Assembly Procedure for the Coal Body for 789C, 789D and 789D XQ Off-Highway Trucks{7258, 7960} Caterpillar

Off-Highway Truck/Tractor:

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP)

Introduction

This Special Instruction contains the necessary procedures and information for assembling and welding a Coal Truck Body.

The shipping configuration of the Coal Truck Body depends on the destination and the type of transportation that is available. In some cases, the Coal Truck Body may be assembled differently from the factory. The following special instruction covers assembling the Coal Truck Body.

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, well 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 Coal Truck Body. The dispersing of the shielding gases away from the welding area must be kept to a minimum.

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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.

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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

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 adequately lift the truck body.

Below is an example of the approximate weights of the truck body.

Note: The weights that are listed in this document are only approximate weights. The weights represent only one size of Coal Truck Body. Coal 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.

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:

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:

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 Coal Truck Body:

• 400 Brinell

• 450 Brinell

Before welding on the Coal truck body, verify the materials that are used in order to fabricate your particular Coal truck body. There are specific welding procedures for each material. Refer to the following procedures in order to successfully 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 or 450 Brinell Hardness Number Material

The following procedure covers the requirements for welding the assembly of the Coal truck bodies that are fabricated with 400 Brinell material or 450 Brinell 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, etc. before welding.

Tight fitup of the body assemblies is very 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.

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) a minimum of 76.0 mm (3.0 inch) inches in each direction from the weld joint in order to avoid the heat sink effect 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 Caterpillar parts.

Illustration 1	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.

The Site for Assembly

The following photographs are of the shipping configuration.

The Coal Truck Body will be delivered in four assemblies.

• Center Body Assembly

• Left Body Assembly

• Right Body Assembly

• Canopy Assembly

Illustration 2	g01289125
View of the center body assembly that is unloaded (1) Center body assembly

Illustration 3	g01289118
View of the left and right body assemblies as the assemblies are shipped (2) Left body assembly (3) Right body assembly

Illustration 4	g01289196
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 5	g01289213

1. Position center body assembly (1) inside the work area.

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Illustration 6	g01289258
View of the edges that need to be cleaned prior to assembly

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Illustration 7	g01289279
Prepare the rib joints for welding.

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Illustration 8	g01289458
Prepare the front transition plate and the front wall for welding.

2. Use a grinder in order to clean the welding areas of center body assembly (1). Completely remove all paint, rust, scale, slag, dirt, moisture, etc. before welding. Refer to Illustration 8 through Illustration 12.

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

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Illustration 9	g01283478
Top view of spacer (6)

3. Fabricate six spacers (6) 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 other body assemblies.

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Illustration 10	g01289461
View of spacer (6) that is tack welded to center body assembly (1)

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Illustration 11	g01289467
View of the spacers that are tack welded along the right side of the center body assembly

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Illustration 12	g01289476
View of the spacers that are tack welded along the right side of the front wall

4. Tack weld 3 spacers (6) to the right side of center body assembly (1). Repeat for the left side of center body assembly (1). Refer to Illustration 10 through Illustration 12.

   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.

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Illustration 13	g01289480
View of the miscellaneous attachments that are tack welded to the center body assembly (4) Canopy rock guard (5) Rock ejector brackets

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

6. Remove the 14 bolts and nuts that are located inside canopy rock guard (4) .

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Illustration 14	g01289491
View of preparing to turn over the center body assembly

7. Attach four suitable lifting devices to the center body assembly. Attach two of the lifting devices to the two lifting eyes that are located along the left side of the body assembly and secure to a suitable hoist. Attach the other two lifting devices to the two lifting eyes that are located along the right side of the body assembly and secure to another suitable hoist. The center assembly weighs approximately 10530 kg (23150 lb).

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Illustration 15	g01289516

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

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Illustration 16	g01289536

9. 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.

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Illustration 17	g01289544
View of the two lifting devices that are attached to the bottom side of the center body assembly

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Illustration 18	g01289563
View of one lifting device that is attached to the lifting eye toward the front of the center body assembly

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Illustration 19	g01289577
View of one lifting device that is attached to the lifting eye toward the rear of the center body assembly

10. 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 18 through Illustration 19.

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Illustration 20	g01289579
View of center body assembly (1) that is being turned over

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Illustration 21	g01289580
View of center body assembly (1) that is turned over

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

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Illustration 22	g01289584

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

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Illustration 23	g01289588

13. 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.

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Illustration 24	g01289602

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

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

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Illustration 25	g01344806

16. 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.

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Illustration 26	g01289618

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

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Illustration 27	g01289635

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

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Illustration 28	g01289636
View of attaching two lifting devices to the left body assembly

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Illustration 29	g01289641
View of moving left body assembly (2) away from right body assembly (3)

19. 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 6300 kg (14000 lb).

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

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Illustration 30	g01289802

21. Position the left body assembly onto the ground.

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

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Illustration 31	g01289818

23. Raise left body assembly (2) .

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Illustration 32	g01320381
View of one lifting device that is attached to the lifting eye that is located toward the front of the left body assembly

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Illustration 33	g01345034
View of one lifting device that is attached to the lifting eye that is located toward the rear of the left body assembly

24. Attach two 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.

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Illustration 34	g01345638
View of left body assembly (2) that is being turned over

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

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Illustration 35	g01345644

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

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Illustration 36	g01345926
View of positioning wood blocks underneath the front wall and rear corner of the left body assembly

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

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Illustration 37	g01346053
Prepare this edge for welding.

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Illustration 38	g01346118
Prepare this edge for welding.

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Illustration 39	g01346123
Prepare this edge for welding.

28. Use a grinder in order to clean the welding areas of the left body assembly. Completely remove all paint, rust, scale, slag, dirt, moisture, etc. before welding. Refer to Illustration 37 through Illustration 39.

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

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

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Illustration 40	g01346249
View of left body assembly (2) that is aligned with center body assembly (1)

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Illustration 41	g01346259
View of the alignment plates that are used to align the body assemblies. The alignment plates are located on the front wall of the left body assembly

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Illustration 42	g01346280
View of the alignment plates that are located along the floor seam of the left body assembly

30. Position the left body assembly (2) against center body assembly (1). Refer to Illustration 40 through Illustration 42.

    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) .

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Illustration 43	g00824846
View of five 8T-0674 Bolts (8) and of five 7X-0851 Nuts (7) that are located on the bottom of center body assembly (1) and left body assembly (2)

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Illustration 44	g00824847
View of two 8T-0674 Bolts (8) and of two 7X-0851 Nuts (7) that are located on the inside of the front wall

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Illustration 45	g01346283
View of 8T-0674 Bolt (8) and of 7X-0851 Nut (7) that are installed

31. Install seven 8T-0674 Bolts (8) and seven 7X-0851 Nuts (7). Do not tighten the bolts and nuts.

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Illustration 46	g01346303
View of center body assembly (1), left body assembly (2), and spacer (6)

32. Tighten seven 8T-0674 Bolts (8) and 7X-0851 Nuts (7) until center body assembly (1) and left body assembly (2) are tight against three spacers (6) .

    Note: Spacers (6) 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) .

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

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Illustration 47	g01346310
View of the angles and wedges that can be used along the outside of the front wall for alignment of the body assemblies

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Illustration 48	g01346487
View of the angles and wedges that can be used along the inside of the front wall for alignment of the body assemblies

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Illustration 49	g01346713
View of the angles and of the wedges that can be used along the floor seam for alignment of the body assemblies

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Illustration 50	g01346714
View of the angles and of the wedges that can be used along the ribs of the floor for alignment of the body assemblies

34. Use angles and wedges to help align the left body assembly (2) to the center body assembly (1). Refer to Illustration 47 through Illustration 50.

    Note: Before tack welding any angles to the body assembly, use a grinder in order to clean the welding areas. Completely remove all paint, rust, scale, slag, dirt, moisture, etc. 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.

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

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

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Illustration 51	g01346720
View of gap spacing (D) that is necessary along the seam between the center body assembly and the left body assembly (D) 6.0 mm (0.24 inch)

36. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left body assembly.

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

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Illustration 52	g01346748

37. 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" ".

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

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Illustration 53	g01346756
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.

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Illustration 54	g01346842
View of the areas that are tack welded along the outside of the front wall

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

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Illustration 55	g01356120
View of right body assembly (3) that is aligned with center body assembly (1)

40. Repeat Step 19 through Step 36 for right body assembly (3). The right body assembly weighs approximately 6300 kg (14000 lb).

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Illustration 56	g01366230
(E) 7680 mm (302.4 inch)

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

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Illustration 57	g01355755
This view of the body upside-down shows measuring the front wall to obtain dimension (E) .

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Illustration 58	g01359002

41. 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.

42. Repeat Step 37 through Step 39 for right body assembly (3) .

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

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Illustration 59	g01356166

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

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

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Illustration 60	g01356174

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

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

48. Weld the floor seam back-up 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.

49. Remove the slag after every weld pass.

50. Repeat Step 44 through Step 49 for the right body assembly.

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Illustration 61	g01356188

51. 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" ".

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

53. 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.

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

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Illustration 62	g01356358
(W1) 6.0 mm (0.24 inch) Fillet weld

55. 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.

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

    Note: Remove the slag after every weld pass.

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

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

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Illustration 63	g01354718
Typical view of the body that is being turned over

59. Position two suitable cranes (G) and (H) 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.

60. Attach three sets of suitable lifting devices to the body. Attach one set of lifting devices to the lifting eyes on the bottom of the body. Attach the remaining two sets of lifting devices through the side walls. This is shown in Illustration 64 one set on each side of the body. The body assembly weighs approximately 23200 kg (51000 lb).

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Illustration 64	g01354701
Typical view of the body that is being turned over

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

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

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Illustration 65	g01354702
Typical view of the body that is being turned over

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Illustration 66	g01354708
Typical view of the body that is being turned over

63. Both cranes should lift the body to a suitable height. Slowly lower crane (H) and raise crane (G) until the body in vertical.

64. Lifting device (L) should be moved in the direction of the arrow that is shown in Illustration 68 for future use.

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Illustration 67	g01354709
Typical view of the body that is being turned over

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

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Illustration 68	g01354711
Typical view of the body that is being turned over

66. Reposition crane (H) to the other side of the body and position the boom toward the body. Connect lifting device (L) to the crane and slowly raise the lifting device until the lifting device is tight.

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Illustration 69	g01354712
Typical view of the body that is being turned over

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

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

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

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Illustration 70	g01354713
Typical view of the body that is being turned over

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Illustration 71	g01354714
Typical view of the body that is being turned over

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

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Illustration 72	g01354716
Typical view of the body that is being turned over

70. Slowly lower both cranes (G) and (H) and position the body onto the wood blocks.

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

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Illustration 73	g01358428
View of gap spacing (D) that is necessary along the seam between the center body assembly and the left body assembly (D) 6.0 mm (0.24 inch)

72. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left body assembly.

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

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Illustration 74	g01358576

73. Remove three spacers (6) that are located between center body assembly (1) and left body assembly (2) .

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Illustration 75	g01354764
(W2) 16 mm (0.7 inch) Bevel groove weld

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

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

76. 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.

77. Repeat Step 72 through Step 76 for the right body assembly.

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Illustration 76	g01354783
(W3) 10 mm (0.4 inch) Bevel groove weld

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

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

80. 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.

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

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Illustration 77	g01354788
(W4) 16 mm (0.7 inch) Bevel groove weld

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

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

84. 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.

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

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

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

Installation of the Canopy Assembly and Guards

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Illustration 78	g01354811
View of the canopy from the back.

1. Locate canopy assembly (9) .

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Illustration 79	g01354885

Note: Dimension (F) needs to be equal to dimension (E) in order to ensure the proper fit. Dimension (E) is given in Illustration 56 of the ""Assembly Procedure" " section.

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Illustration 80	g01354892
Prepare canopy assembly (9) for welding.

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Illustration 81	g01354906
Prepare this edge for welding.

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

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Illustration 82	g01354937

3. 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, etc. before welding.

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Illustration 83	g01354964

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

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Illustration 84	g01355101

5. Attach a suitable lifting device to canopy assembly (9). Use three cables in the configuration. The canopy assembly (9) weighs approximately 4000 kg (9000 lb).

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Illustration 85	g01355155

6. Raise canopy assembly (9) for installation.

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Illustration 86	g01355166

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

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Illustration 87	g01355219
View of positioning the canopy to the body

7. Position the canopy to the body.

8. 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 (14) in order to secure the canopy assembly to the side walls.

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Illustration 88	g01355221
Angles and wedges may be used for alignment of the canopy to the body.

9. Use angles and wedges 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, etc. before welding.

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Illustration 89	g01355224

10. 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.

11. 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.

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Illustration 90	g01355247
(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

12. Preheat the bottom side of canopy assembly (9) 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.

13. 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.

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Illustration 91	g01358954
(W7) 10 mm (0.4 inch) Bevel groove weld

14. Weld the inside of canopy assembly (9) to the front wall and to the side walls.

    Note: Remove the slag after every weld pass.

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Illustration 92	g01355589
View of rock guard (4) that will be installed

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Illustration 93	g01355590

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

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Illustration 94	g01355591
View of rock guard (4) before installation onto the body

16. 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.

17. Attach a suitable lifting device in order to position rock guard (4) for welding. Rock guard (4) weighs approximately 56 kg (123 lb).

18. Hang the canopy rock guard with the attached clips.

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Illustration 95	g01358008
View of the installed rock guards (W8) 6 mm (0.24 inch) Bevel groove weld (W9) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

19. Weld rock guard (4) to canopy assembly (9) 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.

20. Repeat Step 15 through 19 for the other side.

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Illustration 96	g01355618
View of the left plate

21. 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, etc. before welding.

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Illustration 97	g01358009
View of plate (10) before welding (W10) 8 mm (0.3 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration (W11) 8 mm (0.3 inch) Fillet weld (W12) 6 mm (0.2 inch) Bevel groove weld

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

22. Use a suitable lifting device in order to position transition plate (10) to the body and the canopy. Transition plate (10) weighs approximately 30 kg (66 lb).

    Note: Before welding transition cap plates (10) and (11), verify that transition cap plates (10) and (11) 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.

23. Weld plate (10) to the body.

24. Repeat Step 21 through 23 for the other side.

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Illustration 98	g01355640

25. Use a grinder in order to clean the welding areas of the body and plate (12). Completely remove all paint, rust, scale, slag, dirt, moisture, etc. before welding.

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Illustration 99	g01355685
View of the right side of the body (W13) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.06 inch) root penetration

26. Position plate (12) to the body and the canopy.

    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.

27. Weld plate (12) to the body.

28. Repeat Step 25 through 28 for the other side.

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.

2. Ensure that all welds have been inspected.

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

3. Clean the entire truck body.

4. 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 100	g00828899

Note: Rock ejector bracket (5) is an optional factory installed item. Refer to Special Instructions, "789C Off-Highway Truck Assembly Procedure" for proper alignment of the 238-8577 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.