Assembly Procedure of The Truck Os Mcoal Mining Body Part2

6/9/23, 11:58 AM SIS 2.
Assembly Procedure for the Dual Slope Body for the 777D, 777D HAA, 777E, and 777 Off-Highway Trucks {7258, 7960} (REHS0033-
2022/08/24
07)
SMCS - 7258, 7960 i08989501

Off-Highway Truck/Tractor
777 (S/N: 7W81-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; AGY1-UP)
PSP
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777E (S/N: KYD1-UP; KDP1-UP; KDZ1-UP)
Revision History:
202 0009
3 2
Table 1
Revision Summary of Changes
03: / 06 1 6 D
5 / 0
Added the 777 S/N:7W8 serial number prefix.
8 9
Replaced 114-2310 with 300-5715.
07
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Replaced 114-2311 with 300-5716.
Updated Illustration 56.
Introduction H S
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This special instruction contains the necessary procedures and information for the assembly and welding of the dual slope body for the 777D, 777E
and the 777 Off-Highway Truck.
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The entire body and the liners of the dual slope body for the 777D, 777E and the 777 Off-Highway Truck will arrive on one tractor-trailer. The left
side body assembly, the canopy, and miscellaneous plates will be nested inside the right side body assembly and welded in place. An additional
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parts box will also accompany the shipping. Support the components when removing the shipping welds with a cutting torch to stabilize the
components. Use the proper lifting eyes and the designated lifting holes in the truck body to lift and position the truck body for the following
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procedures. This special instruction covers the shipping configuration of the truck body that is shown in Illustration 3. There could be variations in
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the procedure for shipping.
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Note: Do not perform any procedures that are outlined in this publication or order any parts until you have read this publication thoroughly.
The suggested tools and equipment should be readily available at the site for the assembly. If the part and equipment are not available, the
assembly will be more difficult and more time will be necessary to complete the assembly.
The assembly procedure that is given in this instruction is with both the right side body and left side body assemblies in the upside-down position.
The body assemblies are slid together and the bodies are then welded. The truck body is then turned over and the remaining welding and
assembly is completed. The truck body can be assembled in the right side up position but the assembly time will be substantially increased. Some
photographs of the truck body in this publication may be shown in either position for illustrative purposes.
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.
Make sure the lifting cables and other lifting devices are strong
enough to support the machine.
A flat, smooth, drained area 25 m (80 ft) by 30 m (100 ft) is needed for the assembly.
One mobile crane with a total lifting capacity of 31780 kg (70063 lb) can be used for this procedure. See Weights.
Weights
The weights that are listed are approximate.
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Table 2
Approximate Shipping Weights
Description Weight
Body Assembly (Total) 15778 kg (34784 lb)
Body Assembly (Right Side) 9398 kg (20719 lb)
Body Assembly (Left Side) 4372 kg (9638 lb)
Canopy Assembly 1617 kg (3565 lb)
Plate Assembly (Rock Ejector)
19 kg (42 lb)
Right or Left Side
Guard Assembly
52 kg (115 lb)
Right or Left Side
Plate 115 kg (254 lb)
Plate Assembly (Slipper) 47 kg (104 lb)
Bracket Assembly (Cylinder) 55 kg (121 lb)
Liners 5461 kg (12039.4298 lb)
Body Assembly
12135 kg (26753.0637 lb)
Right Side with Liners
Body Assembly
5756 kg (12689.7927 lb)
Left Side with Liners
Canopy with Liners 1926 kg (4246.0981 lb)
Parts List
Table 3
Required Parts
Item Qty Part Number Description

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023 33 0 SIS 2.0
1 1 128-0623 Canopy Assembly

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2 1 128-0668 Body Assembly (left side)
3 1 128-0626 Body Assembly (right side)
4 7 2J-3507
Full Nut
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1 X 8
Bolt
5 7 2B-7218
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1 X 8
6 1 128-5240 Bracket Assembly (Cylinder)
Plate Assembly (Rock ejector)
7 1 5T-9443
right side
Plate Assembly (Rock ejector)
8 1 5T-9442
left side
9 1 8X-2558 Plate Assembly (Slipper)
10 1 128-5239 Plate
Guard As
11 1 300-5715
Canopy Rock Guard (right side)
Guard As
12 1 300-5716
Canopy Rock Guard (left side)
13 1 129-0386 Plate (Liner)
14 1 129-0397 Plate (Liner)
15 1 129-0389 Plate (Liner)
16 1 129-0394 Plate (Liner)
Truck Dimensions
Table 4
Measurements for the Truck Body
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Body with canopy 9527 mm (375 inch)

Lengths
Body without canopy 7205 mm (284 inch)
Body with canopy 2933 mm (115 inch)
Height
Body without canopy 2159 mm (85 inch)
Body with canopy and rock guards 6048 mm (238 inch)
Width
Body without canopy and rock guards 5512 mm (217 inch)
Required Tools
Table 5
Required Tools
Qty Tool Number Description

1 1U-9367 Automatic Tape Measure
1 1U-9204 Lever Puller Hoist
As Required 4C-3761 C-Clamp
As Required 4C-5647 Pry Bar
Hydraulic Jack
2 1U-9755
20 Tons
As Required - Wedges
As Required - Sledge Hammer
As required - 400 Amp Welder
1 - Hand Grinder
As Required - Clevis
Numerous - Cables
Chains
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Hooks
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Shackles
1
1
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1.83 m (6 ft) Ladder
1.2192 m (4 ft) Level 0
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Illustration 1 g01010440
View of the wedges and brackets
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Fabricate a number of wedges and brackets prior to the assembly of the body. The bracket should be made from a minimum of 12 mm (0.50 inch)
mild steel. The wedge should be made from a minimum of 20 mm (0.8 inch) mild steel. Table 6 and Illustration 1 have the dimensions that will be
used to make the brackets and wedges.
Table 6
Dimensions for the Brackets and Wedges
Items Dimensions
A 150 mm (6.0 inch)
B 50 mm (2.0 inch)
C 25 mm (1.0 inch)
D 100 mm (4.0 inch)
E 30 mm (1.2 inch)
F 200 mm (7.9 inch)
Weld tolerance 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) A5.5. The finished weld will have the following minimum mechanical properties:
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500 MPa (72519 psi) Tensile Strength
3
420 MPa (60916 psi) Yield Strength
22 percent elongation in 50 mm (2 inch)

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27 N·m (20 lb ft) at −29 °C (−20 °F) Notch Toughness
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The "E7018" electrodes must be stored in an electrode oven at 121 °C (250 °F). Scrap the "E7018" electrodes or recondition the "E7018"
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electrodes if the "E7018" electrodes get damp. Recondition the "E7018" electrodes to the manufacturer's specifications. The following table is the
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electrode's current settings in relation to the electrode's diameters:
Table 7
Parameters for Welding

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Diameter Amperage
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3 mm (.12 inch) 70-140
4 mm (.16 inch) 110-180
5 mm (.20 inch) 190-270
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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
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should not exceed two times the electrode diameter.
As an alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's
shielding gases that are specified for inside welding. The weld that is deposited by the flux cored welding electrode will have the following minimum
mechanical properties:
500 MPa (72519 psi) Tensile Strength
420 MPa (60916 psi) Yield Strength
22 percent elongation in 50 mm (2 inch)

6/9/23, 11:58 AM SIS 2.0
27 N·m (20 lb ft) at −18 °C (0 °F) Notch Toughness
Use only flux cored welding electrodes that have been stored in undamaged packages that resist moisture or use only flux cored welding
electrodes that have been stored in an oven at 120 °C (250 °F).
Welding parameters will vary due to the welding position and due to the manufacturer of the welding electrode. A 1.3 mm (0.051 inch) electrode
diameter will typically have the following welding parameters:
Table 8
Parameters for Welding
Wire Feed Speed Voltage Approximate Amperage

Minimum 200 inches per minute 24 210
Optimum 275 inches per minute 28 250
Maximum 325 inches per minute 29 300
Note: Use the manufacturer's recommended welding electrode parameter.
Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every weld pass. The width of the weld
should not exceed 8.0 mm (0.32 inch) for a fillet weld.
Note: The weld that uses gas shielded wire requires protection from the wind and water. The truck should be covered with a tarp if there is rain.
Table 9
Weld Specifications
Weld Description
W1 10.0 mm (.40 inch)
10 mm (0.40 inch) fillet weld (three rails to length)
W2
The weld should seal the opening.
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5 mm (0.20 inch) bevel groove weld

W3 That weld should be followed with a 10 mm (0.40 inch) V-groove weld in two places. The length of the V-groove weld should be 120 mm
(4.72 inch).(1).
W4 20 mm (0.80 inch) bevel flush weld(2)
W5
W6 PSP 10 mm (0.40 inch) square groove weld
10 mm (0.40 inch) square groove weld
W7
W8 -
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10 mm (0.40 inch) square groove weld (10 ribs)
W9
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Both side (10 ribs)
12 mm (0.4724 inch) fillet weld
5
W10
9
The length of the V-groove weld should be 146 mm (5.75 inch).(3)
W11
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20 mm (0.79 inch) bevel flush weld (2 places)
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Remove the clamp before you finish weld the seam.
W12
W13
W14
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12 mm (0.47 inch) fillet weld (2 places)
10 mm (0.40 inch) fillet weld (two places)
W15
023 3 8 mm (0.32 inch) fillet weld
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W16 6 mm (0.24 inch) fillet weld
W17 10 mm (0.40 inch) bevel groove weld
W18
erp 18 mm (0.71 inch) bevel groove weld
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W19 8 mm (0.32 inch) square groove weld (two places)
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16 mm (0.63 inch) square groove weld (2 places)
W20
See detail J on Illustration 54.
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W21 4 mm (0.16 inch)fillet weld (two places)
W22 8 mm (0.32 inch)bevel groove weld (two places)
W23 4 mm (0.16 inch)bevel groove weld (two rock guards)
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W24 4 mm (0.16 inch)fillet weld (two rock guards)

W25 25 to 75 mm (1.0 to 3.0 inch) skip weld.
two rock guards
W26 10 mm (0.40 inch) square groove weld
W33 16 mm (0.63 inch) groove weld
(1) The opening should be sealed by the weld.
(2) Finish weld after all of the clamps are removed.
(3) Weld the 10 ribs on both sides to the length in Table 13.
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's weight's to determine the application when you
select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows to
see the effect of the lift angle on the working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
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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.
Unpacking the Body Assembly
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Body assembly and the parts box
1. Use a suitable crane and a suitable lifting device to remove the body assembly from the truck. Remove the parts box and the liners (if
equipped) from the truck.
2. Use a lift truck to position the banded box and liners out of the work area.
Installing the clevis onto the canopy
6/9/23, 11:58 AM SIS 2.0
3. Attach the lifting device onto 128-0623 Canopy Assembly (1).
Cutting shipping support
4. Cut the shipping support and remove 128-0623 Canopy Assembly (1) from the remaining body assembly.
Moving the canopy out of the work area
5. Place 128-0623 Canopy Assembly (1) out of the work area.

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Illustration 7
The body sides nested together.
g01013222
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Cutting the shipping support
6. Attach the lifting device to 128-0668 Body Assembly (2). Cut the shipping supports that support the body assembly. Use a suitable crane to
remove 128-0668 Body Assembly (2) from 128-0626 Body Assembly (3).
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Left side of the body assembly
7. Position 128-0668 Body Assembly (2) out of the work area.
Assembly Procedure
Note: Remove any dirt, grease, and paint from any weld areas.
Note: The assembly procedure starts with the body upside-down.
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The right side of the body before being flipped
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Turning the right side of the body
1. Position a suitable crane to turn over 128-0626 Body Assembly (3).

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Position 128-0626 Body Assembly (3) onto blocks upside-down.
6/9/23, 11:58 AM SIS 2.0
The 128-0626 Body Assembly (3) in the upside-down position
2. Position blocks that are the same size under the front rail and the side rail of 128-0626 Body Assembly (3). Elevating and leveling 128-0626
Body Assembly (3) on blocks allows 128-0668 Body Assembly (2) to be slid into position for welding.
Level the back edge of 128-0626 Body Assembly (3).
3. Use enough blocks on the back side of 128-0626 Body Assembly (3) to make the back edge level.
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4. Check the angle with a level. If a 203 mm (8.0 inch) block is used on the front and the side rails to support the body, the height of blocking that
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is needed at the back edge of the body is approximately 875 mm (34.5 inch).
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Illustration 15
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g01013790
128-0668 Body Assembly (2) turned upside-down.
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5. Use a suitable crane and a suitable lifting device to turn over 128-0668 Body Assembly (2).
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6. Turn 128-0668 Body Assembly (2) to the upside-down position.
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Position the two sides together.
7. Attach 128-0668 Body Assembly (2) to a suitable crane and lift into position next to 128-0626 Body Assembly (3).
8. Use the blocks of the same size under the side and front rails on 128-0668 Body Assembly (2) that was used on 128-0626 Body Assembly (3).
The support blocks under the back edge
9. Position a thin piece of bar stock on top of the blocking that supports the back of the body. The bar stock will allow the two halves of the body
to be slid together.
6/9/23, 11:58 AM SIS 2.0
The right side and left side are ready to be placed together.
10. Slide 128-0668 Body Assembly (2) into position next to 128-0626 Body Assembly (3).
11. If necessary, trim the joints to ensure a correct fit. A slight chamfer or a radius on the edge of the backup strip may help assembly.
Install the bolts and nuts.
12. Install the seven 2B-7218 Bolts (5) and 2J-3507 Full Nuts (4) into 128-0668 Body Assembly (2) and 128-0626 Body Assembly (3) to position
the two halves of the body.
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The hydraulic jacks are used to level the body.
13. Use two 1U-9755 Hydraulic Jacks per side to assist in aligning the right side of the body to the left side of the body.
14. Each side can be adjusted with a different jack. Also, a 1U-9204 Lever Puller Hoist can be used to help slide the two halves together.
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The two tabs on the front wall for spacing
The three tabs on the bottom of the body for spacing
Note: These tabs are used to hold the correct gap that is needed for welding.
15. Tighten the seven 2B-7218 Bolts (5) until 128-0668 Body Assembly (2) contacts the five stops that are on 128-0626 Body Assembly (3). Refer
to Illustrations 21 and Illustration 22.
16. Adjust the hydraulic jacks during the assembly procedure, if necessary.
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The gap on the ribs on the front wall
The gap that will be on the floor
17. The five stops hold a gap that is required to ensure a good weld penetration.
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The wedges and brackets that are installed on the floor
18. If a section of the front wall or floor is warped, a welded bracket and a wedge can be used to help align the seam.
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Wedge and bracket
Note: Refer to Table 10 for the correct weld. Install the wedge from the welded side of the bracket.
Note: Only weld the bracket on one side.
Note: Refer to Illustration 1 and Table 6 for dimensions to fabricate the brackets and wedges.
19. The brackets and wedges can be used throughout the welding process to align the weld seams. Use as many brackets and wedges as
required. Remember to grind the tack welds smooth before painting.
Table 10
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Weld Tolerance
Weld Description
W1 10.0 mm (.40 inch)
Critical points of alignment that should be flat and parallel
The back edge should be flat and level.
6/9/23, 11:58 AM
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20. A point that is critical for alignment is at the top of the front wall. The point of contact for the two parts 128-0668 Body Assembly (2) and 128-
0626 Body Assembly (3).
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21. Ensure that the face of the front wall is flat on the inside at the upper horizontal beam before welding. The front wall should be flat at the top to
ensure a good fit of the canopy.
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22. The top of the two side walls should be reasonably parallel. Check the rails visually.
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23. If you are not sure that the rails are straight, place a string in an X between the rails. Measure the distance between the strings. An equal
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distance between the strings will indicate parallel walls. This process is similar for a frame of a door.
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24. The rear edge of the floor should be reasonably flat.
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Note: Before you weld any joint, make sure that all five stops are snug against the edge of the body of the mating surface. Refer to Illustrations
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21 and 22 for the location of the stops.
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Tack weld the ribs on the bottom of the body.
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Tack weld the ribs on the front wall.
25. Completely tack weld each rib on the front wall before finish welding the seams.
Note: Check the alignment again after tack welding the ribs and before finish welding the seams.
Note: Refer to Illustration 31,32,33, and 34, for welding locations. Refer to Tables 11 and 12 for the welding dimensions and specifications for
the front wall and ribs.
26. Remove the bolts, nuts, and brackets from the body prior to finishing the perpendicular welding. Removing the bolts, nuts, and brackets
provides clearance for a good weld on the seam.
27. Repeat the welding procedure for the floor of the truck body. Refer to Illustration 34 for the location of the weld. Refer to Tables 13 and 14 for
the welding dimensions and specifications.
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023 3
View of the front wall
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View of section A-A and welding specifications
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View of section B-B and welding specifications
28. Before you finish weld remove the bolts, nuts, clamps, and brackets.
Table 11
Welding Dimensions
Item Dimensions
G 120 mm (4.8 inch) (6 places)
12 mm (0.48 inch) (2 places)
H
10 mm (0.40 inch) (minimum)(1)
J 8 mm (0.32 inch) (minimum)
K Remove the clamp.
18 mm (0.71 inch)
L
16 mm (0.63 inch) (minimum)
(1) Trim the joint to provide the correct gap, if necessary.
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Table 12
Weld Tolerance
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Item Description
10 mm (0.40 inch) fillet weld (three rails to length)
.
W2
The weld should seal the opening.
5 mm (0.20 inch) bevel groove weld
W3 That weld should be followed with a 10 mm (0.40 inch) V-groove weld in two places. The length of the V-groove weld should be
120 mm (4.72 inch).(1)
W4 20 mm (0.80 inch)bevel flush weld(2)
(1) The opening should be sealed by the weld.
(2) Finish weld after all of the clamps are removed.
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29. Before you finish weld, remove the bolts, nuts, clamps, and brackets.
Table 13
Welding Dimensions
Item Dimensions
M 16 mm (0.63 inch)
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N 146 mm (5.75 inch) H S

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Table 14
023 3
Welding Specifications
Item Description
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W8 10 mm (0.40 inch) square groove weld (10 ribs)
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W9
Both side (10 ribs)
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W10
The length of the V-groove weld should be 146 mm (5.75 inch). (1)
W11
20 mm (0.79 inch) bevel flush weld (2 places)
Remove the clamp before you finish weld the seam.
(1) Weld the 10 ribs on both sides to the length in Table 13.
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Parts box for shipping
30. Prepare to install 128-5240 Bracket Assembly (6) over the joint on the third rib from the front. The welds that are located on number two rib
joint and number four rib joint may need to be ground flush to position 128-5240 Bracket Assembly (6).
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Tabs that are located on the bottom of the frame
Note: The three tabs go to the inside of the outside plate on 128-5240 Bracket Assembly (6).
31. Use a crane and a suitable lifting device to position 128-5240 Bracket Assembly (6).
Locating the bracket that is used for the hoist cylinders
32. Position the inside wall of the outside plate of 128-5240 Bracket Assembly (6) against the three tabs. The 128-5240 Bracket Assembly (6) will
fit onto the backing plate on the bottom of the body.
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33. Measurement (P) in Illustration 40 is the distance between the two bracket assemblies.
34. Outline the position of the bracket on the body and then remove the bracket.
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35. Remove the paint from the body around the outline and the bracket to ensure a good weld.
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36. Reposition 128-5240 Bracket Assembly (6) onto the body and tack weld 128-5240 Bracket Assembly (6) in place.
37. Check the distance between the two brackets.

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023 3
38. Refer to Illustration 40 and Table 15 and 16 for the welding specifications and the locations for 128-5240 Bracket Assembly (6).
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Parts box for shipping
39. Remove 5T-9443 Plate Assembly (7) and 5T-9442 Plate Assembly (8) from the shipping container.
6/9/23, 11:58 AM SIS 2.0
Locating the rock ejector bracket on the bottom of the body
40. Position 5T-9443 Plate Assembly (7) onto the bottom of the left side of the body.
41. Outline the position of the plate assembly.
42. Remove the plate assembly.
43. Remove any dirt or paint from the plate assembly and outlines on the body that will interfere with the weld.
44. Use dimension (R) to position the plate assemblies on the body. Tack weld the plate assemblies. Check the distance before finish welding.
45. Refer to Illustration 40, Tables 15, and 16 for the welding specifications and the location of 5T-9443 Plate Assembly (7).
46. Follow the same procedure for installing 5T-9442 Plate Assembly (8) on the right side of the body.
Note: Tack weld angled braces to 5T-9443 Plate Assembly (7) or 5T-9442 Plate Assembly (8) before the body assembly is turned over. The
angle braces will ensure that the plate assemblies are not bent during the rollover. Only the plate assembly which will hit the ground first will
need to be tack welded with a brace.
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The bottom of the body that shows the specifications and locations of the welds
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47. Clean the weld areas.
Table 15
Welding Dimensions
Item Description
P 1970 ± 6 mm (77.56 ± 0.24 inch)
6/9/23, 11:58 AM SIS 2.0
R 888 ± 2 mm (35 ± 0.079 inch)
Table 16
Item Description
W12 12 mm (0.47 inch) fillet weld (2 places)
W14 10 mm (0.40 inch) fillet weld (two places)
8X-2558 Plate Assembly (9)
48. Remove 8X-2558 Plate Assembly (9) from the parts box and remove any paint or dirt for welding purposes.
6/9/23, 11:58 AM SIS 2.0
The locating tabs on the front wall
49. Position 8X-2558 Plate Assembly (9) over the tabs. The inside edge of the back plate should be against the tabs.
Locate 8X-2558 Plate Assembly (9) on the front wall.
50. Position 8X-2558 Plate Assembly (9) onto the middle rib against the vertical rib that is located on the front wall. The weld on the second rib
may require grinding before positioning 8X-2558 Plate Assembly (9). 8X-2558 Plate Assembly (9) should be symmetrical with the plate
assembly on the right-hand side of the body.
pill
6/9/23, 11:58 AM SIS 2.0
ar I
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51. Outline the plate assembly on the body.
52. Remove 8X-2558 Plate Assembly (9) from the body.
53. Remove the dirt and paint that is in the weld areas on the plate and the body.
54. Reposition the 8X-2558 Plate Assembly (9) over the tabs and into the position onto the front wall.
55. Refer to Illustration 44 and Table 17 for the welding specifications and the location of 8X-2558 Plate Assembly (9).
6/9/23, 11:58 AM SIS 2.0
Table 17
Item Description
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6/9/23, 11:58 AM SIS 2.0

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57. Make sure that all of the bolts and nuts are removed. Remove any bracket and wedges from the bottom before you turn over the body
assembly.
58. Grind off any excessive weld.

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The shipping bracket
59. Remove the shipping bracket from the bottom of 128-0626 Body Assembly (3) before you turn over the body assembly.
NOTICE
Use blocks and supports as necessary so the weight of the
body is not on the body-to-chassis pin brackets and rock
ejector brackets when the body is turned over. Damage to the
brackets can occur.
6/9/23, 11:58 AM SIS 2.0
60. Use the lifting holes in the side walls with straps and sleeves to turn the body assembly. The straps and lifting devices should be installed by a
qualified person. Care should be taken to minimize paint damage that is caused by the placement of the lift cable.
Rotate the body to an upward position.
61. After the body assembly is turned over, place the body assembly on blocks.
Wedges and brackets on the floor
03: 06/0 6D
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8
RE :39+
62. Use the bracket and wedge to make the floor flush at the seam.
63. Remove all the guides and lifting eyes.

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64. Weld the floor and the front wall inside seam. Refer to Illustration 33, Illustration 34, Table 12, and Table 14 for the welding dimensions and
welding specifications.
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Illustration 48
The transition plate
g01017439
c.
65. Position 128-5239 Plate (10) into place at the bottom of the front wall on the inside of the body.
66. Outline the plate onto the floor and the wall of the body.
67. Remove the dirt and paint from the edges of the plate and the outline on the floor and wall.
68. Reinstall 128-5239 Plate (10) onto the floor and the wall.
69. Tack weld the plate into position and check the dimensions before finish welding. Refer to Illustration 49 and Table 18 for the correct welding
specifications and the location.
70. Finish weld 128-5239 Plate (10) to the floor and the front wall.
6/9/23, 11:58 AM SIS 2.0
Weld specifications for the plate
Table 18
Weld Specification
Item Description
72. Grind all the welds flush on the inside of the body so that the body liner (if equipped) will fit flat.
6/9/23, 11:58 AM
PSP SIS 2.0
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202 0009
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Preparing the rock guard
Note: The 300-5715 Guard As (11) and 300-5716 Guard As (12) can be installed on 128-0623 Canopy (1) while 128-0623 Canopy (1) is on
023 3
the ground or after 128-0623 Canopy (1) is installed on the body.
73. Remove the dirt and paint from the weld areas on the canopy and the rock guard.
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Welding the rock guard
74. Position 300-5716 Guard As (12) onto the two hooks that are on the side of the canopy.
6/9/23, 11:58 AM SIS 2.0
75. Weld the rock guard to the canopy. Refer to Illustration 54 and 55 Table 19 for the correct welding specifications and the weld location.
76. Repeat the same procedure for 300-5715 Guard As (11) on the other side of 128-0623 Canopy (1).
Positioning the canopy
77. Remove any dirt and/or paint from the weld areas on the body and canopy.
78. Use a suitable crane and a suitable lifting device to lift 128-0623 Canopy (1) into position.
6/9/23, 11:58 AM SIS 2.0
Check for a good fit on the corner
79. Trim any part of the mounting base that is necessary to acquire a correct fit. The side rail of the canopy should be parallel with the top rail of
the side of the body.
80. Tack weld the canopy into position.
81. Check the canopy for a good fit and for being level.
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82. Weld the canopy to the body assembly. Refer to Illustration 54, Illustration, and55 Table 19 for the welding specifications and the location.
Note: Use the wedges and brackets to pull the canopy and the front wall of the truck body together for welding.
3 /
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Illustration 54
SIS 2.0
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The welding specifications, weld location, and Detail J for the canopy
Welding specifications and location for the canopy
83. Views of the body assembly and the canopy
Table 19
Item Description
W19 8 mm (0.32 inch) square groove weld (two places)
6/9/23, 11:58 AM SIS 2.0
16 mm (0.63 inch) square groove weld (2 places)

W20
See detail J on Illustration 54.
W21 4 mm (0.16 inch fillet weld (two places))
W22 8 mm (0.32 inch bevel groove weld (two places))
W23 4 mm (0.16 inch)bevel groove weld (two rock guards)
W24 4 mm (0.16 inch) fillet weld (two rock guards)
4 mm (0.1575 inch fillet weld)
W25 25 to 75 mm (1.0 to 3.0 inch) skip weld.
two rock guards
Note: Before assembling the body onto the chassis, remove three lifting eyes from the canopy, two lifting from the inside of the body and five
lifting eyes from the bottom.
Note: An assembly procedure for placing the body on the chassis can be found in the Special Instruction, M0119595 , "Assembly Procedure
for the 777E and 777 Off-Highway Trucks".
84. If the body assembly does not include liners, clean all the welds and prepare the body assembly for painting.
85. Paint the body.

Note: All liners except those plates over the weld joint of the truck body will be installed on the right side assembly, left side assembly, and the
canopy. The remaining liners must be installed in the field.
6/9/23, 11:58 AM
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.
The liners for the body
86. Use a suitable crane and a lifting device to position the liner into position.
Note: If any section of the floor is warped, use a wedge and a bracket to align the seam.
87. Position 129-0386 Plate (13) into the body assembly and tack weld into place.
6/9/23, 11:58 AM SIS 2.0
91. Refer to Illustration 56, Table20, and Table 21 for the welding specifications and the location.
Table 20
Welding Dimension
Item Description
S 12 mm (0.4724 inch)
T 14 mm (0.5512 inch)
U 20 mm (0.7874 inch)
V 20 mm (0.7874 inch)
W 12 mm (0.4724 inch)
Y 22 mm (0.8661 inch)
Z 16 mm (0.6299 inch)
Table 21
Item Description
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92. Clean all welds.
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93. Use a grinder to clean the welding areas of the left body assembly. Completely remove all rust, scale, slag, dirt, moisture, etc before painting.
94. Paint the body.

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i01941388
© 2023 Caterpillar Inc.

Assembly Procedure of The Truck Os Mcoal Mining Body Part2

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Assembly Procedure of The Truck Os Mcoal Mining Body Part2

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6/9/23, 11:58 AM SIS 2.

SMCS - 7258, 7960 i08989501

Revision Summary of Changes

Improper assembly procedures could result in injury or death.

Approximate Shipping Weights

Item Qty Part Number Description

1 1 128-0623 Canopy Assembly

Measurements for the Truck Body

Body with canopy 9527 mm (375 inch)

Qty Tool Number Description

Weld tolerance and Parameters

22 percent elongation in 50 mm (2 inch)

Parameters for Welding

500 MPa (72519 psi) Tensile Strength

420 MPa (60916 psi) Yield Strength

22 percent elongation in 50 mm (2 inch)

27 N·m (20 lb ft) at −18 °C (0 °F) Notch Toughness

Parameters for Welding

Wire Feed Speed Voltage Approximate Amperage

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

5 mm (0.20 inch) bevel groove weld

W24 4 mm (0.16 inch)fillet weld (two rock guards)

Specifications for Cables, Chains, and Lifting Devices

Unpacking the Body Assembly

3. Attach the lifting device onto 128-0623 Canopy Assembly (1).

5. Place 128-0623 Canopy Assembly (1) out of the work area.

Note: The assembly procedure starts with the body upside-down.

03: /06/0 16D

1. Position a suitable crane to turn over 128-0626 Body Assembly (3).

Note: Only weld the bracket on one side.

N 146 mm (5.75 inch) H S

37. Check the distance between the two brackets.

41. Outline the position of the plate assembly.

42. Remove the plate assembly.

R 888 ± 2 mm (35 ± 0.079 inch)

52. Remove 8X-2558 Plate Assembly (9) from the body.

W16 6 mm (0.24 inch) fillet weld

58. Grind off any excessive weld.

63. Remove all the guides and lifting eyes.

PSP SIS 2.0

80. Tack weld the canopy into position.

16 mm (0.63 inch) square groove weld (2 places)

85. Paint the body.

94. Paint the body.

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