Assembly Procedure of The Truck Os Mcoal Mining Body

6/9/23, 11:57 AM SIS 2.
2022/07/06 Assembly Procedure for the Coal Truck Body {7258, 7960} (REHS4424-02)
SMCS - 7258, 7960 i08750902

Off-Highway Truck/Tractor
777 (S/N: 7M21-UP; 7W21-UP; 7M31-UP; 7W31-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; AGY1-UP)
777F (S/N: JRP1-UP)
PSP
202 0009-
777G (S/N: TNM1-UP; RDR1-UP)
Revision History:
3 2
Table 1
Revision Summary of Changes

03: / 06 1 6 D
02 Added new serial number prefixes.
57 / 0 9
Introduction
RE :38+
H S 0
This Special Instruction contains the necessary procedures and information for assembling and welding a Coal Truck Body.
© 2 442 8:00
The shipping configuration of the Coal Truck Body depends on the destination and the type of transportation that is available. In some cases, the
023 4
Coal Truck Body may be assembled differently from the factory. The following special instruction covers assembling the Coal Truck Body.
Do not perform any procedures or order any parts until this publication is read thoroughly.
Cat
The recommended tools and equipment should be present during assembly. If the recommended tools or equipment are not present, assembly will
erp
be more difficult and more time will be necessary to complete the assembly.
illa
A flat, smooth, drained area 25 m (80 ft) by 30 m (100 ft) is needed for the assembly.
rI
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522Assembly%2520Procedure%2520for%2520the%2520Coal%2520Truck%2520Body%2520%257B7258%252C%25207960%257D… 1/99
ar I
nc.
6/9/23, 11:57 AM SIS 2.0
Note: An enclosed structure is recommended for the assembly of the Coal Truck Body. The dispersing of the shielding gases away from the
welding area must be kept to a minimum.
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.
The assembly begins with the Center Body Assembly that is turned over. The Left Hand Body Assembly and the Right Hand Body Assembly are
welded to the Center Body Assembly. The body assembly is turned over. The Canopy Assembly is installed.
Note: The serial number of the truck body is stamped on the edge of each section.
Parts List
Table 2
Attachments for the 321-5410 Coal Truck Body
Item Qty Part Number Description

1 1 321-5315 Center Body Assembly
2 1 321-5316 Left Hand Body Assembly
6/9/23, 11:57 AM SIS 2.0
3 1 321-5317 Right Hand Body Assembly

4 2 321-5326 Canopy Assembly
5 6 - Spacers
6 14 8T-0674 Bolt
7 14 7X-0851 Nut
8 2 326-8273 Plate
9 2 321-5327 Plate
10 2 321-5329 Plate
11 1 326-7975 Plate As
12 1 321-5501 Plate As
13 2 321-5444 Plate As
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.
Table 3
Approximate Shipping Weights
Description Weight
Center Body Assembly 6500 kg (14330 lb)
Left Hand Body Assembly 3700 kg (8160 lb)
Right Hand Body Assembly 3700 kg (8160 lb)
Canopy Assembly 2250 kg (4960 lb)
Note: The weights that are listed in this document are only approximate weights. The weights represent only one size of Coal Truck Body. Coal
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.
6/9/23, 11:57 AM
023 24 0 SIS 2.0
Use the MSO in order to determine lifting requirements.
Cat
Table 4
erp
Required Tools
illa
r In
Qty Tool Number Description
1 3S-6224 Electric Hydraulic Pump Gp
1
1
1U-9367
164-3310
Automatic Tape Measure
Infrared Thermometer
c.
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
As Required - Wood Blocks
2 - Preheating Equipment
4 - 400 Amp Welder
1 - Hand Grinder
4 - Clevis 38 mm (1.5 inch)
Cables
Chains
Numerous -
Hooks
Shackles
1 - 1.83 m (6 ft) Ladder
1 - 3.66 m (12 ft) Ladder
1 - 1.83 m (6 ft) Level
6/9/23, 11:57 AM SIS 2.0
1 - Plumb Bob
Weld Specifications and Parameters

Note: Personal breathing protection should be worn by the welders. Personal breathing protection will prevent fumes from entering the lungs of the
person that is welding. Use a 1U-8088 Type H Respirator for respiratory protection.
All of the welders must be qualified in Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). All of the welders must be
qualified in groove welding and fillet welding in the vertical position. Refer to the American National Standards Institute (ANSI)/American Welding
Society (AWS) D1.1. Prior to welding, the process must have been used by the welders during the last six months. Welding qualifications must be
documented and welding qualifications must be current.
The surrounding area must be a minimum temperature of 16 °C (60 °F) before welding and during welding.
The proper stick welding electrode for Shielded Metal Arc Welding (SMAW) is E7018 American National Standards Institute (ANSI)/American
Welding Society (AWS) A5.1. The finished weld will have the following minimum mechanical properties:
480 MPa (69600 psi) Tensile Strength
400 MPa (58000 psi) Yield Strength
22 percent elongation in 50 mm (2 inch)
27 N·m (20 lb ft) at −29 °C (−20 °F) Impact Toughness
The "E7018" electrodes must be stored in an electrode oven at 121 °C (250 °F). Scrap the "E7018" electrodes or recondition the "E7018"
electrodes if the "E7018" electrodes get damp. Recondition the "E7018" electrodes to the manufacturer's specifications. The following table is the
electrode's current settings in relation to the electrode's diameters:
Table 5
Parameters for Welding
:57 /09 D
RE :38+
6/9/23, 11:57 AM SIS 2.0
Diameter Amperage
3 mm (.12 inch)
4 mm (.16 inch)
70-140
110-180 H S
© 2 442 8:000
023 4
5 mm (.20 inch) 190-270
Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every weld pass. The width of the weld
should not exceed two times the electrode diameter.
Cat
erp
As an alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's
shielding gases that are specified for inside welding. The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible
illa
hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical
r In
properties:
c.
480 MPa (69600 psi) Tensile Strength
400 MPa (58000 psi) Yield Strength
22 percent elongation in 50 mm (2 inch)
27 N·m (20 lb ft) at −29 °C (−20 °F) Impact Toughness
Use only flux cored welding electrodes that have been stored in undamaged packages that resist moisture or use only flux cored welding
electrodes that have been stored in an oven at 120 °C (250 °F).
Welding parameters will vary due to the welding position and due to the manufacturer of the welding electrode. A 1.3 mm (0.051 inch) electrode
diameter will typically have the following welding parameters:
Table 6
Parameters for Welding
Wire Feed Rate Voltage Approximate Amperage
6/9/23, 11:57 AM SIS 2.0
Minimum 200 inches per minute 24 210

Optimum 275 inches per minute 28 250
Maximum 325 inches per minute 29 300
Note: Use the manufacturer's recommended welding electrode parameter.
Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every weld pass. The width of the weld
should not exceed two times the electrode diameter.
Refer to "Weld Specifications and Parameters" for more welding guidelines.
Welding Instructions
The following materials are used in order to fabricate the Coal Truck Body:
400 Brinell
450 Brinell
Before welding on the Coal truck body, verify the materials that are used in order to fabricate your particular Coal Truck Body. There are specific
welding procedures for each material. Refer to the following procedures in order to weld the materials during the assembly of the truck body.
Note: When two or more different materials need to be welded together, use the procedure for the material that has the more stringent
requirements.
400 Brinell or 450 Brinell Hardness Number Material

The following procedure covers the requirements for welding the assembly of the Coal Truck Bodies that are fabricated with 400 Brinell material or
450 Brinell material. Refer to "Weld Specifications and Parameters" for qualifications, safety, and welding electrode parameters. Attach the welding
ground cable directly to the body assembly. Protect all of the machined areas from sparks and spatter that are produced by welding, chipping, and
grinding operations.
PSP
-
6/9/23, 11:57 AM SIS 2.0
202 0009
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.
NOTICE
3 /
03: 06/0 16D 2
5 7 9
400 Brinell and 450 Brinell are sensitive to hydrogen induced
RE :38+
cracking. Cleanliness of the weld joints and of the consumables
is of utmost importance.
H S
© 2 442 8:00 0
Tight fitup of the body assemblies is important. Ensure that every effort is made in order to minimize the gap spacing. Minimizing the gap spacing
reduces the residual stresses.
023 4
In order to minimize the possibility of cracking, use large tack welds. The tack welds should have a maximum width of 8 mm (0.32 inch) and a
Cat
length of 75 mm (3 inch).
erp
A Tiger Torch can be used in order to preheat the material that is welded. Preheating is most critical during the tack welding procedure and during
the welding of the root pass. Refer to table 7 for the required preheat temperature of the weld area.
illa
r In
Table 7
Preheat Temperatures
Combined Thickness of Material Welding Preheat

0 mm (0.0 inch) to 65 mm (2.6 inch) 100 °C (212 °F)
c.
66 mm (2.6 inch) to 100 mm (3.9 inch) 125 °C (257 °F)
greater than 100 mm (3.9 inch) 175 °C (350 °F)
Ensure that the weld groove and 76 mm (3 inch) in each direction from the weld groove is preheated to the specified temperature. Verify the
preheat temperature with a 164-3310 Infrared Thermometer or with a temperature stick.
6/9/23, 11:57 AM SIS 2.0
The minimum interpass temperature should equal the preheat temperature. The maximum interpass temperature should not exceed 250 °C
(480 °F).
Note: The above preheat and interpass temperatures are for mild restraint to moderate restraint. If clamping devices are utilized in order to reduce
the gap spacing to less than 3 mm (0.12 inch), use the next higher preheat temperature, when possible. Additional stresses are offset by using the
next higher preheat temperature.
Note: When the ambient temperature is below 0 °C (32 °F), the initial preheat temperature should be raised to 121 °C (250 °F). Preheat 76.0 mm
(3.0 inch) in each direction from the weld joint. Temperature control will help avoid possible heat sink of the floorplates.
Inspect all welded areas. Hydrogen induced cracking normally occurs within 72 hours of welding. Allow the welded areas to cool for 48 hours to 72
hours prior to performing a visual inspection. If any welding areas are suspected of being cracked during the visual inspection, then use the dye
penetrant process or the magnetic particle inspection process in order to inspect the welding areas. The welds shall be free from the following
defects: cracks, porosity, undercut and incomplete fusion. All weld quality shall conform to American National Standards Institute (ANSI)/American
Welding Society (AWS) D14.3.
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weight's in order to determine the
application when you select the 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.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Illustration 1
Cat
Lift angles for lifting slings.
g00629745
erp
(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.
illa
(C) The load capacity is 70% of the working load limit for the sling.
(D) The load capacity is 50% of the working load limit for the sling.
The Site for Assembly

r In
c.
The following photographs are of the shipping configuration.
The Coal Truck Body will be delivered in four assemblies.
6/9/23, 11:57 AM SIS 2.0
Center Body Assembly
Left Hand Body Assembly
Right Hand Body Assembly
Canopy Assembly
Illustration 2 g01659753
(1) Center body assembly
6/9/23, 11:57 AM SIS 2.0
(2) Left-hand body assembly
(3) Right-hand body assembly
ater
pill
6/9/23, 11:57 AM SIS 2.0
ar I
n c.
(4) Canopy assembly
Assembly Procedure
6/9/23, 11:57 AM SIS 2.0
1. Position center body assembly (1) inside the work area.
EH 8+0
© 2 S442 8:00
6/9/23, 11:57 AM SIS 2.0
023 4
Cat
erp
illa
r In
c.
Illustration 6 is a view of the edges that need to be cleaned prior to assembly.
6/9/23, 11:57 AM SIS 2.0
Prepare the rib joints for welding.
Prepare the front transition plate and the front wall for welding.
2. Use a grinder in order to clean the welding areas of center body assembly (1). Completely remove all paint, rust, scale, slag, dirt, and moisture
before welding. Refer to Illustration 6 through Illustration 8.
Note: All of the welding areas on center body assembly (1) should now be cleaned.
6/9/23, 11:57 AM
023 0092 SIS 2.0
03: /06/0 16D

RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
Illustration 9
illa g01660599
r In
Top view of spacer (5).
3. Fabricate six spacers (5) with the following dimensions:
c.
(A) Length ... 50.8 mm (2 inch)
(B) Width ... 25.4 mm (1 inch)
(C) Thickness ... 6.0 mm (0.25 inch)
Note: The spacers will be used to obtain the correct root opening of 6.0 mm (0.24 inch) between the center body assembly and the two other
body assemblies.
6/9/23, 11:57 AM SIS 2.0
View of spacer (5) that is tack welded to center body assembly (1).
6/9/23, 11:57 AM SIS 2.0
Illustration 11
PSP g01661308
View of the location of the spacers that are tack welded along the right side of the center body assembly.
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
View of the location of the spacers that are tack welded along the right side of the front wall.
illa
4. Tack weld three spacers (5) to the right side of center body assembly (1). Repeat for the left side of center body assembly (1). Refer to
Illustration 10 through Illustration 12.
r In
Note: Before tack welding, preheat the welding areas to the proper temperature. Refer to "Weld Specifications and Parameters". Use 164-
3310 Infrared Thermometer in order to check for the proper preheat temperature.
c.
6/9/23, 11:57 AM SIS 2.0
View of preparing to turn over the center body assembly.
5. Attach four suitable lifting devices to the center body assembly. Attach two of the lifting devices to the two lifting eyes that are located along the
left side of the body assembly and secure to a suitable hoist. Attach the other two lifting devices to the two lifting eyes that are located along
the right side of the body assembly and secure to another suitable hoist. The center assembly weighs approximately 6500 kg (14330 lb).
6/9/23, 11:57 AM SIS 2.0
6. Use the two hoists in order to turn over center body assembly (1).
llar
Inc
6/9/23, 11:57 AM SIS 2.0
7. Remove the lower lifting devices from the hoist and from the lower lifting eyes.
Note: Leave the other two lifting devices attached to the center body assembly and to the hoist.
.
View of the two lifting devices that are attached to the bottom side of the center body assembly.
8. Attach one lifting device to the lifting eye that is located on the bottom side of the center body assembly. Attach one lifting device to the lifting
eye that is located on the front wall of the center body assembly. Secure the lifting devices to a suitable hoist. Refer to Illustration 16.
6/9/23, 11:57 AM SIS 2.0
View of center body assembly (1) that is being turned over.
202 424 0
3C
6/9/23, 11:57 AM SIS 2.0
ater
View of center body assembly (1) that is turned over.
pill
9. Use the two hoists in order to finish turning over center body assembly (1).
ar I
n c.
10. Remove the two lifting devices that are attached to the floor.
6/9/23, 11:57 AM SIS 2.0
11. Attach one lifting device to the lifting eye that is located on the bottom side of the center body assembly. Attach one lifting device to the lifting
eye that is located on the front wall of the center body assembly. Secure the lifting devices to a suitable hoist.
3:5 6/09 6D
RE 7:38+
6/9/23, 11:57 AM SIS 2.0
H S
© 2 442 8:000
023 4
Cat
erp
illa
r In
Illustration 21
12. Use the two hoists in order to raise center body assembly (1) level.
13. Locate the center body assembly in the center of the work area.
c.
g01661357
6/9/23, 11:57 AM SIS 2.0
14. Position two 203 mm (8.0 inch) wood blocks underneath the front wall. Position two 203 mm (8.0 inch) wood blocks underneath the rear of the
body assembly.
6/9/23, 11:57 AM
PSP SIS 2.0
-
202 0009
3 /
03: 06/0 16D 2
5 7
RE :38+ 9
H S
© 2 442 8:00 0
023 4
Illustration 23
Cat
15. Remove the lifting devices from center body assembly (1).
g01661359
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
16. Locate left-hand body assembly (2) and right-hand body assembly (3) in the work area.
View of attaching two lifting devices to the left-hand body assembly.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
Illustration 26
5 7
RE :38+ 9 g01664076
H
View of moving left-hand body assembly (2) away from right-hand body assembly (3).
0
17. Attach two suitable lifting devices to the lifting holes that are located in the left-hand body assembly. Secure the lifting devices to a suitable
S
© 2 442 8:00
hoist. The left-hand body assembly weighs approximately 3700 kg (8160 lb).
023 4
18. Move left-hand body assembly (2) away from right-hand body assembly (3).
Cat
erp
illa
r In
c
6/9/23, 11:57 AM SIS 2.0 c.
19. Position the left-hand body assembly onto the ground.
20. Use a grinder in order to clean the welding areas of the left-hand body assembly. Completely remove all paint, rust, scale, slag, dirt, and
moisture before welding.
6/9/23, 11:57 AM SIS 2.0
21. Raise left-hand body assembly (2).
Cat
erp
6/9/23, 11:57 AM SIS 2.0
Illustration 29
il g01664135
View of one lifting device that is attached to the lifting eye that is located toward the front of the left-hand body assembly.
lar
Inc
.
View of one lifting device that is attached to the lifting eye that is located toward the rear of the left-hand body assembly.
22. Attach two lifting devices to the two lifting eyes that are located on the bottom side of the left-hand body assembly. Secure the lifting devices to
a suitable hoist.
6/9/23, 11:57 AM SIS 2.0
View of left-hand body assembly (2) that is being turned over.
23. Use both hoists in order to turn over left-hand body assembly (2).
RE 38 +
6/9/23, 11:57 AM
H S
© 2 442 8:00 0
SIS 2.0
023 4
Cat
erp
illa
r In
c.
24. Remove the two lifting devices that are attached to the lifting holes in the left-hand body assembly.
6/9/23, 11:57 AM SIS 2.0
View of positioning wood blocks underneath the front wall and rear corner of the left-hand body assembly.
25. Lower left-hand body assembly (2) to the ground. Position the front wall and the rear corner of left-hand body assembly (2) onto wood blocks
or a suitable support block.
Prepare this edge for welding.
202 0009
3
6/9/23, 11:57 AM SIS 2.0
/
03: 06/0 16D 2
5 7
RE :38+ 9
H S
© 2 442 8:000
023 4
Cat
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
26. Use a grinder in order to clean the welding areas of the left-hand body assembly. Completely remove all paint, rust, scale, slag, dirt, and
moisture before welding. Refer to Illustration 34 through Illustration 36.
Note: All of the welding areas on the left-hand body assembly should now be cleaned.
27. Use a suitable hoist to raise left-hand body assembly (2).
View of left-hand body assembly (2) that is aligned with center body assembly (1).
6/9/23, 11:57 AM SIS 2.0
PSP
202 0009-
03: 3 / 0 2 1 6
5 6 / 0 D
7
RE :38+ 9
Illustration 38
H S
© 2 442 8:00 0 g01664146
View of the alignment plates that are used to align the body assemblies. The alignment plates are located on the front wall of the left-hand body assembly.
023 4
Cat
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
View of the alignment plates that are located along the floor seam of the left-hand body assembly.
28. Position the left-hand body assembly (2) against center body assembly (1). Refer to Illustration 37 through Illustration 39.
Note: The alignment plates ease the alignment of left-hand body assembly (2) to center body assembly (1).
Note: 1U-9204 Lever Puller Hoist can be used to align left-hand body assembly (2) against center body assembly (1).
View of five bolts (6) and of five nuts (7) located on the bottom of center body assembly (1) and left-hand body assembly (2).
6/9/23, 11:57 AM SIS 2.0
View of two bolts (6) and of two nuts (7) that are located on the inside of the front wall.
pill
6/9/23, 11:57 AM SIS 2.0
ar I
29. Install seven bolts (6) and seven nuts (7). Do not tighten the bolts and nuts. nc.
View of center body assembly (1), left-hand body assembly (2), and spacer (5).
30. Tighten seven bolts (6) and seven nuts (7) until center body assembly (1) and left-hand body assembly (2) are tight against three spacers (5).
Note: Spacers (5) are used to obtain the correct root opening of 6.0 mm (0.24 inch) between center body assembly (1) and left-hand body
assembly (2).
31. Remove the lifting devices from left-hand body assembly (2).
6/9/23, 11:57 AM SIS 2.0
View of the angles and wedges that can be used along the outside of the front wall for alignment of the body assemblies.
©2 4 0 0
023 24
6/9/23, 11:57 AM SIS 2.0
Illustration 45
Cat g01664754
View of the angles and wedges that can be used along the inside of the front wall for alignment of the body assemblies.
erp
illa
r In
c.
View of the angles and of the wedges that can be used along the floor seam for alignment of the body assemblies.
32. Use angles and wedges to help align the left-hand body assembly (2) to the center body assembly (1). Refer to Illustration 44 through
Illustration 46.
Note: Also, the body assemblies can be aligned by the use of bolts, nuts, and lugs.
Note: Before tack welding any angles to the body assembly, use a grinder in order to clean the welding areas. Completely remove all paint,
rust, scale, slag, dirt, and moisture before welding.
6/9/23, 11:57 AM SIS 2.0
View of gap spacing (D) that is necessary along the seam between the center body assembly and the left-hand body assembly.
(D) 6.0 mm (0.24 inch)
33. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left-hand body assembly.
Note: If necessary, use an air carbon arc to enlarge gap spacing (D) to 6.0 mm (0.24 inch). Use a grinder to clean the slag from gap (D).
03: 06/0 6D
5
6/9/23, 11:57 AM SIS 2.0
7
RE :38+ 9
H S
© 2 442 8:000
023 4
Cat
erp
illa
r In
c.
View of right-hand body assembly (3) that is aligned with center body assembly (1).
34. Repeat Step 17 through Step 33 for right-hand body assembly (3). The right-hand body assembly weighs approximately 3700 kg (8160 lb).
6/9/23, 11:57 AM SIS 2.0
(E) 6150 mm (242 inch)
Note: Dimension (E) is measured at the highest point and the outermost point forward.
6/9/23, 11:57 AM
PSP SIS 2.0
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
This view of the body upside-down shows measuring the front wall to obtain dimension (E).
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
35. Before tack welding right body assembly (3) to center body assembly (1), ensure that the overall width of the front wall equals dimension (E). If
necessary, equally maneuver left-hand body assembly (2) and right-hand body assembly (3) until the overall width does equal dimension (E).
Dimension (E) must be equal to dimension (F) in order for canopy assembly (4) to fit correctly with the assembled body.
36. Before tack welding, preheat the welding areas of center body assembly (1) and left-hand body assembly (2) to the proper preheat
temperature. Refer to "Weld Specifications and Parameters". Use 164-3310 Infrared Thermometer in order to check for the proper preheat
temperature.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
3
8+0
Bottom view of the areas that are tack welded along the floor seam and the rib joints.
H
Note: As required, trim the ends of the ribs in order to achieve 100% penetration of the joint.
© 2 S442 8:00
023 4
Cat
erp
illa
r In
c
6/9/23, 11:57 AM SIS 2.0 nc.
View of the areas that are tack welded along the outside of the front wall.
37. Tack weld the left-hand body assembly to the center body assembly.
38. Repeat Step 36 through Step 37 for right-hand body assembly (3).
39. Remove all nuts, bolts, lugs, wedges, and angles. Grind the welds smooth.
40. Use a string or a straight edge in order to ensure that the side walls are correctly aligned.
6/9/23, 11:57 AM SIS 2.0
41. Weld temporary braces (G) in order to prevent the side wall and the floor from moving.
42. Preheat the seam between center body assembly (1) and left-hand body assembly (2).
Note: Before welding, preheat the welding areas to the proper temperature. Refer to "Weld Specifications and Parameters". Use 164-3310
Infrared Thermometer in order to check for the proper preheat temperature.
6/9/23, 11:57 AM
Cat SIS 2.0
erp
il lar
Inc
.
(W1) 5 mm (0.20 inch) Fillet weld
(W2) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.060 inch) root penetration
6/9/23, 11:57 AM SIS 2.0
(W3) 5 mm (0.20 inch) Double side bevel groove weld
(W4) 8 mm (0.32 inch) Double side fillet weld with 1.5 mm (0.060 inch) root penetration
RE 38+0
H
6/9/23, 11:57 AM SIS 2.0
© 2 S442 8:00
023 4
Cat
erp
illa
r In
c.
(W6) 4 mm (0.16 inch) V-groove weld on top of a 10 mm (0.40 inch) bevel groove weld
43. Weld the seam between the left-hand body assembly and the center body assembly.
Note: Remove the slag after every weld pass.
44. Repeat Step 42 through Step 43 for the right-hand body assembly.
45. Preheat the floor seam.

6/9/23, 11:57 AM SIS 2.0
(W7) 8 mm (0.32 inch) V-groove weld
(W8) 8 mm (0.32 inch) Bevel groove weld with a 5 mm (0.20 inch) thick, 12 mm (0.47 inch) tall fillet weld on top
(W9) 5 mm (0.20 inch) Fillet weld
46. Weld the floor seam between the left-hand body assembly and center body assembly.
47. Repeat weld (W7) for the five remaining floor ribs. Repeat weld (W8) on both sides of the five remaining floor ribs. Repeat weld (W9) for the
five remaining segments.
49. Move the body from the building to the outside.
6/9/23, 11:57 AM
202 0009 SIS 2.0
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
Illustration 60
erp g01629413
illa
Typical view of the body that is being turned over
50. Position two suitable cranes (H) and (J) near the upside-down assembled body.
r In
Note: If the lifting device becomes wrapped around the corner of the body, use the proper precautions in order to ensure safety.
c.
6/9/23, 11:57 AM SIS 2.0
51. Attach three sets of suitable lifting devices to the body. Attach one lifting device to the lifting eyes on the bottom of the body. Attach one set of
lifting devices through each of the two side walls. Refer to Illustration 61. The body assembly weighs approximately 20000 kg (44100 lb).
52. Attach lifting device (K) to crane (H) and lifting device (L) to crane (J). Lifting device (M) is not used at this time.
53. Only use one signalman for both of the cranes.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
54. Both cranes should lift the body to a suitable height. Slowly lower crane (J) and raise crane (H) until the body is vertical.
55. Lifting device (M) should be moved in the direction of the arrow for future use.
6/9/23, 11:57 AM SIS 2.0
56. Lower crane (H) and position the body vertically on the ground. Keep lifting device (K) tight so that the body does not fall. Disconnect lifting
device (L) from crane (J) and from the lifting eyes on the bottom of the body.
57. Reposition crane (J) to the other side of the body and position the boom toward the body. Connect lifting device (M) to the crane and slowly
raise the lifting device until the lifting device is tight.
pill
ar I
6/9/23, 11:57 AM SIS 2.0
nc.
58. Slowly lift the body with crane (H) while you rotate the boom of crane (H) away from the body.
Note: Do not allow the bottom of the body to move outward.
59. Once the body has started to tip, start to lower the lifting device on crane (H) and continue to rotate the boom away from the body.
6/9/23, 11:57 AM SIS 2.0
© 2 442 8:00
023 4
6/9/23, 11:57 AM SIS 2.0
Cat
erp
60. When the body starts to be dragged toward crane (H), slowly begin to raise crane (J). Raise crane (J) until the body is close to being level.
Position wood blocks under the body.
illa
r In
c.
61. Slowly lower both cranes (H) and (J) and position the body onto the wood blocks.
62. Before finish welding reposition the body inside the building.
6/9/23, 11:57 AM SIS 2.0
View of gap spacing (D) that is necessary along the seam between the center body assembly and the left body assembly.
(D) 6.0 mm (0.24 inch)
63. Ensure that there is a 6.0 mm (0.24 inch) gap spacing (D) that separates the center body assembly from the left-hand body assembly.
Note: If necessary, use an air carbon arc to enlarge gap spacing (D) to 6.0 mm (0.24 inch). Use a grinder to clean the slag from gap (D).
6/9/23, 11:57 AM
/
03: 06/0 16D 2 SIS 2.0
5 7
RE :38+ 9
H S
© 2 442 8:000
023 4
Cat
erp
illa
Illustration 71
r In g01667954
c.
64. Remove three spacers (5) that are located between center body assembly (1) and left-hand body assembly (2).
6/9/23, 11:57 AM SIS 2.0
65. Preheat the welding areas of center body assembly (1) and left-hand body assembly (2) to the proper temperature.
(W10) 14 mm (0.55 inch) Bevel groove weld
66. Weld the floor seam that connects left-hand body assembly (2) and center body assembly (1).
PSP
6/9/23, 11:57 AM SIS 2.0
-
202 0009
3 /
03: 06/0 16D 2
5 7
RE :38+ 9
H S
© 2 442 8:00 0
Illustration 74
023 4 g01668073
Cat
68. Preheat the welding areas of the front wall to the proper temperature.
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
69. Weld the seam of the front wall between left-hand body assembly (2) and center body assembly (1).
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
Illustration 76
5 7
RE :38+ 9 g01668153
H S
© 2 442 8:00 0
023 4
Cat
erp
illa
r In
c
Inc
.
6/9/23, 11:57 AM SIS 2.0
71. Use a grinder in order to clean the welding areas of plates (8). Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.
72. Preheat the welding areas of plates (8) to the proper temperature.
73. Weld plate (8) that connects left-hand body assembly (2) and center body assembly (1).
Installation of the Canopy Assembly

6/9/23, 11:57 AM SIS 2.0
View of the canopy from the back.
1. Locate canopy assembly (4).
3C
ater
6/9/23, 11:57 AM SIS 2.0
pill
ar I
nc.
Note: Dimension (F) needs to be equal to dimension (E) in order to ensure the proper fit. Dimension (E) is given in Illustration 49 of the
"Assembly Procedure" section.
6/9/23, 11:57 AM SIS 2.0
Prepare canopy assembly (4) for welding.
6/9/23, 11:57 AM 7
RE :38+ 9 SIS 2.0
Illustration 82
Prepare canopy assembly (4) for welding.
H S
© 2 442 8:000 g01668294
023 4
2. Use a grinder in order to clean the weld areas of canopy assembly (4). Completely remove all paint, rust, scale, slag, dirt, and moisture before
welding.
Cat
erp
illa
rI nc.
3. Use a grinder in order to clean the welding areas of the body. Completely remove all paint, rust, scale, slag, dirt, and moisture before welding.
6/9/23, 11:57 AM SIS 2.0
4. Attach a suitable lifting device to canopy assembly (4). Canopy assembly (4) weighs approximately 2250 kg (4960 lb).
P-0
6/9/23, 11:57 AM
202 009 SIS 2.0
Illustration 85
03: 3 / 0 2 1
g01355155
6
6
Typical view of the canopy that is being installed.
5. Raise canopy assembly (4) for installation.
57 / 0 9 D
RE :38+
H S
© 2 442 8:00 0
023 4
Cat
erp
illa
r In
Illustration 86
Note: When you position the canopy, a guide line may be necessary.
c.
g01355166
6/9/23, 11:57 AM SIS 2.0
6. Position the canopy assembly to the body.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
5 7
RE :38+ 9
Illustration 88
H S
© 2 442 8:00 0 g01668303
View of an angle and wedge that can be used for alignment of the canopy assembly to the body.
7. Use angles and wedges in order to help align the canopy assembly to the front wall and to both side walls. Also, use bolts, lugs, and nuts to
023 4
aid in the alignment procedure.
Note: Before tack welding any angles , bolts, or lugs to the body assembly, use a grinder in order to clean the welding areas. Completely
Cat
remove all paint, rust, scale, slag, dirt, and moisture before welding.
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
8. If necessary, cut the braces that are attached to the front wall in order to aid in the alignment of the canopy assembly to the front wall and to
the side walls.
9. Preheat the weld seams.

10. Once the canopy assembly is aligned, tack weld the canopy assembly to the front wall and to the side walls.
11. Preheat the seams between canopy assembly (4) and the body.
6/9/23, 11:57 AM SIS 2.0
Note: Repeat weld (W13) for the three remaining ribs.
Note: Repeat weld (W14) for the remaining two sections.
erp
6/9/23, 11:57 AM SIS 2.0
ill ar I
nc.
(W16) 8 mm (0.32 inch) Double side fillet weld with 1.5 mm (0.060 inch) root penetration
Note: Repeat weld (W15) for the other side of canopy assembly (4).
Note: Repeat weld (W16) for the three remaining ribs.
6/9/23, 11:57 AM SIS 2.0
Note: Repeat weld (W17) for the other side of canopy assembly (4).
12. Weld canopy assembly (4) to the body.
6/9/23, 11:57 AM S 0
© 2 442 8:00 SIS 2.0
023 4
Cat
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
13. Use a grinder in order to clean the welding areas of two plates (9) and two plates (10). Completely remove all paint, rust, scale, slag, dirt, and
moisture before welding.
6/9/23, 11:57 AM
3 /
03: 06/0 16D 2 SIS 2.0
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
illa
Illustration 96
15. Preheat the seam between plate (9) and the body.
r Ing01669356
c.
6/9/23, 11:57 AM SIS 2.0
16. Weld plate (9) to the body.
PSP
6/9/23, 11:57 AM SIS 2.0
-
202 0009
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
Illustration 98
17. Preheat the seam between plate (10) and the body. 023 4 g01669358
Cat
erp
illa
r In
c.
6/9/23, 11:57 AM SIS 2.0
18. Weld plate (10) to the body.
19. Repeat Step 15 through Step 18 in order to install plate (9) and plate (10) to the right-hand side of the body.
6/9/23, 11:57 AM SIS 2.0
PSP
-
202 0009
3 /
03: 06/0 16D 2
Illustration 100
RE 57 : 9
g01669533
20. Use a grinder in order to clean the welding areas of plate assembly (11). Completely remove all paint, rust, scale, slag, dirt, and moisture
before welding.
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
illa
r In
r In
c.
6/9/23, 11:57 AM SIS 2.0

22. Use a suitable lifting device in order to position plate assembly (11) to the body. Plate assembly (11) weighs approximately 545 kg (1200 lb).
Note: Lifting eyes may be welded onto plate assembly (11) in order to assist in positioning.
6/9/23, 11:57 AM SIS 2.0

23. Preheat the seams between plate assembly (11) and the body.
23
Cat
6/9/23, 11:57 AM SIS 2.0
erp
il lar
Inc
.

(W22) 10 mm (0.40 inch) Flare bevel groove weld
6/9/23, 11:57 AM SIS 2.0

57 : 0 9
6/9/23, 11:57 AM
RE 3 8+0
SIS 2.0
H
© 2 S442 8:00
023 4
Cat
erp
illa
r In
Illustration 105
g01669916
c.
6/9/23, 11:57 AM SIS 2.0

24. Weld plate assembly (11) to the body.
SP-
202 0009
6/9/23, 11:57 AM SIS 2.0
3 /
03: 06/0 16D 2
RE 57 : 9
H 3 8+0
© 2 S442 8:00
023 4
Cat
erp
25. Repeat Step 20 through Step 24 for plate assembly (12).
Miscellaneous illa
r In
1. Remove all lifting eyes, alignment blocks, lugs, stiffeners, and braces from the truck body if shipping is not required. Grind the welds smooth
prior to touch up painting and installation to the chassis.
c
Note: If the body is shipped, some lugs or lifting eyes may be needed for tie-downs.
.
2. Ensure that all welds have been inspected.
Reference: "Weld Specifications and Parameters" and "Welding Instructions"
3. Clean the entire truck body.
4. Repaint the truck body, as needed.
6/9/23, 11:57 AM SIS 2.0
Liner Groups
Note: Body liner plates are installed after the body assembly is completed.
Note: The protection plates for the body should be welded around the entire perimeter. A minimum of three weld passes is necessary in order to
plug the holes or slots.
Installation of the Rock Ejector Brackets

Note: Rock ejector bracket (13) is an optional factory installed item. Refer to Special Instructions, "Off-Highway Truck Assembly Procedure" for the
correct model of truck in order to obtain the proper alignment of the 321-5444 Rock Ejector Bracket.
Note: The procedure that is performed is with an installed body assembly.
6/9/23, 11:57 AM SIS 2.0
Note: When the body is fully assembled, all lifting eyes must be removed from the bottom of the body, floor, front wall, canopy, and side walls. If the
eyes on the bottom of the body are needed for transportation, then remove the lifting eyes before installing the body to the chassis.
PSP
PSP-0009216D
2023/06/09
03:57:26+08:00
i03258152
© 2023 Caterpillar Inc. -
202 0009
3/ 2

Assembly Procedure of The Truck Os Mcoal Mining Body

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Assembly Procedure of The Truck Os Mcoal Mining Body

Uploaded by

Copyright:

Available Formats

6/9/23, 11:57 AM SIS 2.

SMCS - 7258, 7960 i08750902

Revision Summary of Changes

Improper assembly procedures could result in injury or death.

Attachments for the 321-5410 Coal Truck Body

Item Qty Part Number Description

3 1 321-5317 Right Hand Body Assembly

Weights and Required Tools

Approximate Shipping Weights

Use the MSO in order to determine lifting requirements.

Weld Specifications and Parameters

480 MPa (69600 psi) Tensile Strength

400 MPa (58000 psi) Yield Strength

22 percent elongation in 50 mm (2 inch)

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

Parameters for Welding

400 MPa (58000 psi) Yield Strength

22 percent elongation in 50 mm (2 inch)

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

Parameters for Welding

Wire Feed Rate Voltage Approximate Amperage

Minimum 200 inches per minute 24 210

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

Refer to "Weld Specifications and Parameters" for more welding guidelines.

400 Brinell or 450 Brinell Hardness Number Material

Combined Thickness of Material Welding Preheat

Specifications for Cables, Chains, and Lifting Devices

The Site for Assembly

The Coal Truck Body will be delivered in four assemblies.

Center Body Assembly

Left Hand Body Assembly

Right Hand Body Assembly

1. Position center body assembly (1) inside the work area.

03: /06/0 16D

(B) Width ... 25.4 mm (1 inch)

(C) Thickness ... 6.0 mm (0.25 inch)

27. Use a suitable hoist to raise left-hand body assembly (2).

PSP SIS 2.0

45. Preheat the floor seam.

49. Move the body from the building to the outside.

202 0009 SIS 2.0

53. Only use one signalman for both of the cranes.

Installation of the Canopy Assembly

1. Locate canopy assembly (4).

202 009 SIS 2.0

9. Preheat the weld seams.

Note: Repeat weld (W13) for the three remaining ribs.

Note: Repeat weld (W14) for the remaining two sections.

Note: Repeat weld (W16) for the three remaining ribs.

Illustration 101 g01669535

Illustration 102 g01669553

Illustration 103 g01669554

Illustration 104 g01669915

Illustration 106 g01669917

3. Clean the entire truck body.

4. Repaint the truck body, as needed.

Installation of the Rock Ejector Brackets

Illustration 108 g01668235

Note: The procedure that is performed is with an installed body assembly.

You might also like