Procedure To Section and Reassemble The 777F and 777G Off-Highway Truck Body

12/11/2019 777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(SEBP4305 - 163) - Documentation
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Product: TRUCK
Model: 777F TRUCK JRP
Configuration: 777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED
BY C32 Engine
Special Instruction
Procedure to Section and Reassemble the 777F and 777G Off-Highway Truck Body{0679, 7258,
7258, 7258, 7960}
Media Number -REHS9323-00 Publication Date -23/04/2014 Date Updated -23/04/2014
i05675719
Procedure to Section and Reassemble the 777F and 777G Off-Highway

Truck Body{0679, 7258, 7258, 7258, 7960}
SMCS - 0679-016; 7258-016; 7960-016
Off-Highway Truck:
777F (S/N: JRP1-UP; JXP1-UP)
777G (S/N: TNM1-UP; RDR1-UP)
Introduction
This Special Instruction contains the necessary procedures in order to section and assemble the 327-0400 Body
and Canopy As on the above listed 777F and 777G Off-Highway Trucks.
Do not perform any procedures or order any parts until you read this publication. Do not perform any procedures
or order any parts until you understand this publication thoroughly. The recommended tools and equipment should
be present during the body sectioning procedure. If the recommended tools and equipment are not present, the
sectioning procedure will be more difficult and require more time.
A flat, smooth, 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 X Body. The dispersing of the shielding
gases away from the welding area must be kept to a minimum.
ReferenceSpecial Instructions, REHS6064, "Assembly Procedures for the 777 X Body"
ReferenceSpecial Instructions, REHS2594, "Assembly Procedures for 777F Off-Highway Trucks"
ReferenceSpecial Instructions, REHS5053, "Assembly Procedures for 777G Off-Highway Trucks"
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"
The 327-0400 Body and Canopy As can be sectioned into three different configurations depending on the
transportation or logistical requirements.
Configuration 1: Canopy removal only.
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Configuration 2: Canopy removal and either left-hand side body or right-hand side body removal.
Configuration 3: Canopy removal with both left-hand side body and right-hand side body removal.
This special instruction will cover the sectioning of the body into both configuration 1 and configuration 2.
Prior to starting this procedure, ensure that the body assembly is set on proper cribbing on a level surface. If the
body assembly is still attached to the truck, refer to Special Instruction, REHS5053, "Assembly Procedures for
777G Off-Highway Trucks" in order to remove the body assembly from the truck. Place the body assembly on
cribbing in an appropriate work area.
Safety
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.
Falling Hazard. May cause personal injury or death. Always attach

safety lanyard to appropriate fixing point.
Make sure the lifting cables and other lifting devices are strong enough
to support the machine.
Required Parts
Table 1
Required Parts
Item Qty Part Number Description
1 2 258-9492 Brace
2 3 8D-9606 Lifting Eye
3 28 6G-1034 Lug
4 14 8T-0674 Bolt
5 14 7X-0851 Nut
6 4 6G-9687 Eye
7 4 2G-5881 Eye
8 10 5T-5146 Plate
9 4 327-0405 Strip
10 10 327-0387 Strip
11 2 327-0393 Strip
12 2 327-0423 Plate
13 2 327-0426 Strip
14 4 327-0399 Strip
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.
Example of the approximate weights of the truck body.
Table 2
Approximate Shipping Weights
Part Number Description Weight
327-0380 Body Assembly (Center)

7359 kg (16224 lb)
327-0445 Body Assembly (LH)

3012 kg (6640 lb)
327-0475 Body Assembly (RH)

3171 kg (6991 lb)
327-0490 Canopy Assembly

1769 kg (3900 lb)
Note: The weights that are listed in this document are only approximate weights. 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.
Note: Body's that are equipped with a liner group will require individual sections of the liner package to be
removed. The addition of a liner package will significantly increase the individual body section weights. The
extra weight must be accounted for when selecting appropriate lifting equipment.
Table 3
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
1 - Plasma Cutter
Clevis
4 -
38 mm (1.5 inch)
Cables
Chains
As Required -
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
1 6V-6317 Bolt
1 6V-5839 Washer
1 138-7575 Link Bracket
Note: Two mobile cranes are necessary in order to lift the truck body.
Machine Preparation
1. Park the machine on a dry, level, solid surface that is free of any debris.
Note: The surface must be solid enough to support the weight of the machine and any tooling that is used to
support the machine.
2. Make sure that transmission control is in the Parking Brake Applied (P) position.
3. Move the hoist control to the FLOAT position in order to lower the dump body. Refer to Operation and
Maintenance Manual, "Operator Controls" for more information.
4. Install wheel chocks on the machine. Refer to Operation and Maintenance Manual, "Use of Wheel Chocks"
for more information.
5. When wheel chocks are not used, ensure that the machine is unable to roll. Turn the wheels into a suitable
bank or placing the wheels in a suitable ditch.
6. Ensure that the pressure is released from any closed system that will be opened during the maintenance
procedure. Refer to Operation and Maintenance Manual, "System Pressure Release" for more information.
Note: The Advisor display can be used to verify the amount of pressure in each system.
7. For maintenance that requires the truck body to be in the raised position, install the truck body
retaining pins. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)" for more
information.119 mm (4.68503 inch)
8. For this instruction the truck body must be removed from the chassis.
Optional Fabrication Procedure

The following is procedure is for the optional fabrication of the 258-9492 Brace . This brace will be used to
support the front wall during the removal procedure. The brace can be ordered or fabricated.
Illustration 1 g03653131
Fabrication of the front wall angle iron brace
(1) 258-9492 Brace
(A) 3546.5 ± 2 mm (140 ± 0.08 inch)
(B) 89 ± 2 mm (3.5 ± 0.08 inch)
(C) 119 ± 2 mm (4.7 ± 0.08 inch)
(D) 76.2 mm (3 inch)
(E) 76.2 mm (3 inch)
(F) 6.4 mm (0.25 inch)
1. Use ASTM grade A36 or grade A370 steel in order to fabricate brace (1) .
2. Use the dimensions in Illustration 1 in order to fabricate brace (1) .
Removal Procedure
Components of the 327-0400 Body and Canopy As
(A) 327-0380 Body Center
(B) 327-0445 Body LH
(C) 327-0475 Body RH
(D) 327-0490 Canopy As
Canopy Assembly Removal
Top view of the lift eye locations on canopy assembly (A)
(2) 8D-9606 Lifting Eye
(A) 6 ± 2 mm (0.24 ± 0.08 inch)
(B) 245 ± 2 mm (9.65 ± 0.08 inch)
(C) 2005 ± 2 mm (78.94 ± 0.08 inch)
(D) 2578 ± 2 mm (101.50 ± 0.08 inch)
(E) 2520 ± 2 mm (99.21 ± 0.08 inch)
(F) 2583 ± 2 mm (101.70 ± 0.08 inch)
(G) 2526 ± 2 mm (99.45 ± 0.08 inch)
1. Install three lifting eyes (2) onto the upper side of canopy assembly (D). Locate and weld lifting eyes (2) in
the location that is shown in Illustration 3.
(D) Canopy assembly
2. Using suitable lifting straps, attach canopy assembly (D) to a suitable crane. Remove the slack from the
lifting straps in order to support the canopy during the removal process.
Note: The canopy assembly weighs approximately 1769 kg (3900 lb).
3. The following step is only required if the body assembly is equipped with a sideboard group attachment.
Outside view of the right-hand body assembly
(C) Body assembly RH
(D) Canopy assembly
Inside view of the right-hand body assembly
4. If the body is equipped with a sideboard group attachment, the front section of each side board must be
removed at this time. Using a grinder, locate and cut through the welds that are shown in Illustration 5.
Remove the front plate assembly's and retain for reinstallation.
View of the front horizontal ribs
Cutaway view of the center body assembly and the canopy assembly
(A) Center body assembly
(D) Canopy assembly
NOTICE
During the weld removal process, ensure that care is taken to remove
only the weld material. Do not cut into the parent material of the
canopy and body assembly. The canopy wall and the center body
assembly create and overlap joint as seen in Illustration 8. Cut the weld
material only.
5. The canopy ribs and the longitudinal plate welds must be removed in order to allow canopy (D) to be
removed. The welds that must be removed are shown in Illustration 7 and Illustration 8. Use the appropriate
tools in order to remove the welds.
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View of the inside of the body assembly
(D) Canopy assembly
6. Remove the inside welds that connect canopy (D) to the front wall of center body assembly (A). A grinder is
recommended for this application so that the front wall plate is not damaged.
Inside view of the canopy and right-hand body assembly
(D) Canopy assembly
Outside view of the canopy and right-hand body assembly
(D) Canopy assembly
7. The final cuts to be made before the removal of canopy assembly (D) are shown in Illustration 10 and
Illustration 11. Use the appropriate tools and remove the welds that attach canopy assembly (D) to right-
hand body assembly (C) side rails.
View of the canopy assembly being removed
8. Use the hoist and remove canopy assembly (D) from the body.
Note: The overlap joint and any remaining metal slag may make the removal of canopy assembly (D)
difficult. Use a suitable crane and appropriate tool in order to work canopy assembly (D) loose.
Note: The canopy assembly weighs approximately 1769 kg (3900 lb).
9. Place canopy assembly (D) into an appropriate work area. Clean and prepare the previous cut edges, remove
any slag, weld material, and uneven surfaces.
Note: Canopy assembly (D) can be inverted for ease of preparation work.
Weld Removal of Left-Hand Body Assembly
View of the left-hand and center body assembly
(B) Left-hand body assembly
1. Locate and mark the center line of the floor weld joint that attaches left-hand body assembly (B) to center
body assembly (A) .
2. Mark the position of each lower lateral cross rib onto the top of the floor plate. Place the mark at each point
where the bottom lateral rib intersects with the main floor weld seam. Marking the positions will indicate
where the cross ribs are located while cutting the floor weld seam. This procedure will help to avoid cutting
into the cross rib wall material.
Front wall view of the left-hand and center body assembly
3. Locate the weld seam on the front wall plate that attaches left-hand body assembly (B) to center body
assembly (A). Place a mark in the center of the weld seam.
4. Mark the position of the upper front wall lateral rib assembly. Place the mark at each point where the upper
lateral rib intersects with the front wall plates. Marking the positions will indicate where the cross ribs are
located while cutting the front weld seam. This procedure will help to avoid cutting into the cross rib wall
material.
View of the transition plate cover
5. Locate the front transition plate at the inside lower front edge of the body assemblies. Place a mark on the
plate that will show the correct orientation. Cut the welds and remove the transition plate. Retain the
transition plate for later assembly.
6. Attach the following components prior to cutting the welds on the left-hand and right-hand body assembly.
View of the front wall brace
(1) 258-9492 Brace
(H) 618 mm (24 inch)
(J) 2300 mm (90.5 inch)
View of front wall braces (1) installed on the body assembly
7. Install front wall brace (1) onto center body assembly (A). Brace (1) is required to prevent any movement of
the front wall during and after the main weld cutting. Refer ""Optional Fabrication Procedure" " for the
fabrication of this part as needed.
Inside view of the body assembly
(3) 6G-1034 Lug
(L) 55 mm (2.2 inch)
(M) 40 mm (1.6 inch)
(N) 350 mm (13.8 inch)
(P) 350 mm (13.8 inch)
(R) 448 mm (17.6 inch)
(S) 448 mm (17.6 inch)
8. Install eight lugs (3) into the location that is shown in Illustration 18. Lugs (3) must be installed before
cutting the floor and front wall weld seam. The lugs will maintain body rigidity and alignment during the
inverting process, and also used to align the body during the reassembly.
Bottom view of the left-hand body assembly
(3) 6G-1034 Lug
(T) 25 mm (1 inch)
(U) 507 mm (20 inch)
(V) 1437 mm (57 inch)
(W) 2367 mm (93 inch)
(X) 4227 mm (166 inch)
(Y) 5157 mm (203 inch)
9. Install five lugs (3) into the location that is shown in Illustration 19. Install five lugs (3) in the corresponding
position on the center body assembly. Lugs (3) must be installed before cutting the floor and front wall weld
seam. The lugs will maintain body rigidity and alignment during the inverting process, and also used to align
the body during the reassembly.
10. Tack weld a straight edge piece of metal along the weld seam to aid as a guide while cutting. The straight
edge will ensure that a straight cut is made.
11. Begin to cut the weld seam that connects the left-hand body assembly and the center body assembly. Start at
the rear edge of the floor plate and move forward. A plasma cutter should be used to cut the floor plate weld
until the first marking of the lower lateral rib is reached. Refer to the center picture in Illustration 21. Once
this point is reached, use a grinder in order to remove the weld material. Remove the weld down to the
lateral rib material at the position of the rib marking. This procedure should be done in two locations at each
lateral rib. Using grinder will prevent damage to the lower later rib. Once the welds in the area of the lower
lateral rib is removed, a plasma cutter can be used again. Repeat this process for the entire length of the floor
plate.
12. The front wall should be cut in the same way as the floor plate. Use a grinder in the area of the horizontal rib
material, and use the plasma cutter for the rest of the material.
13. Repeat Step 1 through Step 12 for the removal of the welds and the installation of components on the right-
hand body assembly.
Top view of the body assembly bolted together
p y y g
(C) Right-hand body assembly
(3) 6G-1034 Lug
(4) 8T-0674 Bolt
(5) 7X-0851 Nut
14. Once the cutting of the floor plate welds and the front wall welds are fully complete, the body should be
bolted together. Install four bolts (4) and four nuts (5) onto lugs (3) on the front wall.
15. Install ten bolts (4) and ten nuts (5) onto lugs (3) on the underside of the floor plate.
Note: The floor plates of the body assembly are transparent to show the location of lugs (3), bolts (4), and
nuts (5). These components are located on the underside of the floor plates.
Rotate the Body Assembly
1. Clear the body of all tools and debris in preparation for the body to be rotated to the upside down position.
2. Attach a crane and a suitable lifting device to the sidewall of the right-hand body assembly. Attach a second
crane and a suitable lifting device to the lifting eyes on the bottom left-hand side of the center body
assembly. Using both cranes rotate the body assembly to the upside down position.
Note: The body assembly weighs approximately 13542 kg (29855 lb).
3. Lower the body assembly onto appropriate cribbing. Support each section of the body assembly individually.
Each section of the body assembly must be supported separately in order to provide support once the body is
fully separated.
Left-Hand Body Assembly Removal
Bottom view of the left-hand body assembly
(6) 6G-9687 Eye
(A) 270 mm (11 inch)
(B) 400 mm (16 inch)
(C) 270 mm (11 inch)
(D) 400 mm (16 inch)
1. Weld two lift eyes (6) in the location that is shown in Illustration 26.
Bottom view of the left-hand and center body assembly weld joints
2. Cut the welds that are located on the lateral rib assemblies that are on the bottom body assembly and the
front wall assembly. Make sure to cut through the existing weld joints only. A grinder should be used for this
purpose. Refer to Illustration 27.
3. Verify that all of the welds have been cut that attach the side body assemblies from the center body
assembly.
View of removing the left-hand body assembly
(6) 6G-9687 Eye
4. Attach a suitable crane and a suitable lifting device to two lift eyes (6). Once the crane and lifting devices
are secure to the left-hand body assembly, bolts (4) and nuts (5) can be removed. Refer to Step 14 and Step
15 of ""Left-Hand Body Assembly Weld Removal" " for the locations of bolts (4) and nuts (5) .
5. Separate the left-hand body assembly from the center body assembly.
Note: The left-hand body assembly weighs approximately 3012 kg (6640 lb).
View of the left-hand body assembly
6. Move left-hand body assembly (B) away from the main body assembly. Place left-hand body assembly (B)
on appropriate supports to prevent the body assembly from moving while performing additional work.
7. Repeat Step 1 to Step 6 for the right-hand body assembly.
Pre Assembly Preparations

The body sections must be prepared before the sections are welded. Using a grinder, remove any slag debris from
all of the areas that have been cut on each section of the body assembly. Refer to the following steps for the areas
of preparation.
1. Use a grinder in order to clean the areas that are shown above.
View of the backing strips on the lateral ribs
2. Remove the original backing strips from the end of the lateral rib assemblies on each section as shown
above.
3. Remove the original backing strips from the bottom of the floor plate and the front wall assembly on each
section as shown above.
View of the left-hand and center body assemblies
4. The floor plate on the left-hand body assembly should be smoothed and cleaned to a 90 degree edge. The
opposing edge on the center body assembly floor plate should be beveled at a 45 degree angle along the
edge. The 45 degree angle will allow adequate weld penetration into the joint during the assembly process.
View of the front wall on the center body assembly
Top view of the center body assembly
(7) 2G-5881 Eye
(8) 5T-5146 Plate
(A) 200 mm (8 inch)
(B) 200 mm (8 inch)
(C) 600 mm (24 inch)
(D) 600 mm (24 inch)
(E) 50 mm (2 inch)
(F) 50 mm (2 inch)
(G) 5683 mm (224 inch)
(H) 3083 mm (121 inch)
(J) 483 mm (19 inch)
(K) 1370 mm (54 inch)
(L) 270 mm (11 inch)
(M) 270 mm (11 inch)
(N) 775 mm (31 inch)
5. Install four lift eyes (7) onto the top of the floor plate in the location that is shown in Illustration 35. Lift
eyes (7) will aid in lifting and positioning of the center body assembly in the reassembly process.
6. Install ten plates (8) onto the top of the floor plate and front wall in the locations that are shown in
Illustration 34 and Illustration 35. Plates (8) will aid in the section realignment during the body reassembly
procedure.
Installation of Backing Strips

1. Once, the body sections have been cleaned and prepared the backing strips can be installed. The backing
strips are required to complete the welding process during the reassembly procedure.
Right-hand view of the center body assembly
(9) 327-0405 Strip
2. Install two backing strips (9) onto the floor plate of center body assembly (A) in the location that is shown.
View of Area A-A
(P) 10 mm (0.40 inch)
(9) 327-0405 Strip
3. Weld two backing strips (9) to the floor of center body assembly (A) .
4. Repeat Step 2 and Step 3 for the left-hand side of center body assembly (A) .
Front view of the right-hand side of the center body assembly
(R) 10 ± 3 mm (0.4 ± 0.12 inch)
(10) 327-0387 Strip
5. Install five backing strips (10) onto the front lateral ribs of center body assembly (A) .
6. Weld backing strips (10) from point A to point B in the location that is shown in Illustration 38.
Rear view of the right-hand body assembly
(S) 10 ± 3 mm (0.4 ± 0.12 inch)
(11) 327-0393 Strip
8. Install one backing strip (11) onto the rear lateral rib of center body assembly (A) .
9. Weld backing strip (11) from point C to point D in the location that is shown in Illustration 39.
Right-hand view of the center body assembly
(12) 327-0423 Plate
11. Install backing strip (12) onto the front wall of center body assembly (A) in the location that is shown.
View of Area B-B
(T) 15 ± 2 mm (0.60 ± 0.08 inch)
(12) 327-0423 Plate
12. Weld backing strip (12) to front wall of center body assembly (A) .
View of the front wall of the center body assembly
(U) 10 ± 2 mm (0.40 ± 0.08 inch)
(13) 327-0426 Strip
14. Install backing strips (13) onto the front lateral rib on center body assembly (A) in the location that is shown.
15. Weld backing strip (13) to front lateral rib of center body assembly (A) .
View of the inside of the body assembly
(14) 327-0399 Strip
17. Install two backing strips (14) onto the front transition plates on center body assembly (A) in the location
that is shown.
l,
View of area CC
18. Weld two backing strips (14) to the front transition plates of center body assembly (A) and right-hand body
assembly (C) .
19. Repeat Step 17 and Step 18 for the left side of center body assembly (A) and left-hand body assembly (B) .
Assembly Procedure
Refer to Special Instructions, REHS6064, "Assembly Procedures for the 777 X Body" for the proper instructions
on the reassembly of the truck body.
Copyright 1993 - 2019 Caterpillar Inc. Tue Nov 12 2019 16:47:48 GMT-0500 (hora estándar de Colombia)
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12/11/2019 777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(SEBP4305 - 163) - Documentation

Procedure to Section and Reassemble the 777F and 777G Off-Highway

ReferenceSpecial Instructions, REHS6064, "Assembly Procedures for the 777 X Body"

ReferenceSpecial Instructions, REHS2594, "Assembly Procedures for 777F Off-Highway Trucks"

ReferenceSpecial Instructions, REHS5053, "Assembly Procedures for 777G Off-Highway Trucks"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

Configuration 1: Canopy removal only.

Improper assembly procedures could result in injury or death.

Falling Hazard. May cause personal injury or death. Always attach

Weights and Required Tools

Example of the approximate weights of the truck body.

Part Number Description Weight

327-0380 Body Assembly (Center)

327-0445 Body Assembly (LH)

327-0475 Body Assembly (RH)

327-0490 Canopy Assembly

Qty Tool Number Description

1 1U-9367 Automatic Tape Measure

1 164-3310 Infrared Thermometer

1 1U-9204 Lever Puller Hoist

As Required 4C-5647 Pry Bar

As Required - Attachments for Electric Hydraulic Pump

4 - 400 Amp Welder

1 138-7575 Link Bracket

Optional Fabrication Procedure

(1) 258-9492 Brace

(A) 3546.5 ± 2 mm (140 ± 0.08 inch)

(B) 89 ± 2 mm (3.5 ± 0.08 inch)

(D) 76.2 mm (3 inch)

(E) 76.2 mm (3 inch)

(F) 6.4 mm (0.25 inch)

2. Use the dimensions in Illustration 1 in order to fabricate brace (1) .

(A) 327-0380 Body Center

(B) 327-0445 Body LH

(C) 327-0475 Body RH

(D) 327-0490 Canopy As

Canopy Assembly Removal

(2) 8D-9606 Lifting Eye

(A) 6 ± 2 mm (0.24 ± 0.08 inch)

(B) 245 ± 2 mm (9.65 ± 0.08 inch)

(C) 2005 ± 2 mm (78.94 ± 0.08 inch)

(D) 2578 ± 2 mm (101.50 ± 0.08 inch)

(E) 2520 ± 2 mm (99.21 ± 0.08 inch)

(F) 2583 ± 2 mm (101.70 ± 0.08 inch)

(G) 2526 ± 2 mm (99.45 ± 0.08 inch)

Note: The canopy assembly weighs approximately 1769 kg (3900 lb).

(C) Body assembly RH

(D) Canopy assembly

(C) Body assembly RH

(A) Center body assembly

(D) Canopy assembly

(A) Center body assembly

(D) Canopy assembly

(C) Body assembly RH

(D) Canopy assembly

(C) Body assembly RH

(D) Canopy assembly

Note: The canopy assembly weighs approximately 1769 kg (3900 lb).

Weld Removal of Left-Hand Body Assembly

(A) Center body assembly

(B) Left-hand body assembly

(A) Center body assembly

(B) Left-hand body assembly