Assembly Procedure for the X Truck Body for the 793F Off-Highway Truck {0679, 7000, 7250, 7258, 7960} Caterpillar

Off Highway Truck

793F (S/N: SND1-UP; SSP1-UP)

Introduction

This manual contains information to assemble the 306-2680 Body and Canopy As for the 793F Off-Highway Truck. The 306-2680 Body and Canopy As is also referred to as the X body. This Special Instruction must be used with Special Instruction, SEHS0013, "Body Assembly Procedure".

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

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

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

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

Note: The truck body may be field assembled in the upright orientation or in the upside down orientation. For illustrative purposes, the upside down orientation is shown.

Note: An enclosed building is recommended for the welding of any X truck body. The dispersing of the shielding gases away from the welding area must be kept to a minimum.

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.

Show/hide table

Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

Show/hide table

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

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

Reference Section

Reference: Parts Manual, SEBP4987 and Operation and Maintenance Manual, SEBU8406

Reference: Disassembly and Assembly, UENR2257, "793F Off-Highway Truck Field Assembly"

Reference: Special Instruction, REHS1841, "General Welding Procedures"

Reference: Tool Operating Manual, NEHS1120, "Truck Body Lifting Pins"

Reference: Special Instruction, SEHS0013, "Body Assembly Procedure"

Parts List

Weights and Required Tooling

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 as needed.

Table 2 contains examples of the approximate weights of the base truck body, and the base canopy assemblies.

Note: The weights that are listed in this document are only approximate weights. The weights represent only one size of X truck body. X 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 to determine lifting requirements.

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:

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.

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 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.

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.

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.

Weld Types and Locations

Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for the proper weld types and locations. This Special Instruction will also show the locations of all field assembly components.

Welding Instructions

General Preheat Instructions for Truck Body Field Assembly

The following materials are used 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.

Before welding on the truck body, verify the materials that are used to fabricate your particular truck body. There are specific welding procedures for each material. Refer to the following instructions 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 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 to minimize the gap spacing. Minimizing the gap spacing reduces the residual stresses.

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 1	g03032696
Typical view of a Tiger Torch

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

Reference: Refer to Table 10 for the required preheat temperature of the material.

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.

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 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 to avoid the heat sink effect of the floor plates.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturers weight's 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 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 2	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.

Lifting Eyes

Lifting Eye Locations

For handling purposes, lifting eyes are at convenient locations on each model. Only use the following lifting eyes. Once the assembly is complete, the lifting eyes may be removed.

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

The following graphics show the proper lifting eye locations for the 306-2680 Body and Canopy As.

Illustration 3	g03750707
Top view of the lifting eye locations

Illustration 4	g03750709
Bottom view of the lifting eye locations

Fabrication of Lifting Eyes

Refer to the following step to fabricate the lifting eyes.

Show/hide table

Illustration 5	g03750796
Lift eye (A) Radius 100 mm (4 inch) (B) Diameter 100 mm (4 inch) (C) 75 mm (3 inch) (D) 50 mm (2 inch) (E) 8 ± 1 mm (0.315 ± 0.04 inch) Two places (F) 8 ± 1 mm (0.315 ± 0.04 inch) Two places (1) Lift eye

1. Use the steel from Table 11 and the dimensions in Illustration 5 to fabricate 17 lift eyes (1).

   Note: Fabricate the lifting eyes as needed.

Assembly Procedure

Preparation

Ensure all the components for the body have been unloaded from the shipping trucks. Ensure that the build site is suitable and safe.

Note: The serial number of the truck body is stamped on the edge of each section. Before assembling the body, make sure that the serial numbers for all the components match.

Note: The truck body may be field assembled in the upright orientation or in the upside down orientation. For illustrative purposes, the upside down orientation is shown.

Grind and/or sand blast all welding areas of the truck body assemblies. Grind and/or sand blast all welding areas of the components for the truck body assemblies. Completely remove all paint, rust, scale, slag, dirt, moisture, and grease before tack welding and finish welding.

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

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

Reference: "Welding Instructions" and "Welding Specifications and Qualifications"

Reference: "Weld Types and Locations" for the proper welds and the locations of all field assembly components.

Lifting and Rotating the Body and Canopy Assembly

Note: Before lifting any component of the truck body, refer to Table 2. Also, refer to "Specifications for Cables, Chains, and Lifting Devices".

Note: The following steps are for reference purposes only. The following steps show the general location of lift eyes and general rotating procedures.

Reference: Refer to "Lifting Eye Locations" for the location of the lifting eyes for the truck body that is being assembled.

1. Position two suitable cranes or lifting devices near the work area.
   Show/hide table

   Illustration 6	g03347962
   Center body assembly

2. Locate the center body assembly into the work area.

   Note: Perform Step 1 and Step 2 of "Installation of the Right-Hand and Left-Hand Body Assemblies" prior to performing the following step.

3. Use one hoist to attach two suitable lifting devices to the two lifting eyes. The lifting eyes are located along the left-hand side of the center body assembly. The center body assembly weighs approximately 12279 kg (27071 lb).
   Show/hide table

   Illustration 7	g03347988

   Show/hide table

   Illustration 8	g03347992
   Center body assembly

4. Raise center body assembly to a vertical position.

5. Use a second hoist to attach two suitable lifting devices to the lower lift eyes.

6. Use both hoists to raise the center body assembly.

   Note: Maintain tension on the lifting devices that are attached to the left side of the body assembly while performing the next steps.

7. Raise the hoist that is connected to the lower lifting eyes until the floor of the center body assembly is in a horizontal position.
   Show/hide table

   Illustration 9	g03348011
   View of the center body assembly in the horizontal position

8. Locate the center body assembly into the center of the work area.
   Show/hide table

   Illustration 10	g03348024
   View of the center body assembly on wood blocks

9. Position two wood blocks underneath the front wall. Position wood blocks or suitable supporting devices underneath the rear of the body assembly.

   Note: Locate the front wall of center body assembly (1) in the center of the wood blocks. Ensure to leave space for the left-hand and right-hand body assemblies in the procedures that follow.

   Note: Additional wood blocks may be needed. The wood blocks will be used underneath the rear of the body assembly to align with the left-hand and right-hand body assemblies.

10. Lower center body assembly onto the wood blocks and remove all lifting devices.
    Show/hide table

    Illustration 11	g03348044
    Right-hand body assembly

    Note: Use 376-4554 Pin As to lift the body assembly. Refer to Tool Operating Manual, NEHS1120, "Truck Body Lifting Pins".

11. Attach two suitable lifting devices to the 376-4554 Pin As. Secure the lifting devices to a suitable hoist. The approximate weight of right-hand body assembly is 8069 kg (17789 lb).

12. Locate right-hand body assembly into the work area.
    Show/hide table

    Illustration 12	g03348065
    View of the right-hand body assembly

13. Attach two lifting devices to the two lifting eyes in the location that is shown on the right-hand body assembly. Secure the lifting devices to a suitable hoist.

    Note: The lower lifting eyes are to be used to lift the right-hand body assembly only. The lower lifting eyes are not suitable for lifting an entire completed body assembly.

14. Raise the right-hand body assembly.

15. Use both hoists to turn over the right-hand body assembly.

16. Raise the bottom side of the body assembly and lower the top side of the body assembly. Lower the top side of the body assembly until there is not tension on the lifting devices.

17. Remove the lifting devices from the top rail and pin assembly of the right-hand body assembly.
    Show/hide table

    Illustration 13	g03348067
    View of the right-hand body assembly that has been turned over

18. Attach one suitable lifting device to the center lifting eye that is on the bottom of the right-hand body assembly. Secure the lifting device to a suitable hoist.

    Note: Ensure that the right-hand body assembly raises in a level position. If necessary, attach a 1U-9204 Lever Puller Hoist Gp of the proper capacity to the center lift eye. The center lift eye is on the bottom of left-hand body assembly (2). Use the lever puller to level the body assembly.

    Show/hide table

    Illustration 14	g03348075
    View of positioning wood blocks underneath right-hand body assembly

19. Lower the front end of the right-hand body assembly onto the wood blocks that are located under the front end of the center body assembly. Position the rear corner of the right-hand body assembly onto wood blocks that are located under the center body assembly.
    Show/hide table

    Illustration 15	g03350759
    Typical inside view of the alignment plates that are used to align the body assemblies. The alignment plates are on the front wall of the center body assembly

    Show/hide table

    Illustration 16	g03350760
    Typical inside view of the alignment plates that are located along the floor seam of the center body assembly

20. Position the right-hand body assembly against the center body assembly.

    Note: The alignment plates ease the alignment of the right-hand body assembly to the center body assembly.

    Show/hide table

    Illustration 17	g03348243
    View of the right-hand body assembly that is aligned with the center body assembly

21. Secure the right-hand body assembly to the center body assembly.

    Note: Refer to "Installation of the Right-Hand and Left-Hand Body Assemblies" for this procedure.

22. Finish weld the right-hand body assembly to the center body assembly.

    Note: Refer to "Weld Types and Locations" for this procedure.

    Show/hide table

    Illustration 18	g03348248
    View of the right-hand and left-hand body assemblies attached to the center body assembly

23. Repeat Step 11 through Step 22 for the left-hand body assembly.

    Note: The left-hand body assembly weighs approximately 8019 kg (17679 lb).

    Show/hide table

    Illustration 19	g03348333
    View of the body that is being turned over

24. Attach three sets of suitable lifting devices to the body. Attach two lifting devices to the lifting eyes on the bottom of the center body assembly. Attach the remaining set of lifting devices to the side wall lift pins on the left and right side. Attach the lifting devices on the center body assembly to a suitable hoist. The body assembly weighs approximately 31793 kg (70091 lb).

25. The lifting device on the right-hand and left-hand body assemblies are not used at this time.

26. Only use one signalman for both of the cranes.
    Show/hide table

    Illustration 20	g03348350
    View if the body that is being turned over

27. Both cranes should lift the body to a suitable height. Slowly lower one side of the center body assembly until the body is in a vertical position.
    Show/hide table

    Illustration 21	g03348358
    View of the body that is being turned over

28. The lifting device that is attached to the right-hand side rail pins should be moved in the direction of the arrow for future use.

29. Disconnect the lifting device from the lifting eyes on the bottom of the center Body assembly.

30. Connect the lifting device on the right-hand body assembly to a suitable hoist. Slowly lift the body to a level position.
    Show/hide table

    Illustration 22	g03348452
    View of the body that has been turned over

31. Slowly lower both cranes in a level position and place the body assembly on wood blocks.

    Note: Ensure that the body assembly is secure and level on the wood blocks or suitable platform.

    Show/hide table

    Illustration 23	g03348569

32. Attach a suitable lifting device to the canopy assembly. Use three lifting devices in the configuration that is shown. Base canopy assembly weighs approximately 3426 kg (7553 lb).

33. Locate the canopy assembly into the work area.
    Show/hide table

    Illustration 24	g03348597
    View of the canopy and body assembly

34. Align the canopy to the body assembly.

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

35. Hold the canopy assembly in place with the lifting device until the canopy is assembled to the body assembly.

    Note: Refer to "Installation of the Canopy Assembly" for this procedure.

36. Finish weld the canopy assembly to the body assemblies.

    Note: Refer to "Weld Types and Locations" for this procedure.

Installation of the Right-Hand and Left-Hand Body Assemblies

Illustration 25	g03402039
View of the body assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly

During the assembly process of the body assemblies a root opening of 6.0 mm (0.25 inch) must be maintained between the body assemblies. Fabrication of spacers may be required. Refer to the following steps to fabricate the required spacers.

Show/hide table

Illustration 26	g03050177
View of fabricated spacer

1. Fabricate six spacers with the following dimensions:

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

   (B) Length ... 50.8 mm (2 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 left and right-hand body assemblies.

   Show/hide table

   Illustration 27	g03050230
   View of spacers that are tack welded to center body assembly (1). (1) Center body assembly

2. Tack weld six spacers to the center body assembly (1). Place the spacers in a location that will maintain the root opening between the body assemblies. Use the above graphic for a general location.

3. Perform Step 1 through Step 20 of the "Lifting and Rotating the Body and Canopy Assembly" prior to the following steps.
   Show/hide table

   Illustration 28	g03751037
   View of the location of five bolts (3) and of five nuts (4). (1) Center body assembly (2) Right-hand body assembly (3) Bolt (4) Nut

   Show/hide table

   Illustration 29	g03751136
   Inside view of two bolts (3) and of two nuts (4) that are ontheinsidethe front wall. (1) Center body assembly (2) Right-hand body assembly (3) Bolt (4) Nut

4. Align the lugs on center body assembly (1) to the lugs on right-hand body assembly (2).

5. Install seven bolts (3) and seven nuts (4). Hand tighten the bolts and nuts at this time. Refer to Illustration 28 and 29.
   Show/hide table

   Illustration 30	g03058900
   Typical view of lever puller hoist

6. If necessary, a 1U-9204 Lever Puller Hoist can be used to align the body assemblies.

7. After the assemblies are aligned, tighten seven bolts (3) and seven nuts (4). Ensure that center body assembly (1) and right-hand body assembly (2) are tightened against the installed spacers. Refer to Illustration 28 and 29.

   Note: 6 mm (0.25 inch) root opening in the floor plate weld joint must be maintained for proper assembly.

8. Ensure that right-hand body assembly (2) is level with center body assembly (1).
   Show/hide table

   Illustration 31	g01283695
   Typical view

   Show/hide table

   Illustration 32	g02726495
   Typical view

9. If necessary, use alignment blocks and wedges to level right-hand body assembly (2) with center body assembly (1). Refer to Illustrations 31 and 32.

10. Ensure that all lifting devices are removed from the body assemblies.

11. Repeat Step 4 through Step 10 for left-hand body assembly (3).

    Note: The left-hand body assembly weighs approximately 8019 kg (17679 lb).

    Show/hide table

    Illustration 33	g03351117
    Typical view of the front of the body assembly (A) 6946 mm (273.5 inch) (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly

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

    Show/hide table

    Illustration 34	g03405661
    Typical view of the canopy assembly (B) 6946 ± 2 mm (273.5 ± 0.08 inch) (10) Canopy assembly

12. Before tack welding left-hand body assembly (5) and right-hand body assembly (2) to center body assembly (1) a measurement must be taken. Ensure that the inside width of the front wall equals dimension (A). If necessary, maneuver right-hand body assembly (2) until the inside width does equal dimension (A). Dimension (A) must be equal to dimension (B) in order for canopy assembly (10) to fit correctly with the assembled body.
    Show/hide table

    Illustration 35	g00862597
    Typical view of preheating and tack welding

13. Tack weld the entire body assembly. Evenly space the tack welds at 610 mm (24 inch) intervals. Each tack weld should be 76 mm (3.0 inch) in length.

14. Preheat the body assemblies and the rib supports.

15. Finish weld the body assembly joints and the rib supports. Remove the slag after every weld pass.

    Note: Before finish welding the joints remove all clamps, spacers, guides, nuts, and bolts. Grind the welds of the components that have been removed.

    Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

    Show/hide table

    Illustration 36	g03351316

16. Alignment of center holes in the center body assembly after welding must permit free entry of 128.95 mm (5.08 inch) diameter alignment gage.

Rotate the Body Assembly

1. Perform Step 24 through Step 31 of "Lifting and Rotating the Body and Canopy Assembly" to rotate the body assembly.

Installation of the Canopy Assembly

Show/hide table

Illustration 37	g03404818
View of positioning the canopy to the body. (6) Canopy assembly

1. Align canopy assembly (6) to the body assembly.

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

   Show/hide table

   Illustration 38	g03751597
   Typical view of an angle and wedge that can be used for alignment of the canopy to the body.

2. Angles and wedges may be used to help align canopy assembly (6) to the front wall and to both side walls.
   Show/hide table

   Illustration 39	g03404557
   Typical rear view

3. The braces that are attached to the front wall may be cut to aid in the alignment of the canopy assembly.

4. Once the canopy assembly is aligned, tack weld the canopy assembly to the front wall and to the side walls. Evenly space the tack welds at 610 mm (24 inch) intervals. Each tack weld should be 76 mm (3.0 inch) in length.

5. Finish weld the canopy assembly onto the body assembly.

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

6. Once the final weld is complete, remove all braces that are attached to the front wall.

Installation of the Front Components

Installation of Access Plates

Show/hide table

Illustration 40	g03404563
Front view of the body and canopy assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (7) Plate

1. Install two plates (7) in the location that is shown. Plates (7) are on the front of the left-hand and right-hand body assemblies, just below the canopy assembly.

2. Finish weld two plates (7).

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of Cover Plates

Show/hide table

Illustration 41	g03751758
View of cover plates that have been installed (1) Center body assembly (2) Right-hand body assembly (8) Cover (9) Bolt (10) Washer

1. Install three covers (8) onto the right-hand body assembly (2).

2. Use 12 bolts (9) and 12 hard washers (10) to install the covers.

Installation of the Canopy Wrapper Plates and Corner Transition Plates

Show/hide table

Illustration 42	g03404852
View of theinsidethe body assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (11) Plate (12) Plate (13) Plate

1. Weld suitable lifting eyes onto two plates (11). Use a suitable lifting device to place plates (11) in the location that is shown. Plates (11) are located between the canopy and the body assemblies.

   Note: The approximate weight of one plate (11) is 166 kg (366 lb).

2. Weld suitable lifting eyes onto plate (12). Use a suitable lifting device to place plate (12) in the location that is shown. Plate (12) is on left-hand body assembly (5) .

   Note: The approximate weigh of plate (12) is 40 kg (88 lb).

3. Weld suitable lifting eyes onto plate (13). Use a suitable lifting device to place plate (13) in the location that is shown. Plate (13) is on right-hand body assembly (5) .

   Note: The approximate weigh of plate (13) is 40 kg (88 lb).

4. Remove the lifting eyes and grind the welds smooth.

5. Finish weld two plates (11), plate (12), and plate (13) to the body assembly.

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Transition Plate

Show/hide table

Illustration 43	g03751850

1. Install suitable lifting eyes to plate (14).

2. Use a suitable lifting device to position plate (14). Plate (14) is on the front portion of center body assembly (1).

   Note: Plate (14) weighs approximately 294 kg (648 lb)

3. Finish weld plate (14).

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Rock Guards

Show/hide table

Illustration 44	g03751897
View of the left side of the canopy assembly (5) Left-hand body assembly (6) Canopy assembly (15) Guard assembly (16) Guard assembly

1. Install a suitable lifting eye to two guard assemblies (15) and (16).

2. Use a suitable lifting device to position the guard assemblies. Guard assembly (15) is on the left-hand side of canopy assembly (6). Guard assembly (16) is on the right-hand side of canopy assembly (6).

   Note: Guard assembly (15) weighs approximately 57 kg (126 lb)

   Note: Guard assembly (16) weighs approximately 81 kg (179 lb)

3. Finish weld guard assemblies (15) and (16).

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Body Down Indicator

Show/hide table

Illustration 45	g03751916
View of body down indicator on the canopy assembly (6) Canopy assembly (17) Plate

Show/hide table

Illustration 46	g03751917
View of Area A (C) 50 ± 3 mm (2 ± 0.12 inch) (D) 60 ± 5 mm (2.5 ± 0.20 inch) (17) Plate

1. Position plate (17) in the location that is shown. Plate (17) is on the front corner of canopy assembly (6).

2. Finish weld plate (17) to the inside canopy assembly (6).

   Reference: Refer to Special Instruction, SEHS0013, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Miscellaneous Item

Illustration 47	g03751956
Bottom view (A) Bracket (18) Bracket Assembly

Note: Bracket assembly (16) is installed during the truck assembly procedure. Refer to Disassembly and Assembly, UENR2257, "793F Off-Highway Truck Field Assembly" for the proper installation procedures.

Note: Brackets (A) are to be used for fall protection devices only. Not intended for lifting purposes.

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.

2. Ensure that all welds have been inspected.

   Reference: "Welding Specifications and Qualifications" and "Welding Instructions"

3. Clean the entire truck body.

4. Repaint the truck body, as needed.

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

   For questions regarding liner installation, the Technical Communicator (TC) should submit a DSN service request for response.