[Keith Seymore]

The assembly manual is compiled in UPC order (no relation to assembly order).

So UPC 0 = Labels/literature
UPC 1 = body structure
UPC 2 = Frames
UPC 3 = Front axle
UPC 4 = Rear axle
UPC 5 = Brakes
UPC 6 = engine
UPC 7 = transmission
UPC 8 = exhaust
UPC 10 = tire/wheel
UPC 11 = front end sheet metal, radiator support
UPC 14 = bumpers

The major categories then break down into subcategories for greater detail.

The pages were kept in multiple three ring binders; each area of the plant (Cab Shop, Trim, Chassis, Final, Repair) would have a complete set, kept in either the Production or Inspection office. The individual assemblers did not refer to the sheets; if there was a question then the production supervisor or his quality man would make the trek to the office and research the answer along with the inspection representative.

It is cumbersome, at best, to use, even for those guys that have grown up with it. But once you have the major categories memorized then you can at least start off looking close to what you are after and zero in from there. Any inspection guy worth his salt got pretty proficient at that.

We still use the assembly manual ("Production Assembly Document", or "PAD" sheets) today although they are stored and accessed electronically.

The other comment I would make is that the assembly manual views the components they way they are received at the final assembly location; that is, engines, transmisssions, rear axles, steering gear boxes are all intact commodities (like a "black box"). The Service Manual and, to a greater degree, the Unit Repair manual, allow you to see inside those black boxes.

K