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

Off-Highway Trucks:

785 (S/N: 8GB1-UP)

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

785C (S/N: 1HW1-UP; APX1-UP)

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

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

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

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: 4AR1-UP; 4GZ1-UP; ATY1-UP)

793D (S/N: FDB1-UP)

Introduction

This Special Instruction contains the necessary procedures and information for assembling and welding a flat floor truck body.

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

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

The recommended tools, standard mechanics 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. Refer to Illustration 2 for the site of assembly.

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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 upright or with the Center Body Assembly that is turned over. The Left Body Assembly and the Right Body Assembly are welded to the Center Floor Assembly. The Canopy Assembly is installed. The Tie-In Plates, Transition Plates, and Body Liners are then installed.

The approximate weight of the truck body depends on the configuration of the truck body. The weight range of the truck bodies varies upon the truck model. Use one or two mobile cranes to adequately lift the truck body.

Note: The Liner Group and the Impact Liner are options on the flat floor truck bodies.

Weights and Required Tools

Table 1

Shipping Weight for the 261-0086 Flat Floor Truck Body
Description	Weight
Center Floor Assembly	14,100 kg (31,100 lb)
Left Body Assembly	8300 kg (18,300 lb)
Right Body Assembly	8300 kg (18,300 lb)
Canopy Assembly	800 kg (1760 lb)
Right Canopy Assembly	200 kg (430 lb)

Table 2

Shipping Weight for the 154-4535 Flat Floor Truck Body
Description	Weight
Center Floor Assembly	13,100 kg (29,000 lb)
Left Body Assembly	6900 kg (15,200 lb)
Right Body Assembly	6800 kg (15,000 lb)
Canopy Assembly	2600 kg (5700 lb)

Table 3

Shipping Weight for the 156-5499 Flat Floor Truck Body
Description	Weight
Center Floor Assembly	11,500 kg (25,300 lb)
Left Body Assembly	5400 kg (11,900 lb)
Right Body Assembly	5400 kg (11,900 lb)
Canopy Assembly	1800 kg (4000 lb)

Table 4

Required Tools
Tool Number	Description	Qty
1U-9754	Hydraulic Jack	2
1U-9332	Air/Hydraulic Jack Gp	As Required
1U-9204	Lever Puller Hoist	1
4C-3761	C-Clamp	As Required
1U-9368	Automatic Tape Measure	1
	Wedges	As Required
	Sledge Hammer	As Required
9U-6241	Hand Grinder	1
4C-9798	Magnetic Bar with String	2
4C-5647	Pry Bar	As Required
	Clevis 38 mm (1.5 inch)	4
	Cables 1.5 m (5 feet)	2
	Cables 1.8 mm (6 feet)	2
	Plumb Bob	1
140-7738	Lifting Sling	4

Parts List

Table 5

Attachments for the 154-4535 Flat Floor Truck Body Assembly
Item	Qty	Part Number	Description
1	1	154-4536	Center Body Assembly
2	1	154-4537	Left Body Assembly
3	1	154-4538	Right Body Assembly
4	1	154-4539	Canopy Assembly
5	2	8X-3945	Guard As
6	2	154-3429	Plates
7	2	154-3432	Bars
8	2	154-4548	Plates
9	2	154-4546	Rock Ejector Assembly
10	1	8X-6394	Plate As
11	16	2B-7218	Bolts
12	16	2J-3507	Full Nuts

Table 6

Attachments for the 177-7527 Liner Group for the 789 Flat Floor Truck Body Assembly
Item	Qty	Part Number	Description
13	2	178-0221	Plates
14	2	177-7530	Plates

Table 7

Attachments for the 261-0086 Flat Floor Truck Body Assembly
Item	Qty	Part Number	Description
1	1	154-3417	Flat Floor Body
2	1	168-6280	Body
3	1	261-0087	Body
4	1	154-3420	Canopy As
5	1	154-3419	Canopy As
6	2	8X-3945	Guard As
7	2	5T-9614	Shield As
8	2	154-3429	Plates
9	4	154-3432	Bars
10	3	169-5859	Plates
11	2	154-3427	Bracket As
12	1	154-3434	Plate
13	3	169-7344	Strips
14	18	8T-0674	Bolts
15	18	7X-0851	Nuts

Table 8

Attachments for the 156-5499 Flat Floor Truck Body Assembly
Item	Qty	Part Number	Description
1	1	136-8200	Center Body Assembly
2	1	136-8220	Left Body Assembly
3	1	136-8210	Right Body Assembly
4	1	136-8230	Canopy As
5	2	8W-3666	Guard As
6	2	163-8483	Transition Plates
7	2	163-8480	Plates
8	2	163-8484	Plates
9	2	163-8485	Plate As
10	1	163-8477	Plate
12	16	2B-7218	Bolts
13	16	2J-3507	Full Nuts
14	1	255-3312	Plate As

Weld Specifications and Parameters

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

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

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

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

• 480 MPa (69600 psi) Tensile Strength

• 400 MPa (58000 psi) Yield Strength

• 22 percent elongation in 50 mm (2 inch)

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

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

Table 9

Parameters for Welding
Diameter	Amperage
3 mm (.12 inch)	70-140
4 mm (.16 inch)	110-180
5 mm (.20 inch)	190-270

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

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

• 480 MPa (69600 psi) Tensile Strength

• 400 MPa (58000 psi) Yield Strength

• 22 percent elongation in 50 mm (2 inch)

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

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

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

Table 10

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

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

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

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

Welding Instructions

The following materials are used in order to fabricate the flat floor truck body:

• 400 Brinell

• 450 Brinell

Before welding on the flat floor truck body, verify the materials that are used in order to fabricate your particular flat floor 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 Hardness Number or 450 Brinell Hardness Number Material

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

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

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

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 11 for the required preheat temperature of the weld area.

Table 11

Preheat Temperatures
Combined Thickness of Material	Welding Preheat
0 mm (0.0 inch) to 65 mm (2.6 inch)	100 °C (212 °F)
66 mm (2.6 inch) to 100 mm (3.9 inch)	125 °C (257 °F)
greater than 100 mm (3.9 inch)	175 °C (350 °F)

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

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

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

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

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

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weight's in order to determine the application when you select the items that follow: 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 of Assembly

Note: The assembly procedure that is listed in this Special Instruction is for the 789 flat floor body. The assembly procedure for the 785 flat floor body and the 793 flat floor body are identical to the 789 flat floor body.

Note: The call out arrows with the numbers in the photos and illustrations indicate a part number. The directional arrows indicate an action or an area that is the point of focus.

Illustration 2	g00656621
This is a view of the flat floor truck body components on railroad cars. (1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly (3) 154-4538 Right Body Assembly

The flat floor truck body components will be delivered in three modules.

The flat floor truck body components will be delivered by a rail car or by a flat bed trailer.

Illustration 3	g00656622
This is a view of the flat floor truck body components that are unloaded. (2) 154-4537 Left Body Assembly (3) 154-4538 Right Body Assembly

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Be sure all personnel are clear of equipment while equipment is being lowered. Failure to stay clear may result in personal injury.

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Personal injury or death can result from worn wire rope cable. Worn or frayed cable could break causing injury. Check the wire rope cable. If cable is worn or is frayed install a new cable.

Unload the flat floor truck body components.

1. Place the modules in the center of the workplace.

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Illustration 4	g00656642
This is a view of the brackets that are removed. (1) 154-4536 Center Body Assembly (4) 154-4539 Canopy Assembly

2. Attach a crane to the canopy assembly. Remove the shipping brackets from the 154-4536 Center Body Assembly (1). Place the 154-4539 Canopy Assembly (4) in front of the 154-4536 Center Body Assembly (1) .

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Illustration 5	g00656652
This is a view of miscellaneous plates that are tack welded to the 154-4537 Left Body Assembly (2) . (2) 154-4537 Left Body Assembly (5) 8X-3945 Guard Assembly (9) 154-4546 Rock Ejector Assembly (13) 178-0221 Plate (14) 177-7530 Plate

3. Remove the shipping brackets and plates. Place the plates away from the site of assembly.

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Illustration 6	g01404247
This is a view of the setup for the flat floor body.

4. Configure the components for assembly.

Flat Floor Truck Body Assembly Procedure

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NOTICE
The body may be assembled in the upright position, or the body may be assembled in the downward position.

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NOTICE
The following procedure is performed with the body assembly right side up or in the upward position.

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NOTICE
The lifting devices that are shown in this publication are not Caterpillar parts.

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Illustration 7	g00658814
This is a view of the 154-4536 Center Body Assembly (1) on blocks.

1. Place the 154-4536 Center Body Assembly (1) on blocks.

   Note: The 154-4536 Center Body Assembly (1) should be level.

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Illustration 8	g00656858
This is a view of the 154-4536 Center Body Assembly (1) .

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Illustration 9	g00656864
This is a view of the 154-4538 Right Body Assembly (3) .

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Illustration 10	g00656876
This is a view of the rib joints that are cleaned.

2. Remove the paint from the surfaces that will be welded. Use a grinder to remove the paint. The parts may be sand blasted.

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Illustration 11	g01283478
This is a top view of spacers.

3. Fabricate six spacers 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 12	g01390293
This is a view of the spacer that is tack welded to the center body assembly.

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Illustration 13	g01387416
This is a view of the spacers that are tack welded along the right side of the center body assembly.

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Illustration 14	g01387424
This is a view of the spacers that are tack welded along the right side of the front wall.

4. Tack weld three spacers to the right side of the center body assembly. Repeat for the left side of the center body assembly. Refer to Illustration 12 through Illustration 14.

   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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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

5. Inspect the joints and the backing plates on the 154-4536 Center Body Assembly (1), the 154-4537 Left Body Assembly (2), and the 154-4538 Right Body Assembly (3).

6. Grind a bevel on the rib backing plates. This will ease assembly.

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Illustration 15	g00656907
This is a view of the 154-4538 Right Body Assembly (3).

7. Weld a lifting eye to the center of the 154-4538 Right Body Assembly (3). Attach lifting cables to the 154-4538 Right Body Assembly (3) .

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Illustration 16	g00656929
This is a view of the 154-4538 Right Body Assembly (3) that is aligned with the 154-4536 Center Body Assembly (1) .

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Illustration 17	g00656947
This is a view of the alignment plates that are used to align the body assemblies. (1) 154-4536 Center Body Assembly (3) 154-4538 Right Body Assembly

8. Position the 154-4538 Right Body Assembly (3) against the 154-4536 Center Body Assembly (1) .

   Note: The alignment plate eases the alignment of the 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

   Note: A lever puller can be used to align 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

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Illustration 18	g00656959
This is a view of the 2B-7218 Bolt (11) and of the 2J-3507 Nut (12) that is installed.

9. Install eight 2B-7218 Bolts (11) and eight 2J-3507 Nuts (12). Do not tighten the bolts and nuts.

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Illustration 19	g00657130
This is a view of the jack stands that are placed under the 154-4538 Right Body Assembly (3) .

10. Place the jack stands under the 154-4538 Right Body Assembly (3).

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Illustration 20	g00657132
This is a view of the 2B-7218 Bolts (11) and 2J-3507 Nuts (12) that are used.

11. Tighten the eight 2B-7218 Bolts (11) and the eight 2J-3507 Nuts (12). This helps to align the 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (2) .

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Illustration 21	g00657136

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Illustration 22	g00657135
This is a view of the angles and wedges that are used for alignment of the body assemblies. (1) 154-4536 Center Body Assembly (3) 154-4538 Right Body Assembly

12. Use angles and wedges to help align the 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

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Illustration 23	g00657138
This is a view of the air/hydraulic jack that is used for alignment. (1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly

13. An air/hydraulic jack helps to vertically align the 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

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Illustration 24	g01405254
This is a view of the gap that separates the rib joints. (A) 7 ± 1 mm (0.28 ± 0.04 inch) (B) 6 ± 1 mm (0.24 ± 0.04 inch)

14. There is a 7 ± 1 mm (0.28 ± 0.04 inch) gap (A) that separates the rib seams. There is a 6 ± 1 mm (0.24 ± 0.04 inch) gap (B) that separates the floor seams. The gap separates the 154-4538 Right Body Assembly (3) and the 154-4536 Center Body Assembly (1) .

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

15. The 154-4538 Right Body Assembly (3) should be level with the 154-4536 Center Body Assembly (1) .

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Illustration 25	g00657273
(1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly (3) 154-4538 Right Body Assembly

16. Repeat Step 2 through Step 14 for the 154-4537 Left Body Assembly (2) .

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

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

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Illustration 26	g00657334
This is a view of the 154-4538 Right Body Assembly (3) that is tack welded in place.

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Illustration 27	g00657236
This is a view of the areas that are tack welded. (1) 154-4536 Center Body Assembly (3) 154-4538 Right Body Assembly

19. Tack weld the 154-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

    Note: Tack weld each rib together.

20. Repeat Step 2 through Step 19 for the 154-4537 Left Body Assembly (2) .

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Illustration 28	g00657280
This is a view of the alignment plates that are removed.

21. Remove the alignment plates.

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Illustration 29	g00657300
This is a view of the support bar that is removed. (1) 154-4536 Center Body Assembly (3) 154-4538 Right Body Assembly

22. Remove the support bars from the 154-4536 Center Body Assembly (1) .

23. Preheat the welding areas to the proper temperature. Refer to ""Welding Instructions" ".

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

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Illustration 30	g00657368
This is an illustration of the bottom of the body assembly.

25. Clean the surfaces that are welded.
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    Table 12

    Welding Dimensions for Illustration 30
    Item	Dimension
    A	7 ± 1 mm (0.28 ± 0.04 inch)
    B	1256.5 ± 3 mm (49.47 ± 0.12 inch)
    C	1256.5 ± 3 mm (49.47 ± 0.12 inch)
    D	6 ± 1 mm (0.24 ± 0.04 inch)
    E	170 ± 6 mm (6.70 ± 0.24 inch)
    F	7 ± 1 mm (0.28 ± 0.04 inch)

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    Table 13

    Welding Tolerances for Illustration 30
    Weld	Description
    W1	20 mm (0.78 inch) bevel flush weld (3 Sides, 2 Places)
    W2	12 mm (0.47 inch) fillet weld with a 1.5 mm (0.06 inch) penetration
    W3	20 mm (0.79 inch) bevel flush weld (2 Places)
    W4	12 mm (0.48 inch) bevel groove weld (3 Sides, 18 Places)

26. Weld the bottom of the floor first. Refer to Illustration 30, Table 12, and Table 13.

    Note: Refer to Illustration 58, Table 22, Table 23, Illustration 59, Table 24, and Table 25 for the 793 Off Highway Truck.

    Note: Refer to Illustration 63, Table 32, Table 33, Illustration 64, Table 34, and Table 35 for the 785 Off Highway Truck.

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Illustration 31	g00657370
This is an illustration of the front wall of the body assembly.

27. Weld the top of the floor and both sides of the front wall. Refer to Illustration 31, Table 14, and Table 15.

    Note: Refer to Illustration 59, Table 24, and Table 25 for the 793 Off Highway Truck.

    Note: Refer to Illustration 64, Table 34, and Table 35 for the 785 Off Highway Truck.

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    Table 14

    Welding Dimensions for Illustration 31
    Item	Dimension
    G	6 mm (0.24 inch) minimum
    H	50 ± 6 mm (1.97 ± 0.24 inch)
    I	6 ± 2 mm (0.24 ± 0.08 inch) (4 Places, Trim to provide gap shown.)
    J	76 ± 6 mm (3 ± 0.24 inch)
    K	7974 mm (314 inch)
    L	7112 mm (280 inch)

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    Table 15

    Welding Tolerances for Illustration 31
    Weld	Description
    W5	16 mm (0.63 inch) square groove weld (2 Places, Trim to provide gap shown.)
    W6	10 mm (0.34 inch) fillet weld with a 1.5 mm (0.06 inch) penetration (6 Places)
    W7	16 mm (0.40 inch) square groove weld (4 Places)
    W8	5 mm (0.20 inch) bevel groove weld followed by a 10 mm (0.40 inch) V-groove weld (2 Places)

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Illustration 32	g00657330
This is a view of the inside of the body assembly that is welded.

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Illustration 33	g00658736
This is a view of the front of the body assembly that is welded. (1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly

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Illustration 34	g00657335
This is a view of the rib joints that are welded.

28. Weld the 145-4537 Left Body Assembly (2) to the 154-4536 Center Body Assembly (1). Weld the 145-4538 Right Body Assembly (3) to the 154-4536 Center Body Assembly (1) .

Installation of the Canopy Assembly

1. There are two different options for the installation of the 154-4539 Canopy Assembly (4). Install the 154-4539 Canopy Assembly (4) with the body assembly in the upward position or install the 154-4539 Canopy Assembly (4) with the body assembly in the downward position.

   Note: The Canopy Assembly for the 793 Off Highway Truck is assembled with two pieces. Refer to Illustration 60, Table 26, and Table 27.

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NOTICE
The following procedure is performed with the body assembly right side up or in the upward position.

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Illustration 35	g00657390
(1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly (3) 154-4538 Right Body Assembly

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Illustration 36	g00658038
This is an illustration of the areas that are cleaned for the installation of the 154-4539 Canopy Assembly (4) .

2. Remove paint from the surfaces that will be welded on the front wall of the body assembly. Refer to Illustration 36.

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Illustration 37	g01405257
This is an illustration of the areas that are cleaned for the installation of the 154-4539 Canopy Assembly (4) .

3. Remove paint from the surfaces that will be welded on the 154-4539 Canopy Assembly (4). Refer to Illustration 37.

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Illustration 38	g00657463
This is a view of the paint that is removed for the 8X-3945 Guard Assemblies (5) .

4. Remove paint from the 154-4539 Canopy Assembly (4) for the installation of the 8X-3945 Guard Assemblies (5) .

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Illustration 39	g00657487
This is a view of the clips for the 8X-3945 Guard Assembly (5) .

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Illustration 40	g00657490
This is a view of the guard assembly that is installed. (4) 154-4539 Canopy Assembly (5) 8X-3945 Guard Assembly

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Illustration 41	g00657546
This is an illustration of the body assembly. (4) 154-4539 Canopy Assembly (5) 8X-3945 Guard Assembly

5. Attach two 8X-3945 Guard Assemblies (5) to the 154-4539 Canopy Assembly (4). Hang the 8X-3945 Guard Assemblies (5) with the attached clips. Refer to Illustration 41, Table 16, Illustration 50, and Table 19.

   Note: Refer to Illustration 61, Table 28, and Table 29 for the 793 Off Highway Truck.

   Note: Refer to Illustration 65, Table 36, and Table 37 for the 785 Off Highway Truck.

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   Table 16

   Welding Dimensions for Illustration 41
   Item	Dimension
   M	1220 mm (48 inch)

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   Table 17

   Welding Tolerances for 41
   Weld	Description
   W9	8 mm (0.32 inch) fillet weld with 1.5 mm (0.06 inch) penetration (2 Places, Both Sides)
   W10	6 mm (0.24 inch) fillet weld
   W11	10 mm (0.40 inch) fillet weld with 1.5 mm (0.06 inch) penetration

6. Attach an appropriate lifting device to the 154-4539 Canopy Assembly (4). Use three cables in the configuration.

   Note: The front of the 154-4539 Canopy Assembly (4) is higher than the back of the 154-4539 Canopy Assembly (4). Angle the 154-4539 Canopy Assembly (4) to the angle of the sidewalls.

7. Lift the 154-4539 Canopy Assembly (4) for installation.

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Illustration 42	g00657555
This is a view of the 154-4539 Canopy Assembly (4) that is installed.

8. Position the 154-4539 Canopy Assembly (4) horizontally. Center the 154-4539 Canopy Assembly (4) to the body assembly.

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Illustration 43	g00657577
This is a view of the lever puller that is used to align the canopy assembly. (3) 154-4538 Right Body Assembly (4) 154-4539 Canopy Assembly

9. Attach lifting eyes to the 154-4539 Canopy Assembly (4). Attach a lever puller and chain to the lifting eye. Use the lever puller to align the 154-4539 Canopy Assembly (4).

   Note: Angles and wedges may be used to place the 154-4539 Canopy Assembly (4) .

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Illustration 44	g00663167
This is a view of the 154-4539 Canopy Assembly (4) that is trimmed.

10. Trim the 154-4539 Canopy Assembly (4) for a tight fit.

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Illustration 45	g00657585
This is a view of the 154-4539 Canopy Assembly (4) that is tack welded. (3) 154-4538 Right Body Assembly (4) 154-4539 Canopy Assembly

11. Tack weld the 154-4539 Canopy Assembly (4) in place.

    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 46	g01405269
This is an illustration of the areas under the 154-4539 Canopy Assembly (4) that are welded.

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Illustration 47	g00657659
This is a view of the outside of the canopy assembly that is welded. (3) 154-4538 Right Body Assembly (4) 154-4539 Canopy Assembly

12. Weld the 154-4539 Canopy Assembly (4) to the front wall assembly and sidewall assemblies. Refer to Illustration 41 and Table 17.

    Note: Refer to Illustration 62 and Table 30 for the 793 Off Highway Truck.

    Note: Refer to Illustration 65, Table 36, and Table 37 for the 785 Off Highway Truck.

13. After the 154-4539 Canopy Assembly (4) is secured, detach the lifting cables.

Installation of the Front Wall to Canopy Tie-In Plates

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Illustration 48	g01405272
This is an illustration of the 154-4548 Plates (8) that are installed.

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Illustration 49	g00659261
This is an illustration of the 154-4548 Plate (8) .

1. Clean the surfaces that are welded. Weld a temporary lifting eye to the 154-4548 Plate (8). Place the two 154-4548 Plates (8) in place.

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Illustration 50	g00657603
This is an illustration of the front of the body assembly. (5) 8X-3945 Guard Assembly (8) 154-4548 Plate (10) 8X-6394 Body Down Indicator

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Illustration 51	g01401621

2. Weld the 154-4548 Plates (8) in place. Refer to Illustration 50, Table 18, and Table 19.

   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: Refer to Illustration 62 for the 793 Off Highway Truck.

   Note: Refer to Illustration 66 and Table 38 for the 785 Off Highway Truck.

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   Table 18

   Welding Dimensions for Illustration 50
   Item	Dimension
   N	1250 ± 3 mm (49 ± 0.12 inch)

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   Table 19

   Welding Tolerances for Illustration 50
   Weld	Description
   W12	10 mm (0.40 inch) fillet weld with a 1.5 mm (0.06 inch) penetration (2 Plates)
   W13	10 mm (0.40 inch) fillet weld with a 1.5 mm (0.06 inch) penetration (2 Plates)
   W14	3 mm (0.12 inch) fillet weld (A to B)
   W15	4 mm (0.16 inch) bevel groove weld
   W16	4 mm (0.16 inch) fillet skip weld (25 mm - 75 mm places)
   W17	4 mm (0.16 inch) fillet weld (25 mm - 75 mm places)
   W18	4 mm (0.16 inch) bevel groove weld

3. Remove the temporary lifting eyes from the 154-4548 Plates (8) .

4. Install the 8X-6394 Body Down Indicator (10) to the 154-4539 Canopy Assembly (4). Refer to Illustration 50, Table 18, and Table 19.

   Note: Refer to Illustration 61, Table 28, and Table 29 for the 793 Off Highway Truck.

   Note: Refer to Illustration 64, Table 36, and Table 37 for the 785 Off Highway Truck.

Installation of the Transition Plates

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Illustration 52	g00657683
(1) 154-4536 Center Body Assembly (2) 154-4537 Left Body Assembly (3) 154-4538 Right Body Assembly

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Illustration 53	g00657702
This is a view of the areas that are cleaned.

1. Remove paint from the surfaces that will be welded.

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Illustration 54	g00657712
This is a view of the 154-3432 Bar (7) that is installed.

2. Install a 154-3432 Bar (7) on the 154-4537 Left Body Assembly (2). Repeat on the 154-4538 Right Body Assembly (3) .

   Note: Grind the 154-3432 Bar (7) for a proper fit.

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Illustration 55	g00657717
This is an illustration of the 154-3432 Bars (7) that are placed.

3. Weld the 154-3432 Bar (7) to the floor assembly and to the front wall assembly.

   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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   Table 20

   Welding Tolerances for Illustration 55
   Weld	Description
   W19	8 mm (0.32 inch) fillet skip weld (25 mm - 100 mm, 2 Plates, Both Sides)

4. Attach a lifting device to the 154-3429 Transition Plate (6). Place the 154-3429 Transition Plate (6) in the front of the body assembly.

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Illustration 56	g00657789
This is a view of the 154-3429 Transition Plate (6) that is placed.

5. Use angles and wedges to help place the 154-3429 Transition Plates (6) .

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Illustration 57	g00657756
This is a view of the welded 154-3429 Transition Plates (6) .

6. Weld the 154-3429 Transition Plates (6) to the floor assembly, the front wall assembly, and the sidewall assembly. Refer to Illustration 55 and Table 20.

   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: Refer to Illustration 61, Table 28, and Table 29 for the 793 Off Highway Truck flat floor body.

   Note: Refer to Illustration 66 and Table 38 for the 785 Off Highway Truck flat floor body.

793 Off Highway Truck Flat Floor Truck Body Weld Illustrations

The following illustrations are for the 793 Off Highway Truck. Use these illustrations in place of the illustrations that are used in the manual.

Table 21

Attachments for the 261-0086 Flat Floor Truck Body
Item	Qty	Part Number	Description
1	1	154-3417	Flat Floor Body
2	1	168-6280	Body
3	1	261-0087	Body
4	1	154-3420	Canopy As
5	1	154-3419	Canopy As
6	2	8X-3945	Guard As
7	2	5T-9614	Shield As
8	2	154-3429	Plates
9	4	154-3432	Bars
10	3	169-5859	Plates
11	2	154-3427	Bracket As
12	1	154-3434	Plate
13	3	169-7344	Strips
14	18	8T-0674	Bolts
15	18	7X-0851	Nuts

Illustration 58	g00659378
This is an illustration of the bottom of the 793 Off Highway Truck body assembly. (7) 5T-9614 Shield Assembly (9) 154-3432 Bar (11) 154-3427 Rock Ejector Assembly (14) 8T-0674 Bolt (15) 7X-0851 Nut

Table 22

Welding Dimensions for Illustration 58
Item	Distance
A	1310.50 ± 3 mm (51.60 ± 0.12 inch)
B	2059 ± 2 mm (81.06 ± 0.08 inch)

Table 23

Welding Tolerances for Illustration 58
Weld	Description
W1	20 mm (0.80 inch) bevel groove weld (3 Places)

Illustration 59	g00659932
This is an illustration of the welded front wall and floor. (1) 154-3417 Center Body Assembly (2) 168-6280 Left Body Assembly (3) 261-0087 Right Body Assembly

Table 24

Welding Dimensions for Illustration 59
Item	Dimension
C	7110 mm (279.92 inch)
D	7569 mm (298 inch)
E	6 ± 1 mm (0.24 ± 0.04 inch)
F	12 ± 1 mm (0.47 ± 0.04 inch)
G	13 mm (0.51 inch) ( 11 mm (0.43 inch) minimum)

Table 25

Welding Tolerances for Illustration 59
Weld	Description
W2	13 mm (0.51 inch) bevel groove weld (2 Places, Trim to provide gap shown.)

Illustration 60	g00659973
This is an illustration of the two-piece canopy assembly that is welded. (4) 154-3420 Canopy Assembly (5) 154-3419 RH Canopy Assembly (14) 8T-0674 Bolt (15) 7X-0851 Nut

Table 26

Welding Dimensions for Illustration 60
Item	Dimension
H	6 mm (0.24 inch)
I	6 mm (0.24 inch)
J	12 ± 3 mm (0.47 ± 0.12 inch)
K	13 ± 3 mm (0.51 ± 0.12 inch)

Table 27

Welding Tolerances for Illustration 60
Weld	Description
W3	6 mm (0.24 inch) square groove weld
W4	6 mm (0.24 inch) fillet skip weld with a 1.50 mm (0.06 inch) penetration (30 mm - 100 mm)
W5	5 mm (0.20 inch) fillet weld
W6	6 mm (0.24 inch) square groove weld
W7	6 mm (0.24 inch) fillet skip weld with a 1.50 mm (0.06 inch) penetration (30 mm - 100 mm)

Illustration 61	g00659978
This is a view of the front of the body assembly. (1) 154-3417 Center Body Assembly (2) 168-6280 Left Body Assembly (3) 261-0087 Right Body Assembly (4) 154-3420 Canopy Assembly (5) 154-3419 RH Canopy Assembly (6) 8X-3945 Guard Assembly (8) 154-3429 Transition Plate (9) 154-3432 Bar (12) 154-3434 Body Down Indicator

Table 28

Welding Dimensions for Illustration 61
Item	Dimension
L	910 ± 3 mm (35.83 ± 0.12 inch)
M	33 ± 1 mm (1.30 ± 0.04 inch)

Table 29

Welding Tolerances for Illustration 61
Weld	Description
W8	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W9	5 mm (0.20 inch) bevel groove weld (2 Places)
W10	5 mm (0.20 inch) fillet skip weld (2 Places, 25 mm - 75 mm)
W11	8 mm (0.32 inch) fillet skip weld with a 1.50 mm (0.06 inch) penetration (2 Plates, 25 mm - 100 mm)
W12	8 mm (0.32 inch) fillet skip weld with a 1.50 mm (0.06 inch) penetration (25 mm - 100 mm)

Illustration 62	g01407368
This is an illustration of the tie-in plates that are installed. (10) 169-5859 Plate (13) 169-7344 Strip

Table 30

Welding Tolerances for Illustration 62
Weld	Description
W13	6 mm (0.24 inch) bevel groove weld (8 places)

785 Off Highway Truck Flat Floor Truck Body Weld Illustrations

The following illustrations are for the 785 Off Highway Truck. Use these illustrations in place of the illustrations that are used in the manual.

Table 31

Attachments for the 156-5499 Flat Floor Truck Body
Item	Qty	Part Number	Description
1	1	136-8200	Center Body Assembly
2	1	136-8220	Left Body Assembly
3	1	136-8210	Right Body Assembly
4	1	136-8230	Canopy As
5	2	8W-3666	Guard As
6	2	163-8483	Transition Plates
7	2	163-8480	Plates
8	2	163-8484	Plates
9	2	163-8485	Plate As
10	1	163-8477	Plate
12	16	2B-7218	Bolts
13	16	2J-3507	Full Nuts
14	1	255-3312	Plate As

Illustration 63	g00665177
This is an illustration of the floor assembly. (1) 136-8200 Center Body Assembly (2) 136-8220 Left Body Assembly (3) 136-8210 Right Body Assembly (9) 163-8485 Rock Ejector Assembly (12) 2B-7218 Bolt (13) 2J-3507 Nut

Table 32

Welding Dimensions for Illustration 63
Item	Dimension
A	10 ± 1 mm (0.40 ± 0.04 inch)
B	10 ± 1 mm (0.40 ± 0.04 inch)
C	10 ± 1 mm (0.40 ± 0.04 inch)
D	1125 ± 3 mm (44.30 ± 0.12 inch)
E	1125 ± 3 mm (44.30 ± 0.12 inch)

Table 33

Welding Tolerances for Illustration 63
Weld	Description
W1	1.50 mm (0.06 inch) bevel flush weld (2 Places)
W2	20 mm (0.80 inch) bevel flush weld (2 Places)
W3	12 mm (0.47 inch) fillet weld with 1.50 mm (0.06 inch) penetration to the length shown (Both Sides, 20 Ribs)
W4	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (20 Places)
W5	12 mm (0.47 inch) bevel groove weld (3 Sides, 2 Places)
W6	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W7	12 mm (0.47 inch) bevel flush weld
W8	20 mm (0.08 inch) bevel flush weld (3 Sides, 2 Places)
W9	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (4 Places)

Illustration 64	g01402808
This is an illustration of the welds for the front wall. (1) 136-8200 Center Body Assembly (2) 136-8220 Left Body Assembly (3) 136-8210 Right Body Assembly (14) 255-3312 Plate As

Table 34

Welding Dimensions for Illustration 64
Item	Dimension
F	10 mm (0.40 inch) (4 Places, Trim to provide gap shown.)
G	6120 mm (241 inch)
H	99 ± 5 mm (4.0 ± 0.2 inch)
J	9.6 mm (0.40 inch)
K	6 mm (0.24 inch)
L	10 ± 1 mm (0.40 ± 0.04 inch)

Table 35

Welding Tolerances for Illustration 64
Weld	Description
W10	3 mm (0.12 inch) double side bevel weld
W11	10 mm (0.40 inch) square groove weld (4 Places)
W12	16 mm (0.63 inch) square groove weld (2 Places)
W13	16 mm (0.63 inch) square groove weld (2 Places)
W14	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W15	12 mm (0.47 inch) bevel flush weld (2 Places)

Illustration 65	g01402953
This is an illustration of the canopy assembly. (4) 136-8230 Canopy Assembly (5) 8W-3666 Guard Assembly (9) 163-8485 Rock Ejector Assembly (14) 255-3312 Plate As

Table 36

Welding Dimensions for Illustration 65
Item	Dimension
M	674 mm (26.54 inch)
N	430 ± 5 mm (17 ± 0.2 inch)
P	53 ± 3 mm (2 mm ± 0.12 inch)

Table 37

Welding Tolerances for Illustration 65
Weld	Description
W16	6 mm (0.24 inch) fillet weld
W17	4 mm (0.1575 inch) bevel groove weld (2 Places)
W18	6 mm (0.24 inch) fillet skip weld (2 Places, 25 mm - 75 mm)
W19	8 mm (0.32 inch) bevel groove weld (2 Places)
W20	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W21	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)

Illustration 66	g01402972
This is an illustration of the front of the body assembly. (6) 163-8483 Transition Plate (7) 163-8480 Bar (8) 163-8484 Plate

Table 38

Welding Tolerances for Illustration 66
Weld	Description
W22	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Plates)
W23	10 mm (.040 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Plates)
W24	8 mm (0.32 inch) fillet skip weld (2 Places, 25 mm - 100 mm)

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: Weld around the entire perimeter of the liner plates. A minimum of three weld passes is necessary in the plug holes or slots.

Installation of the Rock Ejector Brackets

Illustration 67	g01389955

Note: The rock ejector brackets are 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 rock ejector brackets.

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.