Assembly Procedure for the Coal Truck Body{7258, 7960} Caterpillar

Off-Highway Truck/Tractor:

777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; AGY1-UP)

777F (S/N: JRP1-UP)

777G (S/N: TNM1-UP; RDR1-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, 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 Hand Body Assembly and the Right Hand 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 lift 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 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, and grease before welding.

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

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

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

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

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

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

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

Inspect all welded areas. 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 Hand Body Assembly

• Right Hand Body Assembly

• Canopy Assembly

Illustration 2	g01659753
(1) Center body assembly

Illustration 3	g01660574
(2) Left-hand body assembly (3) Right-hand body assembly

Illustration 4	g01668254
(4) Canopy assembly

Assembly Procedure

Illustration 5	g01660595

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

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Illustration 6	g01660596
Illustration 6 is a view of the edges that need to be cleaned prior to assembly.

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Illustration 7	g01660597
Prepare the rib joints for welding.

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Illustration 8	g01660598
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, and moisture before welding. Refer to Illustration 6 through Illustration 8.

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

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Illustration 9	g01660599
Top view of spacer (5) .

3. Fabricate six spacers (5) 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	g01660601
View of spacer (5) that is tack welded to center body assembly (1) .

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Illustration 11	g01661308
View of the location of the spacers that are tack welded along the right side of the center body assembly.

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Illustration 12	g01661310
View of the location of the spacers that are tack welded along the right side of the front wall.

4. Tack weld three spacers (5) 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	g01661313
View of preparing to turn over the center body assembly.

5. 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 6500 kg (14330 lb).

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Illustration 14	g01661315

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

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Illustration 15	g01661316

7. 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 16	g01661317
View of the two lifting devices that are attached to the bottom side of the center body assembly.

8. Attach one lifting device to the lifting eye that is located on the bottom side of the center body assembly. Attach one lifting device to the lifting eye that is located on the front wall of the center body assembly. Secure the lifting devices to a suitable hoist. Refer to Illustration 16.

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Illustration 17	g01661353
View of center body assembly (1) that is being turned over.

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Illustration 18	g01661354
View of center body assembly (1) that is turned over.

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

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Illustration 19	g01661355

10. Remove the two lifting devices that are attached to the floor.

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Illustration 20	g01661356

11. Attach one lifting device to the lifting eye that is located on the bottom side of the center body assembly. Attach one lifting device to the lifting eye that is located on the front wall of the center body assembly. Secure the lifting devices to a suitable hoist.

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Illustration 21	g01661357

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

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

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Illustration 22	g01661358

14. 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 23	g01661359

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

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Illustration 24	g01664074

16. Locate left-hand body assembly (2) and right-hand body assembly (3) in the work area.

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Illustration 25	g01664075
View of attaching two lifting devices to the left-hand body assembly.

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Illustration 26	g01664076
View of moving left-hand body assembly (2) away from right-hand body assembly (3) .

17. Attach two suitable lifting devices to the lifting holes that are located in the left-hand body assembly. Secure the lifting devices to a suitable hoist. The left-hand body assembly weighs approximately 3700 kg (8160 lb).

18. Move left-hand body assembly (2) away from right-hand body assembly (3) .

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Illustration 27	g01664133

19. Position the left-hand body assembly onto the ground.

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

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Illustration 28	g01664134

21. Raise left-hand body assembly (2) .

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Illustration 29	g01664135
View of one lifting device that is attached to the lifting eye that is located toward the front of the left-hand body assembly.

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Illustration 30	g01664137
View of one lifting device that is attached to the lifting eye that is located toward the rear of the left-hand body assembly.

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

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Illustration 31	g01664138
View of left-hand body assembly (2) that is being turned over.

23. Use both hoists in order to turn over left-hand body assembly (2).

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Illustration 32	g01664139

24. Remove the two lifting devices that are attached to the lifting holes in the left-hand body assembly.

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Illustration 33	g01664140
View of positioning wood blocks underneath the front wall and rear corner of the left-hand body assembly.

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

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Illustration 34	g01664141
Prepare this edge for welding.

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Illustration 35	g01664142
Prepare this edge for welding.

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Illustration 36	g01664143
Prepare this edge for welding.

26. Use a grinder in order to clean the welding areas of the left-hand body assembly. Completely remove all paint, rust, scale, slag, dirt, and moisture before welding. Refer to Illustration 34 through Illustration 36.

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

27. Use a suitable hoist to raise left-hand body assembly (2) .

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Illustration 37	g01664145
View of left-hand body assembly (2) that is aligned with center body assembly (1) .

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Illustration 38	g01664146
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-hand body assembly.

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Illustration 39	g01664147
View of the alignment plates that are located along the floor seam of the left-hand body assembly.

28. Position the left-hand body assembly (2) against center body assembly (1). Refer to Illustration 37 through Illustration 39.

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

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

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Illustration 40	g01664717
View of five bolts (6) and of five nuts (7) located on the bottom of center body assembly (1) and left-hand body assembly (2) .

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Illustration 41	g01664719
View of two bolts (6) and of two nuts (7) that are located on the inside of the front wall.

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Illustration 42	g01664720

29. Install seven bolts (6) and seven nuts (7). Do not tighten the bolts and nuts.

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Illustration 43	g01664722
View of center body assembly (1), left-hand body assembly (2), and spacer (5) .

30. Tighten seven bolts (6) and seven nuts (7) until center body assembly (1) and left-hand body assembly (2) are tight against three spacers (5) .

    Note: Spacers (5) are used to obtain the correct root opening of 6.0 mm (0.24 inch) between center body assembly (1) and left-hand body assembly (2) .

31. Remove the lifting devices from left-hand body assembly (2) .

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Illustration 44	g01664723
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 45	g01664754
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 46	g01664755
View of the angles and of the wedges that can be used along the floor seam for alignment of the body assemblies.

32. Use angles and wedges to help align the left-hand body assembly (2) to the center body assembly (1). Refer to Illustration 44 through Illustration 46.

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

    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, and moisture 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 47	g01346720
View of gap spacing (D) that is necessary along the seam between the center body assembly and the left-hand body assembly. (D) 6.0 mm (0.24 inch)

33. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left-hand 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 48	g01356120
View of right-hand body assembly (3) that is aligned with center body assembly (1) .

34. Repeat Step 17 through Step 33 for right-hand body assembly (3). The right-hand body assembly weighs approximately 3700 kg (8160 lb).

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Illustration 49	g01664816
(E) 6150 mm (242 inch)

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

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Illustration 50	g01664817
This view of the body upside-down shows measuring the front wall to obtain dimension (E) .

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Illustration 51	g01664818

35. 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, equally maneuver left-hand body assembly (2) and right-hand body assembly (3) until the overall width does equal dimension (E). Dimension (E) must be equal to dimension (F) in order for canopy assembly (4) to fit correctly with the assembled body.

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Illustration 52	g01664757

36. Before tack welding, preheat the welding areas of center body assembly (1) and left-hand body assembly (2) to the proper preheat temperature. Refer to ""Welding Instructions" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.

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Illustration 53	g01664813
Bottom 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.

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Illustration 54	g01664814
View of the areas that are tack welded along the outside of the front wall.

37. Tack weld the left-hand body assembly to the center body assembly.

38. Repeat Step 36 through Step 37 for right-hand body assembly (3) .

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

40. Use a string or a straight edge in order to ensure that the side walls are correctly aligned.

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Illustration 55	g01664820

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

42. Preheat the seam between center body assembly (1) and left-hand body assembly (2) .

    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.

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Illustration 56	g01666218
(W1) 5 mm (0.20 inch) Fillet weld (W2) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

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Illustration 57	g01666315
(W3) 5 mm (0.20 inch) Double side bevel groove weld (W4) 8 mm (0.32 inch) Double side fillet weld with 1.5 mm (0.060 inch) root penetration

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Illustration 58	g01667795
(W5) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration (W6) 4 mm (0.16 inch) V-groove weld on top of a 10 mm (0.40 inch) bevel groove weld

43. Weld the seam between the left-hand body assembly and the center body assembly.

    Note: Remove the slag after every weld pass.

44. Repeat Step 42 through Step 43 for the right-hand body assembly.

45. Preheat the floor seam.

    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.

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Illustration 59	g01666221
(W7) 8 mm (0.32 inch) V-groove weld (W8) 8 mm (0.32 inch) Bevel groove weld with a 5 mm (0.20 inch) thick, 12 mm (0.47 inch) tall fillet weld on top (W9) 5 mm (0.20 inch) Fillet weld

46. Weld the floor seam between the left-hand body assembly and center body assembly.

    Note: Remove the slag after every weld pass.

47. Repeat weld (W7) for the five remaining floor ribs. Repeat weld (W8) on both sides of the five remaining floor ribs. Repeat weld (W9) for the five remaining segments.

48. Repeat Step 45 through Step 47 for the right-hand body assembly.

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

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Illustration 60	g01629413
Typical view of the body that is being turned over

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

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

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Illustration 61	g01629414
Typical view of the body that is being turned over

51. Attach three sets of suitable lifting devices to the body. Attach one lifting device to the lifting eyes on the bottom of the body. Attach one set of lifting devices through each of the two side walls. Refer to Illustration 61. The body assembly weighs approximately 20000 kg (44100 lb).

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

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

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Illustration 62	g01629419
Typical view of the body that is being turned over

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Illustration 63	g01629420
Typical view of the body that is being turned over

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

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Illustration 64	g01629421
Typical view of the body that is being turned over

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

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Illustration 65	g01629422
Typical view of the body that is being turned over

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

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

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Illustration 66	g01629424
Typical view of the body that is being turned over

58. Slowly lift the body with crane (H) while you rotate the boom of crane (H) away from the body.

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

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

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Illustration 67	g01629427
Typical view of the body that is being turned over

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Illustration 68	g01629430
Typical view of the body that is being turned over

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

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Illustration 69	g01629432
Typical view of the body that is being turned over

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

62. Before finish welding reposition the body inside the building.

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Illustration 70	g01667873
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)

63. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left-hand 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 71	g01667954

64. Remove three spacers (5) that are located between center body assembly (1) and left-hand body assembly (2) .

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Illustration 72	g01668040

65. Preheat the welding areas of center body assembly (1) and left-hand body assembly (2) to the proper temperature.

    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.

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Illustration 73	g01666219
(W10) 14 mm (0.55 inch) Bevel groove weld

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

    Note: Remove the slag after every weld pass.

67. Repeat Step 63 through Step 66 for the right-hand body assembly.

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Illustration 74	g01668073

68. Preheat the welding areas of the front wall to the proper temperature.

    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.

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Illustration 75	g01668095
(W11) 10 mm (0.40 inch) Bevel groove weld

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

    Note: Remove the slag after every weld pass.

70. Repeat Step 68 through Step 69 for the right-hand body assembly.

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Illustration 76	g01668153

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Illustration 77	g01668155

71. Use a grinder in order to clean the welding areas of plates (8). Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.

72. Preheat the welding areas of plates (8) to the proper temperature.

    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.

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Illustration 78	g01668174
(W12) 14 mm (0.55 inch) Bevel groove weld

73. Weld plate (8) that connects left-hand body assembly (2) and center body assembly (1) .

    Note: Remove the slag after every weld pass.

74. Repeat Step 71 through Step 73 for the right-hand body assembly.

Installation of the Canopy Assembly

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Illustration 79	g01668274
View of the canopy from the back.

1. Locate canopy assembly (4) .

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Illustration 80	g01668276

Note: Dimension (F) needs to be equal to dimension (E) in order to ensure the proper fit. Dimension (E) is given in Illustration 49 of the ""Assembly Procedure" " section.

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Illustration 81	g01668293
Prepare canopy assembly (4) for welding.

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Illustration 82	g01668294
Prepare canopy assembly (4) for welding.

2. Use a grinder in order to clean the weld areas of canopy assembly (4). Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.

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Illustration 83	g01668297

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

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Illustration 84	g01668298

4. Attach a suitable lifting device to canopy assembly (4). Canopy assembly (4) weighs approximately 2250 kg (4960 lb).

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Illustration 85	g01355155
Typical view of the canopy that is being installed.

5. Raise canopy assembly (4) for installation.

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Illustration 86	g01355166
Typical view of the canopy that is being installed.

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

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Illustration 87	g01355219
Typical view of the canopy that is being installed.

6. Position the canopy assembly to the body.

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Illustration 88	g01668303
View of an angle and wedge that can be used for alignment of the canopy assembly to the body.

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

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

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Illustration 89	g01668306

8. 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.

9. Preheat the weld seams.

   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.

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

11. Preheat the seams between canopy assembly (4) and 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.

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Illustration 90	g01668309
(W13) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration (W14) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

Note: Repeat weld (W13) for the three remaining ribs.

Note: Repeat weld (W14) for the remaining two sections.

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Illustration 91	g01668311
(W15) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration (W16) 8 mm (0.32 inch) Double side fillet weld with 1.5 mm (0.060 inch) root penetration

Note: Repeat weld (W15) for the other side of canopy assembly (4) .

Note: Repeat weld (W16) for the three remaining ribs.

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Illustration 92	g01668313
(W17) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration (W18) 10 mm (0.40 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

Note: Repeat weld (W17) for the other side of canopy assembly (4) .

12. Weld canopy assembly (4) to the body.

    Note: Remove the slag after every weld pass.

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Illustration 93	g01668314

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Illustration 94	g01669333

13. Use a grinder in order to clean the welding areas of two plates (9) and two plates (10). Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.

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Illustration 95	g01669336

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

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Illustration 96	g01669356

15. Preheat the seam between plate (9) and 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.

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Illustration 97	g01669355
(W19) 6 mm (0.24 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

16. Weld plate (9) to the body.

    Note: Remove the slag after every weld pass.

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Illustration 98	g01669358

17. Preheat the seam between plate (10) and 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.

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Illustration 99	g01669354
(W20) 6 mm (0.24 inch) Bevel groove weld

18. Weld plate (10) to the body.

    Note: Remove the slag after every weld pass.

19. Repeat Step 15 through Step 18 in order to install plate (9) and plate (10) to the right-hand side of the body.

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Illustration 100	g01669533

20. Use a grinder in order to clean the welding areas of plate assembly (11). Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.

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Illustration 101	g01669535

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

22. Use a suitable lifting device in order to position plate assembly (11) to the body. Plate assembly (11) weighs approximately 545 kg (1200 lb).

    Note: Lifting eyes may be welded onto plate assembly (11) in order to assist in positioning.

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Illustration 102	g01669553

23. Preheat the seams between plate assembly (11) and 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.

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Illustration 103	g01669554
(W21) 10 mm (0.40 inch) Bevel groove weld (W22) 10 mm (0.40 inch) Flare bevel groove weld (W23) 10 mm (0.40 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

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Illustration 104	g01669915
(W24) 10 mm (0.40 inch) Bevel groove weld (W25) 10 mm (0.40 inch) Flare bevel groove weld (W26) 10 mm (0.40 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration

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Illustration 105	g01669916
(W27) 10 mm (0.40 inch) Flare bevel groove weld (W28) 10 mm (0.40 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration (W29) 10 mm (0.40 inch) Flare bevel groove weld

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Illustration 106	g01669917
(W30) 10 mm (0.40 inch) Flare bevel groove weld (W31) 10 mm (0.40 inch) Flare bevel groove weld

24. Weld plate assembly (11) to the body.

    Note: Remove the slag after every weld pass.

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Illustration 107	g01669918

25. Repeat Step 20 through Step 24 for plate assembly (12) .

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 108	g01668235

Note: Rock ejector bracket (13) is an optional factory installed item. Refer to Special Instructions, "Off-Highway Truck Assembly Procedure" for the correct model of truck in order to obtain the proper alignment of the 321-5444 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 remove the lifting eyes before installing the body to the chassis.