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

Assembly Procedure for the X Truck Body for 789D and 789D XQ Off-Highway Trucks{7258, 7258, 7960}

Usage:

789D SHH

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

Introduction

This manual contains information in order to assemble the 344-7350 Body and Canopy As for the 789D Off-Highway Truck. The 344-7350 Body and Canopy As is also referred to as the X body. This Special Instruction must be used with Special Instruction, REHS7986, "Body Assembly Procedure".

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

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

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

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

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

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

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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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Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.

Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

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

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

Reference Section

ReferenceParts Manual, SEBP5054 and Operation and Maintenance Manual, SEBU8242

ReferenceSpecial Instructions, REHS5076, "Assembly Procedure for the 789D Off-Highway Truck"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceTool Operating Manual, NEHS1120, "Truck Body Lifting Pins"

ReferenceSpecial Instruction, REHS7986, "Body Assembly Procedure"

Parts List

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Table 1
Required Parts for the 344-7350 Body and Canopy As
Item	Qty	Part Number	Description
1	1	362-3951	Body As (CTR)
2	1	362-3952	Body As (RH)
3	14	8T-0674	Bolt
4	14	7X-0851	Nut
5	1	362-3953	Body (LH)
6	2	154-3455	Plate As
7	1	196-5351	Plate
8	1	8W-0108	Bracket As
9	1	8X-5418	Block
10	1	362-3954	Canopy As
11	1	428-9300	Cover
12	2	8X-2940	Cover
13	12	8T-4190	Bolt
14	12	8T-4122	Hard Washer
15	1	352-7596	Cover
16	2	352-7588	Plate As
17	2	303-0620	Plate
18	1	303-0549	Plate
19	4	352-1870	Guard As
20	1	384-4985	Guard As
21	1	380-1419	Guard As
22	1	356-6022	Plate As
23	2	303-0517	Bracket As

Weights and Required Tooling

The approximate weight of the truck body depends on the configuration of the truck body. Use one or two mobile cranes to lift the truck body as needed.

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

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Table 2
Approximate Shipping Weights for the 344-7350 Body and Canopy As
Description	Weight
362-3951 Body (CTR)	11913 kg (26500 lb)
362-3952 Body (RH)	7141 kg (16000 lb)
362-3953 Body (LH)	7110 kg (16000 lb)
362-3954 Canopy As	2661 kg (6000 lb)

Note: The weights that are listed in this document are only approximate weights. The weights represent only one size of X truck body. X truck bodies can vary in size and weight. Refer to the machine shipping order (MSO) that was shipped with the truck body for specific weights. Use the MSO in order to determine lifting requirements.

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Table 3
Required Tools and Equipment
Qty	Tool Number	Description
2	-	90700 kg (200000 lb) Crane
2	-	5440 kg (12000 lb) Lift Truck
2	-	12 m (40 ft) High Lift
4	-	400 Amp Welder
2	-	Preheating Equipment
2	-	Hand Grinder
2	-	0.61 m (2 ft) Metal Stand
2	-	0.9 m (3 ft) Metal Stand
1	-	1.83 m (6 ft) Ladder
1	-	3.66 m (12 ft) Ladder
1	-	1.83 m (6 ft) Level
1	-	Plumb Bob
1	1U-9367	Automatic Tape Measure
1	164-3310	Infrared Thermometer
5	1U-9204	Lever Puller Hoist
4	376-4554	Pin As
As Required	3S-6224	Electric Hydraulic Pump Gp
As Required	-	Attachments for Electric Hydraulic Pump
As Required	4C-3761	C-Clamp
As Required	4C-5647	Pry Bar
As Required	-	Sledge Hammer
As Required	-	Lifting Devices (Hooks, Chains, Slings)
As Required	-	203 mm (8 inch) by 203 mm (8 inch) by 0.9 m (3 ft) Wood Blocks
As Required	-	Wedges ⁽¹⁾
6	-	Spacer ⁽²⁾

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^( 1 )	Use with the alignment blocks
^( 2 )	Fabricated part

Welding Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts.

Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

Oil
Grease
Paint
Dirt
Rust
Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode. Use the manufacturers shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

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Table 4
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1 H8"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -18 °C (20 ft lb @ -0 °F)

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters.

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Table 5
Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate	Voltage	Amperage
7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute	24 to 28	190 to 240

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Table 6
Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate	Voltage	Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute	23 to 27	180 to 220

Note: The settings listed above are recommendations-based on experience from welding in the horizontal, vertical-up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. Higher parameters are acceptable to use for welding in the flat position.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

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Table 7
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -29 °C (20 ft lb @ -20 °F)

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturers specifications.

The table that follows shows the settings for the welding current based on electrode diameter.

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Table 8
Welding Current for Low Hydrogen Electrodes
Diameter	Amperage Rating
3.2 mm (1/8 inch)	105-155
4.0 mm (5/32 inch)	130-200
4.8 mm (3/16 inch)	200-275

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Weld Inspection and Acceptance Criteria

Visual inspection is the primary method for determining weld quality. Abrasion resistant steel plates, which are part of the body structure, are susceptible to hydrogen induced cracking or delayed cracking. This type of cracking normally occurs within 72 hours of welding. As a result, allow the welding areas to cool for 48 hours to 72 hours prior to performing a final visual inspection. Any areas identified as suspect during the visual inspection shall be verified as acceptable or unacceptable. Using a supplemental inspection technique such as dye penetrant or magnetic particle testing.

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Table 9
Defect Name	ISO 6520 Defect Reference Number	Remarks	Defect Limit
Cracks - Longitudinal, Transverse, Radiating, Crater, Disconnected, Branching	1011, 1012, 1013, 1014, 1023, 1024, 1031, 1033, 1034, 1045, 1046, 1047, 1051, 1053, 1054, 1061, 1063, 1064	--	Not Permitted
Crack - Transverse	1021	Hard Surfacing Welds Only	Permitted
Crack - Transverse	1021	Joining Welds	Not Permitted
Porosity	2011, 2012, 2014, 2017	Maximum Diameter for a Single Pore	1 mm (0.040 inch)
		Maximum Pores in Any 300 mm (11.81 inch) Length of Weld	6
		Maximum Number of Pores in Any 50 mm (2.0 inch) of Weld Length for Welds Less Than 300 mm (11.81 inch) in Length	1
Clustered Porosity	2013	Maximum Length of Cluster in Any Weld	3 mm (0.120 inch)
Elongated Cavities	2015	Maximum Height or Width	3 mm (0.120 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Elongated Cavities	2016	Maximum Dimension of Any Single Cavity	3 mm (0.120 inch)
Elongated Cavities	2016	Maximum Total Length of Affected Area in Any Weld	10% of Weld Length Not to Exceed 25 mm (1.00 inch)
Shrinkage Cavities	2021, 2024, 2025	Maximum Diameter or Length	1 mm (0.040 inch)
Slag or Flux Inclusions	3011, 3012, 3014, 3021, 3022, 3024	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Oxide Inclusions	3031, 3032, 3033	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Puckering (Oxide Inclusion - Aluminum)	3034	--	Not Permitted
Metallic Inclusion	3041, 3042, 3043	--	Not Permitted
Lack of Fusion	4011, 4012, 4013	Visual (Breaking the Surface)	Not Permitted
		Subsurface Maximum Height or Width	1 mm (0.040 inch)
		Subsurface Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Lack of Penetration	402, 4021	Maximum Reduced Penetration	10% of Nominal Penetration Not to Exceed 1 mm (0.040 inch)
Lack of Penetration	402, 4021	Maximum Allowed Total Length of Reduced Penetration	10% of Weld Length
Undercut	5011, 5012, 5013, 5014, 5015	Maximum Depth Measured From Plate Surface - Any Length	0.5 mm (0.020 inch)
Excess Weld Metal - Groove Weld Reinforcement (Convexity)	502	Any Length	--
		Weld Face Width 5 mm (0.20 inch) or Less	1 mm (0.040 inch)
		Weld Face Width Over 5 mm (0.20 inch) But Less Than 10 mm (0.40 inch)	1.5 mm (0.060 inch)
		Weld Face Width Over (10 mm)(0.40 inch) But Less Than 20 mm (0.80 inch)	2 mm (0.080 inch)
		Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch)	3 mm (0.120 inch)
		Weld Face Width 30 mm (1.20 inch) and Over	4 mm (0.160 inch)
Excess Weld Metal - Fillet Weld Convexity	503	Convexity Affects Weld Toe Angle, Reducing Fatigue Life	90 Degrees
		Weld Toe Angles of 135 Degrees and More Are Better	--
		Defect Limits Expressed as Minimum Toe Angles Allowed	--
Excess Penetration	5041, 5042, 5043	Without Drawing Limitation	2 mm (0.080 inch) (Any Length)
		With "Melt - Thru" and "Flush" Weld Symbols	1 mm (0.040 inch) (Any Length)
		With "Melt - Thru" and "Grind Flush" Symbols	Not Permitted (After Grinding)
Incorrect Weld Toe	505	When 1E2995 Applies (Expressed as a Toe Radius Rather Than a Toe Angle)	3 mm (0.120 inch) Minimum Radius
Overlap	5061, 5062	Expressed as Minimum Toe Angle	90 Degrees
Fillet Weld Leg Size - Undersize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Undersize	1 mm (0.040 inch)
		Maximum Length of Undersize Weld	10% of Total Weld Length If At Least 10% of Total Weld Length is at Least 1 mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted
Fillet Weld Leg Size - Oversize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Oversize	+25% (max 3 mm (0.120 inch))
		Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond). Without Correction Provided the Excess Does not Interfere with Satisfactory End Use of the Component (Distortion, Fit-Up Interference).	--
Fillet Weld - Linear Length when specified at less than the length of the joint	--	Weld Size ≤ 6.5 mm (0.256 inch)	± 6.5 mm (0.256 inch)
	--	Weld Size ≥ 6.5 mm (0.256 inch)	± 12.5 mm (0.492 inch)
Fillet Weld Throat Size - Undersize	5213	Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root	Not Permitted
Fillet Weld Throat Size - Undersize	5213	Weld Crater Only - Maximum Undersize	2 mm (0.080 inch) MAX - and Not to Exceed 20% of Specified Throat, Not Inclusive of Penetration Beyond the Weld Root (0.7 x Leg Size)
Incompletely Filled Groove Weld	511	Careful Consideration Needs to be Given When Plate Mismatch is Apparent	Not Permitted
Incompletely Filled Groove Weld	511	Weld Depth Must be Maintained as a Minimum	--
Root Concavity on Open Root Groove Welds	515, 5013	Maximum Depth measured From Plate Surface or Tube Inner Surface - Any Length	0.5 mm (0.020 inch)
Poor Restart (Tie - In)	5171, 5172	Measured in Terms of Excess Weld Metal (Fillet Weld Convexity) or Overlap on Groove Welds, Lack of Fusion, or Insufficient Throat	--
		Excess Weld Metal on Fillet Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
		Overlap on Groove Welds, Defect Limits Expressed as Minimum Toe Angles Allowed	90 Degrees
		Lack of Fusion - Visual Maximum Length Per Restart	3 mm (0.120 inch)
		Insufficient Weld Throat	Not Permitted
Stray Arc Strike	601	--	Not Permitted
Slag Residue	615	SMAW, SAW, FCAW, GMAW	Not Permitted
Slag Residue	615	GTAW	Silicon Residue Permitted Unless Removal Specified by Drawing Note
Combined Discontinuities	--	Total Maximum Combined Length of All Imperfections in a Weld, Expressed as a Percent of Total Weld Length	15%
Combined Discontinuities	--	(No Single Type of Imperfection Can Exceed the Limits for That Single Type of Imperfection)	--

Weld Types and Locations

ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for the proper weld types and locations. This Special Instruction will also show the locations of all field assembly components.

Welding Instructions

General Preheat Instructions for Truck Body Field Assembly

The following materials are used in order to fabricate the large mining truck (LMT) truck bodies :

"A656 Gr.80". Side bolsters, bottom ribs, horizontal ribs, and exterior plates.
400 Brinell hardness number (BNH) steel. Base body plates, canopy wrapper, and interior transition plates.
450 Brinell hardness number (BNH) steel. Liner plates, rock boxes, and wear bars.

Base material must be a minimum temperature of 16° C (60° F) before welding and during welding. Prior to work engagement, the recommended procedure is to apply heat to weld joints to sweat out residual build-up of condensation.

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NOTICE

400 BNH steel and 450 BNH steel are sensitive to hydrogen induced cracking. Cleanliness of the weld joints and of the consumables is of utmost importance.

Before welding on the truck body, verify the materials that are used in order to fabricate your particular truck body. There are specific welding procedures for each material. Refer to the following instructions in order to weld the materials during the assembly of the truck body successfully.

400 Brinell Hardness or 450 Brinell Hardness Material

The following procedure covers the requirements for welding the assembly of the LMT truck bodies. This instruction is to provide an overall guideline of the recommended preheat requirements. This instruction applies to the welding procedure for truck bodies that are fabricated with 400 BHN steel or 450 BHN steel. Refer to ""Welding Specifications and Qualifications" " for qualifications, safety, and welding electrode parameters. Attach the welding ground cable directly to the body assembly. Protect all of the machined areas from sparks and spatter that are produced by welding, chipping, and grinding operations.

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

Tight fit up 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. A maximum tack weld size of 6 mm (0.25 inch) fillet weld with a length of 75 mm (3 inch) is recommended.

Preheating is most critical during the tack welding procedure and during the welding of the root pass.

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Illustration 1	g03032696
Typical view of a Tiger Torch

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

ReferenceRefer to Table 10 for the required preheat temperature of the material.

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Table 10
Preheat Temperatures for 400 BHN Steel or 450 BHN Steel
Combined Thickness of Material	Welding Preheat
10 mm (0.39 inch) to 19 mm (0.75 inch)	100 °C (212 °F)
20 mm (0.79 inch) to 40 mm (1.58 inch)	125 °C (250 °F)
greater than 40 mm (1.58 inch)	175 °C (350 °F)

Ensure that the weld groove and 75 mm (3 inch) in each direction from the weld joint is preheated to the specified temperature. Verify the preheat temperature with a 164-3310 Infrared Thermometer or with a temperature stick.

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NOTICE

When a gas flame is used to preheat, the gas flame must be removed from the base material for a minimum of 1 minute. After 1 minute, verify the base material temperature with an 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: If the ambient temperature is below 0 °C (32 °F), then the initial preheat temperature should be raised to 121 °C (250 °F). The raised preheat temperature needs to be a minimum of 75 mm (3 inch) in each direction from the weld joint in order to avoid the heat sink effect of the floor plates.

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.

Lifting Eye Locations

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

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

Note: Lifting eyes may need to be field installed in the general areas as shown.

Refer to the following graphic for the lifting eye locations for the 344-7350 Body and Canopy As .

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Illustration 3	g03347951
View of the lifting eyes locations

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Illustration 4	g03349057
View of the lifting eyes locations

Assembly Procedure

Preparation

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

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

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

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

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

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

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

Lifting and Rotating the Body and Canopy Assembly

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

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

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

Position two suitable cranes or lifting devices near the work area.

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Illustration 5	g03347962
Center body assembly

Locate the center body assembly into the work area.
Note: Perform Step 1 and Step 2 of ""Installation of the Right-Hand and Left-Hand Body Assemblies" " prior to performing the following step.

Use one hoist in order to attach two suitable lifting devices to the two lifting eyes. The lifting eyes are located along the left-hand side of the center body assembly. The center body assembly weighs approximately 111913 kg (26500 lb).

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Illustration 6	g03347988

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Illustration 7	g03347992
Center body assembly

Raise center body assembly to a vertical position.

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

Use both hoists in order to raise the center body assembly.
Note: Maintain tension on the lifting devices that are attached to the left side of the body assembly while performing the next steps.

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

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Illustration 8	g03348011
View of the center body assembly in the horizontal position

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

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Illustration 9	g03348024
View of the center body assembly on wood blocks

Position two wood blocks underneath the front wall. Position wood blocks or suitable supporting devices underneath the rear of the body assembly.
Note: Locate the front wall of center body assembly (1) in the center of the wood blocks. Ensure to leave space for the left-hand and right-hand body assemblies in the procedures that follow.
Note: Additional wood blocks may be needed. The wood blocks will be used underneath the rear of the body assembly in order to align with the left and right body assemblies.

Lower center body assembly onto the wood blocks and remove all lifting devices.

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Illustration 10	g03348044
Right-hand body assembly

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

Attach two suitable lifting devices to the 376-4554 Pin As . Secure the lifting devices to a suitable hoist. The approximate weight of right-hand body assembly is 7141 kg (16000 lb).

Locate right-hand body assembly into the work area.

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Illustration 11	g03348065
View of the right-hand body assembly

Attach two lifting devices to the two lifting eyes in the location that is shown on the right-hand body assembly. Secure the lifting devices to a suitable hoist.
Note: The lower lifting eyes are to be used to lift the right-hand body assembly only. The lower lifting eyes are not suitable for lifting an entire completed body assembly.

Raise the right-hand body assembly.

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

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

Remove the lifting devices from the top rail and pin assembly of the right-hand body assembly.

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Illustration 12	g03348067
View of the right-hand body assembly that has been turned over

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

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Illustration 13	g03348075
View of positioning wood blocks underneath right-hand body assembly

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

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Illustration 14	g03350759
Typical inside view of the alignment plates that are used to align the body assemblies. The alignment plates are located on the front wall of the center body assembly

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Illustration 15	g03350760
Typical inside view of the alignment plates that are located along the floor seam of the center body assembly

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

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Illustration 16	g03348243
View of the right-hand body assembly that is aligned with the center body assembly

Secure the right-hand body assembly to the center body assembly.
Note: Refer to ""Installation of the Right-Hand and Left-Hand Body Assemblies" " for this procedure.

Finish weld the right-hand body assembly to the center body assembly.
Note: Refer to ""Weld Types and Locations" " for this procedure.

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Illustration 17	g03348248
View of the right-hand and left-hand body assemblies attached to the center body assembly

Repeat Step 11 through Step 22 for the left-hand body assembly.
Note: The left-hand body assembly weighs approximately 7110 kg (16000 lb).

Install the bottom components while the truck body is in the position that is shown in Illustration 17.
Note: Refer to ""Installation of the Bottom Components" " for this procedure.

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Illustration 18	g03348333
View of the body that is being turned over

Attach three sets of suitable lifting devices to the body. Attach two lifting devices to the lifting eyes on the bottom of the center body assembly. Attach the remaining set of lifting devices to the side wall lift pins on the left and right side. Attach the lifting devices on the center body assembly to a suitable hoist. The body assembly weighs approximately 126164 kg (280000 lb).

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

Only use one signalman for both of the cranes.

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Illustration 19	g03348350
View if the body that is being turned over

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

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Illustration 20	g03348358
View of the body that is being turned over

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

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

Connect the lifting device on the right-hand body assembly to a suitable hoist. Slowly lift the body to a level position.

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Illustration 21	g03348452
View of the body that has been turned over

Slowly lower both cranes in a level position and place the body assembly on wood blocks.
Note: Ensure that the body assembly is secure and level on the wood blocks or suitable platform.

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Illustration 22	g03348569

Attach a suitable lifting device to the canopy assembly. Use three lifting devices in the configuration that is shown. Base canopy assembly weighs approximately 2661 kg (6000 lb).

Locate the canopy assembly into the work area.

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Illustration 23	g03348597
View of the canopy and body assembly

Align the canopy to the body assembly.
Note: When you position the canopy, a guide line may be necessary.

Hold the canopy assembly in place with the lifting device until the canopy is assembled to the body assembly.
Note: Refer to ""Installation of the Canopy Assembly" " for this procedure.

Finish weld the canopy assembly to the body assemblies.
Note: Refer to ""Weld Types and Locations" " for this procedure.

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

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Illustration 24	g03347001
View of the body assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly

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Illustration 25	g03050177
View of fabricated spacer

Fabricate six spacers with the following dimensions:
(A) Width ... 25.4 mm (1 inch)
(B) Length ... 50.8 mm (2 inch)
(C) Thickness ... 6.0 mm (0.25 inch)
Note: The spacers will be used to obtain the correct root opening of 6.0 mm (0.24 inch) between the center body assembly and the left and right-hand body assemblies.

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Illustration 26	g03050230
View of spacers that are tack welded to center body assembly (1) . (1) Center body assembly

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

Perform Step 1 through Step 20 of the ""Lifting and Rotating the Body and Canopy Assembly" " prior to the following steps.

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Illustration 27	g03350906
View of the location of five bolts (3) and of five nuts (4) . (1) Center body assembly (2) Right-hand body assembly (3) Bolt (4) Nut

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Illustration 28	g03350945
Inside view of two bolts (3) and of two nuts (4) that are located on the inside of the front wall. (1) Center body assembly (2) Right-hand body assembly (3) Bolt (4) Nut

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

Install seven bolts (3) and seven nuts (4). Hand tighten the bolts and nuts at this time. Refer to Illustration 27 and 28.

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Illustration 29	g03058900
Typical view of lever puller hoist

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

After the assemblies are aligned, tighten seven bolts (3) and seven nuts (4). Ensure that center body assembly (1) and right-hand body assembly (2) are tightened against the installed spacers. Refer to Illustration 27 and 28.
Note: 6 mm (0.25 inch) root opening in the floor plate weld joint must be maintained for proper assembly.

Ensure that right-hand body assembly (2) is level with center body assembly (1) .

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Illustration 30	g01283695
Typical view

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Illustration 31	g02726495
Typical view

If necessary, use alignment blocks and wedges in order to level right-hand body assembly (2) with center body assembly (1). Refer to Illustrations 30 and 31.

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

Repeat Step 4 through Step 10 for left-hand body assembly (3) .
Note: The left-hand body assembly weighs approximately 7110 kg (16000 lb).

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Illustration 32	g03351117
Typical view of the front of the body assembly (A) 6471 mm (254.76 inch) (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly

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

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Illustration 33	g03351161
Typical view of the canopy assembly (B) 6474 mm (254.88 inch) (10) Canopy assembly

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

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Illustration 34	g00862597
Typical view of preheating and tack welding

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

Preheat the body assemblies and the rib supports.

Finish weld the body assembly joints and the rib supports. Remove the slag after every weld pass.
Note: Before finish welding the joints remove all clamps, spacers, guides, nuts, and bolts. Grind the welds of the components that have been removed.
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

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Illustration 35	g03351316

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

Installation of the Bottom Components

Installation of the Mud Flap Bracket

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Illustration 36	g03403535
Bottom view of the body assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (6) Plate As

Install plates (6) in the locations that are shown. Plates (6) are located toward the front center of right-hand body assembly (2) and left-hand body assembly (5) .

Finish weld plates (6) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Plate and Bracket Assembly for the Safety Cable

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Illustration 37	g03351194
Bottom view of the body assembly (1) Center body assembly (5) Left-hand body assembly (7) Plate (8) Bracket As

Install plate (7) and bracket assembly (8) in the location that is shown. Plate (7) and bracket (8) are located toward the rear of center body assembly (1) .

Finish weld plate (7) and bracket assembly (8) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of Mud Guard Mounting Block

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Illustration 38	g03351258
Bottom view of the body assembly (1) Center body assembly (5) Left-hand body assembly (9) Block

Install block (9) in the location that is shown. Block (9) is located toward the rear of center body assembly (1) and left-hand body assembly (5) .

Finish weld block (9) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Rotate the Body Assembly

Perform Step 25 through Step 32 of ""Lifting and Rotating the Body and Canopy Assembly" " in order to rotate the body assembly.

Installation of the Canopy Assembly

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Illustration 39	g03351305
View of positioning the canopy to the body. (10) Canopy assembly

Align canopy assembly (10) to the body assembly.
Note: When you position the canopy, a guide line may be necessary.

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Illustration 40	g03335389
Typical view of an angle and wedge that can be used for alignment of the canopy to the body.

Angles and wedges may be used in order to help align canopy assembly (10) to the front wall and to both side walls.

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Illustration 41	g03347016
Rear view

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

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

Finish weld the canopy assembly onto the body assembly.
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

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

Installation of the Front Components

Installation of Access Cover

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Illustration 42	g03351328
Front view of the body and canopy assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (11) Cover

Install two covers (11) in the location that is shown. Cover (11) is located on the front of the left-hand and right-hand body assemblies, just below the canopy assembly.

Finish weld two covers (11) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of Cover Plates

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Illustration 43	g03351358
View of cover plates that have been installed (1) Center body assembly (2) Right-hand body assembly (12) Cover (13) Bolt (14) Washer (15) Cover

Install two covers (12) and one cover (15) onto the right-hand body assembly (2) .

Use 12 bolts (13) and 12 hard washers (14) in order to install the covers.

Installation of Front Mud Flap Bracket

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Illustration 44	g03351379
Front view (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (16) Plate Assembly

Position two plate assemblies (16) in the location that is shown.
Note: Plate assembly (16) weighs approximately 6.5 kg (14.4 lb).

Finish weld plate assembly (16) to the front of right-hand body assembly (3) and left-hand body assembly (5) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Center Body Plate and Canopy Wrapper Plates

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Illustration 45	g03351390
View of the front plate on the body assembly (1) Center body assembly (2) Right-hand body assembly (5) Left-hand body assembly (17) Plate (18) Plate

Weld suitable lifting eyes onto two plates (17). Use a suitable lifting device in order to place plates (17) in the location that is shown. Plates (17) are located between the canopy and the body assemblies.
Note: The approximate weigh of plate (17) is 166 kg (366 lb).

Weld suitable lifting eyes onto plate (18). Use a suitable lifting device in order to place plate (18) in the location that is shown. Plate (18) is located on the front wall of center body assembly (1) between left-hand body assembly (5) and right-hand body assembly (2) .
Note: The approximate weigh of plate (18) is 322.7 kg (711.43 lb).

Remove the lifting eyes and grind the welds smooth.

Finish weld two plates (17) and one plate (18) to the body assembly.
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Installation of the Rock Guards

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Illustration 46	g03351417
View of the left side of the canopy assembly (5) Left-hand body assembly (10) Canopy assembly (19) Guard assembly (20) Guard assembly (21) Guard assembly

Install a suitable lifting eye to two guard assemblies (19), guard assembly (20), and guard assembly (21) .

Use a suitable lifting device in order to position the guard assemblies. Two guard assemblies (19), guard assembly (20), and guard assembly (21) are located on canopy assembly (10) and left-hand body assembly (5) .

Use the metal strips that are located on canopy assembly (10) and left-hand body assembly (5) in order to locate the guard assemblies.
Note: There should be a 6 mm (0.236 inch) gap between each guard assembly.
Note: Guard assembly (19) weighs approximately 30.16 kg (67 lb). Guard assembly (20) weighs approximately 10 kg (22 lb) Guard assembly (21) weighs approximately 10 kg (22 lb).

Finish weld guard assemblies (19), guard assembly (20), and guard assembly (21) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Repeat Step 1 through Step 4 for the installation of two guard assemblies (19) on the right-hand side of the canopy assembly.

Installation of the Body Down Indicator

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Illustration 47	g03351436
View of body down indicator on the canopy assembly (10) Canopy assembly (22) Plate assembly

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Illustration 48	g03504157
View of Section A-A (C) 15.34 mm (0.60 inch) (D) 22.31 mm (0.88 inch) (22) Plate assembly

Position plate assembly (22) in the location that is shown. Plate assembly (22) is located on the front corner of canopy assembly (10) .

Finish weld plate assembly (22) to the inside of canopy assembly (10) .
ReferenceRefer to Special Instruction, REHS7986, "Body Assembly Procedure" for specific locations, dimensions, and welds required for the installation of field assembly components.

Miscellaneous Item

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Illustration 49	g03351446
Bottom view (A) Bracket (23) Bracket Assembly

Note: Bracket assembly (23) is installed during the truck assembly procedure. Refer to Special Instructions, REHS5076, "Assembly Procedure for the 789D Off-Highway Truck" for the proper installation procedures.

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

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.