. Use a grinder in order to remove the tack welds that secure rock ejector brackets (5) and canopy rock guards (4) to the center body assembly. Refer to Illustration 13.

  1. Remove the fourteen bolts and fourteen nuts that are located inside canopy rock guard (4) .



    Illustration 14g01405066

    View of preparing to turn over the center body assembly.

  1. Use one hoist in order to attach two suitable lifting devices to the two lifting eyes that are located along the left-hand side of the center body assembly. The center body assembly weighs approximately 12061 kg (26590 lb).



    Illustration 15g01405073

    View of preparing to turn over the center body assembly.

  1. Use a second hoist in order to attach two suitable lifting devices to the lifting eyes that are located along the right-hand side of the center body assembly. The center body assembly weighs approximately 12061 kg (26590 lb).



    Illustration 16g01405111

  1. Use the two hoists in order to turn over center body assembly (1) .



    Illustration 17g01405112

  1. Remove the lower lifting devices from the hoist and from the lower lifting eyes.

    Note: Leave the other two lifting devices attached to the center body assembly and to the hoist.




    Illustration 18g01289544

    View of the two lifting devices that are attached to the bottom side of the center body assembly.




    Illustration 19g01405309

    View of one lifting device that is attached to the lifting eye toward the front of the center body assembly.




    Illustration 20g01405310

    View of one lifting device that is attached to the lifting eye toward the rear of the center body assembly.

  1. Attach two lifting devices to the two lifting eyes that are located on the bottom side of the center body assembly. Secure the lifting devices to a suitable hoist. Refer to Illustration 19 through Illustration 20.



    Illustration 21g01405475

    View of center body assembly (1) that is being turned over.




    Illustration 22g01405477

    View of center body assembly (1) that is turned over.

  1. Use the two hoists in order to finish turning over center body assembly (1) .



    Illustration 23g01405479

  1. Remove the two lifting devices that are attached to the floor and to the front wall.



    Illustration 24g01405480

  1. Attach two lifting devices to the two other lifting eyes that are located on the bottom side of the center body assembly. Secure the lifting devices to a suitable hoist.



    Illustration 25g01405481

  1. Use the two hoists in order to raise center body assembly (1) .

  1. Locate the center body assembly in the center of the work area.



    Illustration 26g01405557

  1. Position two 203 mm (8.0 inch) wood blocks underneath the front wall. Position two 203 mm (8.0 inch) wood blocks underneath the rear of the body assembly.



    Illustration 27g01405558

  1. Remove the lifting devices from center body assembly (1) .



    Illustration 28g01412497

  1. Locate left body assembly (2) and right body assembly (3) in the work area.



    Illustration 29g01412536

    View of attaching two lifting devices to the left body assembly.




    Illustration 30g01412647

    View of moving left body assembly (2) away from right body assembly (3) .

  1. Attach two suitable lifting devices to the lifting holes that are located in the left body assembly. Secure the lifting devices to a suitable hoist. The left body assembly weighs approximately 6993 kg (15420 lb).

  1. Move left body assembly (2) away from right body assembly (3) .



    Illustration 31g01412649

  1. Position the left body assembly onto the ground.

  1. Use a grinder in order to clean the welding areas of the left body assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 32g01412650

  1. Raise left body assembly (2) .



    Illustration 33g01405784

    View of one lifting device that is attached to the lifting eye that is located toward the front of the left body assembly.




    Illustration 34g01405785

    View of one lifting device that is attached to the lifting eye that is located toward the rear of the left body assembly.

  1. Attach two suitable lifting devices to the two lifting eyes that are located on the bottom side of the left body assembly. Secure the lifting devices to a suitable hoist.



    Illustration 35g01412651

    View of left body assembly (2) that is being turned over.




    Illustration 36g01412652

    View of left body assembly (2) that is being turned over.

  1. Use both hoists in order to turn over left body assembly (2).



    Illustration 37g01412653

  1. Remove the two lifting devices that are attached to the lifting holes in the left body assembly.



    Illustration 38g01412654

    View of lowering left body assembly (2) .




    Illustration 39g01412894

    View of positioning wood block underneath the rear corner of the left body assembly.

  1. Lower left body assembly (2) to the ground. Position the rear corner of left body assembly (2) onto wood blocks or a suitable support block.



    Illustration 40g01412898

    View of the rib that is located on the front wall of the left body assembly.




    Illustration 41g01412899

    View of the edge that is located on the front wall of the left body assembly.




    Illustration 42g01412913

    View of the rib that is located on the floor of the left body assembly.

  1. Use a grinder in order to clean the welding areas of the left body assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding. Refer to Illustration 40 through Illustration 42.

    Note: All of the welding areas on the left body assembly should now be cleaned.

  1. Use a suitable hoist to raise left body assembly (2) .



    Illustration 43g01412933

    View of left body assembly (2) that is aligned with center body assembly (1) .




    Illustration 44g01406356

    View of the front alignment plates that are used to align the body assemblies. The alignment plates are located on the front wall of the left body assembly.




    Illustration 45g01406315

    View of the bottom alignment plates that are located along the floor seam of the left body assembly.

  1. Position the left body assembly (2) against center body assembly (1). Refer to Illustration 44 through Illustration 45.

    Note: The alignment plates ease the alignment of left body assembly (2) to center body assembly (1) .

    Note: 1U-9204 Lever Puller Hoist can be used to align left body assembly (2) against center body assembly (1) .




    Illustration 46g01406318

    View of five bolts (13) and of five nuts (12) that are located on the bottom of center body assembly (1) and left body assembly (2) .




    Illustration 47g01406608

    View of two bolts (13) and of two nuts (12) that are located on the inside of the front wall.




    Illustration 48g01407521

  1. Install seven bolts (13) and seven nuts (12). Do not tighten the bolts and nuts.



    Illustration 49g01413238

  1. Place a 203 mm (8.0 inch) wood block underneath the front wall of the left body assembly.



    Illustration 50g01408856

    View of center body assembly (1), left body assembly (2), and spacer (11) .

  1. Tighten seven bolts (8) and nuts (7) until center body assembly (1) and left body assembly (2) are tight against three spacers (11) .

    Note: Spacers (11) are used to obtain the correct root opening of 6.0 mm (0.24 inch) between center body assembly (1) and left body assembly (2) .

  1. Remove the lifting devices from left body assembly (2) .



    Illustration 51g01406685

    View of an angle and wedge that can be used along the outside of the front wall for alignment of the body assemblies.




    Illustration 52g01413241

    View of an angle and wedge that can be used along the inside of the front wall for alignment of the body assemblies.




    Illustration 53g01346713

    View of an angle and wedge that can be used along the floor seam for alignment on the bottom of the body assemblies.




    Illustration 54g01346714

    View of an angle and wedge that can be used along the ribs of the floor for alignment on the bottom of the body assemblies.

  1. Use angles and wedges as necessary in order to help align the left body assembly (2) to the center body assembly (1). Refer to Illustration 49 through Illustration 54.

    Note: Also, the body assemblies can be aligned by the use of bolts, nuts, and lugs.

    Note: Before tack welding any lugs, bolts, or angles to the body assembly, use a grinder in order to clean the welding areas. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.

    Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.




    Illustration 55g01346720

    View of root opening (D) that is necessary along the seam between the center body assembly and the left body assembly.

    (D) 6.0 mm (0.24 inch)

  1. Ensure that there is a 6.0 mm (0.24 inch) root opening (D) that separates the center body assembly from the left body assembly.

    Note: If necessary, use an air arc gouging in order to enlarge root opening (D) to 6.0 mm (0.24 inch). Use a grinder to clean the slag from gap (D) .




    Illustration 56g01408078

    View of right body assembly (3) that is aligned with center body assembly (1) .

  1. Repeat Step 20 through Step 37 for right body assembly (3). The right body assembly weighs approximately 7036 kg (15515 lb).



    Illustration 57g01407065

    (E) 6468 mm (254.65 inch)

    Note: Dimension (E) is measured at the highest point and the outermost point forward.




    Illustration 58g01407066

    View of the body upside-down shows measuring the front wall to obtain dimension (E) .




    Illustration 59g01407068

  1. Before tack welding right body assembly (3) to center body assembly (1), ensure that the overall width of the front wall equals dimension (E). If necessary, maneuver right body assembly (3) until the overall width does equal dimension (E). Dimension (E) must be equal to dimension (F) in order for canopy assembly (9) to fit correctly with the assembled body.



    Illustration 60g01407059

  1. Before tack welding, preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper preheat temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.



    Illustration 61g01407092

    View of the areas that are tack welded along the floor seam and the rib joints.

    Note: As required, trim the ends of the ribs in order to achieve 100% penetration of the joint for the square groove weld.




    Illustration 62g01413242

    View of the areas that are tack welded along the outside of the front wall.

  1. Tack weld the left body assembly to the center body assembly.

  1. Repeat Step 40 through Step 42 for the right body assembly.

    Note: The right body assembly weighs approximately 7036 kg (15515 lb).

  1. Remove all nuts, bolts, lugs, wedges, and angles. Grind the welds smooth.



    Illustration 63g01413243

  1. Use a string or a straight edge in order to ensure that the side walls are correctly aligned and that the floor is flat.

  1. Weld temporary braces (G) in order to prevent the side wall and the floor from moving.



    Illustration 64g01407129

  1. Preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the floor seam backup strip that connects left body assembly (2) and center body assembly (1) .

    Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 47 through Step 49 for the right body assembly.



    Illustration 65g01407155

  1. Preheat the rib joints of center body assembly (1) and left body assembly (2) .

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the rib joints between the left body assembly and the center body assembly.

    Note: 100% weld penetration is essential.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 51 through Step 53 for the right body assembly.



    Illustration 66g01413563

    (W1) 8 mm (0.32 inch) Square groove weld

  1. Preheat the front wall.

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the seam of the front wall between the left body assembly and center body assembly.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 55 and Step 56 for the right body assembly.

  1. Move the body from the building to the outside.



    Illustration 67g01282589

    Typical view of the body that is being turned over

  1. Position two suitable cranes (H) and (J) near the upside-down assembled body.

    Note: If the lifting device becomes wrapped around the corner of the body, use the proper precautions in order to ensure safety.




    Illustration 68g01402239

    Typical view of the body that is being turned over

  1. Attach three sets of suitable lifting devices to the body. Attach one lifting device to the lifting eyes on the bottom of the body. Attach one set of lifting devices through each of the two side walls. Refer to Illustration 68. The body assembly weighs approximately 26500 kg (58425 lb).

  1. Attach lifting device (K) to crane (H) and lifting device (L) to crane (J). Lifting device (M) is not used at this time.

  1. Only use one signalman for both of the cranes.



    Illustration 69g01402350

    Typical view of the body that is being turned over




    Illustration 70g01402352

    Typical view of the body that is being turned over

  1. Both cranes should lift the body to a suitable height. Slowly lower crane (J) and raise crane (H) until the body is vertical.



    Illustration 71g01402360

    Typical view of the body that is being turned over

  1. Lifting device (M) should be moved in the direction of the arrow for future use.



    Illustration 72g01402353

    Typical view of the body that is being turned over

  1. Lower crane (H) and position the body vertically on the ground. Keep lifting device (K) tight so that the body does not fall. Disconnect lifting device (L) from crane (J) and from the lifting eyes on the bottom of the body.

  1. Reposition crane (J) to the other side of the body and position the boom toward the body. Connect lifting device (M) to the crane and slowly raise the lifting device until the lifting device is tight.



    Illustration 73g01402354

    Typical view of the body that is being turned over

  1. Slowly lift the body with crane (H) while you rotate the boom of crane (H) away from the body. This will cause the body to tip.

    Note: Do not allow the bottom of the body to move outward.

  1. Once the body has started to tip, start to lower the lifting device on crane (H) and continue to rotate the boom away from the body.



    Illustration 74g01402355

    Typical view of the body that is being turned over




    Illustration 75g01402357

    Typical view of the body that is being turned over

  1. When the body starts to be dragged toward crane (H) slowly begin to raise crane (J). Raise crane (J) until the body is close to being level. Position wood blocks under the body.



    Illustration 76g01283134

    Typical view of the body that is being turned over

  1. Slowly lower both cranes (H) and (J) and position the body onto the wood blocks.

  1. Before finish welding is started, reposition the body inside the building.



    Illustration 77g01407286

    View of root opening (D) that is necessary along the seam between the center body assembly and the left body assembly.

    (D) 6.0 mm (0.24 inch)

  1. Ensure that there is a 6.0 mm (0.24 inch) root opening (D) that separates the center body assembly from the left body assembly.

    Note: If necessary, use an air carbon arc to enlarge root opening (D) to 6.0 mm (0.24 inch). Use a grinder to clean the slag from gap (D) .




    Illustration 78g01408936

  1. Remove three spacers (11) that are located between center body assembly (1) and left body assembly (2) .



    Illustration 79g01413244

    (W2) 16 mm (0.7 inch) Bevel groove weld

  1. Preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the floor seam that connects left body assembly (2) and center body assembly (1) .

    Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 74 through Step 76 for the right body assembly.



    Illustration 80g01413245

    (W3) 16 mm (0.63 inch) Bevel groove weld

  1. Preheat the welding areas of the front wall to the proper temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the seam of the front wall between left body assembly (2) and center body assembly (1) .

    Note: Remove the slag after every weld pass.

  1. Repeat Step 78 through Step 80 for the right body assembly.



    Illustration 81g01413246

    (W4) 16 mm (0.7 inch) V-groove weld

  1. Preheat the welding areas of the front transition plates to the proper temperature. Refer to ""Welding Instructions" ".

  1. Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the front transition plates that connect left body assembly (2) and center body assembly (1) .

    Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 82 through Step 84 for the right body assembly.

  1. Remove all nuts, bolts, lugs, wedges, and angles. Grind the welds smooth.

  1. Remove all braces from the sidewall to the center section.

Installation of the Canopy Assembly and Guards




    Illustration 82g01407599

    View of the canopy from the back.

  1. Locate canopy assembly (6) .



    Illustration 83g01407068

    Note: Dimension (F) needs to be equal to dimension (E) in order to ensure the proper fit. Dimension (E) is given in Illustration 57 of the ""Assembly Procedure" " section.




    Illustration 84g01407604

    Prepare canopy assembly (6) for welding.




    Illustration 85g01407606

    Prepare canopy assembly (6) for welding.

  1. Use a grinder in order to clean the weld areas of the canopy assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 86g01407618

    Prepare canopy assembly (6) for welding.

  1. Use a grinder in order to clean the welding areas of the rock guards on both sides of the canopy assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 87g01413247

  1. Use a grinder in order to clean the welding areas of the body assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 88g01407694

  1. Attach a suitable lifting device to canopy assembly (6). Use three cables in the configuration. The canopy assembly (9) weighs approximately 2146 kg (4735 lb).



    Illustration 89g01407712

    Typical view of canopy that is being installed.

  1. Raise canopy assembly (6) for installation.



    Illustration 90g01409756

    Typical view of canopy that is being installed.

    Note: When you position the canopy a guide line may be necessary.




    Illustration 91g01407714

    Typical view of canopy that is being installed.

  1. Position the canopy to the body.

  1. Align the lugs that are attached to the canopy assembly with the studs that are attached to the walls of the body. Use 7X-0851 Nuts (12) in order to secure the canopy assembly to the side walls.



    Illustration 92g01413250

    View of an angle and wedge that can be used for alignment of the canopy to the body.

  1. Use angles and wedges as necessary in order to help align the canopy assembly to the front wall and to both side walls. Also, use bolts, lugs, and nuts to aid in the alignment procedure.

    Note: Before tack welding any angles, bolts, or lugs to the body assembly, use a grinder in order to clean the welding areas. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.




    Illustration 93g01413251

  1. If necessary, cut the braces that are attached to the front wall in order to aid in the alignment of the canopy assembly to the front wall and to the side walls.

  1. Once the canopy assembly is aligned, tack weld the canopy assembly to the front wall and to the side walls.

    Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.




    Illustration 94g01407733

    (W5) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

    (W6) 6 mm (0.24) Bevel groove weld

  1. Preheat the bottom side of canopy assembly (6) and the front wall.

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld the bottom side of the canopy assembly to the front wall and to the side walls.

    Note: Remove the slag after every weld pass.




    Illustration 95g01407739

    View of rock guard (4) that will be installed.




    Illustration 96g01407741

  1. Use a grinder in order to clean the welding areas of guard assembly (4). Completely remove all paint, rust, scale, slag, dirt, moisture, etc. before welding.

  1. Use a grinder in order to clean the welding area of the body. Completely remove all paint, rust, scale, slag, dirt, moisture, etc. before welding.



    Illustration 97g01414973

  1. Use one 6V-6317 Bolt , one 6V-5839 Washer , and one 138-7575 Link Bracket in order to attach a suitable lifting device to guard assembly (4). Guard assembly (4) weighs approximately 80.55 kg (180 lb).



    Illustration 98g01414791

    Typical view of guard assembly (4) before installation onto the body.

  1. Position guard assembly (4) to the clips that are provided on canopy (6) .



    Illustration 99g01414221

    View of the installed rock guards.

    (W7) 6 mm (0.24 inch) Bevel groove weld

    (W8) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

  1. Weld guard assembly (4) to canopy assembly (6) and the body.

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

    Note: Remove the slag after every weld pass.

  1. Repeat Step 14 through 18 for the other side.



    Illustration 100g01409075

  1. Use a grinder in order to clean the welding area of wrapper plates (7). Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 101g01413255

    (W9) 8 mm (0.3 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

    (W10) 8 mm (0.3 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

    Note: Lifting eyes may be welded onto plate (10) in order to assist in positioning.

  1. Preheat the canopy assembly (6) and wrapper plates (7) .

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Use a suitable lifting device in order to position wrapper plate (7) over the canopy assembly and the front wall. The average weight of a wrapper plate is approximately 166 kg (370 lb).

  1. Weld wrapper plates (7) to canopy assembly (6) .

    Note: Remove the slag after every weld pass.

  1. Weld the bottom side of the canopy assembly to the front wall and to the side walls.

    Note: Remove the slag after every weld pass.




    Illustration 102g01409095

    View of the right side plate.

  1. Use a grinder in order to clean the welding areas of the body and plate (10). Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 103g01413256

    View of plate (10) before welding.

    (W11) 8 mm (0.3 inch) Bevel groove weld

    (W12) 8 mm (0.3 inch) Bevel groove weld

    Note: Lifting eyes may be welded onto plate (10) in order to assist in positioning.

  1. Use a suitable lifting device in order to position transition plate (10) to the body and the wrapper plate. Transition plate (14) weighs approximately 20.030 kg (45 lb).

    Note: Before welding transition cap plates (9) and (10), verify that transition cap plates (9) and (10) are positioned on the correct side of the body.

    Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld plate (10) to the body and the wrapper plate.

  1. Repeat Step 25 through 27 for the other side.



    Illustration 104g01409098

  1. Use a grinder in order to clean the welding area of plate (8). Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 105g01408181

  1. Use a grinder in order to clean the welding area of the body and the canopy. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 106g01408182

    (W14) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

    (W15) 8 mm (0.3 inch) Square groove weld

  1. Weld plate (8) to the body and the canopy.

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Repeat Step 29 through 31 for the other side.

Installation of the Body Down Indicator




    Illustration 107g01404741

  1. Use a grinder in order to clean the welding area of the indicator on the front of the canopy. Completely remove all paint, rust, scale, slag, dirt, moisture, and so on, before welding.



    Illustration 108g01404742

  1. Use a grinder in order to clean indicator (14). Completely remove all paint, rust, slag, dirt, moisture, and so on, before welding.



    Illustration 109g01404743

    (A) 1097.5 ± 3 mm (43.21 ± 0.12 inch)

    (B) 60 ± 5 mm (2.4 ± 0.2 inch)

  1. Position indicator (14) to the inside of canopy (6) .

    Note: Measurement (A) is from the inside of the sidewall assembly.

  1. Once indicator (14) is aligned correctly, tack weld indicator (14) to the inside of canopy (6) .

    Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.




    Illustration 110g01404745

    (W16) 6 mm (0.24 inch) Fillet weld

  1. Preheat indicator (14) and the inside of canopy (6) .

    Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

  1. Weld indicator (14) to the inside of canopy (6) .

    Note: Remove the slag after every weld pass.

Miscellaneous

  1. Remove all lifting eyes, alignment blocks, lugs, stiffeners, and braces from the truck body if shipping is not required. Grind the welds smooth prior to touch up painting and installation to the chassis.

    Note: If the body is shipped, some lugs or lifting eyes may be needed for tie-downs.

  1. Ensure that all welds have been inspected.

    Reference""Weld Specifications and Parameters" " and ""Welding Instructions" "

  1. Clean the entire truck body.

  1. Repaint the truck body, as needed.

Liner Groups

Note: Body liner plates are installed after the body assembly is completed.

Note: The protection plates for the body should be welded around the entire perimeter. A minimum of three weld passes is necessary in order to plug the holes or slots.

Installation of the Rock Ejector Brackets




Illustration 111g01404727

Note: Rock ejector bracket (5) is an optional factory installed item. Refer to Special Instructions, "789 Off-Highway Truck Assembly Procedure" for proper alignment of the 303-0517 Rock Ejector Bracket .

Note: The procedure that is performed is with an installed body assembly.

Note: When the body is fully assembled, all lifting eyes must be removed from the bottom of the body, floor, front wall, canopy, and side walls. If the eyes on the bottom of the body are needed for transportation then the lifting eyes need to be removed before installing the body to the chassis.

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