Assembly Procedure For the 785B and 785C Dual Slope Truck Body{7258, 7960} Caterpillar

Off-Highway Truck:

785B (S/N: 6HK1-UP)

785C (S/N: APX1-UP; 5AZ1-UP)

Introduction

This Special Instruction contains the necessary procedure and information for the welding of the 785B and the 785C truck body.

The shipping configuration of the 785B and the 785C truck body is dependent upon the destination and the type of the transportation that is available. In some instances, a varying (degree) of completion on the truck body will already be assembled. The following Special Instruction illustrates the complete assembly of the truck body.

Show/hide table

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.

The suggested tools and equipment should be readily available at the job site for the assembly. If the tools are not available, the assembly will be more difficult and more time will be needed to complete the assembly.

The body of the truck is positioned upside-down in this assembly procedure. The right-hand body assembly is installed, and then the left-hand body is installed and welded. The truck body is then turned over and the remaining welding and the assembly is completed. The body can be assembled right side, but the assembly will be faster if you start with the body upside-down.

Note: Some of the photographs in this Special Instruction may be shown in either position.

Two mobile cranes will be needed for the assembly of the truck body. The cranes will need to have a total lifting capacity of 45000 kg (100,000 lb).

A flat, smooth, drained area 55/75 m (180/246 ft) by 55/75 m (180/246 ft) is needed for the assembly.

Weights

Show/hide table

NOTICE
When a hoist is used to lift any part or assembly, make sure that the hoist has the necessary capacity. Refer to table 1 for the approximate weight.

Table 1

Standard Body
Body And Canopy Assembly	21507 kg	47315 lb
Body Assembly (Center)	9923 kg	21831 lb
Body Assembly (Left Side )	4389 kg	9656 lb
Body Assembly (right side)	4389 kg	9656 lb
Canopy Assembly	2121 kg	4666 lb
Liner (Attachment)	7650 kg	16800 lb
Sideboard Assembly (Attachment)	679 kg	1500 lb
Cable Group (Body)	45 kg	100 lb

Dimensions

Table 2

Length
Body With Canopy	10620 mm	418 in
Body Without Canopy	8063 mm	317 in

Table 3

Width
Body	6642 mm	261 in

Table 4

Height
Body Without Canopy	3265 mm	129 in
Body With Canopy	2600 mm	102 in

Parts List

Table 5

Parts that are required to Install Body (Attachments)
Item	Qty	Part Number	Description
1	1	113-8013	Center Body Assembly
2	1	113-8011	Body Assembly (RH)
3	1	113-8012	Body Assembly (LH)
4	1	8W-9245	Canopy As
5	1	112-6180	Plate As (RH)
6	1	112-6181	Plate As (LH)
7	1	8X-6394	Plate As
8	1	8W-3666	Guard As (RH)
9	1	8W-3667	Guard As (LH)
10	1	8X-1190	Brace
11	4	8X-1189	Brace
12	16	2B-7218	Bolt
13	16	2J-3507	Full Nut
14	1	8X-6452	Block
15	1	114-5012	Guard As
16	4	8W-7184	Shield As
17	1	2A-6954	Plate
18	1	5T-5858	Plate
19	1	8W-0108	Bracket As
20	1	111-9776	Angle (1)
21	1	111-9824	Angle (RH) (1)
22	2	7I-4795	Body (Sideboard) (2)
23	2	2A-7036	Rail (2)
24	2	2A-7028	Plate (2)
25	2	2A-7029	Plate (2)
26	2	114-4582	Body Sidewall Cap (3)
27	2	2A-6952	Plate (3)
27A	2	2A-6953	End Cap (3)
28	1	114-4583	Tail Extension As (4)
29	1	113-8264	Plate
30	1	113-8267	Plate
31	2	114-4675	Plate
32	1	114-4657	Extension Liner (Assembly) (5)
33	1	114-8658	Plate (6)
34	2	114-8659	Plate

( 1 )	The angle is part of the shipping support, and must be removed.
( 2 )	The sideboard assembly (22) is partially assembled at the factory. Install the sideboard after you have welded the canopy assembly to the body assembly.
( 3 )	Install cap assembly (26) after you have welded the canopy assembly to the body assembly.
( 4 )	Tail extension assembly (28) can be ordered as a complete assembly.
( 5 )	Extension liner (assembly) (32) can be ordered as a complete assembly when the tail extension is ordered.
( 6 )	Plate (33) will be installed at the factory. If extension liner (32) is ordered, only two plates (34) will require welding.

Table 6

Parts that are required to Install Liner (Attachments)
Item	Qty	Part Number	Description	Weight
35	1	114-6368	Plate	795 kg (1752 lb)
36	2	114-6377	Plate	37 kg (82 lb)
37	2	114-6374	Plate	1300 kg (2866 lb)
38	2	114-6372	Plate	337 kg (743 lb)
39	2	114-6371	Plate	393 kg (866 lb)
40	2	114-6378	Plate	118 kg (260 lb)
41	2	114-6373	Plate	94 kg (207 lb)
42	2	114-6367	Plate	22 kg (49 lb)
43	2	114-6366	Plate	33 kg (73 lb)
44	2	114-6375	Plate	196 kg (432 lb)
45	2	114-6376	Plate	175 kg (386 lb)
46	2	114-6369	Plate	52 kg (115 lb)
47	2	114-6370	Plate	59 kg (130 lb)

Required Tools

Table 7

Required Tools
Qty	Tool Number	Description
1	1U-9367	Automatic Tape Measure
1	1U-9204	Lever Puller Hoist
4	1U-9755	Hydraulic Jack 20 Tons
As Required	4C-3761	C-Clamp
As Required	4C-5647	Pry Bar
As Required	-	Wedges
As Required	-	Sledge Hammer
As required	-	400 Amp Welder
As Required	-	Clevis
Numerous	-	Cables Chains Hooks Shackles
1	-	Hand Grinder
1	-	1.83 m (6 ft) Ladder
1	-	1.2192 m (4 ft) Level
1	-	Plate Clamp (1 Ton)

Illustration 1	g01010440
View of the wedges and brackets

Fabricate a number of wedges and brackets prior to the assembly of the body. The bracket should be made from a minimum of 12 mm (0.50 inch) mild steel. The wedge should be from a minimum of 20 mm (0.8 inch) mild steel. Refer to Table 8 and Illustration 1 for the dimensions that will be used to make the brackets and wedges.

Table 8

Dimensions for the Brackets and Wedges
Items	Dimensions
A	150 mm (6.0 inch)
B	50 mm (2.0 inch)
C	25 mm (1.0 inch)
D	100 mm (4.0 inch)
E	30 mm (1.2 inch)
F	200 mm (7.9 inch)

Illustration 2	g01024486
(A) 406 mm (16 inch) (1 piece) (B) 20 mm (0.78 inch) fillet weld (4 places) (C) 610 mm (24 inch) (2 pieces)

Refer to Illustration 2 and Illustration 19 for the fabrication of a tool that is needed to align the ribs on the underside of the truck body.

Welding Specifications and Qualifications

Show/hide table

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode. Use the manufacturers shielding gases that are specified (typically 75% argon and 25% carbon dioxide). 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:

Table 9

Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1 H8"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -18 °C (20 ft lb @ -0 °F)

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters.

Table 10

Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate	Voltage	Amperage
7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute	24 to 28	190 to 240

Table 11

Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate	Voltage	Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute	23 to 27	180 to 220

Note: The settings listed above are recommendations-based on experience from welding in the horizontal, vertical-up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. Higher parameters are acceptable to use for welding in the flat position.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

Table 12

Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -29 °C (20 ft lb @ -20 °F)

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturers specifications.

The table that follows shows the settings for the welding current based on electrode diameter.

Table 13

Welding Current for Low Hydrogen Electrodes
Diameter	Amperage Rating
3.2 mm (1/8 inch)	105-155
4.0 mm (5/32 inch)	130-200
4.8 mm (3/16 inch)	200-275

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Weld Inspection and Acceptance Criteria

Visual inspection is the primary method for determining weld quality. Abrasion resistant steel plates, which are part of the body structure, are susceptible to hydrogen induced cracking or delayed cracking. This type of cracking normally occurs within 72 hours of welding. As a result, allow the welding areas to cool for 48 hours to 72 hours prior to performing a final visual inspection. Any areas identified as suspect during the visual inspection shall be verified as acceptable or unacceptable. Using a supplemental inspection technique such as dye penetrant or magnetic particle testing.

Table 14

Defect Name	ISO 6520 Defect Reference Number	Remarks	Defect Limit
Cracks - Longitudinal, Transverse, Radiating, Crater, Disconnected, Branching	1011, 1012, 1013, 1014, 1023, 1024, 1031, 1033, 1034, 1045, 1046, 1047, 1051, 1053, 1054, 1061, 1063, 1064	--	Not Permitted
Crack - Transverse	1021	Hard Surfacing Welds Only	Permitted
Crack - Transverse	1021	Joining Welds	Not Permitted
Porosity	2011, 2012, 2014, 2017	Maximum Diameter for a Single Pore	1 mm (0.040 inch)
		Maximum Pores in Any 300 mm (11.81 inch) Length of Weld	6
		Maximum Number of Pores in Any 50 mm (2.0 inch) of Weld Length for Welds Less Than 300 mm (11.81 inch) in Length	1
Clustered Porosity	2013	Maximum Length of Cluster in Any Weld	3 mm (0.120 inch)
Elongated Cavities	2015	Maximum Height or Width	3 mm (0.120 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Elongated Cavities	2016	Maximum Dimension of Any Single Cavity	3 mm (0.120 inch)
		Maximum Total Length of Affected Area in Any Weld	10% of Weld Length Not to Exceed 25 mm (1.00 inch)
Shrinkage Cavities	2021, 2024, 2025	Maximum Diameter or Length	1 mm (0.040 inch)
Slag or Flux Inclusions	3011, 3012, 3014, 3021, 3022, 3024	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Oxide Inclusions	3031, 3032, 3033	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Puckering (Oxide Inclusion - Aluminum)	3034	--	Not Permitted
Metallic Inclusion	3041, 3042, 3043	--	Not Permitted
Lack of Fusion	4011, 4012, 4013	Visual (Breaking the Surface)	Not Permitted
		Subsurface Maximum Height or Width	1 mm (0.040 inch)
		Subsurface Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Lack of Penetration	402, 4021	Maximum Reduced Penetration	10% of Nominal Penetration Not to Exceed 1 mm (0.040 inch)
		Maximum Allowed Total Length of Reduced Penetration	10% of Weld Length
Undercut	5011, 5012, 5013, 5014, 5015	Maximum Depth Measured From Plate Surface - Any Length	0.5 mm (0.020 inch)
Excess Weld Metal - Groove Weld Reinforcement (Convexity)	502	Any Length	--
		Weld Face Width 5 mm (0.20 inch) or Less	1 mm (0.040 inch)
		Weld Face Width Over 5 mm (0.20 inch) But Less Than 10 mm (0.40 inch)	1.5 mm (0.060 inch)
		Weld Face Width Over (10 mm)(0.40 inch) But Less Than 20 mm (0.80 inch)	2 mm (0.080 inch)
		Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch)	3 mm (0.120 inch)
		Weld Face Width 30 mm (1.20 inch) and Over	4 mm (0.160 inch)
Excess Weld Metal - Fillet Weld Convexity	503	Convexity Affects Weld Toe Angle, Reducing Fatigue Life	90 Degrees
		Weld Toe Angles of 135 Degrees and More Are Better	--
		Defect Limits Expressed as Minimum Toe Angles Allowed	--
Excess Penetration	5041, 5042, 5043	Without Drawing Limitation	2 mm (0.080 inch) (Any Length)
		With "Melt - Thru" and "Flush" Weld Symbols	1 mm (0.040 inch) (Any Length)
		With "Melt - Thru" and "Grind Flush" Symbols	Not Permitted (After Grinding)
Incorrect Weld Toe	505	When 1E2995 Applies (Expressed as a Toe Radius Rather Than a Toe Angle)	3 mm (0.120 inch) Minimum Radius
Overlap	5061, 5062	Expressed as Minimum Toe Angle	90 Degrees
Fillet Weld Leg Size - Undersize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Undersize	1 mm (0.040 inch)
		Maximum Length of Undersize Weld	10% of Total Weld Length If At Least 10% of Total Weld Length is at Least 1 mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted
Fillet Weld Leg Size - Oversize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Oversize	+25% (max 3 mm (0.120 inch))
		Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond). Without Correction Provided the Excess Does not Interfere with Satisfactory End Use of the Component (Distortion, Fit-Up Interference).	--
Fillet Weld - Linear Length when specified at less than the length of the joint	--	Weld Size ≤ 6.5 mm (0.256 inch)	± 6.5 mm (0.256 inch)
		Weld Size ≥ 6.5 mm (0.256 inch)	± 12.5 mm (0.492 inch)
Fillet Weld Throat Size - Undersize	5213	Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root	Not Permitted
		Weld Crater Only - Maximum Undersize	2 mm (0.080 inch) MAX - and Not to Exceed 20% of Specified Throat, Not Inclusive of Penetration Beyond the Weld Root (0.7 x Leg Size)
Incompletely Filled Groove Weld	511	Careful Consideration Needs to be Given When Plate Mismatch is Apparent	Not Permitted
		Weld Depth Must be Maintained as a Minimum	--
Root Concavity on Open Root Groove Welds	515, 5013	Maximum Depth measured From Plate Surface or Tube Inner Surface - Any Length	0.5 mm (0.020 inch)
Poor Restart (Tie - In)	5171, 5172	Measured in Terms of Excess Weld Metal (Fillet Weld Convexity) or Overlap on Groove Welds, Lack of Fusion, or Insufficient Throat	--
		Excess Weld Metal on Fillet Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
		Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
		Lack of Fusion - Visual Maximum Length Per Restart	3 mm (0.120 inch)
		Insufficient Weld Throat	Not Permitted
Stray Arc Strike	601	--	Not Permitted
Slag Residue	615	SMAW, SAW, FCAW, GMAW	Not Permitted
		GTAW	Silicon Residue Permitted Unless Removal Specified by Drawing Note
Combined Discontinuities	--	Total Maximum Combined Length of All Imperfections in a Weld, Expressed as a Percent of Total Weld Length	15%
		(No Single Type of Imperfection Can Exceed the Limits for That Single Type of Imperfection)	--

Welding Instructions

General Preheat Instructions for Truck Body Field Assembly

The following materials are used in order to fabricate the large mining truck (LMT) truck bodies :

• "A656 Gr.80". Side bolsters, bottom ribs, horizontal ribs, and exterior plates.

• 400 Brinell hardness number (BNH) steel. Base body plates, canopy wrapper, and interior transition plates.

• 450 Brinell hardness number (BNH) steel. Liner plates, rock boxes, and wear bars.

Base material must be a minimum temperature of 16° C (60° F) before welding and during welding. Prior to work engagement, the recommended procedure is to apply heat to weld joints to sweat out residual build-up of condensation.

Show/hide table

NOTICE
400 BNH steel and 450 BNH steel are sensitive to hydrogen induced cracking. Cleanliness of the weld joints and of the consumables is of utmost importance.

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

400 Brinell Hardness or 450 Brinell Hardness Material

The following procedure covers the requirements for welding the assembly of the LMT truck bodies. This instruction is to provide an overall guideline of the recommended preheat requirements. This instruction applies to the welding procedure for truck bodies that are fabricated with 400 BHN steel or 450 BHN steel. Refer to ""Welding Specifications and Qualifications" " 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, and grease before welding.

Tight fit up 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. A maximum tack weld size of 6 mm (0.25 inch) fillet weld with a length of 75 mm (3 inch) is recommended.

Preheating is most critical during the tack welding procedure and during the welding of the root pass.

Illustration 3	g03032696
Typical view of a Tiger Torch

A Tiger Torch can be used in order to preheat the material that is welded.

ReferenceRefer to Table 15 for the required preheat temperature of the material.

Table 15

Preheat Temperatures for 400 BHN Steel or 450 BHN Steel
Combined Thickness of Material	Welding Preheat
10 mm (0.39 inch) to 19 mm (0.75 inch)	100 °C (212 °F)
20 mm (0.79 inch) to 40 mm (1.58 inch)	125 °C (250 °F)
greater than 40 mm (1.58 inch)	175 °C (350 °F)

Ensure that the weld groove and 75 mm (3 inch) in each direction from the weld joint is preheated to the specified temperature. Verify the preheat temperature with a 164-3310 Infrared Thermometer or with a temperature stick.

Show/hide table

NOTICE
When a gas flame is used to preheat, the gas flame must be removed from the base material for a minimum of 1 minute. After 1 minute, verify the base material temperature with an 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: If the ambient temperature is below 0 °C (32 °F), then the initial preheat temperature should be raised to 121 °C (250 °F). The raised preheat temperature needs to be a minimum of 75 mm (3 inch) in each direction from the weld joint in order to avoid the heat sink effect of the floor plates.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturers 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 Caterpillar parts.

Illustration 4	g00629745
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.

General Preparation

Note: The GMAW (Gas Metal Arc Welding) procedure will require approximately182 kg (400 lb) of 1.70 mm (0.065 inch) wire. The GMAW (Gas Metal Arc Welding) procedure will also require approximately 182 kg (400 lb) of 1.10 mm (0.045 inch) wire. Use AWS E70S-3 solid wire (gas shield) for the GMAW weld procedure. As an alternative, the SMAW - Shielded Metal Arc Welding procedure will require approximately 450 kg (1000 lb) of AWS E7018 Electrodes.

Approximately 250 hours will be required to complete the assembly of the truck body and liners. You will need a crew of four welders and one crane operator.

Illustration 5	g01024755

Illustration 6	g01024769

Note: The truck body will be shipped by a railroad car or the truck body will be shipped by a tractor-trailer.

Illustration 7	g01024773
View of sequence numbers

Illustration 8	g01024796
View of sequence numbers

Show/hide table

NOTICE
The brackets and the angles are welded to hold the modules together during shipment. Do not attempt to lift the body from the railroad car or tractor trailer with these brackets or angles. After the module is removed, the brackets and the angles must be removed and the areas ground smooth for welding.

Note: The sequence numbers are stamped at the ends of the side bodies. The sequence numbers are also stamped at the center of the center body. Before the assembly of the bodies, make sure that the sequence numbers match.

Lift the modules off the transport vehicles. Start disassembling the tack welds that hold the modules together.

Note: To permit the assembly procedure to proceed without repositioning the modules, spread the modules evenly over the assembly area.

Lifting Procedure

Note: For handling purposes, the lifting eyes are located at convenient spots on each modules. Use these lifting eyes only. Once, the module is welded in position the lifting eyes may be removed. After the removal of the lifting eyes, grind the area smooth. Remove only the lifting eyes that will interfere with ordinary assembly or an operation procedure.

Illustration 9	g01026889
View of the correct lifting procedure with lifting eyes for the center body

Illustration 10	g01026893
View of the correct lifting procedure for the side walls of the truck body

Note: Later truck bodies could have lifting holes for installation and removal of the truck body.

Illustration 11	g01026896
An example of a plate clamp that is used to remove the plates from the module after the tack welds have been removed.

Upside-Down Body Assembly

Show/hide table

NOTICE
All electrodes must be dry. Do not weld in areas when there is strong movement of air, or in temperatures less than 16 °C (60 °F). Keep the weld area at the desired temperature.

Note: Use only AWS E7018 electrodes and/or AWS E70S-3 solid wire (gas shield). AWS E70T-1 or AWS E71T-1 flux cored gas shielded wire may also be used. If E70T-1 Flux cored wire is used, the body must be turned so that all of the welds are made in the flat position.

Note: Remove all of the stops and guides when the stops and the guides are no longer needed. Grind the metal smooth.

Illustration 12	g01026898
(1) 113-8013 Center Body Assembly

1. Place 113-8013 Center Body Assembly upside-down on blocking. Use two 203 mm (8 inch) blocks on the front of the center body. Refer to Illustration 12 for the correct positioning of the blocks. Ensure that there is room for the installation of 113-8011 Body Assembly (RH) (2) and for the installation of 113-8012 Body Assembly (LH) (3) .

Show/hide table



Illustration 13	g01027192

2. The height of the blocking is shown below.
   • The rear of the center body without the side rails is approximately 1397 mm (55 inch) high.

   • The rear of the center body with the side rail is approximately 1905 mm (75 inch) high.

   • The front of the center body with the side rails or without the side rails is approximately 203 mm (8 inch) high.

Show/hide table



Illustration 14	g01027193

3. Clean all the surfaces before you start welding.

   Note: Before you start any welding procedures, clean both of the inside and the outside of the weld joints of the center body. Also, clean the left-hand and the right-hand body.

Show/hide table



Illustration 15	g01027199
(1) 113-8013 Center Body Assembly (2) 113-8011 Body Assembly (RH)

Note: Illustration 15 shows the alignment of the right-hand body to the center body.

4. Check center body (1), left-hand body (3) and right-hand body (2) for the correct alignment. If necessary, trim all of the joints for a correct fit. Grinding a slight chamfer or a radius on the edge of the backup strips may help in the alignment.

Show/hide table



Illustration 16	g01027202
(1) 113-8013 Center Body Assembly (3) 113-8012 Body Assembly (LH) (12) 2B-7218 Bolt (13) 2J-3507 Full Nut

Note: Illustration 16 shows the bolts that are used to secure center body (1) and the left-hand body (3) together before starting the welding procedure.

5. Fasten both 113-8012 Body Assembly (LH) (3) and 113-8011 Body Assembly (RH) (2) to 113-8013 Center Body Assembly (1). Use 16 2B-7218 Bolts (12) and 16 2J-3507 Full Nuts (13). To bring the left-hand and the right-hand body together with the center body, tighten the bolts.

Show/hide table



Illustration 17	g01027204
(1) 113-8013 Center Body Assembly (2) 113-8011 Body Assembly (RH)

Note: Illustration 17 shows the alignment of the right-hand body to the center body.

6. Use a 4C-6952 Lever Puller , a winch, or a crane to assist in pulling the right-hand body assembly into position with the center body.

Show/hide table



Illustration 18	g01027206
1U-9755 Hydraulic Jack

Note: Illustration 18 shows a hydraulic jack in the position to align the three components.

7. To align the right-hand assembly and the left-hand assembly to the center body in the most effective way, use a 1U-9755 Hydraulic Jack . Use two per side.

   Note: Ensure that the body assemblies have the correct gap before beginning any tack welds on the seams of the ribs. Close attention should be given to the initial alignment procedure. Refer to Illustration 29 and Illustration 30 for the dimensions and for the weld tolerances.

Show/hide table



Illustration 19	g01027208
1U-9755 Hydraulic Jack

Show/hide table



Illustration 20	g01041992
Special tool

Note: Illustration 19 shows the special tool that was fabricated earlier. The tool is welded into position. The hydraulic jack positions the left-hand and the right-hand body to the center body for a tack weld.

8. Use the hydraulic jack and the special tool to position each rib into position for tack welding. Complete a tack weld on each rib. Remove the special tool. Move to the next rib and repeat the procedure.

   Note: After you have removed the special tool, the brackets, and the braces, remove the welds and grind the welds smooth.

Show/hide table



Illustration 21	g01027239
Tack weld

Note: Illustration 21 shows the tack welds of the right-hand body to the center body.

9. Tack weld each of the ribs together before you finish the weld seam.

Show/hide table



Illustration 22	g01027241

10. Illustration 22 shows the completed weld of the rib (seam) of the right-hand body to the center body. The bolts, the nuts, and the brackets will be removed after you have finished the seam weld. Refer to Illustration 30 for weld tolerances.

    Note: Remove the bolts, the nuts, and the brackets from the truck body before you finish welding perpendicular to the completed seam weld.

11. Repeat Step 10 for welding the ribs of the left-hand body to the center body.

Show/hide table



Illustration 23	g01027242
View of the right-hand body and center body (weld seam)

Note: Illustration 23 shows the welds that are completed for all of the seams.

12. Repeat this procedure for welding the seams of the left-hand body to the center body.

Show/hide table



Illustration 24	g01027244
Inside front wall

13. In order to align the seam for the front wall, a wedge and a bracket can be used.

    Note: The bracket and the wedge can be used to align the seams throughout the welding procedure. Use as many brackets and wedges as required. Grind the tack welds smooth after the brackets have been removed.

Show/hide table



Illustration 25	g01027243
View of the front wall of the right-hand body that is welded to the center body

14. To ensure the proper alignment, tack weld the front wall completely before you finish weld.

    Note: In order to ensure that the front edge is straight at the horizontal beam, use a level. This step is important for the canopy to fit correctly.

Installation of the Cable Bracket and the Rock Ejector

Show/hide table



Illustration 26	g01027245
(5) 112-6180 Plate As (RH) (6) 112-6180 Plate As (RH)

1. Illustration 26 shows the weld area for the mounting plates for the installation of the rock ejectors. The dimensions in Table 16 are for reference. Refer to Special Instructions, "Assembly Procedures for 784C Tractors and 785C Off-Highway Trucks" for proper alignment of the 112-6180 Plate As .
   Show/hide table

   Table 16

   Weld (Dimensions)
   Item	Dimensions
   C	1125 ± 3 mm (44.3 ± 0.12 inch)
   D	1125 ± 3 mm (44.3 ± 0.12 inch)

Show/hide table



Illustration 27	g01027248
View of the body in the process of being turned over

Show/hide table



Illustration 28	g01027249
View of the body that has almost been turned over

2. Use a suitable lifting device in order to turn over the body.

Show/hide table



Illustration 29	g01240404
Underside of the truck body The Illustration also shows the cable mounting brackets.

3. To install the cable mounting brackets, refer to Table 18 for welding dimensions.
   Show/hide table

   Table 17

   Welding Tolerances
   Item	Description
   W2	10 mm (.40 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (four places)
   W3	10 mm (.40 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two places)
   W4	6 mm (.23 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two places)
   W5	20 mm (.78 inch) bevel weld (2 places) (1)
   W6	12 mm (.48 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (20 ribs on both sides) (2)
   W7	10 mm (.40 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (20 places)
   W8	12 mm (.48 inch) bevel flush weld (18 ribs)
   W9	12 mm (.48 inch) bevel flush weld (18 ribs on both sides)
   W10	6 mm (.23 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two places)
   W11	12 mm (.43 inch) bevel flush weld
   W12	20 mm (.78 inch) bevel flush weld
   W13	12 mm (.48 inch) fillet weld (2 gussets on both sides)
   W14	10 mm (.40 inch) fillet weld (two gussets)
   W15	12 mm (.48 inch) square groove weld (2 places)
   W16	12 mm (.48 inch) bevel groove weld (2 places)
   W17	12 mm (.48 inch) bevel groove weld (3 plates)
   W18	12 mm (.48 inch) fillet weld (both ends)
   W19	12 mm (.48 inch) fillet weld (both ends)
   W20	12 mm (.48 inch) bevel groove weld (2 places)
   W21	16 mm (.63 inch) flush bevel weld with a 4 mm (0.16 inch) of penetration (3 plates)
   W22	25 mm (1 inch) flush V-groove weld (2 places)

   Show/hide table

   ( 1 )	Before you finish weld the joint, remove clamps, spacers, and guides.
   ( 2 )	Seal the openings by welding.

   Show/hide table

   Table 18

   Welding Dimensions for Illustration 29
   Item	Dimensions
   E	1348 ± 5 mm (53 ± 0.2 inch)
   F	1653 ± 2 mm (65 ± 0.08 inch)

   Show/hide table

   Table 19

   Welding Dimensions for Illustration 31
   Item	Dimensions
   G	140 ± 2.0 mm (5.5 ± 0.8 inch)
   H	75 ± 2.0 mm (3.0 ± 0.08 inch)

   Show/hide table

   Table 20

   Welding Dimensions for Illustration 30 and Illustration 32
   Item	Dimensions
   J	6.0 ± 1.0 mm (.24 ± 0.4 inch)
   K	120.0 ± 6.0 mm (4.72 ± .24 inch)
   L	45 ± 2.0 mm (1.77 ± 0.08 inch)

Show/hide table



Illustration 30	g01027477
Section F-F

4. In order to weld the floor seam and the floor (ribs), refer to Table 20 for the welding dimensions. Refer to Table 17 for the weld tolerances. The floor seam and the floor (ribs) are located on the underside of the truck body.

Show/hide table



Illustration 31	g01028555
Section A-A (14) 8X-6452 Block

5. Refer to Table 17 and Table 19 in order to install 8X-6452 Block to the underside of center body (1) .

Show/hide table



Illustration 32	g01028557
Section K-K (19) 8W-0108 Bracket As

6. Install 8W-0108 Bracket As (19) on the bottom of center body (1). Refer to Table 17 for the welding tolerances and refer to Table 20 for the welding dimensions.

Show/hide table



Illustration 33	g01041994
Section M-M

7. Refer to Table 17 for the welding tolerances that are used in order to weld the floor seams that are referred to in Illustration 33.

8. Ensure that all weld seams have been completed.

Installation of Tail Extension Assembly

Illustration 34	g01028754
(28) 114-4583 Tail Extension Assembly (29) 113-8264 Plate (30) 113-8267 Plate (31) 114-4675 Plate

Note: If the body has a tail extension, the tail extension should be installed in the upside-down position.

Table 21

Welding Dimensions
Item	Dimensions
M	60 degrees
N	6.0 ± 2.0 (.24 ± 0.8 inch)
P	14 ± 2 mm (.55 ± 0.08 inch)
R	16 degrees

Table 22

Welding Tolerances
Item	Description
W13	12 mm (.48 inch) fillet weld (2 gussets on both sides)
W14	10 mm (.40 inch) fillet weld (two gussets)
W15	12 mm (.48 inch) square groove weld (2 places)
W16	12 mm (.48 inch) bevel groove weld (2 places)
W17	12 mm (.48 inch) bevel groove weld (3 plates)
W18	12 mm (.48 inch) fillet weld (both ends)
W19	12 mm (.48 inch) fillet weld (both ends)
W20	12 mm (.48 inch) bevel groove weld (2 places)
W21	16 mm (.63 inch) flush bevel weld with a 4 mm (0.16 inch) of penetration (3 plates)
W22	25 mm (1 inch) flush V-groove weld (2 places)

1. Locate 113-8267 Plate (30) and 113-8264 Plate (29). Refer to Table 22 in order to install the plates to the body with the following welds:
   • W13

   • W14

   Note: 114-4583 Tail Extension As (28) can be ordered as an assembly.

2. Refer to Table 22 for the finish weld tolerances of the extension plates.
   • W15

   • W16

   • W17

3. Install two 114-4675 Plates (31) with the following welds:

• W18

• W19

• W20

• W21

• W22

Note: The body must be in the UP position in order to complete these welds.

Installation of the Canopy and the Guard Assemblies

Note: The canopy can be installed to the body in the upside-down position. The canopy can also be installed to the body in the UP position. The body is shown in the UP position for the installation of the canopy and the guard assemblies.

Note: Make sure that the canopy has notches that are cut out in order to fit the body. If the canopy is not cut correctly, the canopy will not fit properly. The notches are required at both ends of the canopy.

Illustration 35	g01028868
View of notches on the canopy

Illustration 36	g01028869
View of notches on the canopy

Show/hide table



Illustration 37	g01029088
(4) Canopy assembly (10) 8X-1190 Brace (11) 8X-1189 Brace

1. In order to install brace (10) and brace (11), refer to Table 23 for the welding dimensions and refer to Table 24 for the welding tolerances.

2. If the body liners are available, install the liners before you install the canopy to the body. Tack weld the liners first. Then install the canopy to the body. After you have installed the canopy to the body, finish the welds for the liners.

Table 23

Welding Dimensions
Item	Dimensions
S	660 mm (26 inch)
T	39 ± 1.0 (1.54 ± 0.4 inch)
U	162 ± 1 mm (6.38 ± 0.04 inch)
V	135 ± 3 mm (5.3 ± .12 inch)
W	19 ± 1 mm (.75 ± 0.04 inch)

Table 24

Welding Tolerances
Item	Description
W28	8 mm (.31 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two places) toward the inside of the canopy
W29	8 mm (.31 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two places) on the outside of the canopy
W30	8 mm (.31 inch) bevel groove weld (two places)
W31	6 mm (.24 inch) bevel groove weld with a 1.5 mm (0.06 inch) of penetration (two sides) Weld at both ends with five braces
W32	6 mm (.48 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration Weld at both ends with five braces

Illustration 38	g01029160
View of the canopy liners

Note: Illustration 38 shows the correct lifting method for the alignment and for the installation of the canopy.

Illustration 39	g01029161
(44) 114-6375 Plate (45) 114-6376 Plate

Note: For an easier installation, install 114-6375 Plate (44) and 114-6376 Plate (45) on the ground.

Illustration 40	g01029166
View of the right-hand side of the canopy (8) 8W-3666 Guard As

Show/hide table



Illustration 41	g01029164
View of the left-hand side of the canopy (9) 8W-3667 Guard As

1. 8W-3666 Guard As (8) and 8W-3667 Guard As (9) should be installed before the canopy is installed on the body.

Show/hide table



Illustration 42	g01029169
View of the right-hand side of the canopy (4) 8W-9245 Canopy

2. Lower the canopy onto the body.

Show/hide table



Illustration 43	g01029170
View of the front side of the truck body (4) 8W-9245 Canopy (8) 8W-3666 Guard As (9) 8W-3667 Guard As (10) 8X-1190 Brace (11) 8X-1189 Brace

3. Refer to Table 25 in order to install 8W-3666 Guard As (8) and 8W-3667 Guard As (9) to 8W-9245 Canopy As (4) with the following welds:
   • W23

   • W24

   • W25

   Show/hide table

   Table 25

   Welding Tolerances
   Item	Description
   W23	4 mm (.16 inch) bevel groove weld
   W24	4 mm (.16 inch) fillet weld "25-75 mm (1.0-3.0 in) skip weld"
   W25	4 mm (.16 inch) bevel groove weld (four places)
   W26	10 mm (.40 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration
   W27	10 mm (.40 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration on the inside of the body

Show/hide table



Illustration 44	g01029171
View of brace (10) at the front of truck body

Show/hide table



Illustration 45	g01029172
View from the inside of the truck body

Note: Illustration 45 shows the canopy in the process of being welded to the truck body.

4. Tack weld the brackets to the body. To fit the canopy to the body, use wedges. Tack weld the canopy in place. Remove the temporary brackets and remove the wedges before you finish welding.

5. Weld canopy (4) to the body with the following welds: Refer to Illustration 37 and refer to Table 24.
   • W28

   • W29

   • W30

   Refer to Illustration 43. Refer to Table 25 for welding tolerances for the following welds:

   • W26

   • W27

6. Weld one short 8X-1190 Brace (10) on the left side of the canopy with the dimensions that are shown. The four long 8X-1189 Braces (11) go to the right side of brace (10). Refer to Illustration 43 and refer to Table 25.

Note: After the canopy is installed to the body and all of the finished welds have been completed, remove the lifting eyes. Install the remaining liners.

Weld the Sideboard Assemblies to the Body

Show/hide table



Illustration 46	g01029174
(22) 7I-4795 Body (Sideboard) (23) 2A-7036 Rail (24) 2A-7028 Plate (25) 2A-7029 Plate

1. Refer to Table 26 for welding dimensions. Refer to Table 27 for welding tolerances.

Illustration 47	g01029175
Gussets and sideboards

Note: For a proper fit, ensure that the gussets are flush with the side plates before you install the sideboards. The sideboards may have been preassembled at the factory. Also, the sideboards may have been installed at the factory.

Illustration 48	g01029178
(22) 7I-4795 Body (Sideboard) (23) 2A-7036 Rail (24) 2A-7028 Plate (25) 2A-7029 Plate

1. If the sideboards are factory installed, install the following:
   • 2A-7036 Rail (23)

   • 2A-7028 Plate (24 ) (outside)

   • 2A-7029 Plate (25) (inside)

   Install the plates and the rail with the following welds:

   • W33

   • W34

   • W35

   • W36

   • W37

   • W38

   • W39

   Note: Plate (24) and plate (25) are not shown in the photo.

   Show/hide table

   Table 26

   Welding Dimensions
   Item	Dimensions
   A	250 ± 5.0 mm (9.8 ± 0.2 inch)
   X	1004 ± 5 mm (39.5 ± .20 inch)
   Y	10 mm (0.40 inch) Minimum
   Z	1196 ± 5 mm (47.1 ± .20 inch)
   AA	5.0 ± 1.5 mm (.20 ± .06 inch)

   Show/hide table

   Table 27

   Welding Tolerances
   Item	Description
   W33	10 mm (.40 inch) fillet weld with a 2.5 mm (1 inch) of penetration (three plates) (two sides)
   W34	10 mm (.31 inch) bevel groove weld (three plates) (two sides)
   W35	5 mm (.20 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration (two sides)
   W36	10 mm (.40 inch) fillet weld with a 2.5 mm (1 inch) of penetration (two sides)
   W37	5 mm (.20 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration 50 mm (2 inch) Skip weld the two sides.
   W38	5 mm (.20 inch) fillet weld with a 1.5 mm (0.06 inch) of penetration 50 mm (2 inch) Skip weld the two sides.
   W39	10 mm (.4 inch) square weld (two sides)

2. If the sideboards are not factory installed, install 7I-4795 Sideboard (22). Use 2A-7036 Rail (23) as a guide with the dimension as shown. Tack weld the sideboard before you finish weld. Finish weld with the following welds:
   • W33

   • W34

Show/hide table



Illustration 49	g01029203
Chain that holds the sideboards in position for welding

Note: If necessary, tack weld the lifting eyes to the side of the body. Use a chain with a come-along hook to pull the sideboard to the body for a proper fit.

Show/hide table



Illustration 50	g01029206

3. After the sideboards are welded, remove all lifting eyes that are no longer needed.

Weld the Cap Assembly (Sidewall) to the Body

Illustration 51	g01030900
(26) 114-4582 Body Sidewall Cap (27) 2A-6952 Plate

1. Install 114-4582 Body Sidewall Cap (26) and 2A-6952 Plate (27) to the truck body. Refer to Table 28 for welding dimensions and to Table 29 for welding tolerances.

Table 28

Welding Dimension
Item	Description
AY	10 ± 2 mm (0.40 ± 0.08 inch) (two places)
AZ	18 ± 2 mm (0.71 ± 0.08 inch)

Table 29

Welding Tolerances
Item	Description
W35A	10 mm (.40 inch) groove weld with a 10.5 mm ( .40 inch) of penetration
W36A	10 mm (.40 inch) groove weld (two places)
W37A	10 mm (.40 inch) bevel groove weld (two places)
W38A	10 mm (.40 inch) bevel groove weld (two places)
W39A	10 mm (.40 inch) square groove weld (four places)
W40A	5 mm (.20 inch) fillet weld (two caps)

Note: The sidewall (caps) can be used to protect the truck body if the sideboards are not installed.

Inside Up Body Assembly

1. Remove the following and grind the area smooth:
   • Shipping brackets

   • Lifting eye

   • Alignment (floor brackets)

   Show/hide table

   Table 30

   Welding Tolerances
   Item	Description
   W40	12 mm (.47 inch) bevel groove weld on the front of the body (inside) (both sides)
   W41	20 mm (.47 inch) bevel groove weld on the bottom of the body (both sides)

Show/hide table



Illustration 52	g01030958
View of the center body and the left-hand body

Show/hide table



Illustration 53	g01030960
Inside view of the front weld seam between the center body and the right-hand body.

Note: If the truck body is equipped with liners, weld (W40) and weld (W41) must be flush.

Show/hide table



Illustration 54	g01030962
(20) 111-9776 Angle (LH) (21) 111-9824 Angle (RH)

2. Remove 111-9776 Angle (20) and 111-9824 Angle (21) that were used for support during shipment and used during the welding procedure. Grind the area smooth.

Show/hide table



Illustration 55	g01031006
View of the front body (17) 2A-6954 Plate (18) 5T-5858 Plate

Show/hide table



Illustration 56	g01031008

3. Install 2A-6954 Plate (17) and 5T-5858 Plate (18) in the corners on the inside of the body. Trim plates (17) and (18). For a correct fit, trim the plates. Install the plates with the following welds and dimensions: Refer to Table 31 and Table 32.
   • W42

   • W43

   Show/hide table

   Table 31

   Welding Dimensions
   Item	Dimensions
   AB	400 ± 5 mm (15.7 ± .20 inch)

   Show/hide table

   Table 32

   Welding Tolerances
   Item	Description
   W42	14 mm (.55 inch) bevel groove weld (2 plates)
   W43	8 mm (.31 inch) "staggered intermittent weld (2 plates) 25-100 mm (1.0-4.0 inch) weld"

Installation of the Shield Assemblies, the Muffler Guard, and the Plate Assembly

Illustration 57	g01031043
(16) 8W-7184 Shield As

Illustration 58	g01031338
(16) 8W-7184 Shield As

1. Locate two 8W-7184 Shield As (16). Install the shield assemblies with the following welds and dimensions: Refer to Table 33 and refer to Table 34.
   • W43A

   • W44

   • W45

   • W46

   Show/hide table

   Table 33

   Welding Dimensions
   Item	Dimensions
   AC	334 ± 3 mm (13.1 ± 0.12 inch)
   AD	12 mm (0.47 inch)
   AE	35 ± 3 mm (1.38 ± 0.12 inch)

   Show/hide table

   Table 34

   Welding Tolerances
   Item	Description
   W43A	4 mm (.16 inch) bevel groove weld (four places)
   W44	6 mm (.24 inch) bevel groove weld "skip weld 50-200 mm (2-8 inch) (4 places)"
   W45	6 mm (.24 inch) V-groove weld (two places)
   W46	6 mm (.24 inch) fillet weld with a 1.5 mm (.06 inch) of penetration (four places)

Show/hide table



Illustration 59	g01031088
(7) 8X-6394 Plate As (15) 114-5012 Guard As

Show/hide table



Illustration 60	g01031092
View of the lifting eye that is welded onto 114-5012 Guard As (15)

2. Tack weld a lifting eye onto 114-5012 Guard As (15). Use a crane to position the guard onto the body.

3. After you have positioned the guard, finish weld the guard with the following welds and dimensions:
   • W47

   • W48

   Refer to Table 35 and Table 36 for the proper dimensions and tolerances.

   Note: Remove the lifting eye and grind the tack weld flush.

4. Locate 8X-6394 Plate As (7) and install the plate assembly. Refer to Illustration 59. Install the plate assembly with the following weld:
   • W49

   Refer to Table 35 and Table 36 for the proper dimensions and tolerances.

Table 35

Welding Dimensions
Item	Dimensions
AF	35 ± 3 mm (1.6 ± .20 inch)
AG	40 ± 5 mm (1.6 ± .20 inch)

Table 36

Welding Tolerances
Item	Description
W47	4 mm (.16 inch) bevel groove weld
W48	4 mm (.16 inch) fillet skip weld "skip weld 50-200 mm (2-8 inch) (four places)"
W49	3 mm (.12 inch) fillet weld A to B

Installation of Body Liner Plates (If Equipped)

Illustration 61	g01068725
Body liner plates and the sequence for the installation of the plates (35) 114-6368 Plate (36) 114-6377 Plate (37) 114-6374 Plate (38) 114-6372 Plate (39) 114-6371 Plate (40) 114-6378 Plate (41) 114-6373 Plate (42) 249-3306 Plate (43) 114-6367 Plate (44) 114-6366 Plate (45) 114-6375 Plate (46) 114-6376 Plate (47) 114-6369 Plate (48) 114-6370 Plate

Note: Take your time and make sure that plate (35) is positioned correctly. This action will make the assembly procedure for the rest of the plates easier.

Show/hide table



Illustration 62	g01068742
Location of the body liner plates

1. Refer to Table 37 for welding dimensions. Refer to Table 38 for welding tolerances.

Show/hide table



Illustration 63	g01031489
Installation of the body liner plates in the body of the truck

2. After you have finished welding the body, install the body liner plates. Refer to Illustration 61 and Illustration 63. Also, refer to Table 37 and Table 38 for the welding dimensions and tolerances.

3. Install the body liner plates with the following welds:
   • W50

   • W51

   • W52

   • W53

   • W54

   • W55

   • W56

4. Tack weld all of the body liners in the correct position. Finish weld after all of the body liners have been tack welded into position.

   Note: The installation of plate (35) is critical for the alignment of the remaining plates. Take a measurement from the center line of the truck body and approximately 25.4 mm (1.0000 inch) from the back of the truck body in order to achieve the proper alignment that is needed for plate (35) to be installed correctly.

   Show/hide table

   Table 37

   Welding Dimensions
   Item	Dimensions
   AH	20 ± 1 mm (.78 ± .04 inch)
   AJ	12 ± 1 mm (.47± .04 inch)
   AK	8 ± 1 mm (.31± .04 inch)

   Show/hide table

   Table 38

   Welding Tolerances
   Item	Description
   W50	10 mm (.40 inch) fillet weld (28 places) (39 holes)
   W51	6 mm (.23 inch) fillet weld (eight places)
   W52	20 mm (.78 inch) square groove weld (3 places)
   W53	6 mm (.23 inch) square groove weld
   W54	10 mm (.40 inch) square groove weld (four places)
   W55	20 mm (.78 inch) bevel groove weld (2 places)
   W56	12 mm (.47 inch) square groove weld (2 places)

Show/hide table



Illustration 64	g01038903

5. Install the remaining body liner plates. Refer to Illustration 64. Weld the body liner plates with the following welds:
   • W57A

   • W57B

   • W57C

   • W58

   • W59

6. Refer to Table 39 for welding dimensions. Refer to Table 40 for welding tolerances.

Table 39

Welding Dimensions
Item	Dimensions
AL	10 ± 2 mm (.40 ± .08 inch)
AM	35 ± 5 mm (1.38 ± .20 inch)
AN	12 ± 1 mm (.47 ± .04 inch)
AP	10 ± 1 mm (.40 ± .04 inch)
AR	49 ± 5 mm (1.93 ± .20 inch)
AS	48 ± 5 mm (1.89 ± 0.20 inch)

Table 40

Welding Tolerances
Item	Description
W57A	10 mm (.40 inch) bevel groove weld
W57B	4 mm (.40 inch) fillet weld (12 places) (28 slots)
W57C	10 mm (.40 inch) bevel groove weld (two plates)
W58	10 mm (.40 inch) square groove weld (two places)
W59	20 mm (.80 inch) fillet weld (2 places)

Installation of Tail Extension (Liner)

Show/hide table



Illustration 65	g01032014
(A) Extension liner (B) Body liner (C) Plate (tail) (32) 114-8657 Extension Liner (33) 114-8658 Plate (34) 114-8659 Plate

1. Install 114-8658 Plate and two 114-8659 Plates to the tail extension with the following welds:
   • W60

   • W61

   • W62

   • W63

   Note: If you order the 114-4583 Tail Extension , you can get the 114-8657 Extension Liner already assembled.

2. Refer to Table 41 for welding dimensions. Refer to Table 42 for welding tolerances.
   Show/hide table

   Table 41

   Welding Dimensions
   Item	Dimensions
   AT	16 degrees
   AU	20 ± 2 mm (.79 ± .08 inch)

   Show/hide table

   Table 42

   Welding Tolerances
   Item	Description
   W60	20 mm (.78 inch) bevel groove weld (2 places)
   W61	10 mm (.40 inch) fillet weld (two places)
   W62	10 mm (.40 inch) fillet weld (three plates)
   W63	10 mm (.40 inch) fillet weld (three plates)

3. Remove all of the lifting eyes and the brackets that were installed temporarily.

4. Clean the body completely and paint the body completely.