- Off-Highway Truck/Tractor:
- 793 (S/N: 3SJ1-UP)
- 793B (S/N: 1HL1-UP)
- 793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
- 793B (S/N: 1HL1-UP)
Introduction
This Special Instruction contains the necessary procedures and information for assembling and welding a Mine Specific Design truck body.
The Mine Specific Design truck body is also referred to as the MSD II truck body.
The shipping configuration of the MSD II truck body depends on the destination and the type of transportation that is available. In some cases, the MSD II truck body may be assembled differently from the factory. The following special instruction covers assembling the MSD II 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 MSD II 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. |
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The assembly begins with the Center Body Assembly that is turned over. The Left Body Assembly and the Right Body Assembly are welded to the Center Body Assembly. The body assembly is turned over. The Canopy Assembly is installed.
Note: The serial number of the truck body is stamped on the edge of each section.
Parts List
| Attachments for the 253-1455 Body and Canopy As MSD II Truck Body | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 232-1756 | Center Body Assembly |
| 2 | 1 | 232-1757 | Body (LH) |
| 3 | 1 | 232-1758 | Body (RH) |
| 4 | 2 | 191-2196 | Guard As |
| 5 | 2 | 233-1880 | Bracket As |
| 6 | 6 | - | Spacers |
| 7 | 14 | 7X-0851 | Nuts |
| 8 | 14 | 8T-0674 | Bolts |
| 9 | 1 | 251-7540 | Canopy As |
| 10 | 2 | 230-0089 | Plate |
| 11 | 1 | 230-9015 | Plate |
| 12 | 1 | 230-9016 | Plate |
| 13 | 2 | 209-4420 | Plate |
| 14 | 1 | 196-6009 | Plate |
| 15 | 2 | 8X-2940 | Cover |
| 16 | 8 | 8T-4190 | Bolt |
| 17 | 8 | 8T-4122 | Hard Washer |
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.
Below are examples of the approximate weights of the truck body.
| Approximate Shipping Weights | |
|---|---|
| Description | Weight |
| Center Body Assembly | 10886 kg (24000 lb) |
| Left Body Assembly | 5443 kg (12000 lb) |
| Right Body Assembly | 5443 kg (12000 lb) |
| Canopy Assembly | 2858 kg (6300 lb) |
Note: The weights that are listed in this document are only approximate weights. The weights represent only one size of MSD II truck body. MSD II 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.
| Required Tools | ||
|---|---|---|
| Qty | Tool Number | Description |
| 1 | 3S-6224 | Electric Hydraulic Pump Gp |
| 1 | 1U-9367 | Automatic Tape Measure |
| 1 | 164-3310 | Infrared Thermometer |
| 1 | 1U-9204 | Lever Puller Hoist |
| As Required | 4C-3761 | C-Clamp |
| As Required | 4C-5647 | Pry Bar |
| As Required | - | Attachments for Electric Hydraulic Pump |
| As Required | - | Wedges |
| As Required | - | Sledge Hammer |
| 2 | - | Preheating Equipment |
| 4 | - | 400 Amp Welder |
| 1 | - | Hand Grinder |
| 4 | - | Clevis 38 mm (1.5 inch) |
| Numerous | - | Cables Chains Hooks Shackles |
| 1 | - | 1.83 m (6 ft) Ladder |
| 1 | - | 3.66 m (12 ft) Ladder |
| 1 | - | 1.83 m (6 ft) Level |
| 1 | - | Plumb Bob |
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 6 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 manufacturers specifications. The following table is the electrodes current settings in relation to the electrodes diameters:
| 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 manufacturers 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:
| 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 manufacturers 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 Materials" " for more welding guidelines.
Welding Materials
The following materials are used in order to fabricate the MSD II Truck Body:
- 400 Brinell hardness number
- 450 Brinell hardness number
Before welding on the MSD II truck body, verify the materials that are used in order to fabricate your particular MSD II truck body. There are specific welding procedures for each material. Refer to the following procedures in order to weld the materials successfully 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 MSD II truck bodies that are fabricated with 400 Brinell hardness number material or 450 Brinell hardness number material. Refer to ""Weld 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. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
| 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 the utmost importance. |
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).
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| Illustration 1 | g01286162 |
View of a TigerTorch | |
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.
| 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 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) inches in each direction from the weld joint. This heating will help avoid possible heat sink of the floor plates.
All welded areas must 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 manufacturers weight's in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
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| 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. | |
The Site for Assembly
The following photographs are of the shipping configuration.
The MSD II truck body will be delivered in four assemblies.
- Center body assembly
- Left body assembly
- Right body assembly
- Canopy assembly
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| Illustration 3 | g00822849 |
View of the center body assembly that is unloaded. (1) Center body assembly | |
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| Illustration 4 | g01403936 |
View of the body assemblies that are unloaded. (2) Left body assembly (3) Right body assembly | |
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| Illustration 5 | g00822852 |
View of the miscellaneous attachments that are tack welded to center body assembly (1) . (1) Center body assembly (4) Canopy rock guard (5) Rock ejector brackets | |
Assembly Procedure
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| Illustration 6 | g00822853 |
- Position center body assembly (1) inside the work area.
- Use a grinder in order to clean the welding areas of center body assembly (1). Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. Refer to Illustration 7 through Illustration 10.
Note: All of the welding areas on center body assembly (1) should now be cleaned.
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| Illustration 7 | g00822854 |
View of center body assembly (1) that is cleaned. | |
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| Illustration 8 | g00822855 |
View of the edges that are cleaned. | |
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| Illustration 9 | g00822856 |
View of the rib joints that are cleaned. | |
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| Illustration 10 | g00822857 |
View of the front transition plate and the front wall that is cleaned. | |
- Fabricate six spacers (6) with the following dimensions:
- 6.0 mm (0.24 inch) thick
- 50.8 mm (2 inch) long
- 25.4 mm (1 inch) wide
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.
- 6.0 mm (0.24 inch) thick
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| Illustration 11 | g00822859 |
Top view of spacer (6) . | |
- Tack weld 3 spacers (6) to the right side of center body assembly (1). Repeat for the left side of center body assembly (1). Refer to Illustration 12 through Illustration 14.
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
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| Illustration 12 | g00822861 |
View of spacer (6) that is tack welded to center body assembly (1) . | |
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| Illustration 13 | g01388430 |
View of the spacers that are tack welded along the right side of the center body assembly. | |
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| Illustration 14 | g01388431 |
View of the spacers that are tack welded along the right side of the front wall. | |
- Use a grinder in order to remove the tack welds that secure rock ejector brackets (5) and canopy rock guards (4) to the center body assembly. Refer to Illustration 15 through Illustration 17.
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| Illustration 15 | g00822864 |
View of the miscellaneous attachments that are tack welded to the center body assembly. (4) Canopy rock guard (5) Rock ejector brackets | |
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| Illustration 16 | g00822865 |
View of removing tack welds from rock ejector brackets (5) . | |
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| Illustration 17 | g00822866 |
View of removing the tack welds from canopy rock guard (4) . | |
- Remove the 14 bolts and nuts that are located inside canopy rock guard (4) .
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| Illustration 18 | g00822867 |
View of the hardware that is located inside canopy rock guard (4) . | |
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| Illustration 19 | g00822868 |
View of the hardware that is removed from inside canopy rock guard (4) . | |
- 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.
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| Illustration 20 | g00822869 |
View of preparing to turn over the center body assembly. | |
- Use the two hoists in order to turn over center body assembly (1) .
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| Illustration 21 | g01123368 |
- 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 22 | g00822871 |
- Attach two lifting devices to the two lifting eyes that are located on the bottom side of the center body assembly. Secure the lifting devices to a suitable hoist. Refer to Illustration 23 through Illustration 25.
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| Illustration 23 | g01123391 |
View of the two lifting devices that are attached to the bottom side of the center body assembly. | |
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| Illustration 24 | g00822872 |
View of one lifting device that is attached to the lifting eye toward the front of the center body assembly. | |
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| Illustration 25 | g00822873 |
View of one lifting device that is attached to the lifting eye toward the rear of the center body assembly. | |
- Use the two hoists in order to finish turning over center body assembly (1) .
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| Illustration 26 | g01123411 |
View of center body assembly (1) that is being turned over. | |
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| Illustration 27 | g01123571 |
View of center body assembly (1) that is turned over. | |
- Remove the two lifting devices that are attached to the floor and to the front wall.
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| Illustration 28 | g01123583 |
- Attach two lifting devices to the two other lifting eyes that are located on the bottom side of the center body assembly. Secure the lifting devices to a suitable hoist.
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| Illustration 29 | g01123608 |
- Use the two hoists in order to raise center body assembly (1) level.
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| Illustration 30 | g01124158 |
- Locate the center body assembly in the center of the work area.
- Position two 203 mm (8.0 inch) wood blocks underneath the front wall. Position a suitable 2.74 m (9.0 ft) metal stand at the rear of the body assembly.
Note: Ensure that the center body assembly is level once located on the wood blocks and on the metal stand.
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| Illustration 31 | g01123641 |
- Remove the lifting devices from center body assembly (1) .
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| Illustration 32 | g01123673 |
- Locate left body assembly (2) and right body assembly (3) in the work area.
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| Illustration 33 | g01403939 |
- Attach two suitable lifting devices to the lifting holes that are located in the left body assembly. Secure the lifting devices to a suitable hoist.
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| Illustration 34 | g00822885 |
View of attaching two lifting devices to the left body assembly. | |
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| Illustration 35 | g01124184 |
View of moving left body assembly (2) away from right body assembly (3) . | |
- Move left body assembly (2) away from right body assembly (3) .
- Position the left body assembly onto the ground.
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| Illustration 36 | g00822887 |
- Use a grinder in order to clean the welding areas of the left body assembly. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
- Raise left body assembly (2) .
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| Illustration 37 | g01124237 |
- Attach two lifting devices to the two lifting eyes that are located on the bottom side of the left body assembly. Secure the lifting devices to a suitable hoist.
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| Illustration 38 | g01403957 |
View of one lifting device that is attached to the lifting eye that is located toward the front of the left body assembly. | |
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| Illustration 39 | g01403970 |
View of one lifting device that is attached to the lifting eye that is located toward the rear of the left body assembly. | |
- Use both hoists in order to turn over left body assembly (2).
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| Illustration 40 | g01404006 |
View of left body assembly (2) that is being turned over. | |
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| Illustration 41 | g01404007 |
View of turning over left body assembly (2) . | |
- Remove the two lifting devices that are attached to the lifting holes in the left body assembly.
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| Illustration 42 | g01404010 |
- Lower left body assembly (2) to the ground. Position the rear corner of left body assembly (2) onto a suitable metal stand.
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| Illustration 43 | g00822894 |
View of lowering left body assembly (2) . | |
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| Illustration 44 | g00822895 |
View of positioning a metal stand underneath the rear corner of the left body assembly. | |
- Use a grinder in order to clean the welding areas of the left body assembly. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. Refer to Illustration 45 through Illustration 47.
Note: All of the welding areas on the left body assembly should now be cleaned.
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| Illustration 45 | g00822896 |
View of the edge that is along the inside of the front wall that is cleaned. | |
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| Illustration 46 | g01404042 |
View of the edge that is along the outside of the front wall that is cleaned. | |
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| Illustration 47 | g00822898 |
View of the rib joints that are cleaned and the edges that are cleaned. | |
- Use a suitable hoist to raise left body assembly (2) .
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| Illustration 48 | g00822894 |
- Position the left body assembly (2) against center body assembly (1). Refer to Illustration 47 through Illustration 51.
Note: The alignment plates ease the alignment of left body assembly (2) to center body assembly (1) .
Note: 1U-9204 Lever Puller Hoist can be used to align left body assembly (2) against center body assembly (1) .
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| Illustration 49 | g01404043 |
View of left body assembly (2) that is aligned with center body assembly (1) . | |
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| Illustration 50 | g00823484 |
View of the alignment plates that are used to align the body assemblies. The alignment plates are located on the front wall of the left body assembly. | |
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| Illustration 51 | g00823485 |
View of the alignment plates that are located along the floor seam of the left body assembly. | |
- Install seven 8X-0674 Bolts (8) and seven 7X-0851 Nuts (7). Do not tighten the bolts and nuts.
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| Illustration 52 | g01407558 |
View of five 8X-0674 Bolts (8) and of five 7X-0851 Nuts that are located on the bottom of center body assembly (1) and left body assembly (2) . | |
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| Illustration 53 | g01407587 |
View of two 8X-0674 Bolts (8) and of two 7X-0851 Nuts that are located on the inside of the front wall. | |
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| Illustration 54 | g00823486 |
View of 8X-0674 Bolt (8) and of 7X-0851 Nut (7) that are installed. | |
- Place a 203 mm (8.0 inch) wood block underneath the front wall of the left body assembly.
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| Illustration 55 | g00822900 |
- Place a suitable metal stand and wood blocks underneath the side wall of the left body assembly.
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| Illustration 56 | g00823483 |
View of the metal stand and the wood blocks that are positioned underneath the side wall of the left body assembly. | |
- Tighten seven 8X-0674 Bolts (8) and 7X-0851 Nuts (7) until center body assembly (1) and left body assembly (2) are tight against three spacers (6) .
Note: Spacers (6) are used to obtain the correct root opening of 6.0 mm (0.24 inch) between center body assembly (1) and left body assembly (2) .
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| Illustration 57 | g00823488 |
View of 8X-0674 Bolt (8) and of 7X-0851 Nut (7) that are tightened. | |
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| Illustration 58 | g00823487 |
View of center body assembly (1), left body assembly (2), and spacer (6) . | |
- Remove the lifting devices from left body assembly (2) .
- Use angles and wedges to help align the left body assembly (2) to the center body assembly (1). Refer to Illustration 59 through Illustration 62.
Note: Before tack welding any angles to the body assembly, use a grinder in order to clean the welding areas. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
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| Illustration 59 | g01123740 |
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 60 | g00823490 |
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 61 | g00823491 |
View of the angles and of the wedges that can be used along the floor seam for alignment of the body assemblies. | |
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| Illustration 62 | g00823492 |
View of the angles and of the wedges that can be used along the ribs of the floor for alignment of the body assemblies. | |
- Also, the body assemblies can be aligned by the use of bolts, nuts, and lugs.
Note: Before tack welding any lugs or bolts to the body assembly, use a grinder in order to clean the welding areas. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
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| Illustration 63 | g00823494 |
View of a bolt, a nut, and a lug that is used in order to align the rib joints of the body assemblies. | |
- Ensure that there is a 6.0 mm (0.24 inch) gap spacing (A) that separates the center body assembly from the left body assembly.
Note: If necessary, use an air arc in order to enlarge gap spacing (A) to 6.0 mm (0.24 inch). Use a grinder to clean the slag from gap (A) .
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| Illustration 64 | g00823495 |
View of gap spacing (A) that is necessary along the seam between the center body assembly and the left body assembly. (A) 6.0 mm (0.24 inch) | |
- Repeat Step 19 through Step 38 in order to position the right body assembly (3). The right body assembly weighs approximately 5443 kg (12000 lb).
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| Illustration 65 | g01123791 |
View of right body assembly (3) that is aligned with center body assembly (1) . | |
- Before tack welding left body assembly (2) and right body assembly (3) to center body assembly (1), ensure that the overall width of the front wall equals dimension (B). If necessary, maneuver right body assembly (3) until the overall width does equal dimension (B). Dimension (B) must be equal to dimension (F) in order for canopy assembly (9) to fit correctly with the assembled body.
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| Illustration 66 | g01407589 |
(B) 6946.0 mm (273.5 inch) | |
Note: Dimension (B) is measured at the highest point and the outermost point forward.
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| Illustration 67 | g01123800 |
View of the body upside-down shows measuring the front wall to obtain dimension (B) . | |
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| Illustration 68 | g01388435 |
- Before tack welding, preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper preheat temperature. Refer to ""Welding Materials" ".
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| Illustration 69 | g00823496 |
View of preheating center body assembly (1) and left body assembly (2) . | |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
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| Illustration 70 | g00823497 |
View of checking for the proper preheat temperature of the body assemblies. | |
- Tack weld the left body assembly to the center body assembly.
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| Illustration 71 | g00823498 |
View of the areas that are tack welded along the floor seam and the rib joints. | |
Note: As required, trim the ends of the ribs in order to achieve 100% penetration of the joint for the square groove weld.
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| Illustration 72 | g01123785 |
View of the areas that are tack welded along the outside of the front wall. | |
- Repeat Step 41 through Step 43 for the right body assembly (3) .
Note: The right body assembly weighs approximately 5443 kg (12000 lb).
- Remove all nuts, bolts, lugs, wedges, and angles. Grind the welds smooth.
- Remove three spacers (6) that are located between center body assembly (1) and left body assembly (2) .
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| Illustration 73 | g00823487 |
- Preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper temperature. Refer to ""Welding Materials" ".
| | |
| Illustration 74 | g00823496 |
View of preheating center body assembly (1) and left body assembly (2) . | |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
| | |
| Illustration 75 | g00823497 |
View of checking for the proper preheat temperature of the body assemblies. | |
- Weld the floor seam that connects left body assembly (2) and center body assembly (1) .
Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.
Note: Remove the slag after every weld pass.
 | |
| Illustration 76 | g00823830 |
- Repeat Step 46 through Step 49 for the right body assembly.
- Use a string or a straight edge in order to ensure that the side walls are correctly aligned and that the floor is flat.
 | |
| Illustration 77 | g01124083 |
- Weld temporary braces (C) in order to prevent the side wall and the floor from moving.
- Preheat the rib joints of center body assembly (1) and left body assembly (2) .
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ".
 | |
| Illustration 78 | g01123816 |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
- Weld the rib joints between the left body assembly and the center body assembly.
Note: 100% weld penetration is essential.
Note: Remove the slag after every weld pass.
 | |
| Illustration 79 | g00823832 |
- Repeat Step 53 through Step 55 for the right body assembly.
- Preheat the front wall.
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 80 | g01123844 |
- Weld the seam of the front wall between the left body assembly and center body assembly.
Note: Remove the slag after every weld pass.
- Repeat Step 57 and Step 58 for the right body assembly.
- Move the body from the building to the outside.
- Position two suitable cranes (A) and (B) 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.
 | |
| Illustration 81 | g00922517 |
- Attach three sets of suitable lifting devices to the body. Attach lifting device (D) to the lifting eyes on the bottom of the right body assembly. Attach lifting device (C) to the lifting eyes on the top of the left body assembly. Attach lifting device (E) to the lifting eyes on the top of the right body assembly. As shown in Illustration 83.
 | |
| Illustration 82 | g00922519 |
- Attach lifting device (C) to crane (A) and lifting device (D) to crane (B). Lifting device (E) is not used at this time.
 | |
| Illustration 83 | g00922518 |
- Only use one signalman for both of the cranes.
- Both cranes should lift the body to a suitable height. Slowly lower crane (B) and raise crane (A) until the body in vertical.
 | |
| Illustration 84 | g00922520 |
 | |
| Illustration 85 | g00922521 |
- Lifting device (E) should be moved in the direction of the arrow for future use.
- Lower crane (A) and position the body vertically on the ground. Keep lifting device (C) tight so that the body does not fall. Disconnect lifting device (D) from crane (B) and from the lifting eyes on the bottom of the body.
 | |
| Illustration 86 | g00922522 |
- Reposition crane (B) to the other side of the body and position the boom toward the body. Connect lifting device (E) to the crane and slowly raise the lifting device until the lifting device is tight.
 | |
| Illustration 87 | g00922523 |
- Slowly lift the body with crane (A) while rotating the boom of crane (A) away from the body, causing the body to tip.
 | |
| Illustration 88 | g00922554 |
- Once the body has started to tip, start to lower the lifting device on crane (A) and continue to rotate the boom away from the body.
Note: Do not allow the bottom of the body to move outward.
- When, the body starts to be dragged toward crane (A) slowly begin to raise crane (B). Raise crane (B) until the body is close to being level. Position wood blocks under the body.
 | |
| Illustration 89 | g00922555 |
 | |
| Illustration 90 | g00922556 |
- Slowly lower both cranes (A) and (B) and position the body onto the wood blocks.
 | |
| Illustration 91 | g00922557 |
- Before finish welding, reposition the body inside the building.
- Preheat the welding areas of center body assembly (1) and left body assembly (2) to the proper temperature. Refer to ""Welding Materials" ".
 | |
| Illustration 92 | g00823834 |
View of preheating center body assembly (1) and left body assembly (2) . | |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 93 | g00823836 |
View of checking for the proper preheat temperature of the body assemblies. | |
- Weld the floor seam that connects left body assembly (2) and center body assembly (1) .
Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.
Note: Remove the slag after every weld pass.
 | |
| Illustration 94 | g00823837 |
- Repeat Step 74 through Step 76 for the right body assembly.
- Preheat the welding areas of the front wall to the proper temperature. Refer to ""Welding Materials" ".
 | |
| Illustration 95 | g00823838 |
View of the weld seam that is located on the inside of the front wall between center body assembly (1) and left body assembly (2) . | |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 96 | g00823839 |
- Weld the seam of the front wall between left body assembly (2) and center body assembly (1) .
Note: Remove the slag after every weld pass.
 | |
| Illustration 97 | g00823840 |
- Repeat Step 78 through Step 80 for the right body assembly.
- Preheat the welding areas of the front transition plates to the proper temperature. Refer to ""Welding Materials" ".
 | |
| Illustration 98 | g00823841 |
View of preheating the front transition plates. | |
- Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 99 | g00823842 |
- Weld the front transition plates that connect left body assembly (2) and center body assembly (1) .
Note: Ensure that the maximum interpass temperature does not exceed 250 °C (480 °F). Use 164-3310 Infrared Thermometer in order to check for the proper interpass temperature.
Note: Remove the slag after every weld pass.
 | |
| Illustration 100 | g00823843 |
- Repeat Step 82 through Step 84 for the right body assembly.
- Remove all nuts, bolts, lugs, wedges, and angles. Grind the welds smooth.
- Remove all braces from the sidewall to the center section.
Installation of the Canopy Assembly and Guards
- Locate canopy assembly (9) .
 | |
| Illustration 101 | g01128837 |
View of the canopy from the back. | |
- Use a grinder in order to clean the weld areas of the canopy assembly. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 102 | g01130913 |
View of canopy assembly (9) that is cleaned. | |
 | |
| Illustration 103 | g01130948 |
View of the cleaned areas of the canopy in order to be welded. | |
- Use a grinder in order to clean the welding areas of the rock guards on both sides of the canopy assembly. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 104 | g01130917 |
- Use a grinder in order to clean the welding areas of the body assembly. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 105 | g01130978 |
- Attach a suitable lifting device to canopy assembly (9). Use three cables in the configuration.
 | |
| Illustration 106 | g01132498 |
- Raise canopy assembly (9) for installation.
 | |
| Illustration 107 | g01128872 |
- Position the canopy to the body.
 | |
| Illustration 108 | g01128970 |
Note: When, you position the canopy a guide line may be necessary.
 | |
| Illustration 109 | g01131109 |
View of positioning the canopy to the body. | |
- Align the lugs that are attached to the canopy assembly with the studs that are attached to the walls of the body. Use 7X-0851 Nuts (14) in order to secure the canopy assembly to the side walls.
 | |
| Illustration 110 | g01130750 |
View of the studs and the lugs that are used in order to align the canopy to the body for welding. | |
- Use angles and wedges to help align the canopy assembly to the front wall and to both side walls. Also, use bolts, lugs, and nuts to aid in the alignment procedure.
Note: Before tack welding any angles, bolts, or lugs to the body assembly, use a grinder in order to clean the welding areas. Remove all paint, rust, scale, slag, paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 111 | g01130688 |
View of an angle and wedge that can be used for alignment of the canopy to the body. | |
- 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.
 | |
| Illustration 112 | g00824509 |
- Once the canopy assembly is aligned, tack weld the canopy assembly to the front wall and to the side walls.
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 113 | g01130642 |
 | |
| Illustration 114 | g01130686 |
View of the right side of the canopy | |
- Preheat the bottom side of canopy assembly (9) and the front wall.
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 115 | g00824512 |
- Weld the bottom side of the canopy assembly to the front wall and to the side walls.
Note: Remove the slag after every weld pass.
 | |
| Illustration 116 | g01130999 |
- Use a grinder in order to clean the welding areas of rock guards (4). Remove all paint, rust, scale, slag, paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 117 | g01131041 |
- Use a grinder in order to clean the welding area (A) of the body. Remove all paint, rust, scale, slag, paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 118 | g01403893 |
View of rock guard (4) that is welded together before installing onto the body. | |
- Attach a suitable lifting device in order to position rock guards (4) .
- Hang the canopy rock guard with the attached clips.
- Weld rock guard (4) and rock guard (10) to canopy assembly (9) and the body.
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 119 | g01403890 |
View of the installed rock guards. | |
- Repeat Step 14 through 18 for the other side.
- Use a grinder in order to clean the welding area of wrapper plates (10). Remove all paint, rust, scale, slag, paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding. before welding.
 | |
| Illustration 120 | g01403898 |
- Preheat the canopy assembly (9) and wrapper plates (10) .
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 121 | g00824510 |
- Weld wrapper plates (10) to canopy assembly (9) .
Note: Remove the slag after every weld pass.
 | |
| Illustration 122 | g00824511 |
- Weld the bottom side of the canopy assembly to the front wall and to the side walls.
Note: Remove the slag after every weld pass.
- Use a grinder in order to clean the welding areas of the body and plate (11). Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 123 | g01403904 |
View of the left plate. | |
- Position plate (11) to the body and the wrapper plate.
Note: Before welding transition cap plates (11) and (12), verify that transition cap plates (11) and (12) are positioned on the correct side of the body.
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 124 | g01403907 |
View of plate (12) before welding. A lifting eye can be welded onto the plate in order to lift the plate into position. | |
- Weld plate (11) to the body and the wrapper plate.
- Repeat Step 24 through 26 for the other side.
- Use a grinder in order to clean the welding area of plate (13). Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 125 | g01403915 |
- Use a grinder in order to clean the welding area of the body and the canopy. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 126 | g01131371 |
- Weld plate (13) to the body and the canopy.
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 127 | g01131653 |
- Repeat Step 28 through 30 for the other side.
- Remove all nuts, bolts, lugs, wedges, and angles from the canopy assembly. Grind the welds smooth.
- Remove the lifting eyes from the body assembly. Remove the lifting eyes from the sidewalls and the floor plates.
Note: Some lugs may be needed in order to tie down the body during shipping to the mine site. Remove all lifting lugs prior to touch up painting and installation to the chassis.
- Paint welded metal or bare metal.
Note: Before painting, ensure that all welds have been inspected. Refer to ""Welding Materials" ".
Installation of Liner Group
Note: Many configurations of liners are available for the MSD II body. Below is a typical installation of a liner group on an MSD II body for a 793C.
| Parts that are required to install the MSD II liner group for the 793C body | ||
| Item | Qty | Description |
| 1 | 1 | Wear plate |
| 2 | 2 | Impact plate |
 | |
| Illustration 128 | g01126264 |
View of wear plate (1) and impact plates (2) that are installed. | |
Note: Body liner plates are installed after the body assembly is completed.
- Locate wear plate (1) .
 | |
| Illustration 129 | g01126725 |
- Prepare wear plate (1) for welding. Use a grinder in order to remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding around all outside edges (A) and inside all holes (B) .
 | |
| Illustration 130 | g01126765 |
- Locate two impact plates (2) .
 | |
| Illustration 131 | g01126728 |
View of the two impact plates (2) that are tack welded to the center section for shipping. | |
- Use a grinder in order to remove tack welds (C) from impact plates (2) .
 | |
| Illustration 132 | g01126834 |
- Prepare two impact plates (2) for welding. Use a grinder in order to remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding around all outside edges and inside all holes.
 | |
| Illustration 133 | g01126840 |
- Use a suitable lifting device in order to position the wear plate (1) and the two impact plates (2) on the floor of the body.
 | |
| Illustration 134 | g01126939 |
 | |
| Illustration 135 | g01127164 |
Note: Lifting eyes (D) can be welded on wear plate (1) in order to lift the plate into position.
- Identify the areas for grinding by using a paint stick to trace the outside edges and inside holes of each wear plate (1) and two impact plates (2) to the body.
- Remove wear plate (1) and two impact plates (2) from the floor of the body.
 | |
| Illustration 136 | g01126995 |
View of the body after the impact plates are traced and removed from the floor. | |
- Clean all marked areas of the body (E) in order to prepare for the welding of wear plate (1) and two impact plates (2). Use a grinder in order to remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 137 | g01127020 |
- Use a grinder in order to level the welded floor of the center section, left section, and right section.
 | |
| Illustration 138 | g01127006 |
- Reposition impact plates (2) and wear plate (1) .
 | |
| Illustration 139 | g01127027 |
View of ballast (F) in order to hold wear plate (1) to the floor of the body for welding. | |
- Tack weld impact plate (2) to the floor of the body.
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
Note: If necessary, use ballast (F) in order to hold the plate flat to the floor.
- Weld one impact plate (2) to the floor of the body.
- Repeat the process from Steps 12 and 13 for the remaining plates.
Installation of the Body Down Indicator
- Use a grinder in order to clean the welding area of the indicator on the front of the canopy. Remove all paint, rust, scale, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 140 | g01393033 |
Front view of the canopy | |
- Use a grinder in order to clean indicator (14). Remove all paint, rust, slag, paint, rust, scale, slag, dirt, moisture before welding.
 | |
| Illustration 141 | g01403856 |
View of the body down indicator | |
- Position indicator (14) to the inside of canopy (9) .
Note: Measurement (A) is from the inside of the sidewall assembly.
 | |
| Illustration 142 | g01403858 |
(A) 1101.7 ± 3 mm (43.38 ± 0.12 inch) (B) 60 ± 5 mm (2.4 ± 0.2 inch) | |
- Once indicator (14) is aligned correctly, tack weld indicator (14) to the inside of canopy (9) .
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.
- Preheat indicator (14) and the inside of canopy (9) .
Note: Before welding, preheat the welding areas to the proper temperature. Refer to ""Welding Materials" ". Use 164-3310 Infrared Thermometer in order to check for the proper preheat temperature.
 | |
| Illustration 143 | g01403859 |
- Weld indicator (14) to the inside of canopy (9) .
Note: Remove the slag after every weld pass.
Installation of the Cover Plates
- Install two covers (15) onto the right-hand body assembly (2) .
 | |
| Illustration 144 | g03514676 |
View of cover plates that have been installed (1) Center body assembly (2) Right-hand body assembly (15) Cover (16) Bolt (17) Washer | |
- Use eight bolts (16) and eight hard washers (17) in order to install the covers.
Miscellaneous
- 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.
- Ensure that all welds have been inspected.
Reference""Weld Specifications and Parameters" " and ""Welding Materials" "
- Clean the entire truck body.
- Repaint the truck body, as needed.
Installation of the Rock Ejector Brackets
 | |
| Illustration 145 | g01387092 |
Note: Rock ejector bracket (5) 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 233-1880 Bracket As .
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 must be removed before installing the body to the chassis.