Assembly Procedure For The Dual Slope Body For The 777F and 777G Off-Highway Truck

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Welcome: r160vxc
Product: TRUCK
Model: 777F TRUCK JRP
Configuration: 777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine
Special Instruction
Assembly Procedure for the Dual Slope Body for the 777F and 777G Off-Highway Truck{7258,
7960}
Media Number -REHS2653-03 Publication Date -31/07/2012 Date Updated -31/07/2012
i04889074
Assembly Procedure for the Dual Slope Body for the 777F and 777G
Off-Highway Truck{7258, 7960}
SMCS - 7258-016; 7960-016
Off-Highway Truck/Tractor:
777F (S/N: JRP1-UP)
777G (S/N: TNM1-UP; RDR1-UP)
Introduction
This special instruction contains the necessary procedures and information for the assembly and welding of the
dual slope body for the 777F and 777G Off-Highway Truck.
The entire body and the liners of the dual slope body for the 777F and 777G 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 parts box will also accompany the shipping. Support the components
when removing the shipping welds with a cutting torch in order to stabilize the components. Use the proper lifting
eyes and the designated lifting holes in the truck body in order to lift and position the truck body. This special
instruction covers the shipping configuration of the truck body that is shown in Illustration 3. There could be
variations in the procedure for shipping.
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.
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Do not attempt to assemble this machine until you read and you
understand the assembly instructions.
Improper assembly procedures could result in injury or death.
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.
Table 1
Approximate Shipping Weights
Description Weight
Body Assembly (Total)

15875 kg (34998 lb)
Body Assembly (Right Side)

9248 kg (20388 lb)
Body Assembly (Left Side)

4374 kg (9643 lb)
Canopy Assembly
1773 kg (3909 lb)
Plate Assembly (Rock Ejector)
Right or Left Side 19 kg (42 lb)
Canopy Rock Guard
Right or Left Side 56 kg (123 lb)
Canopy Rock Guard
Left Side 17 kg (37.5 lb)
Transition Plate
115 kg (254 lb)
Plate Assembly (Slipper)

47 kg (104 lb)
Bracket Assembly (Cylinder)

54 kg (119 lb)
Steel Liners
5432 kg (11975 lb)
Rubber Liners
6672 kg (14709 lb)
Body Assembly
Right Side with Steel Liners Only 12731 kg (28067 lb)
Body Assembly
Right Side with Steel Liners and Rubber Liners 14863 kg (32767 lb)
Body Assembly
Left Side with Steel Liners Only 5968 kg (13157 lb)
Body Assembly
Left Side with Steel Liners and Rubber Liners 8100 kg (17857 lb)
Canopy with Steel Liners Only

2042 kg (4502 lb)
Parts List
Table 2
Required Parts for the Installation of the 242-3170 Body and Canopy As for the 777F and 777G Truck
Qty Part Number Description
1 251-0950 Canopy As
1 251-0940 Body As (LH side)
1 128-0626 Body As (RH side)
7 2J-3507 Full Nut
7 2B-7218 Bolt
1 128-5240 Bracket As
1 8X-2558 Plate Assembly (Slipper)
1 128-5239 Transition Plate
114-2310 (1) Guard As (RH side)
1
290-3281 (1) Guard As (LH side)
1
1
2 377-6360 (3) (1) Plate As
(1)
Used on 777F Dual Slope Body.
(2)
Used on 777G Dual Slop Body, and 777F replacement body.
(3)
Not required if the truck is equipped with side boards.
Table 3
Required Parts for the Installation of the 297-2804 Body Liner Gp for the 277-3212 Dual Slope Body for
the 777G Off-Highway Truck (If Equipped) and Replacement Body for 777F Off-Highway Truck
2 129-0386 (1) Plate
2 129-0387 Plate
1 129-0388 Plate
1 129-0389 (1) Plate
1 129-0390 Plate
2 129-0393 Plate
1 129-0394 (1) Plate
2 129-0395 Plate
2 129-0397 (1) Plate
1 129-0399 Plate
4 297-2802 Plate
2 297-2803 Plate
2 359-4908 (2) Plate
(1)
Plate to be installed after finish welding body and canopy assembly.
(2)
Position and weld side plates after corner plates.
Table 4
Required Parts for the Installation of 242-3145 Rubber Body Liner Gp for the 242-3170 Dual Slope Body
for the 777F and 777G Truck (If Equipped)
1 269-8517 (1) Rubber Liner Assembly

1 270-0368 Tail Bar Plate Assembly
128 308-6689 Weld Stud
128 274-1338 Rubber Plug
128 2J-3506 Full Nut
128 7X-0564 Hard Washer
2 305-3438 (1) Plate
2 129-0391 Plate
2 129-0392 Plate
2 129-0400 Plate
2 129-0393 Plate
2 129-0395 Plate
2 129-0397 (2) Plate
2 129-0387 Plate
2 129-0386 (2) Plate
4 297-2802 Plate
2 297-2803 Plate
(1)
Place rubber liners and plate assemblies in truck body to locate weld studs.
(2)
Plate to installed after finish welding body and canopy.
Truck Dimensions
Table 5
Measurements for the Truck Body
Body with canopy

9828 mm (386.93 inch)
Lengths
Body without canopy
7229 mm (284.61 inch)
Body with canopy

2954 mm (116.30 inch)
Height
Body without canopy
2196 mm (86.46 inch)
Width Body with canopy and rock guards
6048 mm (238.11 inch)
Body without canopy and rock guards

5512 mm (217.01 inch)
Required Tools
List of tools that are needed to assemble the body.
Table 6
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
Cables
Chains
Numerous -
Hooks
Shackles
1 -
1.83 m (6 ft) Ladder
1 -
1.2192 m (4 ft) Level
Illustration 1 g01010440
View of the wedges and brackets
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 7 and Illustration 1 give the dimensions that will be used to make the brackets and wedges.
Table 7
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 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) A5.5. The finished weld 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)
• 27 N·m (20 lb ft) at −29 °C (−20 °F) Notch 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 8
Parameters for Welding
Diameter Amperage
70-140
3 mm (.12 inch)
110-180
4 mm (.16 inch)
190-270
5 mm (.20 inch)
Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every
weld pass. The width of the weld should not exceed two times the electrode diameter.
As an alternative process, use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding
electrode and the 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)
• 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 9
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.
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.
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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
Body assembly, parts box, and rubber body liners
1. Use a suitable crane and a suitable lifting device in order to remove the body assembly from the truck. One
mobile crane with a total lifting capacity of 31780 kg (70063 lb) can be used for this procedure. See
Weights. Remove the parts box and the liners (if equipped) from the truck.
2. Use a lift truck in order to position the banded box and liners away from the work area.
Installing the clevis onto the canopy
3. Attach the lifting device onto 251-0950 Canopy Assembly .
Cutting shipping support
4. Cut the shipping support and remove 251-0950 Canopy Assembly from the remaining body assembly.
5. Place 251-0950 Canopy Assembly away from the work area.
The body sides nested together.
Cutting the shipping support
6. Attach the lifting device to 251-0940 Body Assembly . Cut the shipping supports that support the body
assembly. Use a suitable crane in order to remove 251-0940 Body Assembly from 128-0626 Body
Assembly . 251-0940 Body Assembly weighs about 4288 kg (9453 lb).
Left side of the body assembly
7. Position 251-0940 Body Assembly away from the work area.
Assembly Procedure
Procedure for the Assembly of 242-3170 Body and Canopy As for the 777F and 777G Truck
Table 10
Required Parts for the Installation of the 242-3170 Body and Canopy As for the 777F and 777G Truck
Item Qty Part Number Description
1 1 251-0950 Canopy As
2 1 251-0940 Body As (LH side)
3 1 128-0626 Body As (RH side)

4 7 2J-3507 Full Nut
5 7 2B-7218 Bolt
6 1 128-5240 Bracket As
7 1 8X-2558 Plate Assembly (Slipper)
8 1 128-5239 Transition Plate
9 1
10 1
11 1
12 2 377-6360 (3) (1) Plate As
(1)
Used on 777F Dual Slope Body.
(2)
Used on 777G Dual Slop Body, and 777F replacement body.
(3)
Not required if the truck is equipped with side boards.
Note: Remove any dirt, grease, and paint from any weld areas.
Note: The assembly procedure starts with the body upside-down.
The right side of the body before being flipped
Turning the right side of the body
1. Position a suitable crane in order to turn over body assembly (right side) (3). Body assembly (right side) (3)
weighs approximately 9248 kg (20388 lb).
Position body assembly (right side) (3) onto blocks upside-down.
Body assembly (right side) (3) in the upside-down position
2. Position blocks that are the same size under the front rail and the side rail of body assembly (right side) (3).
Positioning body assembly (right side) (3) on blocks and making body assembly (right side) (3) level allows
body assembly (left side) (2) to be slid into position for welding.
Level the back edge of body assembly (right side) (3) .
3. Use enough blocks on the back side of body assembly (right side) (3) to make the back edge level.
4. Check the angle with a level. If a 203 mm (8.0 inch) block is used on the front and the side rails in order to
support the body, the height of blocking that is needed at the back edge of the body is approximately 875
mm (34.5 inch).
Body assembly (left side) (2) turned upside-down.
5. Use a suitable crane and a suitable lifting device in order to turn over body assembly (left side) (2). Body
assembly (left side) (2) weighs approximately 4374 kg (9643 lb).
6. Turn body assembly (left side) (2) to the upside-down position.
7. Make sure that the edges of the joints on body assembly (left side) (2) and on body assembly (right side) (3)
have been cleaned and prepared for welding. If necessary, trim the joints in order to ensure a correct fit. A
slight chamfer or a radius on the edge of the backup strip may help assembly.
Position the two sides together.
8. Attach body assembly (left side) (2) to a suitable crane and lift into position next to body assembly (right
side) (3). Body assembly (left side) (2) weighs approximately 4374 kg (9643 lb).
9. Use the blocks of the same size under the side and front rails on body assembly (left side) (2) that were used
on body assembly (right side) (3) .
The support blocks under the back edge
10. 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.
The right side and left side are ready to be placed together.
11. Slide body assembly (left side) (2) into position next to body assembly (right side) (3) .
Install the bolts and nuts.
12. Install seven bolts (5) and seven full nuts (4) into body assembly (left side) (2) and body assembly (right
side) (3) in order to position the two halves of the body.
The hydraulic jacks are used to level the body.
13. Use two 1U-9755 Hydraulic Jacks per side in order 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.
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 in order to hold the correct gap that is needed for welding.
15. Tighten seven bolts (5) until body assembly (left side) (2) contacts the five stops that are on body assembly
(right side) (3). Refer to Illustrations 22 and 23.
16. Adjust the hydraulic jacks during the assembly procedure, if necessary.
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 in order to ensure a good weld penetration. Ensure that there is a
6.0 mm (0.24 inch) gap spacing that separates the right body assembly from the left body assembly.
Note: If necessary, use air arc gouging in order to enlarge the gap spacing to 6.0 mm (0.24 inch). Use a
grinder to clean the slag from the gap.
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.
Wedge and bracket
Note: Refer to Table 11 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 7 for dimensions in order to fabricate the brackets and wedges.
19. The brackets and wedges can be used throughout the welding process in order to align the weld seams. Use
as many brackets and wedges as required. Remember to grind the tack welds smooth before painting.
Table 11
Weld Tolerance
Weld Description
W1
10.0 mm (.40 inch) fillet weld
Critical points of alignment that should be flat and parallel
The back edge should be flat and level.
20. A point that is critical for alignment is at the top of the front wall. The critical point is the point of contact
for body assembly (left side) (2) and body assembly (right side) (3) .
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 in order to ensure a good fit of the canopy.
22. The top of the two side walls should be reasonably parallel. Check the rails visually.
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 distance between the strings will indicate parallel walls. This process is similar
for a frame of a door.
24. The rear edge of the floor should be reasonably flat.
(G) 5200 mm (205 inch)
25. Before finish welding right body assembly (3) to left body assembly (2), ensure that the inside width of the
front wall equals dimension (G). If necessary, maneuver right body assembly (2) until the inside width does
equal dimensions (G). Dimension (G) must be equal to dimension (Q) in order for canopy assembly (1) to fit
correctly with the assembled body. Dimension (Q) is given in Illustration 60.
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 22 and 23 for the location of the stops.
Tack weld the ribs on the bottom of the body.
Tack weld the ribs on the front wall.
26. 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 Illustrations 33, 34, and 35 for welding locations. Refer to Tables 12 and 13 for the welding
dimensions and specifications for the front wall and ribs.
27. Remove the bolts, nuts, and brackets from the body prior to finish welding the perpendicular welds.
Removing the bolts, nuts, and brackets helps give clearance for a good weld on the seam.
28. Repeat the welding procedure for the floor of the truck body. Refer to Illustration 36 for the welding
locations. Refer to Tables 14 and 15 for the welding dimensions and specifications.
View of the front wall and welding specifications
Section A-A and welding specifications
N1-Welding which uses mild steel, low hydrogen welding filler metals rather than SMAW welding electrodes
Section B-B and welding specifications
29. Remove the bolts, nuts, clamps, and brackets prior to finish welding the horizontal welds.
Table 12
Welding Dimensions
Item Dimensions
G
5200 mm (205 inch)
H
120 ± 2 mm (4.72 ± 0.08 inch) (3 places)
J
5 ± 1 mm (0.20 ± 0.04 inch)
K Remove the clamp before finish welding joint.
L
16 ± 2 mm (0.63 ± 0.08 inch) (minimum) (1)
(1)
Trim the joint in order to provide the correct gap, if necessary.
Table 13
Welding Specifications
Item Description
W2 10 mm (0.40 inch) fillet weld with

2 mm (0.079 inch) weld penetration (three rails to length) (1)
W3
5 mm (0.20 inch) bevel groove weld
W3 should be followed with a
W4 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)
W5
12 mm (0.47 inch)bevel flush weld (2) (3)
W6
10 mm (0.40 inch) square groove weld
W7
10 mm (0.40 inch) square groove weld (both sides)
W8
10 mm (0.40 inch) square groove weld (3)
(1)
The opening should be sealed by the weld.
(2)
Finish weld after all of the clamps are removed.
(3)
Tack welding and welding of the backup strips should be completed from the weld joint side only.
View of the underside of the body assembly and welding specifications
30. Clean all of the weld areas.
Table 14
Welding Dimensions
Item Dimensions
M
16 ± 2 mm (0.63 ± 0.08 inch)
N
146 ± 4 mm (5.75 ± 0.16 inch)
Table 15
Item Description
W9

Both side (10 ribs)
12 mm (0.47 inch) fillet weld with

W10 1.5 mm (0.059 inch) weld penetration
The length of the fillet weld should be
146 mm (5.75 inch). (1)
W11
20 mm (0.79 inch) bevel flush weld (2 places) (2)
(1)
Weld the 10 ribs on both sides.
(2)
Finish weld after all of the clamps are removed.
Parts box for shipping
31. Prepare to install bracket assembly (cylinder) (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 in order to
position bracket assembly (cylinder) (6).
Tabs that are located on the bottom of the frame
Note: The three tabs go to the inside of the outside plate on bracket assembly (cylinder) (6) .
32. Use a suitable crane and a suitable lifting device in order to position bracket assembly (cylinder) (6). Bracket
assembly (cylinder) (6) weighs about 54 kg (119 lb).
Locating the bracket that is used for the hoist cylinders
33. Position the inside wall of the outside plate of bracket assembly (cylinder) (6) against the three tabs. Bracket
assembly (cylinder) (6) will fit onto the backing plate on the bottom of the body.
34. Measurement (P) in Illustration 40 is the distance between the two bracket assemblies.
35. Outline the position of the bracket on the body and then remove the bracket.
36. Remove the paint from the body around the outline and the bracket in order to ensure a good weld.
37. Reposition bracket assembly (cylinder) (6) onto the body and tack weld bracket assembly (cylinder) (6) in
place.
38. Check the distance between the two brackets.
39. Refer to Illustration 40, Table 16, and Table 17 for the specifications for welding and the locations for
bracket assembly (cylinder) (6) .
Note: The plate assemblies for the rock ejectors are preassembled. Tack weld angled braces to the left or
right side plate assembly for the rock ejector before the body assembly is turned over. Tack welding angled
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.
The specifications for welding and location of bracket assembly (cylinder) (6) on the underside of the body assembly
40. Clean the weld areas.
Table 16
Welding Dimension
Item Description
P 1970 ± 3 mm (77.56 ± 0.12 inch)

(The locating tabs should be flush with the inside of the bracket assembly.)
Table 17
Item Description

1.5 mm (0.059 inch) weld penetration (2 places)
W13

1.5 mm (0.059 inch) weld penetration
8X-2558 Plate Assembly (Slipper) (7)
41. Use an appropriate lifting device and remove plate assembly (slipper) (7) from the parts box and remove any
paint or dirt for welding purposes. The approximate weight of plate assembly (slipper) (7) is 41 kg (90 lb).
The locating tabs on the front wall
42. Position plate assembly (slipper) (7) over the tabs. The inside edge of the back plate should be against the
tabs.
Plate assembly (slipper) (7) in position on the front wall
43. Position plate assembly (slipper) (7) onto the middle rib against the vertical rib that is located on the front
wall. Grind the second rib down before positioning plate assembly (slipper) (7). Plate assembly (slipper) (7)
should be symmetrical with the plate assembly (slipper) on the right-hand side of the body.
44. Outline the plate assembly (slipper) on the body.
45. Remove plate assembly (slipper) (7) from the body.
46. Remove the dirt and paint that is in the weld areas on the plate and the body.
47. Reposition plate assembly (slipper) (7) over the tabs and into the position onto the front wall.
48. Refer to Illustration 44 and Table 18 for the specifications for welding and the location of plate assembly
(slipper) (7) .
The specifications for welding and location of plate assembly (slipper) (7) on the front wall
Table 18
Item Description


W16
10 mm (0.40 inch) convex flare-bevel-groove weld
W17
6 mm (0.24 inch) fillet weld
50. 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.
51. Grind off any excessive weld.
The shipping bracket
52. Remove the shipping bracket from the bottom of body assembly (right side) (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.
53. Use the lifting holes in the side walls with straps and sleeves in order to turn the body assembly. The straps
and lifting devices should be installed by a qualified person. Care should be taken in order to minimize paint
damage that is caused by the placement of the lift cable.
Rotate the body to an upward position.
54. After the body assembly is turned over, place the body assembly on blocks.
Wedges and brackets on the floor
55. Use the bracket and wedge in order to make the floor flush at the seam.
56. Remove all the guides and lifting eyes.
57. Weld the floor and the front wall inside seam. Refer to Illustration 35, Illustration 36, Table 13, and Table 15
for the welding dimensions and welding specifications.
58. Tack weld a lifting eye onto transition plate (8). Use a suitable crane and a suitable lifting device in order to
position the transition plate onto the body. Transition plate (8) weighs about 115 kg (254 lb).
The transition plate
59. Place transition plate (8) into position at the bottom of the front wall on the inside of the body.
60. Outline the transition plate onto the floor and the wall of the body.
The outline of the transition plate is clean and prepared for welding.
Close up of the backing plate
61. Remove the dirt and paint from the edges of the plate and the outline on the floor and wall.
62. Reinstall transition plate (8) onto the floor and the wall.
63. Tack weld the transition plate into position and check the dimensions before finish welding. Refer to
Illustration 52 and Table 19 for the correct specifications for welding and the welding locations.
Finish welded plate (8) .
64. Finish weld plate (8) to the floor and the front wall.
Note: Remove the lifting eye and grind the tack weld flush.
Welding specifications for plate (8)
Table 19
Welding Specification
Item Description
W18
18 mm (0.71 inch) convex bevel groove weld
66. Grind all the welds flush on the inside of the body so that the body liner (if equipped) will fit flat.
Preparing the canopy
Note: Canopy Rock Guard (Right Side) (9) and Canopy Rock Guard (Left Side) (10) can be installed on
Canopy Assembly (1) while Canopy Assembly (1) is on the ground or after Canopy Assembly (1) is
installed on the body.
67. Remove the dirt and paint from the weld areas on the canopy and the rock guard.
Positioning the rock guard
68. Tack weld a lifting eye onto Canopy Rock Guard (Right Side) (9). Use a suitable crane to position the guard
onto the body. Canopy Rock Guard (Right Side) (9) weighs about 56 kg (123 lb).
69. Weld the rock guard to the canopy. Refer to Illustration 61, Illustration 62, and Table 20 for the correct
specifications for welding and the welding locations.
71. Repeat the same procedure for Canopy Rock Guard (Left Side) (10) on the other side of Canopy Assembly
(1) .
72. Tack weld a lifting eye onto Canopy Rock Guard (Left Side) (11). Use a suitable crane to position the guard
onto the body. Canopy Rock Guard (Left Side) (11) weighs about 17 kg (37.5 lb).
73. Weld the rock guard to the canopy. Refer to Illustration 63, and Table 20 for the correct specifications for
welding and the welding locations.
Positioning the canopy
74. Remove any dirt and/or paint from the weld areas on the body and canopy.
75. Use a suitable crane and a suitable lifting device in order to lift canopy assembly (1) into position. Canopy
assembly (1) weighs about 1725 kg (3802 lb).
Check for a good fit on the corner
76. 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.
77. Tack weld the canopy into position.
(Q) 5200 mm (205 inch)
78. Check the canopy for a good fit and for being level.
Note: Dimension (Q) needs to be equal to dimension (G) in order to ensure the proper fit. Dimension (G) is
given in Illustration 30.
79. Weld the canopy to the body assembly. Refer to Illustration 61, Illustration 62, and Table 20 for the
specifications for welding and the welding locations.
Note: Use the wedges and brackets in order to pull the canopy and the front wall of the truck body together
for welding.
The specifications for welding, welding locations, and Detail J for the canopy
Welding specifications and location for the rock guards and Detail J for the canopy
81. Views of the body assembly and the canopy
Note: Plate assembly (12) is not required if the truck is equipped with side boards.
(12) Plate assembly
82. Use an appropriate lifting device and position plate assembly (12) onto the side assembly.
Note: The approximate weight of plate assembly (12) is 25 kg (55 lb).
(W61) 6 mm (0.236 inch) Fillet weld
(W62) 8 mm (0.315 inch) Flare bevel groove weld
(12) Plate assembly
83. Weld plate assembly (12) to canopy assembly and side wall cap. Use (W61) for welding plate assembly (12)
to the canopy assembly. Use (W62) for welding plate assembly (12) to the side wall cap.
(12) Plate assembly
84. Weld plate assembly (12) to side wall cap using (W63). Refer to Illustration 66.
(12) Plate assembly
85. Weld inside plate assembly (12) to the canopy assembly using (W64) Refer to Illustration 67.
(W65) 8 mm (0.315 inch) Bevel groove weld
(12) Plate assembly
86. Weld plate assembly (12) to the canopy assembly using (W65). Refer to Illustration 68.
Table 20
Item Description

1.5 mm (0.059 inch) weld penetration (two places)
16 mm (0.63 inch) concave fillet weld with

W20
1.5 mm (0.059 inch) weld penetration (2 places)
See detail J on Illustration 61.
W21
4 mm (0.16 inch) fillet weld (two places)
W22
8 mm (0.32 inch) bevel groove weld (two places)

W24
4 mm (0.16 inch) bevel groove weld (two rock guards)
W25
4 mm (0.16 inch) fillet weld (two rock guards)
4 mm (0.16 inch) fillet weld (two rock guards)

W26
25 to 75 mm (1.0 to 3.0 inch ) skip weld (2 rock guards)
W27
6 mm (0.24 inch) double side fillet weld
W28
6 mm (0.24 inch) double side fillet weld (two gussets)
W61
6 mm (0.236 inch) Fillet weld (two places)
W62
8 mm (0.315 inch) Flare bevel groove weld (two places)
W63
8 mm (0.315 inch) Fillet weld
W64
8 mm (0.315 inch) Fillet weld
W65
8 mm (0.315 inch) Bevel groove weld
87. Repeat Step 82 through Step 86 for the opposite side.
Note: Before assembling the body onto the chassis, remove three lifting eyes from the canopy, the lifting
eyes 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,
REHS2594, "Assembly Procedures for the 777F Off-Highway Trucks"and Special Instruction, REHS5053,
"Assembly Procedures for the 777G Off-Highway Trucks".
88. If the body assembly does not include liners, clean all the welds and prepare the body assembly for painting.
89. Paint the body.
Procedure for the Installation of 297-2804 Body Liner Gp for the 277-
3212 Dual Slope Body for the 777G Off-Highway Truck (If Equipped)
and the Replacement Body for the 777F Off-Highway Truck
Table 21
Required Parts for the Installation of the 297-2804 Body Liner Gp for the 277-3212 Dual Slope Body for
the 777G Off-Highway Truck (If Equipped) and Replacement Body for 777F Off-Highway Truck
1 2 129-0386 (1) Plate
2 2 129-0387 Plate
3 1 129-0388 Plate
4 1 129-0389 (1) Plate
5 1 129-0390 Plate
6 2 129-0393 Plate
7 1 129-0394 (1) Plate
8 2 129-0395 Plate
9 2 129-0397 (1) Plate
10 1 129-0399 Plate
11 4 297-2802 Plate
12 2 297-2803 Plate
13 2 359-4908 (2) Plate
(1)
(2)
Note: All plates 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 plates must be installed in the field.
1. Use a suitable crane and a suitable lifting device in order to move the plates into position.
2. Tack weld a lifting eye onto plate (8) .
(9) Plate
Moving plate (9) into position
3. Move plate (9) onto the body assembly and tack weld plate (8) into position. Plate (9) weighs approximately
135 kg (298 lb).
Moving plate (1) into position
Note: If any section of the floor is warped, use a wedge and a bracket in order to align the seam, or use a C-
clamp in order to align the seam.
View of the wedges and brackets
View of C-clamps
View of plate (9) and plate (1) after welding into position
4. Move plate (1) into the body assembly and tack weld plate (1) into position. Plate (1) weighs approximately
150 kg (331 lb).
5. Tack weld all of the body liners into the correct position. Finish weld after all of the body liners have been
tack welded into position. Refer to Illustration 75 for plate locations. Refer to Illustration 76 and Illustration
77 for plate gap tolerances. Refer to Illustration 78 and Illustration 79 for the specifications for welding, and
the welding locations.
Note: Remove the lifting eye from plate (9) and grind the tack weld flush.
View of plate locations
View of plates and gap tolerances
(B) 12 ± 3 mm (0.47 ± 0.12 inch)
(C) 4 ± 2 mm (0.16 ± 0.08 inch)
(D) 8 ± 3 mm (0.31 ± 0.12 inch)
(E) 12 ± 3 mm (0.47 ± 0.12 inch)
(F) 6 ± 2 mm (0.24 ± 0.08 inch)
(G) 14 ± 3 mm (0.55 ± 0.12 inch)
(H) 7 ± 2 mm (0.28 ± 0.08 inch)
(J) 10 ± 2 mm (0.39 ± 0.08 inch)
(K) 20 ± 3 mm (0.79 ± 0.12 inch)
(L) 22 ± 3 mm (0.87 ± 0.12 inch)
(M) 20 ± 3 mm (0.79 ± 0.12 inch)
(N) 50 ± 3 mm (1.97± 0.12 inch)
View of plates and gap tolerances
(P) 46 ± 3 mm (1.81± 0.12 inch)
(R) 61 ± 5 mm (2.40 ± 0.20 inch)
(S) 12 ± 3 mm (0.47 ± 0.12 inch)
(T) 6 ± 2 mm (0.24 ± 0.08 inch)
(U) 62 ± 3 mm (2.44 ± 0.12 inch)
(V) 31 ± 3 mm (1.22 ± 0.12 inch)
6. Clean all the welds.
Table 22
Approximate Weights
Part Number Description Approximate Weight
129-0386 (1) Plate

150 kg (331 lb)
129-0387 Plate
135 kg (298 lb)
129-0388 Plate
725 kg (1598 lb)
129-0389 (1) Plate

533 kg (1175 lb)
129-0390 Plate
524 kg (1155 lb)
129-0393 Plate
146 kg (322 lb)
129-0394 (1) Plate

133 kg (293 lb)
129-0395 Plate
96 kg (212 lb)
129-0397 (1) Plate
135 kg (298 lb)
129-0399 Plate
1258 kg (2773 lb)
297-2802 Plate
78 kg (172 lb)
297-2803 Plate
33 kg (73 lb)
359-4908 (2) Plate

330 kg (728 lb)
(1)
(2)
Table 23
Item Description

1.5 mm (0.059 inch) weld penetration (two slots)
W2
W3
8 mm (0.31 inch) square groove weld (three places)

1.5 mm (0.059 inch) weld penetration (two plates)
W5



W9
8 mm (0.31 inch) bevel groove weld (field weld)
W10
W11

1.5 mm (0.059 inch) weld penetration (eight slots, six shop welded, and two field welded)
W12 10 mm (0.39 inch) fillet weld



W15








W24

W26

W27




1.5 mm (0.059 inch) weld penetration (48 holes, 40 shop welds, and 8 field welds)
W32



W36
16 mm (0.63 inch) convex bevel groove (2 places)
W37
16 mm (0.63 inch) square groove weld (2 places)


1.5 mm (0.059 inch) weld penetration (field weld)


W42

W44
10 mm (0.39 inch) convex bevel groove weld (two plates)


W47
10 mm (0.39 inch) convex bevel groove weld (two plates)
7. Use a grinder in order to grind all the welds flush. Completely remove all rust, scale, slag, dirt, moisture, and
so on, before painting.
8. Paint the body.
Procedure for the Installation of 242-3145 Rubber Body Liner Gp for

the 277-3213 Dual Slope Body for the 777F and 777G Truck (If
Equipped)
Table 24
Required Parts for the Installation of 242-3145 Rubber Body Liner Gp for the 242-3170 Dual Slope Body
for the 777F and 777G Truck (If Equipped)
1 1 269-8517 (1) Rubber Liner Assembly

11 1 270-0368 Tail Bar Plate Assembly
14 128 308-6689 Weld Stud
15 128 274-1338 Rubber Plug
16 128 2J-3506 Full Nut
17 128 7X-0564 Hard Washer
18 2 305-3438 (1) Plate
19 2 129-0391 Plate
20 2 129-0392 Plate
21 2 129-0400 Plate
22 2 129-0393 Plate
23 2 129-0395 Plate
24 2 129-0397 (2) Plate
25 2 129-0387 Plate
26 2 129-0386 (2) Plate
27 4 297-2802 Plate
28 2 297-2803 Plate
(1)
Place rubber liners and plate assemblies in truck body to locate weld studs.
(2)
Plate to installed after finish welding body and canopy.
Table 25
Approximate Weights
Part Number Description Approximate Weight
269-8517 Rubber Liner Assembly
490 kg (1080 lb)

490 kg (1080 lb)

507 kg (1118 lb)

507 kg (1118 lb)

448 kg (988 lb)

448 kg (988 lb)

171 kg (377 lb)

172 kg (379lb)

204 kg (450 lb)

570 kg (1257 lb)
270-0368 Tail Bar Plate Assembly

97 kg (214 lb)
305-3438 Plate
57 kg (126 lb)
129-0391 Plate
156 kg (344 lb)
129-0392 Plate
124 kg (273 lb)
129-0400 Plate
49 kg (108 lb)
129-0393 Plate
146 kg (322 lb)
129-0395 Plate
96 kg (212 lb)
129-0397 Plate
135 kg (298 lb)
129-0387 Plate
135 kg (298 lb)
129-0386 Plate
150 kg (331 lb)
297-2802 Plate
78 kg (172 lb)
297-2803 Plate
33 kg (73 lb)
Table 26
Item Description
W1
8 mm (0.31 inch) slot weld one slot two plates



1.5 mm (0.059 inch) weld penetration four plates

1.5 mm (0.059 inch) weld penetration two places


1.5 mm (0.059 inch) weld penetration two plates both ends
W8
8 mm (0.31 inch) slot weld two slots four plates
W9

1.5 mm (0.059 inch) weld penetration five holes two plates

1.5 mm (0.059 inch) weld penetration two plates

W13
8 mm (0.31 inch) square groove weld three places
W14



1.5 mm (0.059 inch) weld penetration six plates

W19
16 mm (0.63 inch) square groove weld both sides


W22
8 mm (0.31 inch) square groove weld four places
W23

W25


W28
3 mm (0.12 inch) square groove weld 128 studs

W30


W32
6 mm (0.24 inch) square groove weld two places

1.5 mm (0.059 inch) weld penetration 16 places

1.5 mm (0.059 inch) weld penetration A to B

1.5 mm (0.059 inch) weld penetration one hole two places
Location for the rubber body liners and the plates
(1) Rubber liner assembly
(11) Tail bar plate assembly
(22) Plate
(23) Plate
(24) Plate
(25) Plate
(26) Plate
(27) Plate
(28) Plate
View A-A
(19) Plate
(20) Plate
(21) Plate
View H, F-F, and K
(W) 8 ± 2 mm (0.30 ± 0.08 inch)
(X) 4 ± 2 mm (0.15 ± 0.08 inch)
(Y) 6 ± 2 mm (0.25 ± 0.08 inch)
(Z) 12 ± 2 mm (0.50 ± 0.08 inch)
(AB) 5 ± 2 mm (0.20 ± 0.08 inch) two plates
(AC) 9 ± 3 mm (0.35 ± 0.12 inch)
(AD) 6 ± 3 mm (0.25± 0.12 inch)
(AE) 35 mm (1.40 inch)
(AF) 50 mm (2.00 inch)
(14) Weld stud
(15) Rubber plug
(16) Full nut
(17) Hard washer
View B-B
(L) 5 ± 2 mm (0.20 ± 0.08 inch)
(M) 15 ± 2 mm (0.60 ± 0.08 inch)
(N) 5 ± 2 mm (0.20 ± 0.08 inch)
View A-A
(P) 46 ± 2 mm (1.80 ± 0.08 inch)
(R) 50 ± 3 mm (2.00 ± 0.19 inch)
(S) 12 ± 3 mm (0.50 ± 0.12 inch)
(T) 12 ± 3 mm (0.50 ± 0.12 inch)
(U) 62 ± 3 mm (2.45 ± 0.12 inch)
(V) 15 ± 2 mm (0.60 ± 0.08 inch)
1. Tack weld a lifting eye onto plates (24) .
Typical view of positioning plate
(24) Plate
2. Use a suitable lifting device in order to position plates (24) onto the body assembly and tack weld plates (24)
into position. The approximate weight of plate (24) is 135 kg (298 lb).
Typical view of positioning plates
(25) Plate
(26) Plate
Note: If any section of the floor is warped, use a wedge and a bracket in order to align the seam, or use a C-
clamp in order to align the seam.
Typical view of wedges and brackets
Typical view of C-clamps
Typical view of plate (24), plate (25), and plate (26) after welding into position
3. Use a suitable lifting device in order to position plate (25) onto the body assembly and tack weld plate (25)
4. Use a suitable lifting device in order to position plate (26) onto the body assembly and tack weld plate (26)
5. Tack weld all of the body liners into the correct position. Finish weld after all of the body liners have been
tack welded into position. Refer to Illustration 81 and Illustration 82 for rubber liner and plate locations.
Refer to Illustration 83, Illustration 84, Illustration 85, and Illustration 86 for the gap tolerances. Refer to
Illustration 87, Illustration 88, and Illustration 89 and Table for welding specifications.
View of lifting eyes
View of rubber liner assembly (1) which is attached to a suitable crane and a suitable lifting device
6. Use a suitable crane and a suitable lifting device in order to place the liners into position.
Moving rubber liner assembly (2) into position
7. Position rubber liner assembly (1) and rubber liner assembly (2) in front corners. Rubber liner assembly (1)
weighs approximately 490 kg (1080 lb). Rubber liner assembly (2) weighs approximately 490 kg (1080 lb).
8. Move rubber liner assembly (3) and rubber liner assembly (4) into position. Rubber liner assembly (3)
View of rubber liner assembly (7) and rubber liner assembly (8) in position
11. Move rubber liner assembly (9) into position. Rubber liner assembly (9) weighs approximately 204 kg (450
lb).
12. Move rubber liner assembly (10) into position. Rubber liner assembly (10) weighs approximately 570 kg
(1257 lb).
Moving tail bar plate assembly (11) into position
View of tail bar plate assemblies (11) and (12) in position
View of tail bar plate assemblies (11) and (13) in position
13. Move steel tail bar plate assemblies (11), (12), and (13) into position. Steel tail bar plate assembly (11)
weighs approximately 97 kg (214 lb).
14. Weld steel tail bar plate assemblies (11), (12), and (13) into position. Refer to Illustration 89, and Table 26
for the specifications for welding, welding dimensions, and the welding locations.
Pneumatic needle descaler
View of pneumatic needle descaler in use
15. Grind off paint before welding studs to the truck body.
Stud gun
Stud and guide
View of stud gun during use
Cross-sectional view of the stud and liner
16. If a stud gun is available, then weld studs (14) to the truck body with a stud gun. Refer to Illustration 81, and
Table 26 for the specifications for welding and the welding locations.
17. If a stud gun is not available, then use a center punch to mark the location of the holes. Remove rubber liner
assembly. Use MIG welder to weld around stud (14). Reinstall the rubber liner assembly.
18. Place washer (17) and nut (16) on stud (14). Tighten nut (16) to a torque of 156 ± 30 N·m (115 ± 22 lb ft).
Rubber plugs
19. Place rubber plugs (15) in the holes by using a sledge hammer and soapy water.
20. Attach a suitable lifting device and weld steel plates (27), and (28) into position. Refer to Illustration 81,
Illustration 87, and Table 26 for the specifications for welding, welding dimensions, and the welding
locations.
Note: The approximate weight for plate (27) is 78 kg (172 lb). The approximate weight for plate (28) is 33
kg (73 lb).
21. Attach a suitable lifting device and weld steel plates (18) into position. Refer to Illustration 81, and Table 26
for the specifications for welding, welding dimensions, and the welding locations.
Note: The approximate weight for plate (18) is 57 kg (126 lb).
22. Use a grinder in order to grind all the welds flush. Completely remove all rust, scale, slag, dirt, moisture, and
so on, before painting.
23. Paint the body.
Copyright 1993 - 2017 Caterpillar Inc. Sun Feb 5 14:15:37 UTC-0400 2017
All Rights Reserved. r160vxc
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Assembly Procedure For The Dual Slope Body For The 777F and 777G Off-Highway Truck

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Assembly Procedure For The Dual Slope Body For The 777F and 777G Off-Highway Truck

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777F Off-Highway Truck JRP00001-UP (MACHINE) POWERED BY C32 Engine(SEB...

Improper assembly procedures could result in injury or death.

Body Assembly (Total)

Body Assembly (Right Side)

Body Assembly (Left Side)

Plate Assembly (Slipper)

Bracket Assembly (Cylinder)

Canopy with Steel Liners Only

1 269-8525 (1) Rubber Liner Assembly

Body with canopy

Body with canopy

6048 mm (238.11 inch)

Body without canopy and rock guards

View of the wedges and brackets

Weld tolerance and Parameters

• 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 −29 °C (−20 °F) Notch Toughness

• 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

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

Specifications for Cables, Chains, and Lifting Devices

Lift angles for lifting slings.

Unpacking the Body Assembly

Body assembly, parts box, and rubber body liners

Installing the clevis onto the canopy

3. Attach the lifting device onto 251-0950 Canopy Assembly .

Cutting shipping support

5. Place 251-0950 Canopy Assembly away from the work area.

The body sides nested together.

Cutting the shipping support

Left side of the body assembly

7. Position 251-0940 Body Assembly away from the work area.

3 1 128-0626 Body As (RH side)

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

The right side of the body before being flipped

Turning the right side of the body

Position body assembly (right side) (3) onto blocks upside-down.

Body assembly (right side) (3) in the upside-down position

Level the back edge of body assembly (right side) (3) .

Body assembly (left side) (2) turned upside-down.

6. Turn body assembly (left side) (2) to the upside-down position.

Position the two sides together.

The support blocks under the back edge

Install the bolts and nuts.

The hydraulic jacks are used to level the body.

The two tabs on the front wall for spacing

The three tabs on the bottom of the body for spacing

The gap on the ribs on the front wall

The gap that will be on the floor

The wedges and brackets that are installed on the floor

Wedge and bracket

Note: Only weld the bracket on one side.

Critical points of alignment that should be flat and parallel

The back edge should be flat and level.

24. The rear edge of the floor should be reasonably flat.

(G) 5200 mm (205 inch)

Tack weld the ribs on the bottom of the body.

Tack weld the ribs on the front wall.

View of the front wall and welding specifications