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Instruccin Especial

Procedure for the Inspection, Repair, and Component Replacement on the Frames of Certain Off-Highway
Trucks/Tractors{7000, 7051}
Nmero de medio -REHS0541-18

Fecha de publicacin -22/09/2014

Fecha de actualizacin -22/09/2014


i05934619

Procedure for the Inspection, Repair, and Component Replacement on the Frames of
Certain Off-Highway Trucks/Tractors{7000, 7051}
SMCS - 7000-023-CS ; 7051-023-CS

Off-Highway Truck/Tractor:
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)

Introduction
This Special Instruction contains general information and procedures that can be referenced when you repair the chassis of the
machines that are listed above. Each repair will be unique. You may need to modify the procedures in some situations.
Read the entire special instruction. Understand the information before you perform any procedures. Understand the information
before you order any parts.
Note: Some of the components that are necessary in order to complete procedures in this Special Instruction may not be available
through the normal parts system. In some cases, special orders are required.
Note: For additional information regarding repairing cracked frames contact the subsidiary service engineer, the plant service
engineer and the plant product analyst.
ReferenceSpecial Instruction, REHS2346, "Weld Repair Procedure for the Rear Axle A-Frame and Rear Axle Housing on 785,
789, and 793 Off-Highway Trucks".
When you need to remove components in order to repair the chassis, refer to the appropriate Disassembly and Assembly Manual.
Table 1
Disassembly and Assembly Manuals
Sales Model

Machine Systems

Power Train

784B

SENR5678

SENR5677

784C

SENR1500

SENR1490

785

SENR4020

SENR4010

785B

SENR5678

SENR5677

785C

SENR1500

SENR1490

785C HAA

SENR1500

SENR1490

785D

KENR8312

KENR8308

789

SENR3404

SENR3430

789B

SENR5687

SENR5686

789C

SENR1534

SENR1524

789D

SENR1534

UENR1065

793

SENR4917

SENR4907

793B

SENR5692

SENR5691

793C (S/N: 4AR)

SENR1463

SENR1462

793C (S/N: CBR, ATY, 4GZ)

RENR2535

SENR2534

793D

RENR8332

RENR8328

NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system
during assembly, connection of lines, when components are filled with fluid,
or during any maintenance operation.

NOTICE
Care must be taken to ensure that fluids are contained during performance
of inspection, maintenance, testing, adjusting, and repair of the product. Be
prepared to collect the fluid with suitable containers before opening any
compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog"
for tools and supplies suitable to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and mandates.

Personal injury or death can result from improper lifting or blocking.


When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the
hoist or jack has the correct capacity to lift a component. Install blocks or stands before
performance of any work under a heavy component.
Approximate weights of the components are shown. Clean all surfaces where parts are to be
installed.
Table 2

Approximate Weights of Unloaded Machines


Sales Model

Weight

784B, 784C

88.903 kg (196,828 lb)

785, 785B, 785C, 785D


789, 789B, 789C, 789D
793, 793B, 793C, 793D

102.965 kg (227,891 lb)


130.634 kg (288,728 lb)
147.417 kg (325,000 lb)
Table 3
Approximate Weights of Components

Part
Number

Part Name

Part Name (Modifier)

119-4726

Tube

Rear Cast Cross-Tube

297 kg (655
lb)

793, 793B, 793C, 793D

125-7017

Support

Center Cross-Tube

1370 kg (3020
lb)

793, 793B, 793C, 793D

8X-0898

Rail

Rail

8X-2648

Rail

Rail

290 kg (640
lb)

320-5333

Rail

Rail

382 kg
(842lb)

789D

320-5334

Rail

Rail

382 kg
(842lb)

789D

6G-6499

Shaft (Ball)

Lower Mounting for the Hoist


Cylinder

8X-1213

Shaft (Ball)

Lower Mounting for the Hoist


Cylinder

120-6765

Support

120-6764

Weight

93 kg (205 lb)

Sales Model

785, 785B, 785C, 785D


789, 789B, 789C, 793, 793B, 793C,
793D

785, 785B, 785C, 785D, 789, 789B,


789C, 789D

110 kg (245
lb)

793, 793B, 793C, 793D

Right Side Tail Casting

1026 kg (2262
lb)

793, 793B, 793C, 793D

Support

Left Side Tail Casting

910 kg (2006
lb)

793, 793B, 793C, 793D

8X-2376

Plate

Inside Rear Window Plate

5T-8671

Bracket
Assembly

Steering Box

37 kg (82 lb)
350 kg (775

793, 793B, 793C, 793D


784B, 784C, 785, 785B, 785C,
785D

lb)
5T-6243

Bracket
Assembly

Steering Box

382 kg (842
lb)

789, 789B, 789C, 789D

8X-2283

Bracket
Assembly

Steering Box

375 kg (830
lb)

793, 793B, 793C, 793D

Important Safety Information


The following information is an explanation of various labels that are found in this document.
Warnings
The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.
Notices
A notice informs the technician that component damage can occur as a result of a condition that exists.
Notes
A note contains general information for the technician about the operation that is being performed.
Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic
recommended procedures. Some of the procedures require special tools, devices, or work methods.
Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all
safety information before you perform any repairs or before you perform any maintenance.
Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or
death could occur to you or other persons.
The "Safety Alert Symbol" that is followed by a "Signal Word" identifies a hazard. "DANGER", "WARNING", and
"CAUTION" are "Signal Words".

Ver imagen

Illustration 1

g00008666

The signal word "WARNING" has the following meanings:

Pay Attention !
Become Alert !
Your Safety Is Involved !

The message that appears under the safety alert symbol explains the hazard.

Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service
information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you
perform service work. Special knowledge of the systems and of the components is important. Before you remove any component,
or before you disassemble any component, obtain knowledge of the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in
this document and the safety information on the machine are not all inclusive. You must determine that the tools,
procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication,
maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation,
lubrication, maintenance, and repair procedures will not make the machine unsafe.

Basic Precautions

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.

Always observe the list of basic precautions that follows:

Safety Signs
Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs on the machine before
operating, lubricating, or repairing the machine. Understand all "Safety" signs on the machine before operating, lubricating, or
repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.

Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions. Protective
equipment includes the items that follow: hard hat, protective glasses and protective shoes. In particular, wear protective glasses
when you use a hammer or when you use a sledge hammer. When you weld, use the appropriate protective equipment that is
required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles
and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.

Mounting and Dismounting


Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a machine. Before you
mount the machine, clean any mud or debris from steps, walkways, or work platforms. Always face the machine when you use
steps, handholds, and walkways. When you cannot use the accesses on the machine, use ladders, scaffolds, or work platforms to
perform safe repair operations.

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.

Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a lifting
operation.

Ver imagen

Illustration 2

g00629745

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.

Hot Fluids and Parts


To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug in order to prevent
being sprayed by pressurized liquids. When the machine has been stopped, the danger of hot fluids is greater.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the skin for extended
periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor. In case of contact, immediately wash skin
with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical
attention.

Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor
mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte
to contact skin or eyes. Battery electrolyte is an acid. In case of contact with battery electrolyte, immediately wash the skin with
soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical
attention.

Pressurized Items
1.

Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body
tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is
injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type
of injury.

2.

Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed.
Always make sure that all raised components are blocked correctly. Be alert for possible pressure when you disconnect
any device from a system that utilizes pressure.

3.

Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and
lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires.
Hydraulic lines, tubes, and hoses that are loose can cause fires. Do not bend or strike high-pressure lines. Do not install
lines which have been bent or damaged. Check lines, tubes, and hoses carefully. Do not use your bare hand to check for
leaks. If fluids are injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is
familiar with this type of injury.

4.

Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a protective face
shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205
kPa (30 psi). When you use a pressure washer, keep in mind that the nozzle pressures are high. The nozzle pressures
are frequently above 13790 kPa (2000 psi). Follow all of the recommended practices that are provided by the
manufacturer of the pressure washer.

Welding Specifications and Qualifications

Protect yourself and others; read and understand this warning. Fumes and gases can be
dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin.
Electric shock can kill.
Read and understand the manufacturer's instruction and your employer's safety practices. Keep
your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases
from your breathing zone and the general area. Wear correct eye, ear and body protection. Do
not touch live electric parts.
Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by
the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and
Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent
fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications
Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate
position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal
Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to American Welding
Society (AWS) D1.1 Structural welding code-steel or equivalent nationally or Internationally recognized code or standard for
guidance on welder qualification testing requirements. The welders must have used the process at some time within the last 6
months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Proper Welding Procedure on Machines and Engines with Electronic Controls


Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls,
use the steps that follow:
1.

Turn off the engine. Put the key start switch in the OFF position.

2.

If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect
switch, disconnect the negative battery cable at the battery.

3.

Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the
clamp for the ground cable as close as possible to the area that is being welded. This precaution will reduce the chance
of damage from welding current to the components that follow: bearings, hydraulic components and electrical
components.
Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic
components as a ground point for the welder.

4.

Protect the wiring harnesses from the welding spatter.

Area Preparation
The area to be welded shall be clean, dry, and free of the following contaminants:

Oil
Grease
Paint
Dirt
Rust
Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6 C (60 F).
Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6 C (60 F)
requirement.
Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.
Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces
from the welding spatter.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW 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 (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode is designed to provide
less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode
will have the following minimum mechanical properties:
Table 4
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1 H8"
Tensile Strength

480 MPa (70000 psi)

Yield Strength

400 MPa (58000 psi)

Elongation

22%

Impact Toughness

27 J @ -18 C (20 ft lb @ -0 F)

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux
cored welding electrode diameters.
Table 5
Welding Current for Flux Cored Welding Electrode that Is
1.2 mm (0.045 inch)
Wire Feed Rate
7620 mm (300 inch) Per Minute to
10,160 mm (400 inch) Per Minute

Voltage

Amperage

24 to 28

190 to 240

Table 6
Welding Current for Flux Cored Welding Electrode that Is
1.4 mm (0.052 inch)
Wire Feed Rate
5080 mm (200 inch) Per Minute to
6350 mm (250 inch) Per Minute

Voltage

Amperage

23 to 27

180 to 220

Note: The settings listed above are recommendations which are based on experience for welding in the horizontal, vertical-up,
and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various
formulations by different electrode manufacturers. It is acceptable to use higher parameters than specified for welding in the flat
position.
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing
characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the
size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass
should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.
Low Hydrogen Electrodes for the SMAW Process

As an alternate process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following
requirements.
Table 7
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018"
Tensile Strength

480 MPa (70000 psi)

Yield Strength

400 MPa (58000 psi)

Elongation

22%

Impact Toughness

27 J @ -29 C (20 ft lb @ -20 F)

Low hydrogen electrodes must be stored in an electrode oven at 120 C (250 F). If low hydrogen electrodes get damp, scrap the
low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer's specifications.
The table that follows shows the settings for the welding current based on electrode diameter.
Table 8
Welding Current for Low Hydrogen Electrodes
Diameter

Amperage Rating

3.2 mm (1/8 inch)

105-155

4.0 mm (5/32 inch)

130-200

4.8 mm (3/16 inch)

200-275

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld
should not exceed two times the electrode diameter.
Arc Welding Electrodes for the GMAW Process
The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.
Table 9
Mechanical Properties of Welds from Gas Metal Arc Welding Electrodes That Are Classified as "ANSI/AWS A5.18
ER70S-6"
Tensile Strength
Yield Strength

480MPa (70,000 psi)


400 MPa (58,000 psi)

Elongation

22%

Impact Toughness

27J @ -30 C (20 ft lb @ -20 F)

The use of the GMAW process for field repairs is only recommended for certain conditions. Whenever the GMAW
process is appropriate, specific parameters and equipment will be defined.

Weld Inspection and Acceptance Criteria


Table 10
Defect Name

ISO 6520 Defect


Reference Number

Remarks

Defect Limit

Cracks - Longitudinal,
Transverse, Radiating,
Crater, Disconnected,
Branching

1011, 1012, 1013,


1014, 1023, 1024,
1031, 1033, 1034,
1045, 1046, 1047,
1051, 1053, 1054,
1061, 1063, 1064

--

Not Permitted

Crack - Transverse

1021

Hard Surfacing Welds Only

Permitted

Crack - Transverse

1021

Joining Welds

Not Permitted

Maximum Diameter for a Single Pore

Porosity

Clustered Porosity

2011, 2012, 2014,


2017

2013

Maximum Pores in Any


300 mm (11.81 inch) Length of Weld

Maximum Number of Pores in Any


50 mm (2.0 inch) of Weld Length for
Welds Less Than
300 mm (11.81 inch) in Length

Maximum Length of Cluster in Any


Weld
Maximum Height or Width

Elongated Cavities

Elongated Cavities

Shrinkage Cavities

2015

3 mm (0.120 inch)
25 mm (1.00 inch)

Maximum Length in Any Weld

10% of Weld Length

Maximum Dimension of Any Single


Cavity

3 mm (0.120 inch)

Maximum Total Length of Affected Area


in Any Weld

10% of Weld Length Not to


Exceed
25 mm (1.00 inch)

2016

2021, 2024, 2025

Maximum Diameter or Length

3011, 3012, 3014,


3021, 3022, 3024

1 mm (0.040 inch)
1mm (0.040 inch)

Maximum Length for Any Single


Discontinuity

25 mm (1.00 inch)

Maximum Length in Any Weld

10% of Weld Length

Maximum Height or Width


Oxide Inclusions

3 mm (0.120 inch)

Maximum Length for Any Single


Discontinuity

Maximum Height or Width


Slag or Flux
Inclusions

1 mm (0.040 inch)

3031, 3032, 3033


Maximum Length for Any Single

1mm (0.040 inch)

Discontinuity

25 mm (1.00 inch)

Maximum Length in Any Weld

10% of Weld Length

Puckering (Oxide
Inclusion - Aluminum)

3034

--

Not Permitted

Metallic Inclusion

3041, 3042, 3043

--

Not Permitted

Visual (Breaking the Surface)

Not Permitted

Subsurface Maximum Height or Width


Lack of Fusion

Lack of Penetration

Undercut

Excess Weld Metal Groove Weld


Reinforcement
(Convexity)

Subsurface Maximum Length for Any


Single Discontinuity

25 mm (1.00 inch)

Maximum Length in Any Weld

10% of Weld Length

Maximum Reduced Penetration

10% of Nominal
Penetration Not to Exceed
1mm (0.040 inch)

Maximum Allowed Total Length of


Reduced Penetration

10% of Weld Length

402, 4021

5011, 5012, 5013,


5014, 5015

Maximum Depth Measured From Plate


Surface - Any Length

0.5 mm (0.020 inch)

Any Length

--

Weld Face Width


5 mm (0.20 inch) or Less

1 mm (0.040 inch)

Weld Face Width Over


5 mm (0.20 inch) But Less Than
10 mm (0.40 inch)
502

Weld Face Width Over (10 mm)(0.40 inch)


But Less Than
20 mm (0.80 inch)
Weld Face Width Over
20 mm (0.80 inch) But Less Than
30 mm (1.20 inch)
Weld Face Width
30 mm (1.20 inch) and Over

Excess Weld Metal Fillet Weld Convexity

503

1.5 mm (0.060 inch)

2 mm (0.080 inch)

3 mm (0.120 inch)

4 mm (0.160 inch)

Convexity Affects Weld Toe Angle,


Reducing Fatigue Life

90 Degrees

Weld Toe Angles of 135 Degrees and More


Are Better

--

Defect Limits Expressed as Minimum Toe


Angles Allowed

--

Without Drawing Limitation


Excess Penetration

1mm (0.040 inch)

4011, 4012, 4013

5041, 5042, 5043


With "Melt - Thru" and "Flush" Weld
Symbols

2 mm (0.080 inch) (Any


Length)
1 mm (0.040 inch) (Any

Length)
With "Melt - Thru" and "Grind Flush"
Symbols

Not Permitted (After


Grinding)

Incorrect Weld Toe

505

When 1E2995 Applies (Expressed as a Toe


Radius Rather Than a Toe Angle)

Overlap

5061, 5062

Expressed as Minimum Toe Angle

90 Degrees

Applies to Either Weld Leg Measured


Independent of the Other

--

Maximum Undersize
Fillet Weld Leg Size Undersize

Fillet Weld Leg Size Oversize

Fillet Weld - Linear


Length when specified at
less than the length of the
joint

Fillet Weld Throat Size Undersize

--

Maximum Length of Undersize Weld

Applies to Either Weld Leg Measured


Independent of the Other

--

Maximum Oversize

+25% (max
3 mm (0.120 inch))

Conformance to Design - Fillet Weld Leg


Sizes May be Oversized (Within Defect
Limitations or Beyond) Without Correction
Provided the Excess Does not Interfere
with Satisfactory End Use of the
Component (i.e., Distortion, Fit-Up
Interference, etc.)

--

Weld Size
6.5 mm (0.256 inch)

6.5 mm (0.256 inch)

Weld Size
6.5 mm (0.256 inch)

12.5 mm (0.492 inch)

Nominal Size (0.7 x Leg Size) Not


Inclusive of Penetration Beyond the Weld
Root

Not Permitted

5213
Weld Crater Only - Maximum Undersize

Incompletely Filled
Groove Weld

1 mm (0.040 inch)
10% of Total Weld Length
If At Least 10% of Total
Weld Length is at Least
1 mm (0.040 inch) Over
Nominal Size, Otherwise,
No Undersize Length is
Permitted

--

--

3 mm (0.120 inch)
Minimum Radius

2 mm (0.080 inch) MAX and Not to Exceed 20% of


Specified Throat, Not
Inclusive of Penetration
Beyond the Weld Root (0.7
x Leg Size)

Careful Consideration Needs to be Given


When Plate Mismatch is Apparent

Not Permitted

Weld Depth Must be Maintained as a


Minimum

--

511

Root Concavity on Open


Root Groove Welds

Poor Restart (Tie - In)

Stray Arc Strike

Slag Residue

Combined
Discontinuities

515, 5013

Maximum Depth measured From Plate


Surface or Tube Inner Surface - Any
Length

0.5 mm (0.020 inch)

Measured in Terms of Excess Weld Metal


(Fillet Weld Convexity) or Overlap on
Groove Welds, Lack of Fusion, or
Insufficient Throat

--

Excess Weld Metal on Fillet Welds, Defect


Limits Expressed as Minimum Toe Angles
Allowed

90 Degrees

Overlap on Groove Welds, Defect Limits


Expressed as Minimum Toe Angles
Allowed

90 Degrees

5171, 5172

601

Lack of Fusion - Visual Maximum Length


Per Restart

3 mm (0.120 inch)

Insufficient Weld Throat

Not Permitted

--

Not Permitted

SMAW, SAW, FCAW, GMAW

Not Permitted

GTAW

Silicon Residue Permitted


Unless Removal Specified
by Drawing Note

Total Maximum Combined Length of All


Imperfections in a Weld, Expressed as a
Percent of Total Weld Length

15%

(No Single Type of Imperfection Can


Exceed the Limits for That Single Type of
Imperfection)

--

615

--

In order to verify the quality of the weld, refer to Figure 27 from Caterpillar Specification 1E99 which is shown above in Table
10.

General Weld Repair


1.

Remove any components that prevent access to the cracked weld.

2.

Refer to the ""Area Preparation" " section in this Special Instruction.

3.

Use dye penetrant (PT) or magnetic particle (MT) in order to identify the extent and/or length of the necessary repair.

4.

Protect machined surfaces from sparks and weld debris.

5.

Ensure that the base material is at a minimum temperature of 15.6 C (60 F) before welding. Ensure that a minimum
temperature of 15.6 C (60 F) is maintained throughout the entire welding procedure.

6.

Cracks in the weld and sound metal which are 50.8 mm (2.0 inch) beyond each end of the crack shall be removed by air
carbon arc torch or grinder. Caution should be used to avoid excessive removal of the surrounding base material. Areas
that are gouged by air carbon arc torch shall be later ground and cleaned prior to welding in order to remove all carbon
absorption or contamination. Gouged areas requiring rewelding shall have a root radius of not less than 5 mm (0.20

inch) and a Single V - 60 degree included angle joint preparation to allow the welder reasonable access to reinstate the
weld.
7.

Use dye penetrant (PT) or magnetic particle (MT) to inspect the gouged and ground area in order to ensure that the
crack has been removed before welding commences.

8.

Repair the prepared groove utilizing the recommendations provided in the ""Welding Electrodes and Parameters" "
section in this Special Instruction.

9.

Clean the weld area. Inspect the area that was welded. All weld quality shall conform to specifications in the ""Weld
Inspection and Acceptance Criteria" " section in this Special Instruction.

Walk-Around Inspection of the Frame for the 784B, 784C, 785, 785B, 785C, 785D, 789,
789B, 789C, 789D, 793, 793B, 793C, and 793D Off-Highway Trucks
This Special Instruction provides information on the areas of the frame assembly that should be inspected for cracks. The
following areas are covered in this Special Instruction: castings, welded joints, pump and motor mounts, mounting pads for the
fuel tank, mounting hangers for the fuel tank, mounting pads for the hydraulic tank, mounting hangers for the hydraulic tank and
the fabricated assemblies.
Note: The Operation and Maintenance Manual identifies the intervals for maintenance inspection. The conditions of the site, the
payloads, and the haul road conditions may affect the maintenance interval. Site managers should monitor these intervals
accordingly. Site managers should adjust these intervals accordingly.

Ver imagen

Illustration 3
Typical truck frame
(A) Bracket Assembly (Steering box)
(B) Superstructure
(C) Support (Center cross-tube)
(D) Support (Tail casting)
(E) Support (Rear cross-tube)
(F) Rear motor mount

g00914504

(G) The casting that forms the mounting location for the front suspension cylinder
(H) Fuel/hydraulic tank support
(J) Supports for the hoist cylinder
(K) Pin bores for the control rod

Inspect the Support (Rear Cross-Tube)

Ver imagen

Illustration 4

g00912931

1.

Inspect the welds that are used to hold the rear cross-tube to the tail castings.

2.

Inspect the rear of the support (rear cross-tube).

3.

If any cracks are found in the rear cross-tube, refer to ""General Weld Repair" " section in this Special Instruction. If
the crack cannot be repaired, refer to ""Rear Cross-Tube Replacement for the 793 Off Highway Trucks" " section in
this Special Instruction.

Inspect the Tail Casting

Ver imagen

Illustration 5

g00917160

1.

Inspect the welds that hold the tail casting to the support (rear center).

2.

Inspect the welds that hold the tail casting to the side rails.

3.

Inspect the area around the body pin bore for cracks.

4.

Inspect the pin bore for the suspension cylinder for wear. This area can only be inspected if the pins have been
removed. Refer to Disassembly and Assembly Manual.

5.

Inspect the area around the pin bore for the suspension cylinder for cracks.

6.

Inspect the bore and the area around the bore that is for the body retaining pin.

7.

Repeat this inspection on the other side of the frame.

8.

If any cracks are found in the tail casting, refer to ""General Weld Repair" " section in this Special Instruction. If the
crack cannot be repaired, refer to ""Tail Casting Replacement for 793 Off Highway Trucks" " section in this Special
Instruction.

Inspect the Side Rails

Ver imagen

Illustration 6

g00917238

1.

Inspect the welds that hold the frame rails to the tail castings.

2.

Inspect the side rails.

3.

Inspect the welds that hold the side rails to the support for the suspension cylinders.

4.

Inspect the welds that hold the support for the hoist cylinders to the frame rails.

5.

Inspect the welds that hold the support for the cab to the frame rails.

6.

Inspect the welds that hold the center tube to the frame rails.

7.

Inspect the weld on the plates that make up the rails.

8.

Inspect the welds that are used on bosses and plates that are attached to the side rails. Carefully inspect the welds that
are used to hold on the brackets for the fuel tank and the hydraulic tank.

9.

Inspect the welds that hold the plates that are used for the rear motor mounts.

10. If any cracks are found, refer to the ""Frame Rails Repair" " section in this Special Instruction for the procedure that is
needed to repair the problem.

Inspect the Center Cross-Tube

Ver imagen

Illustration 7

g00917222

1.

Inspect the welds that hold the outside brackets to the frame rails. Inspect the welds that hold the center tube to the two
outside brackets.

2.

Inspect the center cross-tube.

3.

Inspect the welds on any of the bosses, the plates, and/or the brackets that are positioned on the center cross-tube.

4.

If any cracks are found in the center cross-tube, refer to ""General Weld Repair" " section in this Special Instruction. If
the crack cannot be repaired, refer to the ""Center Cross-Tube Replacement 793 Off-Highway Truck" " section.

Inspect the Support for the Hoist Cylinders

Ver imagen

Illustration 8

g00917726

1.

Inspect the welds that hold the center tube between the two supports.

2.

Inspect the support for the hoist cylinder.

3.

Inspect the front strut support.

4.

Inspect the welds that hold the supports to the frame rails.

5.

Inspect the weld that holds the mounting ball to the supports.

6.

Inspect the ball for wear.

7.

Inspect the welds that are used on any bosses or plates.

8.

If any cracks are found, refer to ""General Weld Repair" " section in this Special Instruction. If the ball cannot be
repaired, refer to ""Ball Replacement for the Lower Connection of the Hoist Cylinders" " section in this Special
Instruction.

Inspect the Front Strut Support

Ver imagen

Illustration 9

g00917881

1.

Inspect the weld that holds the side rails to the strut support.

2.

Inspect the front strut support.

3.

Inspect the welds that are used to hold the center tube to the two strut supports.

4.

Inspect the weld that is used on the brackets for the steering cylinders.

5.

Inspect the welds that are used on any bosses or plates.

6.

If any cracks are found refer to ""General Weld Repair" " section in this Special Instruction. If the crack cannot be
repaired, refer to Special Instruction, REHS0172, "Front Strut Frame Casting Replacement" for the procedure that is
needed to repair the problem.

Inspect the Front Side Rails and the Bumper

Ver imagen

Illustration 10

1.

Inspect the weld that holds the front side rails to the strut supports.

2.

Inspect the weld that is used to hold the front side rails to the bumper.

3.

Inspect the weld that is used on the front motor mount.

4.

Inspect the welds that are used on the vertical supports in the front.

5.

Inspect the welds that are used on any bosses or other plates and brackets.

6.

If any cracks are found refer to ""General Weld Repair" " section in this Special Instruction.

Inspect the Upper Superstructure

Ver imagen

g00917893

Illustration 11

g00917919

1.

Inspect the welds that are used to hold the superstructure to the vertical support.

2.

Inspect the welds that are used to hold the superstructure to the side rails in the rear.

3.

Inspect the welds that are used to hold the front suspension cylinders to the superstructure.

4.

Inspect the welds that hold the superstructure to the frame rails.

5.

Inspect the welds that are used on any bosses or other plates.

6.

If any cracks are found, refer to ""General Weld Repair" " section in this Special Instruction. If additional information
is needed, refer to Special Instruction, REHS0452, "Superstructure Repair".

Frame Management/Repair Philosophy


Frame life, as it relates to fatigue, is a function of many variables that include payload, application (condition of haul roads and
load/unload zones), speed, maintenance, and repairs. Frame cracking can be a result of many of these variables. Over the life of
the machine, frame cracking is an expected event in most circumstances. Understanding and managing all of these variables is a
part of general machine maintenance. General machine maintenance is essential to ensuring fully acceptable life of the frame.
Proper frame management practice should include the following: maintenance and repair, documentation and trending. Local
conditions and/or age of equipment may dictate adjustments to your requirements.

Documentation
1.

Any cracks that are identified at inspection or repair should be measured. Any cracks that are identified at inspection or
repair should be documented. This information should be retained for future inspections and trending. Crack
documentation history can show that where cracks are reoccurring, time to propagate, and to what degree of severity.

2.

A crack found at inspection should be marked and dated with paint/etch as to identify any crack growth at future
inspection that is specified by the Operation and Maintenance Manual.

3.

Utilize a crack inspection checklist with identified call out locations on the frame in order to help in the documentation
process. Table 11 shows an example of a crack inspection checklist. The checklist example provides a sequential walkaround inspection which includes a table for capturing locations, comments, and lengths, of cracks.

4.

It is important to maintain a database of fleet frame crack status. The repair labor and downtime requirements for the
fleet should be included in this database.

Maintenance and Repair


1.

Conduct a full frame inspection as per the inspection requirements listed in this document and your Operation and
Maintenance Manual.

2.

Clean the frame prior to inspections.

3.

Utilize an inspection diagram. A walk-around inspection diagram with weld joint locations is included in this
document.

4.

When evaluating frame cracks for repair, crack documentation and trend history can assist in determining potential
crack growth and speed. The sites crack trend data history can determine the priority in completing the repair. If the
sites crack trend data history predicts the crack growth speed to be low risk, then the crack would then be scheduled for
repair at the next scheduled opportunity/preventative maintenance. If the work sites crack trend data history predicts the
crack growth speed to be high risk, then the crack should be repaired immediately.

Trending
1.

Data collected from the crack history documentation reveals crack tendencies.

2.

Evaluating tendencies enables site-specific identification and rankings of crack severity/importance.

3.

The frequency of crack reoccurrences can be identified through the trending process.
Table 11
Frame Inspection Checklist
Date

Equipment
Number
SMU
Inspector
Item

Area

RH Front Frame Rail/Support

RH Upper Strut Mount

K Frame RH

RHR Engine Mount

Front Hydraulic Tank Mount

Rear Hydraulic Tank Mount

OK

Cracked

Comments - Length Location

RH Side Torque Tube and Transition to Frame


Rail

RH Hoist Cylinder Mount

RH Rear Frame Rail

10

RH Tail Casting

11

LH Tail Casting

12

LH Rear Frame Rail

13

LH Hoist Cylinder Mount

14

Rear Fuel Tank Mount

15

Front Fuel Tank Mount

16

LH Side Torque Tube and Transition to Frame


Rail

17

A Frame Mount

18

LHR Engine Mount

19

K Frame LH

20

LH Upper Strut Mount

21

LH Front Frame Rail/Support

22

Cross-Tube

23

RH Fore/Aft Rail

24

RH Fore/Aft Transition

25

LH Fore/Aft Transition

26

LH Fore/Aft Rail

Note: Fill in all areas of the checklist and circle cracked areas on the diagrams.

Ver imagen

Illustration 12

Ver imagen

g01306226

Illustration 13

g01306230

Inspection Intervals
Inspections of the frame assembly for cracks should be conducted during regular maintenance intervals. Some of the areas that
need to be inspected are blocked by one or more components. If the component that is blocking the frame is removed, an
inspection of that area should be performed. It is therefore important to take advantage of the opportunity to inspect those parts of
the frame assembly that are exposed whenever components are removed. As an example, when the hydraulic tank is removed, the
area behind the hydraulic tank should be cleaned and inspected. Cracking on one machine may indicate closer focus in that area
for the rest of the fleet. Refer to Table 12 for the Operation and Maintenance Manual for the off-highway truck/tractor that is
being worked on.
Table 12
Operation and Maintenance Manual
Off-Highway Truck/Tractor

Manual Number

784B

SEBU6517

784C

SEBU7176

785

SEBU6092

785B

SEBU6517

785C S/N:(1HW, APX, 2PZ)

SEBU7173

785C S/N:(5AZ)

SEBU7176

785D

SEBU8350

789

SEBU6039

789B

SEBU6518

789C

SEBU7174

789D

SEBU8242

793

SEBU6333

793B

SEBU6519

793C S/N:(4AR)

SEBU6995

793C XQ S/N:(CBR, ATY, 4GZ)

SEBU7175

793D

SEBU7792

Prepare the Work Area


1.

Before you start to work on the machine, disconnect the battery. Attach a Do Not Operate tag in the operator
compartment.

2.

When possible, make all repairs with the machine parked on a level, hard surface. When you work on the machine or
when you work under the machine, block the machine in order to prevent the machine from rolling. Select an
appropriate site in order to repair the chassis. Select an area that is flat, smooth, and drained. Make sure that there is
sufficient space for the items that follow: machine, components, tools and lifting devices.

3.

Do not work on any machine that is supported only by lift jacks or a hoist. Always use hardwood blocks or jack stands
to support the machine before performing any service or disassembly. Always make sure that the maximum load
capacity of the jack stands is greater than the weight of the machine.

4.

Make sure that the work area around the machine is made safe. Become aware of hazardous conditions that may exist.
If an engine is started inside an enclosure, make sure that the engine exhaust is properly vented.

5.

Before you start a repair, be sure that all protective devices are properly installed and that all protective devices
function correctly. When a guard must be removed or a shield must be removed in order to perform the repair work,
use extra caution.

6.

Always use tools that are in good condition. Before you perform any service work, understand the intended use of the
tools.

7.

Replace all fasteners with fasteners of the same part number. Do not use a lesser quality fastener if replacements are
necessary.

8.

Prepare to stop an engine that has had a recent overhaul. Prepare to stop an engine that has a fuel system that has
recently been worked on. If the engine has not been assembled correctly, the engine can possibly overspeed. If the fuel
settings are not correct, the engine can possibly overspeed. Overspeeding can cause bodily injury, death, or property
damage. Prepare to shut off the fuel and the air supply to the engine in order to stop the engine.

9.

Be careful when you remove cover plates. Gradually back off the last two bolts or the last two nuts that are located at
opposite sides of the cover or the device. Pry the cover loose in order to relieve any spring or other pressure, before you
completely remove the last two bolts or the last two nuts.

10. When you make repairs that require welding, have appropriate reference information. Welding should only be
performed by personnel that are adequately trained. Personnel should be knowledgeable in welding procedures. Make
sure that all repairs that require welding comply with the ANSI/AWS standards.
11. Do not damage wiring during removal operations. When you install the wiring, do not damage the wiring. The wiring
can be damaged in operation by the conditions that follow: contact with sharp corners, rubbing against objects and
contact with hot surfaces. Do not connect the wiring to a line that contains fluid.
12. Tighten connections to the correct torque. Make sure that all heat shields, clamps, and guards are installed correctly in
order to avoid excessive heat, vibration, or rubbing against other parts during operation. Shields that protect against oil
spray onto hot exhaust components in the event of a line, tube, or seal failure must be installed correctly.
13. Do not operate a machine if any rotating part is damaged or if any rotating part contacts any other part during
operation. Any high speed rotating component that has been damaged or altered should be checked for balance before
reusing. Before you start the engine, make sure that all protective devices are properly installed. Before you operate the
machine, make sure that all protective devices are functioning correctly.
14. Use extra caution when you service the rubber belts. Follow all safety instructions in the appropriate manuals. Wear
protective glasses. Block the machine in order to prevent the machine from moving.
15. When you unload components, place the components near the machine. Leave enough space around the machine in
order to maneuver lifting devices. Carefully inspect the parts. Ensure that all parts are undamaged. Organize the parts
for assembly.
16. The repair of the chassis will be easier if the machine is clean. Use a steam cleaner to clean the truck. Be careful with
the steam cleaner. Do not damage electrical wiring or cab windows.

Casting Replacement that Forms the Mounting Location for the Front Suspension
Cylinder on the Axle Frame for 784B, 785, 785B, 789, 789B, 793, 793B, 793C and 793D

In order to replace the casting that forms the mounting location for the front suspension cylinder on the axle frame, refer to
Special Instruction, REHS0172, "Off-Highway Tractor and Truck Front Strut Frame Casting Replacement".

Install the Field Retrofit for the Superstructure of 789, 789B, 789C, 789D, 793, 793B, 793C
and 793D Off-Highway Trucks

Ver imagen

Illustration 14

g00913037

In order to install the field retrofit for the superstructure, refer to Special Instruction, REHS0452, "Weld Repair Procedure for
Field Retrofit of Large Off-Highway Truck Frame Superstructure".

Repair of the Rear Motor Mount Castings


Repair Cracks
1.

Remove the necessary components in order to gain access to the castings for the rear motor mounts.

2.

Thoroughly clean the area around the castings for the rear motor mounts .

Ver imagen

Illustration 15

g00683110

Rear motor mount

3.

Inspect the welds and castings for the rear motor mounts.

4.

If you find a crack, use an air carbon arc to gouge out the crack. Taper the ends of the gouged area in order to provide a
smooth transition to the base metal. Gouge out at least 50.8 mm (2.0 inch) past the end of the crack. Use a grinder to
smooth the gouged area.

5.

Use some liquid dye penetrant to inspect the gouged area in order to ensure that the crack has been removed.
Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.

6.

Weld the gouged area until you reach the original profile.

Additional Fillet Welding of the Rear Motor Mounts

Ver imagen

Illustration 16

g00943250

(A) 50.8 mm (2.00 inch)


(B) 50.8 mm (2.00 inch)
(C) Additional fillet weld

1.

Start at the lower corners of the castings for the rear motor mounts and use an air carbon arc torch to remove 50.8 mm
(2.0 inch) of the horizontal 12.0 mm (.47 inch) fillet welds (A) that secure the motor mounts to the frame. Taper the
ends of the gouged area in order to make a smooth transition into the existing weld.

2.

Start at the lower corners of the castings for the rear motor mounts and use an air carbon arc torch to remove 50.8 mm
(2.0 inch) of the vertical 12.0 mm (.47 inch) fillet welds (B) that secure the motor mounts to the frame. Taper the ends
of the gouged area in order to make a smooth transition into the existing weld.

3.

Start at the end of the gouged areas and apply a 12.0 mm (.47 inch) fillet weld across the bottom of the motor mounts.
Continue the weld around the corner. Continue the welds into the vertical fillet welds at the sides of the motor mounts.
Note: Do not start the weld at the bottom corners of the motor mounts and do not stop the weld at the bottom corners of
the motor mounts.

4.

After you have repaired the welds at the corners of the motor mounts, apply an additional fillet weld (D) over the
existing fillet weld. Apply the fillet weld all the way around the motor mount. Refer to Illustration 16 in order to
determine the profile of the new fillet weld (D) .
Note: Ensure that there is at least an 8.0 mm (.32 inch) radius of transition at the toe of the weld. If necessary, grind the
radius.

Center Cross-Tube Support) Replacement for the 793C and 793D Off-Highway Trucks
Prepare the Frame in Order to Remove the Support (Center Cross-Tube)
1.

Remove the body from the truck. Remove any components that prevent access to the center cross-tube.

2.

Clean the area around the center cross-tube of the items that follow: oil, grease, dirt and paint.
Note: You must stabilize the area near the center cross-tube before you remove the center cross-tube.

3.

Before you stabilize the frame, prepare to take measurements for reference. Record reference dimensions from the
mounting holes for the A-frame to the frame rails. Record reference dimensions in order to position the tank support.

Ver imagen

Illustration 17

g00670054

(1) Square tubing

4.

Obtain two pieces of 101.6 mm (4.0 inch) square tubing (1) with 6.35 mm (.25 inch) thick walls. The square tubing
should be long enough to extend between the frame rails.

5.

Weld the square tubing between the frame rails. Refer to Illustration 17. Weld around each end of the square tubing (1).
Use 8.0 mm (.32 inch) fillet welds.

6.

Use the steel bar stock that is 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) wide to make diagonal braces.

7.

Place supports under the front half of the truck and place supports under the back half of the truck. Place the supports
under the frame rails on each side of the truck.

Remove the Existing Support (Center Cross-Tube)

Ver imagen

Illustration 18
(A) Top rail
(B) Window plate
(C) Window plate
(D) Window plate

g00670052

(E) Tank support


(F) Support (Center cross-tube)

1.

Cut section (A) from the top rail at each side of the frame. Section (A) should begin at the joint between the frame rail
and the casting for the rear pedestal of the superstructure. Refer to Illustration 18.
Note: Record the length of the opening that remains after you remove section (A) .

2.

Remove the window plates (B, C, D, and) the tank supports (E) from the sides of the frame rails.
Note: Save the tank supports (E). The tank supports will be used again.

3.

Remove the existing center cross-tube (F) .

4.

Measure approximately 1128 mm (44.4 inch) forward from the rear welded joint of the former center cross-tube in
order to locate a mark on the inside window plate. The mark will be used to cut an opening for the new 125-7017
Support (Center Cross-Tube) .

5.

Cut the inside window plates in order to make an opening for the new center cross-tube.

Install the New Support (Center Cross-Tube)

Ver imagen

Illustration 19

g00943339

(G) New center cross-tube

Note: Use the SMAW process and "E7018" welding electrode for all welds that secure the new cross-tube. As an
alternate process, the FCAW process can be used with "E71T-1 H8" welding electrode .
1.

Set the new 125-7017 Support (Center Cross-Tube) (G) in place. Use the reference dimensions that were recorded
earlier to position the center cross-tube.

Ver imagen

Illustration 20

g00681518

8X-2648 Rail

2.

Fabricate new top rails. Trim an 8X-2648 Rail . Grind a 30 degree bevel at each end of the 8X-2648 Rail .
Note: Maintain a root opening of 5.0 mm (.20 inch) at each end of the new section of rail.

Ver imagen

Illustration 21

g00681454

Support plate
(H) Cut in order to fit.
(J) 150 mm (5.9 inch)
(K) 300 mm (11.8 inch)
(L) 30 mm (1.2 inch)
(M) 500 mm (19.7 inch)
(N) 10 mm (.4 inches)

3.

Use steel that is 20 mm (.79 inch) thick to fabricate a support plate for the new section of frame rail. The steel must
meet ASTM specification "A572". Refer to Illustration 21.
Note: As an alternative, cut the former support plate from the former rail. If the former support plate is undamaged, use
the former support plate again.

Ver imagen

Illustration 22

g00670244

New top rails


(P) 1071.0 mm (42.16 inch)

4.

Use 12.0 mm (.47 inch) fillet welds to secure the support plate to the 8X-2648 Rail . Weld along the sides of the
support plate and weld along the angles of the support plate. Do not weld across the end of the support plate.

Ver imagen

Illustration 23

g00670248

5.

Tack weld the new top rails in place. Use two 50 mm (2.0 inch) bevel welds (W6) to secure the new sections of top rail
in place.

6.

Tack weld the new center cross-tube in place.

Ver imagen

Illustration 24

Ver imagen

g00670249

Illustration 25

g00681606

(G) New center cross-tube

7.

Use welds (W1) to secure both rear edges of 125-7017 Support (Center Cross-Tube) to the vertical supports within the
frame rails. Weld to the contour that is shown in Illustration 25.

8.

Use 16.0 mm (.63 inch) fillet welds (W2) to join the rear edges of the top rails to both sides of the vertical supports
within the frame rails.

9.

Use 12.0 mm (.47 inch) fillet welds (W3) to join the top and bottom edges of the 125-7017 Support (Center CrossTube) to the top and bottom frame rails. Weld from the inside of the frame rails.

10. Use 16.0 mm (.63 inch) fillet welds (W4) to secure the fore and aft edges of the 125-7017 Support (Center Cross-Tube)
to the inside window plates of the frame rails.
Note: Maintain a 10.0 mm (.40 inch) root opening. Do not extend the weld (W4) into the grooves for the horizontal
welds (W5). The forward edge of the new center support requires an 8X-0597 Backup Strip .
11. Use 16.0 mm (.63 inch) J-groove welds (W5) to secure the top and bottom edges of the 125-7017 Support (Center
Cross-Tube) to the top and bottom frame rails. Weld from the outside of the frame rails.

Ver imagen

Illustration 26
Window plate (Y)
(R) 669.0 mm (26.34 inch)
(S) 1829.0 mm (72.00 inch)

Ver imagen

g00681634

Illustration 27

g00681635

Window plate (X)


(U) 669.0 mm (26.34 inch)
(T) 612.0 mm (24.1 inch)
(V) 13.0 mm (.51 inch)

12. Use steel that is 16.0 mm (.63 inch) thick to fabricate two new outside window plates (Y) and (X) for each frame rail.
The steel should meet ASTM specification "A572". Trim the window plates in order to fit in the frame rails.

Ver imagen

Illustration 28
(E) Tank support
(Y) Window plate
(X) Window plate

13. Position window plate (Y) and window plate (X) on the frame.

g00670250

14. Use 16.0 mm (.63 inch) J-groove welds (W7) to secure the new outside window plates (Y) and (X) in place.
15. Position the tank supports that were removed earlier.
16. Use 8.0 mm (.32 inch) fillet welds to secure the tank supports to the frame rails. Grind a 5.0 mm (.20 inch) radius at the
toe of the fillet weld. Refer to the ""Tank Supports Field Repair Procedure" " in this Special Instruction.

Complete the Installation of the New Support (Center Cross-Tube)


1.

Remove the square tubing that was installed in order to brace the frame.

2.

Grind the areas near the intersection of welds to a smooth contour.

3.

Paint the areas that were repaired.

4.

Install the components that were removed from the truck.

Frame Rails (Repair)


Table 13
Frame Rails
Off-Highway Truck/Tractor

Part Number (1)

785

8X-0898

789

8X-2648

793

8X-2648

(1)

(Bulk) Must be cut to length.

1.

Remove the body of the truck. Refer to Disassembly and Assembly, "Body and Canopy - Remove".

Ver imagen

Illustration 29

g00918307

View of the left outside frame


(A) Bevel groove weld
(B) Tank mount
(C) J-groove
(D) Window plate

2.

Support the truck frame. Remove the fuel or the hydraulic tank. Use jacks on both sides of the frame rail that is
cracked. Raise the frame until the crack is closed.

3.

Remove all of the hardware that will be affected in the area near the center tube. Save all hardware. Record some
reference dimensions from the front mount for the fuel tank to the rear mount for the fuel tank. These measurements
will be used to relocate the front tank mount.

4.

Remove bracket (B) for the front fuel tank by using a arc gouge. Angle the cuts toward window plate (D) away from
the tank mount. Use care when cutting as the tank mount will be reused. Remove window plate (D) by using the carbon
arc gouging along the dotted line shown in Illustration 29. Angle the cut toward window plate (D) away from the top
and the bottom rails. The top and bottom weld joints have a backing plate (C) for the J-groove. When you cut the
window, try not to damage the plates. The vertical weld joints are bevel joints that have a gusset backing. Do not cut
into the gusset.

Ver imagen

Illustration 30

g00918330

Clean weld joints and prepare weld joints.


(C) J-groove
(E) 45 degree bevel with a 2 mm (0.08 inch) land

5.

After window plate (D) is cut and removed, grind off all of the old weld. Use a grinder in order to prepare the joints of
the weld to the original profile. This is shown in illustration 30. Be sure that the weld joints are free of oil, carbon, slag,
or foreign material.

Ver imagen

Illustration 31

g00918335

Frame rail
(F) Inside frame rail
(G) Crack

6.

Inspect the top and bottom rails (F) for cracks. Refer to Special Instruction, SEHS9091 for a reference. If cracks are
located, cut out the crack from the inside of frame rail (F). Weld the cut out areas and grind the area smooth. Back
gouge the repair as shown in Illustration 31. Weld the area that was gouged and grind the area smooth. Inspection of
the rail should be done in order to ensure that the rail is free of cracks. The Ultrasonic inspection procedure should be
used in order to inspect the repair. Use an angle beam transducer that is set up for mild steel. The weld should be
checked from each side. Any internal feature should be repaired.

Ver imagen

Illustration 32

g00918383

Inside window plate


(H) Bulkhead
(D) Inside window plate
(I) Backup strip

7.

Inspect the center cross-tube for cracks. If the tube is cracked, the tube must be repaired. Refer to ""Support (Center
Cross-Tube) Replacement" " section in this Special Instruction. Inspect inside window plate (D) in front of the center
tube. If the window plate is cracked, the window plate must be removed. The weld seam to the rear of the truck has a
backup strip (I). Remove the backup strip (I) and all of the old weld. For the 785 and 789 trucks, inside window plate
(D) will need to be cut at the gusset (bulkhead) (H) at the location shown in Illustration 32 and a weld seam created.
For the 793 truck, cut on the weld seam.
Note: The J-groove seams that run along the frame, top, and bottom of the window plate, will need to be removed.

Ver imagen

Illustration 33

g00918542

Reinforcement plates

8.

Fabricate the required reinforcement plates that are shown in Illustration 33. Use ASTM A572 grade 42 or 40 steel.

Ver imagen

Illustration 34
Outside window plate

9.

Fabricate the required window plates that are shown in Illustration 34. Use ASTM A572 grade 42 or 40 steel.

g00918547

Ver imagen

Illustration 35

g00918604

Backup strip

10. Fabricate the required backup strips that are shown in Illustration 35. Use ASTM A572 grade 42 or 40 steel.

Ver imagen

Illustration 36

g02646598

Inside window plate for 793 Off-Highway Truck


(ZZ) 16.0 mm (0.63 inch)
(ZY) 671.5 mm (26.44 inch) or 677.5 mm (26.67 inch)
(ZX) 669.0 mm (26.34 inch) or 672 mm (26.46 inch)

Note: Measure the length and width of the window plate prior to removal in order to determine the dimensions that are
appropriate for your truck.

Ver imagen

Illustration 37

g02719984

Inside window plate for 789 Off-Highway Truck


(ZW) 16.0 mm (0.63 inch)
(ZV) 1735.0 mm (68.31 inch) or 1570.0 mm (61.81 inch)
(ZU) 594.0 mm (23.39 inch) or 597.0 mm (23.50 inch)

Note: Measure the length and width of the window plate prior to removal in order to determine the dimensions that are
appropriate for your truck.

Ver imagen

Illustration 38

g02720009

Inside window plate for 785 Off-Highway Truck


(ZT) 14.0 mm (0.55 inch)
(ZS) 1626.5 mm (64.04 inch) or 1461.5 mm (57.54 inch)
(ZR) 521.0 mm (20.51 inch) or 524.0 mm (20.63 inch)

Note: Measure the length and width of the window plate prior to removal in order to determine the dimensions that are
appropriate for your truck.
11. Fabricate the required inside window plates that are shown in Illustration 36, Illustration 37, or Illustration 38. Use
ASTM A572 grade 42 or 40 steel.

Ver imagen

Illustration 39

g00918629

Welding the reinforcement plate


(J) Reinforcement plate
(K) 12 mm (0.47 inch) fillet
(L) Weld groove
(M) Existing weld
(N) Groove weld with 12 mm (0.47 inch) fillet

12. After the crack in the bottom rail is repaired, position the plate and tack weld reinforcement plate (J). Weld
reinforcement plate (J) that is shown in illustration 39. Visually inspect the welds. The welds shall be free from cracks,
porosity, undercut, and incomplete fusion. Grind the groove weld flush.

Ver imagen

Illustration 40

g00918696

Welding of the inside window plate


(O) 16 mm (0.63 inch) Fillet
(P) Bevel groove

13. Position the plate and tack weld the inside window plate. The root openings on the sides of the plate need to be a
minimum of 6 mm (0.24 inch) in order to allow for proper fusion of plate corners. Equalize the root opening between
the top and the bottom. Tack weld the window plate. Locate backup strip (I) and tack weld backup strip (I). Weld the
vertical seams (R). Weld the top and bottom J-grooves. After the groove welds are welded around the window plate,
weld a 16 mm (0.63 inch) fillet on the (bulkhead to window) on the inside of the rail. Slag each pass and make sure all
tie-ins are complete. The welds around the window plate should be inspected using ultrasound.

Ver imagen

Illustration 41

g00918706

Welding the outside window plate


(Q) 8 mm (0.32 inch) Fillet tig dressed
(R) Vertical grooves
(S) Bottom grooves

14. Locate and tack weld the outside window plate with a minimum of 6 mm (0.24 inch) root openings on the sides. Weld
the vertical seams (R). Weld the top and bottom horizontal groove weld (S). Slag each pass and make sure all tie-ins
are complete. The welds around the window plate should be inspected with ultrasound. Locate the bracket for the fuel
tank and tack weld the bracket for the fuel tank with the recorded reference dimensions. Refer to ""Tank Support Field
Repair Procedure for the 785, 785B,785C, 785D, 789, 789B, 789C, 789D, 793, 793B, 793C and 793D Off-Highway
Trucks" " for the correct welding size on the tank supports. Blend, grind, and paint as needed.

Tank Support Field Repair Procedure for the 785, 785B,785C, 785D, 789, 789B, 789C,
789D, 793, 793B, 793C and 793D Off-Highway Trucks
This procedure covers the field repair of cracks and to enhance fatigue life of the tank support welds for the 785, 789, 793, OffHighway Trucks.

Repair Procedure

Table 14
Tank Support
Fuel Tank Bracket

Hydraulic Tank Bracket

Front Bracket

Rear Bracket

Front Bracket

Rear Bracket

784

6G-7438

6G-7439

8W-4293

8W-4293

785

6G-7438

6G-7439

8W-4293

8W-4293

789

8W-5359

8W-5354

5T-6465

5T-6464

789D

347-6511

347-6510

5T-6465

5T-6464

793

8X-2571

8X-2572

8X-5936

8X-5936

Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld
pass shall not exceed two times the electrode diameter.
When the base metal temperature is below 0.0 C (32 F), the base metal shall be preheated to 21 C (70 F) and this minimum
temperature maintained during cutting or welding.
Clean the area to be welded from oil, grease, paint and dirt. Attach the welding ground cable directly to the center tube assembly.
Protect all machined surfaces from sparks or spatter produced by the welding, chipping and /or grinding operations.
The weld shall be free from cracks, porosity, undercut and incomplete fusion. All welds quality shall conform to ANS/AWS 14.3
or Caterpillar Specification 1E99.
Welding parameters will vary due to weld position and the manufacturer of welding electrode. For 1.3 mm (0.052 inch) diameter
electrode typical welding parameters.
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass.

Repair Cracks
Begin the repair by removing any cracks with the carbon arc gouging method, or grinding. Cracks must be removed to sound
metal prior to welding. Verify that the crack has been removed by the use of dye penetrant or magnetic particle inspection. Be
sure to clean the prepared groove before welding. Weld repair the prepared groove by using passes that do not exceed two times
the electrode diameter. If the alternate welding process is selected, the welding pass size should not exceed 8 mm (0.31 inch)
fillet weld volume. Remove the slag after each weld pass in order to avoid the possibility of slag inclusions.
Clean and inspect the weld repair. The weld shall be free from cracks, porosity, undercut and incomplete fusion. All welds
quality shall conform to ANS/AWS 14.3 or Caterpillar Specification 1E99.

Tank Support

Ver imagen

Illustration 42

g01144660

After the crack has been repaired, weld a small bead 6 mm (0.24 inch) around the toe of the existing weld as shown in Illustration
42. Use a small grinder to blend the toe of this weld (B) to approximately a 5 mm (0.2 inch) radius as shown in Illustration 42.
This will create a smooth transition from the weld to the rail, therefore reducing the stress concentration. Use a small grinder in
order to grind the top of plate (A) to a gradual radius. This will create a smooth transition from the weld to the tank support.

Outside Window Plates Repair for 784B and 784C Tractors, 785, 785B, 785C, 785D, 789,
789B, 789C, 789D,793, 793B, 793C and 793D Off-Highway Trucks

Ver imagen

Illustration 43

g00943495

(A) Inside window plate


(B) 100 mm (4.0 inch)

1.

Start at the tail casting and remove the inside window plate (A). Remove an additional 100 mm (4.0 inch) (B) from the
remaining window plate.
Note: When you remove the window plate, do not cut into the tail casting.

2.

Locate the crack in the outside window plate. Gouge out the crack from both sides of the plate.
Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.

3.

Weld one side of the crack. Gouge out the remaining side of the crack. Weld the remaining side of the crack. Grind the
welds down to the original profile.

Ver imagen

Illustration 44

4.

Add an 8.0 mm (.32 inch) fillet weld (W1) to the toe of the 12.0 mm (.47 inch) fillet weld that joins the outside window
plate and the tail casting. Grind the 8.0 mm (.32 inch) fillet weld to a radius of 5.0 mm (.20 inch).
Note: You may need to remove the pistol plates in order to gain access to the 12.0 mm (.47 inch) fillet weld.

5.

g00943496

Position the inside window plate and the backup plate.

Note: If necessary, install the pistol plates first. Use a 12.0 mm (.47 inch) fillet weld to secure the pistol plates to the
frame rail and to the tail casting. Maintain a 3.0 mm (.12 inch) root opening.
6.

Apply a 16.0 mm (.63 inch) J-groove weld around the inside window plate from the outside of the frame rail. Extend
the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the bottom of the frame rail past the
vertical joint in the window plates.

7.

Use a 16.0 mm (.63 inch) bevel weld to join the inside window plates.

Rear Window Plate Replacement Near the Tail Casting of 784B and 784C Tractors, 785,
785B, 785C, 785D, 789, 789B, 789C, 789D, 793, 793B, 793C and 793D Off-Highway Trucks

Ver imagen

Illustration 45

g00943390

(A) Outside window plate


(B) 100 mm (4.0 inch)

1.

Start at the tail casting and remove a section (A) of the window plate from the outside of the frame rail. Remove an
additional 100 mm (4.0 inch) (B) from the remaining window plate.
Note: When you remove the window plate, do not cut into the tail casting.

Note: The section of window plate that is removed should be the same size as the inside window plate.

Ver imagen

Illustration 46
(C) Inside window plate

g00943400

(D) 100 mm (4.0 inch)

2.

Start at the tail casting and remove the inside window plate (C). Remove an additional 100 mm (4.0 inch) (D) from the
remaining window plate.
Note: When you remove the window plate, do not cut into the tail casting.

Ver imagen

Illustration 47
(E) New outside window plate

3.

Position a new outside window plate (E) and a backup plate.

Ver imagen

g00679377

Illustration 48

g00943404

Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.
4.

Use a 12.0 mm (.47 inch) fillet weld (W1) to secure the new outside window plate to the tail casting.
Note: Grind the toe of the 12.0 mm (.47 inch) fillet weld to a 5.0 mm (.20 inch) radius.

Note: Illustration 48 does not show the pistol plates. If necessary, remove the pistol plates in order to gain access to
weld (W1) .

Ver imagen

Illustration 49

g00943408

5.

Apply a 16.0 mm (.63 inch) J-groove weld (W2) around the new outside window plate from the outside of the frame
rail. Extend the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the bottom of the frame
rail past the vertical joint in the window plates.

6.

Use a 16.0 mm (.63 inch) bevel weld (W3) to join the outside window plates.

7.

Position the inside window plate and the backup plate.


Note: If necessary, install the pistol plates. Use a 12.0 mm (.47 inch) fillet weld to secure the pistol plates to the frame
rail and to the tail casting. Maintain a 3.0 mm (.12 inch) root opening.

Ver imagen

Illustration 50

g00943409

8.

Apply a 16.0 mm (.63 inch) J-groove weld (W4) around the inside window plate from the outside of the frame rail.
Extend the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the bottom of the frame rail
past the vertical joint in the window plates.

9.

Use a 16.0 mm (.63 inch) bevel weld (W5) to join the inside window plates.

Rear Cross-Tube Replacement for 793, 793B, 793C, and 793D Off-Highway Trucks

Prepare the Frame in Order to Remove the Rear Cross-Tube


Note: The rear cross-tube can be replaced with the body on the truck or with the body off the truck. If you leave the body on the
truck, the body must remain in the DOWN position while the cross-tube is replaced.
1.

Clean the area around the rear cross-tube of the items that follow: oil, grease, dirt and paint.
Note: You must stabilize the area near the rear of the frame before you remove the rear cross-tube. Stabilize the area
near the rear frame in order to maintain the alignment of the bores for the body pins. You can weld braces on the rails
of the frame in order to stabilize the frame. Do not weld the braces too close to the bores for the body pins in order to
prevent distortion.

2.

Before you stabilize the frame, prepare to take measurements for reference. Use a punch to mark the four locations that
follow:
o Mark the rear of the right tail casting directly behind the bore for the body pin.
o Mark the rear of the left tail casting directly behind the bore for the body pin.
o Mark the rear of the left tail casting directly behind the bore for the pin for the suspension cylinder.
o Mark the rear of the right tail casting directly behind the bore for the pin for the suspension cylinder.

3.

Record the measurements that follow:


o Measure the distance across the tail castings above the bores for the body pins. Measure the distance from the
outside of the castings.
o Measure the distance from the top left punch mark to the bottom right punch mark.
o Measure the distance from the top right punch mark to the bottom left punch mark.
o Measure the distance between the bottom two punch marks.

4.

Remove parts that are exposed and remove parts that could be damaged by the repair procedure. Remove the items that
follow: rear lights, backup alarm, lubrication lines and wiring harnesses. Cut the light bar off the cross-tube. Save the
light bar in order to install the light bar on the new rear cast cross-tube.
Note: Record measurements for the location of bosses that will be removed.

Brace the Frame When the Body Is Off

Ver imagen

Illustration 51

g00667082

(A) Frame rail


(B) Square tubing
(C) Steel bar stock

1.

Weld braces on the frame rails of the truck in order to maintain the alignment of the pivot pin bores for the body. Apply
one set of braces ahead of the cross-tube. The braces should consist of the material that follows:

o
o

Obtain two pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The square
tubing (B) should be long enough in order to extend across the frame rails.
Obtain two pieces of steel bar stock (C) that are 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) tall. The
steel bar stock should be as long as the square tubing.

2.

Place one piece of square tubing (B) across the top of the frame rails. Weld the square tubing (B) in place. Start the
weld and stop the weld at least 25.4 mm (1.00 inch) away from the edge of the frame rails (A) .

3.

Place the second piece of square tubing (B) across the bottom of the frame rails (A). Weld the second piece of square
tubing (B) in place directly below the first piece of square tubing (B). Start the weld and stop the weld at least 25.4 mm
(1.00 inch) away from the edge of the frame rails (A) .
Note: Adjustable spreader bars can be used in place of the square tubing (B). Refer to Illustration 53. Use the screw
adjustment to adjust the width of the spreader bar. When you use spreader bars, weld the pads to the inside of the frame
rails. Start the weld and stop the weld at least 25.4 mm (1.00 inch) away from the weld at the edge of the frame rails
(A).

4.

Use the steel bar stock (C) that is 101.6 mm (4 inch) wide to make diagonal braces between the two pieces of square
tubing (B). The diagonal braces are shown in option 1 of Illustration 51.
Note: You can fabricate the diagonal braces from a single plate that is 25.4 mm (1.00 inch) thick. A diagonal brace that
is made from a single piece of plate is shown in option 2 of Illustration 51.

5.

Install braces behind the cross-tube. The brace should consist of the material that follows:
o Obtain two pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The square
tubing (B) should be long enough in order to extend across the frame rails.
o Obtain two pieces of steel bar stock (C) that are 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) tall. The
material should be as long as the square tubing.

Ver imagen

Illustration 52

g00667098

(A) Frame rail


(E) Square tubing
(F) Steel bar stock

6.

Place one piece of square tubing (E) across the top of the tail castings above the pivot pin bores for the body. Weld the
square tubing (E) in place.

7.

Place the second piece of square tubing (E) at the bottom of the tail castings between the upper mounts for the rear
suspension cylinders.

8.

Use the steel bar stock (F) that is 101.6 mm (4.0 inch) wide to make diagonal braces. Weld the braces on the tail
castings from the pivot pin bores for the body to the upper mounts for the rear suspension cylinder. The diagonal braces
are shown in option 3 of Illustration 52.
Note: You can fabricate the diagonal braces from a single plate that is 25.4 mm (1.00 inch) thick. A diagonal brace that
is made from a single plate is shown in option 4 of Illustration 52.

Brace the Frame When the Body Is On

Ver imagen

Illustration 53

g00667093

(A) Frame rail


(B) Spreader bar
(C) Steel bar stock

1.

Weld braces on the frame rails of the truck in order to maintain the alignment of the pivot pin bores for the body. Apply
one set of braces ahead of the cross-tube. The brace should consist of the material that follows:

o
o

2.

Obtain four spreader bars (B) with pads for welding. The spreader bars (B) should have a screw adjustment in
order to extend across the frame rails.
Obtain two pieces of steel bar stock (C) that are 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) tall. The
material should be as long as the spreader bars.

Place two spreader bars (B) across the top of the frame rails. Weld the pads of the spreader bars (B) in place. Start the
weld and stop the weld at least 25.4 mm (1.00 inch) away from the weld at the edge of the frame rails (A) .
Note: Use the jam nuts to secure the screw adjustment.

3.

Place the second set of spreader bars (B) across the bottom of the frame rails (A). Weld the second set of spreader bars
(B) in place directly below the first set of spreader bars (B). Start the weld and stop the weld at least 25.4 mm (1.00
inch) away from the weld at the edge of the frame rails (A) .
Note: Use the jam nuts to secure the screw adjustment.

4.

Use the steel bar stock (C) that is 101.6 mm (4.0 inch) wide to make diagonal braces between the spreader bars (B).
The diagonal braces are shown in option 1 of Illustration 53.
Note: You can fabricate the diagonal braces from a single plate that is 25.4 mm (1.00 inch) thick. A diagonal brace that
is made from a single plate is shown in option 2 of Illustration 53.

Ver imagen

Illustration 54
(A) Frame rail
(B) Spreader bar
(C) Steel bar stock
(H) Shims

g00667101

5.

Install braces behind the cross-tube. The brace should consist of the material that follows:
o Obtain a piece of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The square
tubing (B) should be long enough in order to extend across the frame rails (A) .
o Obtain two pieces of steel bar stock (C) that are 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) tall. The
material should be as long as the square tubing.

6.

Place the shims (H) between the inner flanges of the body for the pivot pin bores and the tail castings. The shims will
prevent the tail castings from distorting when the new cast cross-tube is installed.

7.

Place the piece of square tubing (B) at the bottom of the tail castings between the upper mounts for the rear suspension
cylinders.
Note: Adjustable spreader bars can be used in place of the square tubing (B). Refer to Illustration 54. Use the screw
adjustment to adjust the width of the spreader bar. When you use spreader bars, weld the pads to the inside of the tail
castings.

8.

Use the steel bar stock (C) that is 101.6 mm (4.0 inch) wide to make diagonal braces. Weld the braces on the tail
castings from the pivot pin bores for the body to the upper mounts for the rear suspension cylinder. Refer to option 3 of
Illustration 54.
Note: You can fabricate the diagonal braces from a single plate that is 25.4 mm (1.00 inch) thick. A diagonal brace that
is made from a single plate is shown in option 4 of Illustration 54.

Remove the Existing Rear Cross-Tube

Ver imagen

Illustration 55

g00668683

New 119-4726 Tube


(J) Length of cross-tube

1.

Use a grinder in order to make the ends of the new 119-4726 Cross-Tube square. Use a grinder to restore the chamfer at
the ends of the 119-4726 Cross-Tube . Measure the length (J) of the new cross-tube. Record the measurement (J) .

Ver imagen

Illustration 56

g00668689

(K) Distance from centerline of frame to cut


(M) Width of opening

2.

Establish the center line of the existing cross-tube. Mark a line that is a distance (K) from each side of the center line of
the existing cross-tube. Calculate the distance (K) from the formula that follows.
K = (J 2) + 9.6 mm (.38 inch)
Note: The distance (M) between the outer two lines on the existing cross-tube should be 19.0 mm (.75 inch) wider than
the length (J) of the new cross-tube.

3.

Before you cut the cross-tube from the truck, support the existing cross-tube.

4.

Cut the existing cross-tube from the truck.


Note: A second cut may be needed on the existing cross-tube in order to provide clearance for removal.
Note: Make sure that the opening (M) is no more than 19.0 mm (.75 inch) wider than measurement (J) .

5.

Grind the surface of the transition area until the surface is flush and square. Clean debris away from the inside surfaces
of the casting.

Position the New 119-4726 Cross-Tube for Installation


Prepare The Backup Plates

Ver imagen

Illustration 57

g00668747

Backup plate

1.

There are four backup plates that are used with the 119-4726 Cross-Tube . Cut each backup plate into two pieces along
the length of the backup plate.

Ver imagen

Illustration 58

g00668752

(N) 40.0 mm (1.57 inch)

2.

Obtain eight pieces of steel that can be used to hold the backup plates in position. The steel should have the dimensions
that follow:
o 3.0 mm (.12 inch) thick
o 25.4 mm (1.00 inch) wide
o 203.20 mm (8.00 inch) long

3.

Make a 90 degree bend in the steel. Refer to Illustration 58.

Ver imagen

Illustration 59

g00668756

Backup plate and strip

4.

Weld one steel strip to each piece of backup plate. Refer to Illustration 59.
Note: Before you weld the steel strip in place, refer to Illustration 60 in order to calculate the position of the steel strip.

Ver imagen

Illustration 60

g00668757

(P) Total length of cross-tube and backup plates

5.

Install the backup plates in the new cross-tube. Use the steel strips to hold the backup plates in position.
Note: When the backup plates are positioned in the new cross-tube, the total length (P) of the cross-tube and backup
plates must fit within the opening. When the correct length has been established, tack weld the steel strips in place.

Prepare the Locator Bars in Order to Hold the New Cross-Tube in Position
1.

Obtain eight steel bars in order to support the new cross-tube. The bars should have the dimensions that follow:
o 12.7 mm (.50 inch) thick
o 50.8 mm (2.00 inch) wide
o 203.2 mm (8.00 inch) long

Ver imagen

Illustration 61

g00668759

Rear cross-tube with backup plates and support bars

2.

Weld one locator bar on the top of the new cross-tube at each end of the new cross-tube. Weld the locator bars centrally
on the cross-tube. Allow the locator bars to extend beyond the ends of the new cross-tube. The end of the locator bar,
that extends beyond the end of the cross-tube, will support the cross-tube when the cross-tube is suspended in position.

3.

Weld one locator bar on the back side of the new cross-tube at each end of the new cross-tube. Weld the locator bars
centrally on the cross-tube. Allow the locator bars to extend beyond the ends of the new cross-tube. The end of the
locator bar, that extends beyond the end of the cross-tube, will locate the cross-tube in the fore and aft position.

Set the New Cross-Tube in Place

Ver imagen

Illustration 62

1.

g00668864

Position the new cross-tube in the opening. The new cross-tube should hang from the castings that protrude from the
frame rails. The raised letters on the cross-tube should face toward the front of the machine.
Note: It may be necessary to grind on the locator bars in order to position the cross-tube centrally in the opening.
Note: The new cross-tube weighs approximately 297 kg (655 lb).

2.

After the cross-tube is positioned, weld additional locator bars at the top of the cross-tube. Weld additional locator bars
on the side of the cross-tube. Weld the locator bars on the same side as the existing locator bars. At one end of the
cross-tube, weld the locator bars to the castings. The casting protrudes from the frame rail.
Note: Secure the new cross-tube to the frame rail on only one side. When the secured side is welded, the opposite end
is free in order to float.

3.

On the end of the cross-tube that is secured to the frame, cut the tack welds on the steel strips that hold the backup
plates. Slide the backup plates into position. Tack weld the backup plates to the cross-tube. Remove the steel strips that
held the backup plates.

Weld the New 119-4726 Cross-Tube in Place


1.

Use the SMAW process and "E7018" welding electrode in order to permanently weld the end of the new cross-tube that
is tack welded to the frame. Use two welding operators that start on opposite sides of the secured end of the cross-tube.
Start the welds at the bottom center of the cross-tube and end the welds at the top center of the cross-tube. Stagger the
starts and the stops. Fill the grooved area to a depth of 40.0 mm (1.57 inch). Before you proceed, complete all welding
at the secured end of the cross-tube.
Note: The FCAW process can also be used with "E71T-1 H8" welding electrode.

2.

Allow the welded end of the cross-tube to cool to a temperature of 38 C (100 F). While the welded end cools, slide
the backup plates at the other end of the cross-tube.

3.

Use the SMAW and "E7018" welding electrode in order to weld the four corners on the unsecured end of the crosstube. Weld approximately 76.2 mm (3.00 inch) from the center of each corner in both directions. Fill the corners to a
depth of 26.7 mm (1.05 inch).
Note: The FCAW process can also be used with "E71T-1 H8" welding electrode.

4.

Heat all four corners until the corners are a dull red color. Maintain the dull red color between 2 minutes and 3 minutes.
Allow the corners to cool to a temperature of 38 C (100 F).
Note: The heat treat process will minimize the shrinkage of the cross-tube.

5.

Gouge out the welds at the corners. Finish welding the cross-tube in place. Fill the grooved area to a depth of 40.0 mm
(1.57 inch).

Complete the Installation of the New Rear Cross-Tube


1.

Carefully remove the fixtures that braced the frame. Grind excess welds until the welds are flush. Fill any gouges.

2.

Install the light bracket on the new cross-tube. Weld the new bosses on the cross-tube. Refer to the recorded
dimensions.

3.

Measure the distances between the punch marks. Compare the measurements to the measurements that were taken
previously.
Note: The distance between the punch marks can be 4.5 mm (.17 inch) shorter than the recorded measurement. The
shorter measurement should not affect the pivot pin bores for the body.
Note: In some cases, the pivot pin bores may need to be repaired in order to install the body.

4.

Paint the area that was repaired.

5.

Install the components that were removed earlier.

Rear Support Assembly Replacement

Ver imagen

Illustration 63

1.

g00928869

Start by removing the body and supporting the frame rail with jacks.

Ver imagen

Illustration 64

g00928870

2.

Next the main rail needs to be braced. Cut two pieces of steel tubing to a length of 102 X 102 X 6 mm (4 X 4 X 1/4
inch).

3.

Weld the two braces (2) between the two frame rails. Weld the brace ends (3) with a 6 mm (0.24 inch) fillet welds.

4.

Make some reference measurements from the rear pivot holes to the rail and scribe a line on the rail. Record these
measurements. The recorded measurements will be used to locate the new rear support assembly.

Ver imagen

Illustration 65

g00928909

5.

Remove both rear window plates (1) by cutting around the weld seams.

6.

Angle the cuts toward the window plate so that minimal damage is done to the rail. Make sure that the support
assembly is safely supported before you cut the assembly loose.

7.

Finishing removing the rear support assembly by cutting the inside fillet weld that joins the outside window to the rear
casting.

8.

Cut weld joints (5) at the top and bottom of the rails. Also, cut welds (6) that is located on the inside on the top and
bottom.

9.

After the welds are cut loose, remove the rear support assembly. Prepare the weld joints by grinding the joints to the
original profile.

10. Be sure to remove all paint, oil, grease, slag, weld metal, and dirt.
11. Position the new rear support assembly near the frame. Use the recorded reference dimensions to locate the new rear
support assembly.
12. Tack weld the assembly into position. Weld the outside window plate to the rear casting on the inside of the rail use a
10 mm (0.4 inch) fillet weld. Weld a 10 mm (0.4 inch) weld on the inside along the rear casting to the rail on the top
and bottom as shown in Illustration 65.
13. Next weld the 29 mm (1.14 inch) top and bottom J-groove welds. Alternate between the top and the bottom.
14. Position and tack weld two 2G-7521 Strips (7) to each window (1) .
.

Ver imagen

Illustration 66

g00928912

15. Make strips (7) tack welds from the groove side of assembly.
16. Next tack two 115-3311 Plates to each rail. Weld the vertical 10 mm (0.4 inch) bevel weld joint on both inside window
plates. Weld the outside vertical J-groove joints.
17. Next weld the 10 mm (0.4 inch) J-groove around the inside windows.
Note: Make sure that all welds are tied in properly.
18. Clean and visually inspect all welds. The welds should be free from cracks, porosity, undercut, and incomplete fusion.
Remove the cross bracing and repair the rails.
19. Grind, blend, and paint as needed. All groove welds should be ultrasonically tested for soundness.

Tail Casting Replacement for 793, 793B, 793C and 793D Off-Highway Trucks
This procedure shows the replacement of the right side tail casting. Similar procedures are required for the left side tail casting.
1.

Remove the body from the truck. Remove any components that prevent access to the rear body pivot casting.

2.

Support both rear frame rails with jacks.

Ver imagen

Illustration 67

g00679475

(A) Square tubing


(B) Square tubing
(C) Inside window plate

3.

Obtain two pieces of 101.6 mm (4.0 inch) square tubing (A) with 6.35 mm (.25 inch) thick walls. The square tubing
should be long enough in order to extend between the frame rails.

4.

Obtain two additional pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The square
tubing should be 1059 mm (41.7 inch) long. The square tubing will form braces between the rear cross-tube and the
bracing between the frame rails.

5.

Refer to Illustration 67 in order to brace the rear frame rails with the square tubing.
Note: Position square tubing (A) approximately 140 mm (5.5 inch) from the edge of the inside window plate.

6.

Remove the 8X-2376 Window Plate (C) from the inside of the frame rail.

Ver imagen

Illustration 68

g00679480

(D) Pistol plate


(E) Pistol plate

7.

Remove the 8X-2686 Plate (D) and the 8X-0463 Plate (E) from the inside of the frame rail.

8.

After you make sure that the tail casting is supported, cut the tail casting away from the frame rail and from the rear
cross-tube.

Ver imagen

Illustration 69
(F) Backup plate
(G) Backup plate

g00679486

9.

After you remove the damaged tail casting, remove the two 9P-1037 Backup Plates (F) from the frame rail. Also,
remove the four 120-6766 Backup Plates (G) from the rear cross-tube.

10. Clean the edges of the joints at the frame rail. Clean the edges of the joints at the rear cross-tube. Remove slag and
carbon deposits.
11. Position two new 9P-1037 Backup Plates in the frame rail. Tack weld the backup plates in place.
12. Position four new 120-6766 Backup Plates in the rear cross-tube. Tack weld the backup plates in place.
13. Position the new tail casting in place on the frame rail and on the rear cross-tube. Align the unfinished pivot pin bore of
the new tail casting with the pivot pin bore of the existing tail casting.
Note: The reference dimension between the outer edges of the tail castings is 2085.0 mm (82.09 inch).
14. Tack weld the new tail casting in position.
Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.
15. Weld the new tail casting to the rear cross-tube. Alternate the welds between the top of the rear cross-tube and the
bottom of the rear cross-tube in order to prevent distortion. Also, alternate the welds between the front side of the rear
cross-tube and the back side of the rear cross-tube in order to prevent distortion.
16. Weld the new tail casting to the top of the frame rail and to the bottom of the frame rail.
17. Install the pistol plates. Position the 8X-2686 Plate (D) and the 8X-0463 Plate (E) inside the frame rail. Use a 4K-7004
Bar to connect the two plates.
Note: Grind the plates in order to fit the frame rail and the new tail casting. Maintain a 3.0 mm (.12 inch) root opening.
18. Use a 12.0 mm (.47 inch) fillet weld in order to secure the 8X-2686 Plate (D) and the 8X-0463 Plate (E) to the frame
rail and to the tail casting. Weld the joint between the plates.
19. Tack weld a new 8X-2688 Backup Plate in the frame rail for the inside window plate.
20. Position the 8X-2376 Window Plate on the inside of the frame rail. Use a 16.0 mm (.63 inch) fillet weld in order to join
the inside window plate to the existing side plate of the frame rail.
21. Use a 16.0 mm (.63 inch) J-groove weld to join the inside window plate to the tail casting and to the frame rails.
Note: Do not start the weld on the radius and do not stop the weld on the radius. Stagger the starts and stops.
22. Use a 16.0 mm (.63 inch) J-groove weld to join the outside window plate to the tail casting and to the frame rails.
Note: Do not start the weld on the radius and do not stop the weld on the radius. Stagger the starts and stops.
23. Machine the pivot pin bore of the tail casting to a diameter of 149.93 mm (5.903 inch).
Note: Align the pivot pin bore with the pivot pin bore of the tail casting on the opposite side of the frame.

Procedure to Repair the Bracket Assembly (Steering Box) on the 793C S/N:ATY and 793D

Note: Removal of the engine is required for performing the Advanced Repair. Refer to Disassembly and Assembly Manual,
SENR1461, "3516B Engine Supplement for 793C Off-Highway Truck" and Disassembly and Assembly Manual, RENR8334,
"793D Off-Highway Truck Engine Supplement " for procedure to remove and install the engine.

Ver imagen

Illustration 70

g03714429

View of the general area of repair


(A) Bracket assembly (steering box)
(B) Support assembly

The following procedure applies to the repairs of cracks located in the J-groove welds connecting the steering box to the support
castings. Refer to Illustration 71.

Ver imagen

Illustration 71

g03714443

View of crack present in the weld joint

Illustration 71 represents a typical crack that can occur in the weld joint between the bracket assembly (steering box) (A) and
support assembly (B). The crack shown in Illustration 71 is a fatigue crack that has initiated from the root of the weld and
propagated up through the weld and along the length.
Note: The following information provides details about the weld joints and the base material.

Ver imagen

Illustration 72

g03714473

Cross sectional view of J-groove weld joints


(A) Bracket assembly (steering box)
(B) Support assembly

Illustration 72 depicts the J-groove weld joint design that is present on all four sides between bracket assembly (steering box) (A)
and support assembly (B). As shown, support assembly (B) contains an inherent (or integral) backing for the weld joint.

Ver imagen

Illustration 73

g03714497

Cross sectional view of corner joints

Illustration 73 depicts the corner joint connection that is common on all four sides. Fillet welds are specified at this location (12
mm (0.47 inch) x 20 mm (0.79 inch).
Table 15
Material Type and Thickness
Part Number

Description

Material Type

8X-2272

Bracket

ASTM A27 70-40

8X-2273

Plate

ASTM A572 Gr 42

8X-2274

Plate

ASTM A572 Gr 42

8X-3566

Support

ASTM A27 65-35

Varies

8X-3567

Support

ASTM A27 65-35

Varies

(1)

Thickness
25 mm (0.98 inch) (1)
25 mm (0.98 inch)
20 mm (0.79 inch)

Nominal

Note: The cast bracket plate has been quenched and tempered to obtain higher mechanical properties than listed.

Basic Repair Procedure for the Bracket Assembly (Steering Box)

Ver imagen

Illustration 74

g03714683

View of probable crack initiation site and propagation path to the surface
(A) Bracket assembly (steering box)
(B) Support assembly
(C) Crack

1.

Excavate the full length and depth of crack (C) .


The depth of the crack will likely be the full thickness of the adjacent plate on bracket assembly (steering box) (A).
Therefore, the crack will likely be 20 mm (0.79 inch) to 25 mm (0.98 inch) deep depending on the side of bracket
assembly (steering box) (A) .
Note: There is likely to be small gap between the underside of the plate and the integral backing of support assembly
(B) (shown in Illustration 72).

2.

Verify that the crack has been removed via magnetic particle (MT) or dye penetrant (PT) testing.

Ver imagen

Illustration 75

g03714711

View of crack excavated


(A) Bracket assembly (steering box)
(B) Support assembly

Ver imagen

Illustration 76

g03714740

View of excavation prepared for welding


(A) Bracket assembly (steering box)
(B) Support assembly
(D) 60 degree minimum included angle
(E) 6 mm (0.24 ch) minimum

3.

Gouge, grind, and prepare the area to provide suitable access to the root of the joint.
Note: Gaps at the joint root (especially at the corners) should be reduced by building up with weld metal and
blend sanding.

Ver imagen

Illustration 77

g03714749

View run on/off tab examples

Ver imagen

Illustration 78
View of run on/off tab used in repair process

g03714771

4.

For repairs made on plates with open ends, attach run on/off tabs in order to place weld starts on tabs and outside of
finish weld. Lack of fusion defects associated with weld starts will then be non-existent when tabs are removed.

5.

Inspect all welds visually to ensure that all weld quality meets or exceeds the requirements in the ""Weld Inspection
and Acceptance Criteria" " section.

NOTICE
Use caution when removing run on/off tabs. Avoid gouging or grinding
adjacent base material.

6.

Remove the run on/off tabs and sand the corners to a generous radius.

Ver imagen

Illustration 79

g03714777

View of completed repair

7.

Paint repaired area as needed. Illustration 79 shows a completed repair.

Advanced Procedure to Repair the Bracket Assembly (Steering Box)


Note: Removal of the engine is required for performing the Advanced Repair. Refer to Disassembly and Assembly Manual,
SENR1461, "3516B Engine Supplement for 793C Off-Highway Truck" and Disassembly and Assembly Manual, RENR8334,
"793D Off-Highway Truck Engine Supplement " for procedure to remove and install the engine.
If required, perform ""Basic Repair Procedure for the Bracket Assembly (Steering Box)" " before removing the front
plate.
In order to extend the life of the J-groove weld joints and correct the root gap issues, access to the inside of the bracket
assembly (steering box) is required.

Ver imagen

Illustration 80

g03714959

View of the front plate on the bracket assembly (steering box)


(A) Bracket assembly (steering box)
(B) Front plate

1.

Document and scribe lines for all hardware presently located on front plate (B) .

NOTICE
Use caution not to damage the hardware. Hardware can be reused.

2.

Remove all hardware from front plate (B) .

3.

There is an internal fillet weld connecting the four sides of bracket assembly (steering box) (A) along the length.
Remove the center section of front plate (B) first.

Ver imagen

Illustration 81
View of front plate

g03715378

(B) Front plate


(C) 30 mm (1.18 inch)

4.

Measure 30 mm (1.18 inch) from the edge of the weld on front plate (B) and mark a cut line. Refer to Illustration 81.
Note: The 30 mm (1.18 inch) is to avoid damaging the integral backing strip of the support assembly.

Ver imagen

Illustration 82

g03715439

View of bracket assembly (steering box) with front plate partially removed
(A) Bracket assembly (steering box)

Note: One access has been obtained you will be able to see the internal fillet welds and the inside surface of the top and
bottom plates of bracket assembly (steering box) (A). Refer to Illustration 82.
5.

Gouge/excavate the J-groove welds connecting the remnants of the front plate to the support assembly.

6.

Gouge/excavate the corner fillet welds connecting the top and bottom plates to the remaining part of the front plate.

Ver imagen

Illustration 83

g03715471

View of bracket assembly (steering box) with front plate partially removed
(A) Bracket assembly (steering box)

7.

Continue gouging/cutting the remaining of front plate material (and internal fillet weld) until removed from the top and
bottom plates. Refer to Illustration 83.

8.

Once inside, locate the weld root of the J-groove (externally) on three sides (top/bottom/rear).

Ver imagen

Illustration 84

g03715522

View of the locations to excavate to locate weld root

9.

Use arc/air gouging and grinding to remove part of the integral backing strip to locate the weld root and prepare the
joint for welding.

Ver imagen

Illustration 85

g03715545

View before excavation

Ver imagen

Illustration 86

g03715547

View after excavation

10. Back gouge to sound metal (D) .

Ver imagen

Illustration 87
View of prepared area

g03715553

11. Grind and sand gouged areas to smooth rough edges and remove any carbon and slag residue.
Note: Tungsten carbide burring tools will need to be used in the corners in lieu of grinders/sanders.
12. Visually inspect (with the aid of a good light source) to verify that sound metal has been reached and there are no
discontinuities present to hinder a quality root pass. If anything appears suspicious, then verify with either magnetic
particle (MT) or dye penetrant inspection (PT).
Note: Perform Step 9 through Step 12 on both sides (left and right) before welding.

Ver imagen

Illustration 88

g03715565

View of offset

13. Measure offset (D) between the inside surface of the adjacent plate of bracket assembly (steering box) and the inside
surface of the integral backing strip on the support assembly. Refer to Illustration 88Record the offset dimensions.
Note: Offset will be used to determine fillet weld size.

Ver imagen

Illustration 89

g03715581

View of welding progression

14. Weld the root pass as shown in Illustration 89. Vertical progression is uphill and no starts or stops are allowed in the
corners. Weld the root pass on one side and then the other side.
Note: Use a balanced welding technique in order to equalize the welding distortion between the two sides. For
example, weld the root pass on the left side and the weld the root pass on the right side. Continue this sequence for each
succeeding pass until the groove (excavation) portion is filled.

Ver imagen

Illustration 90

g03715642

View of no weld area previously specified

15. Prior to finishing the weld joint between the support assembly and the bracket assembly (steering box), the fillet weld
that is internal to the bracket assembly (steering box) will need to be modified.
Illustration 90 shows that the internal fillet weld from the factory does not extend all the way to the edge, but is stopped
short by 100 mm (3.94 inch).

Ver imagen

Illustration 91

g03715666

View of the internal fillet weld size

Ver imagen

Illustration 92

g03715667

View of the drain hole in the bracket assembly (steering box)

16. Extend the fillet weld until the fillet weld connects at the corners with the previous welds applied. The size of the fillet
weld is 10 mm (0.40 inch) as shown in Illustration 91. Do not weld the drain hole shut.

Note: Grind the existing weld start/stop to minimize lack of fusion before starting the fillet weld that extends into the
corner.

Ver imagen

Illustration 93

g03716070

View of full penetration groove weld with fillet weld transition

17. The offset was measured in Step 13. This dimension determines the size of the fillet weld that will be added over the
partial J-groove weld in Step 14, and the fillet weld that was completed in Step 16.
Example: If the offset is 10 mm (0.40 inch), then the fillet weld over the J-groove weld will be a 10 mm (0.40 inch) by
10 mm (0.40 inch) fillet weld. The fillet weld size will vary depending on the offset. Illustration 93 depicts the
expectation of the full penetration groove weld and fillet weld.
Note: Use the same welding progression and balanced welding technique in reference to Illustration 89.
18. Visually inspect all welding and ensure that all weld quality meets or exceeds the requirements in the ""Weld
Inspection and Acceptance Criteria" " section.
19. Blend sand all weld starts/stops and any transitions.

Ver imagen

Illustration 94

g03716152

View of prepared edges and surfaces for welding

20. Prepare the edges of the plates and surfaces of the J-groove preparations on the support assembly. Repair any divots or
gouges by welding and sanding. Refer to Illustration 94.

Ver imagen

Illustration 95

g03716209

Dimensions for fabrication of front plate


(E) 1090 mm (42.91 inch)
(F) 355 mm (13.98 inch)
(G) 20 mm (0.79 inch)

21. Use the dimensions in Illustration 95 in order to fabricate a new front plate. Use ASTM A572 Grade 42 material.

Ver imagen

Illustration 96

g03716232

Determine if gap exists


(B) Support assembly
(H) Gap measurement
(J) front plate

22. Fit the fabricated front plate (J) to bracket assembly (steering box) (A) and check for interference or gaps. If gaps exist
between the bottom side of front plate (J) and the integral backing strip on support assembly (B), record the
measurement and build up the support assembly casting accordingly. Refer to Illustration 96.
Note: Gaps should be less than 2 mm (0.079 inch)

Ver imagen

Illustration 97

g03716253

View of support assembly casting built up


(B) Support assembly
(H) Gap measurement

23. Build up support assembly (B) casting by welding to a dimension slightly higher than gap measurement (H) .

Ver imagen

Illustration 98

g03716262

View of support assembly casting sanded to profile

24. Blend sand excess weld material to achieve a smooth J-groove profile with minimal gap.

Ver imagen

Illustration 99

g03716271

View of J-groove minimum requirements


(B) Support assembly
(J) Front plate
(K) 20 mm (0.79 inch)
(L) 45 degree bevel

25. Install front plate (J) and ensure desired fit-up has been achieved. The minimum face opening for a J-groove should be
approximately 20 mm (0.79 inch). Refer to Illustration 99.

Ver imagen

Illustration 100

g03716452

View of optional single V groove


(J) Front plate

26. If access to the root is difficult, grind a bevel (15 to 20 degree) on front plate (J) to increase access. Refer to Illustration
100.
27. Secure front plate (J) in place using 6 mm (0.24 inch) by 50 mm (1.97 inch) fillet welds on all four sides.
28. Attach run on/off tabs as discussed in Step 4 in the ""Basic Repair Procedure for the Bracket Assembly (Steering Box)"
".
29. Weld the root pass at each of the four weld joints before proceeding with the second and third weld passes.

Ver imagen

Illustration 101

g03716470

View of the direction/progression of welding for fillet welds

30. The progression for the J-groove welds will be vertical up. The direction for the top and bottom fillet welds are shown
in Illustration 101. Start each weld pass in the middle and terminate at the end of the joint.

Note: Grind the weld start in the middle to minimize lack of fusion before starting the fillet weld going in the opposite
direction.

Ver imagen

Illustration 102

g03716490

View of weld sizes


(J) Front plate

31. Finish weld front plate (J) using the weld sizes shown in Illustration 102.
Note: Use a balanced welding technique in order to equalize the welding distortion between the four sides. Do not weld
more that two passes at one joint before the next.
32. Inspect all welds visually to ensure that all weld quality meets or exceeds the requirements in the ""Weld Inspection
and Acceptance Criteria" " section.

NOTICE
Use caution when removing run on/off tabs. Avoid gouging or grinding
adjacent base material.

33. Remove the run on/off tabs and sand the corners to a generous radius.
34. Locate and reattach all miscellaneous hardware that was document and removed in Step 1 and Step 2.
35. Paint repaired area as needed.

Steering Box Replacement or Replace the Bracket that is on the Steering Box
The steering box can be replaced or the bracket that is on the steering box can be replaced. To replace the complete steering box,
the engine must be removed. The bracket can be replaced without removing the engine. In either case, a new steering box is
needed in order to complete the repair.
Table 16

Part Numbers for Replacement of the Steering Box


Model

Part Number

784B, 784C, 785, 785B, 785C, 785D

5T-8671

789, 789B, 789C, 789D

5T-6243

793, 793B, 793C, 793D

8X-2283

Complete Steering Box Replacement


1.

Remove any components that prevent access to the center steering box.

2.

Support both front frame rails with jacks.

3.

Measure the distance from the bore diameters in the steering box to the mounting locations for the front suspension
cylinders. Record the measurements to use as a reference when you install the new steering box.

Ver imagen

Illustration 103

g00682679

Typical steering box


(A) Square tubing
(B) Steering box

4.

Obtain two pieces of 101.6 mm (4.0 inch) square tubing (A) with 6.35 mm (.25 inch) thick walls. The square tubing
should be long enough in order to extend between the mounting locations for the front suspension cylinders.

5.

Refer to Illustration 103 in order to place the square tubing (A) between the mounting locations for the front suspension
cylinders.
Note: Use 8.0 mm (.32 inch) fillet welds in order to secure the square tubing (A) to the mounting locations for the front
suspension cylinders.

6.

Use an air carbon arc torch in order to remove the damaged steering box. Angle the torch toward the steering box in
order to prevent damage to the mounting locations for the front suspension cylinders.

7.

Clean slag and carbon deposits from the J-grooves on the mounting locations for the front suspension cylinders.

8.

Use the reference dimensions in order to place the new steering box (B) in position.
Note: You may need to remove the cast backup strip on the J-groove in order to fit the steering box (B) in place. If you
remove the cast backup strip, you will need to use separate backup strips.

9.

Ensure that there is a 5.0 mm (0.20 inch) root opening around each end of the steering box (B) .

Ver imagen

Illustration 104

g00682681

(B) Steering box


(C) Hardware

Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.
10. Start the J-groove welds (W1) at both vertical joints at the front of the steering box (B). Fill the grooves to the halfway
point.
11. Use J-groove welds (W2) to weld both vertical joints at the rear of the steering box (B). Fill the grooves completely.
12. Complete the J-groove welds (W1) at both vertical joints at the front of the steering box (B). Fill the grooves
completely.
13. Use J-groove welds (W3) to weld both joints at the bottom of the steering box (B). Fill the grooves completely.
14. Use J-groove welds (W4) to weld both joints at the top of the steering box (B). Fill the grooves completely.
15. Position any hardware (C) that was removed from the original steering box. Weld the hardware (C) in place.
16. Remove the square tubing (A) that was used to brace the frame. Grind the mounting locations for the front suspension
cylinders to the original profile.
Table 17
Sizes for Welds
Model
784B, 784C, 785, 785B, 785C,
785D

(W1)

(W2)

(W3)

(W4)

20.0 mm (.79
inch)

25.0 mm (.98
inch)

25.0 mm (.98
inch)

25.0 mm (.98
inch)

789, 789B, 789C, 789D

20.0 mm (.79
inch)

20.0 mm (.79
inch)

25.0 mm (.98
inch)

25.0 mm (.98
inch)

793, 793B, 793C, 793D

20.0 mm (.79
inch)

20.0 mm (.79
inch)

25.0 mm (.98
inch)

25.0 mm (.98
inch)

Replace the Bracket that is on the Steering Bracket


The procedure can be performed without removing the engine. Replace the steering bracket whenever the bores are not within the
specifications. A new steering box is needed in order to complete the procedure. This procedure consists of the following
procedures: preparation of the new steering bracket, removal of the worn steering bracket, installation of the new steering bracket
and welding of the new steering bracket.
Preparation of the New Steering Bracket
Note: The following trucks need an updated center arm and associated parts in order to use the steering box part numbers
referenced in Table 18. 785 (S/N: 8GB1-516) and 789 S/N:9ZC1-554. Refer to Service Magazine, SEPD0055, "New Bearing and
Shims Used Between Steering Arm and Frame Bracket" for additional information.

Table 18
Part Numbers for Replacement of the Steering Box
Model

Part Number

784B, 784C, 785, 785B, 785C, 785D

5T-8671

789, 789B, 789C, 789D

5T-6243

793, 793B, 793C, 793D

8X-2283
Table 19
Sizes of Bevels and Sizes of Welds

Model
784B, 784C, 785,
785B, 785C,
785D

789, 789B, 789C,


789D

793, 793B, 793C,


793D

1.

B1

W1

W3

W4

W5

10 mm (0.4
inch)

12.0 mm (0.47
inch)

25.0 mm
(0.98
inch)

10 mm (0.4
inch)

12.0 mm (0.47
inch)

25.0 mm
(0.98
inch)

10 mm (0.4
inch)

12.0 mm X 20 mm
(0.47 inch X 0.8
inch)

20 mm (0.8
inch)

10 mm (0.4
inch)

12.0 mm X 20 mm
(0.47 inch X 0.8
inch)

20 mm (0.8
inch)

10 mm (0.4
inch)

12.0 mm X 20 mm
(0.47 inch X 0.8
inch)

20 mm (0.8
inch)

10 mm (0.4
inch)

12.0 mm X 20 mm
(0.47 inch X 0.8
inch)

20 mm (0.8
inch)

Order a new steering box. Refer to Table 18.

Ver imagen

W2

Illustration 105

2.

g00883071

Remove the casting (1). Use air carbon arc to gouge the fillet welds (A) from the outside corners. Gouge the fillet
welds (B) from the inside corners. Protect the bores from sparks or from grinding material during the removal
procedure. Also protect the bores during the cleanup procedure. Refer to Illustration 105. Remove the bracket from the
steering box. Do not cut into the casting with the gouging rod.
Note: The remaining plate steel will not be needed for this repair.

3.

Once the bracket is removed from the steering box, clean the casting by removing all existing weld deposits with a
grinder.

Ver imagen

Illustration 106

4.

g00883201

Machine the bevel or grind the bevel (B1). The angle of the bevel is 45 degrees. Refer to Table 19 for the size of the
bevels.

Removal of the Worn Bracket from the Existing Steering Box


Note: Be sure to protect all surfaces from sparks and grinding grit.

1.

Remove all hydraulic lines and steering cylinders from the area around the existing bracket assembly.

2.

The center arm will also need to be removed.

Ver imagen

Illustration 107

3.

g00883260

Scribe a line (L1) from the center of the bore across the top of the steering box. Make a center punch on top of the
steering box. This will be used to locate the new bracket.

Ver imagen

Illustration 108

4.

g00883267

Remove the worn bracket. Cut along line (C1) .


Note: For the weld seams (W2), angle the air carbon arc torch straight down in order to remove the weld deposit. Use
caution so that the cast backup is not cut.
Note: The top and bottom seams are fillet welds (W1). The weld joints on the sides of the bracket are J-groove welds
with a backup casting (W2). Refer to Table 19 for the size of the welds.

5.

Clean the J-groove welds that are on the sides of the support castings. Do not gouge the cast backup strip. Clean the top
of the steering box of slag and bottom of the steering box of slag. Then prepare the square edge.

Installation of the New Bracket


Note: Ensure that the casting is beveled. Remove all foreign material from the weld joint.
1.

Use the scribed line on top of the steering box to locate the center bore. Center the bore with the line. Adjust the casting
so that the top weld seams and bottom weld seams are equal. Locate the new casting.

2.

Tack weld the bracket to the steering box and to the support castings.

Weld the New Bracket to the Existing Steering Box


Note: Perform the welding in order to distribute the heat. This will avoid excessive weld distortion. Complete the groove welds
before you begin the fillet welds. For example, place one pass on the top, one pass on the bottom, one pass of the right side, and
one pass on the left side. Repeat this process until the weld seams are complete. Remove the slag after each pass and do not allow
the interpass temperature to exceed 205 C (400 F).

Ver imagen

Illustration 109

g00883312

1.

Weld a bevel groove weld (W3) on the top of the casting and on the bottom of the casting. There is a notch on the
bottom of the casting that is designed to drain the casting. Do not weld over the drain hole (DH). Refer to Table 19 for
the size of the welds.

2.

Once bevel groove weld (W3) is full, weld a fillet weld (W4) on the top of the casting and on the bottom of the casting.
Again, do not weld over the drain hole (DH). Refer to Table 19 for the size of the welds.

3.

Weld J-groove welds (W5) on both sides of the casting. Refer to Table 19 for the size of the welds.

Ver imagen

Illustration 110

g00883357

4.

Smooth the welds from the support casting to the steering box. Place the tie-in at the corners. Blend the weld in order to
match the contour of the support assembly and of the steering box. Grind the welds (G1) at four corners smooth.

5.

Locate any removed hardware. Weld the hardware in place.

6.

Visually inspect all welds. The welds shall be free from cracks, porosity, undercut, and incomplete fusion. Blend the
welds. If necessary, paint the components.

7.

Reassemble all components that were removed in order to make the repair.

Ball Replacement for the Lower Connection of the Hoist Cylinder


1.

Remove any components that prevent access to the ball.

Ver imagen

Illustration 111

g00929222

View of ball installation


(A) Ball
(B) Refer to Table 20.
(C) Refer to Table 20.

2.

Use an air carbon arc torch to remove the worn ball (A). Angle the torch toward the ball in order to prevent damage to
the drop tube casting.

3.

Clean the slag and the carbon from the casting.


Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1 H8" welding electrode.

4.

Locate the new ball (A) in position. Refer to Illustration 111 and Table 20. Use three 8.0 mm (.32 inch) fillet welds that
are equally spaced to tack weld the ball in place. The tack welds should be 50.8 mm (2.0 inch) long.

5.

Use multiple passes to complete the J-groove weld (W1) at the Ball (A). Refer to the Table 20 in order to determine the
size of the J-groove weld (W1) that is required for your machine. Weld each pass completely around the ball in order to
minimize distortion.
Note: Cover the ball in order to protect the machined surfaces from damage due to welding.

6.

Use a hand grinder in order to blend the weld between the ball and the casting. Paint the area around the new ball.
Table 20

Sales Model

Part Number (A)

785, 785B, 785C, 785D

6G-6499 Ball

789, 789B, 789C, 789D

6G-6499 Ball

793B, 793C, 793D

8X-1213 Shaft

Dimension (B)
271 mm (10.67 inch)
298 mm (11.73 inch)
-

Dimension (C)
-

335 mm (13.19 inch)

Weld (W1)
35.0 mm (1.38 inch)
35.0 mm (1.38 inch)
44 mm (1.73 inch)

Replacing the Drop Tube Assembly on the 793C and 793D Off-Highway Trucks
Table 21
Required Parts
Item

Qty

Part Number

Description

125-6968

Support As (1)

125-6969

Plate As

284-7988

Plates

8X-5939

Block

135-7627

Bracket

135-7641

Gusset

8X-2573

Bracket

8X-2574

Gusset

(1)

Also referred to as "Drop Tube As"

Note: The total combined weight of the components in Table 21 is approximately 1390 kg (3064 lb).
1.

Disassemble as required to obtain unrestricted access to the drop tube-to-frame weld joint interfaces. Items to be
removed include the A-frame assembly, drive shaft, hydraulic tank, fuel tank, the hoist cylinders, and any hoses/tubes
that may interfere with welding.

2.

Plug all open hose and tube ends.

3.

Remove all components from the top of the drop tube.

4.

To avoid damage from weld and oxy-fuel cutting torch spatter, protect all exposed machined surfaces, hoses, tubes, and
affected nearby components with flame proof blankets.

5.

Support bottom of frame with suitable stands so that the frame is level in the transverse direction.

Ver imagen

Illustration 112

g02624222

(A) 80 mm (3.15 inch)


(B) Existing drop tube assembly

6.

Layout cut lines 80 mm (3.15 inch) down from pad casting corner, both sides, two castings. Connect layout lines across
each casting end surface.

7.

Using sling straps or choke chains, attach hoist to drop tube castings.

Note: The weight of existing drop tube assembly (B) and associated welded components is approximately 1390 kg
(3064 lb). Be sure to use a suitable lifting device rated for this capacity.

Ver imagen

Illustration 113

g02624242

(B) Existing drop tube assembly

8.

Using an oxy-fuel cutting torch with a tip capable of penetrating 45 mm (1.77 inch) steel thickness, carefully cut along
the lines laid out in Step 6.
Note: The torch cuts must be parallel with the bottom frame rail surface to prevent damage to the drop tube mounting
pad surfaces.

9.

After existing drop tube assembly (B) is free, remove from under truck frame.

Ver imagen

Illustration 114

g02626160

Arrows show the areas on the frame rail pad castings to grind smooth.

10. Remove slag. Then grind the casting faces smooth. Grind the weld metal only. Fill gouges as needed. Then grind flush.
11. Use a suitable tool to determine the flatness of the frame rail pad castings. Ensure that each frame rail pad casting is flat
to within 5.0 mm (0.20 inch) in both directions.
Note: The casting faces are milled from the factory with a course "N" surface finish. Grind only the areas affected
during the cutting operation. There should be no need to grind the inner, undisturbed casting face surfaces.

Ver imagen

Illustration 115

g02626189

View of existing drop tube assembly (B) with original components

12. Take note of the original locations of items (C1), (C2), (D), and (E) on existing drop tube assembly (B) using whatever
measurements are necessary. Then use these measurements to locate and weld the new items to new drop tube
assembly (1).

Ver imagen

Illustration 116

g02627579

(1) New drop tube assembly


(2) Plate assembly
(W2) A 20 mm (0.79 inch) flare-bevel groove weld along top of plate assembly (2).
(W3) A 12 mm (0.47 inch) vertical fillet weld with 1.5 mm (0.06 inch) root penetration on both sides of each gusset. Weld in upward direction.

13. Using the measurements taken in Step 12, locate and weld plate assembly (2) to new drop tube assembly (1) .

Ver imagen

Illustration 117

g02627896

(1) New drop tube assembly


(3) Plates
(4) Block
(W4) An 8 mm (0.31 inch) fillet weld with 1.5 mm (0.06 inch) root penetration all the way around each plate (3).
(W5) A 12 mm (0.47 inch) flare-bevel groove weld along the top and bottom of block (4).

14. Using the measurements taken in Step 12, locate and weld plates (3) and block (4) to new drop tube assembly (1) .

Ver imagen

Illustration 118

g02626204

Arrows show where to grind chamfer.


(1) New drop tube assembly

15. Prepare new drop tube assembly (1) by removing paint from casting weld areas. Then grind a 2 mm (0.08 inch) to 3
mm (0.12 inch), 45 degree chamfer all around the top of both drop tube castings. The arrows in Illustration 118 show
the areas to be ground to a chamfer.

Ver imagen

Illustration 119
Left side view
(1) New drop tube assembly
(F) 548 mm (21.57 inch)
(G) 1464 mm (57.64 inch)
(H) 228 mm (8.98 inch)

Ver imagen

g02629439

Illustration 120
View J - J
(1) New drop tube assembly
(H) 228 mm (8.98 inch)
(K) 85 mm (3.35 inch)

Ver imagen

g02629859

Illustration 121
Right side view
(1) New drop tube assembly
(L) 622 mm (24.49 inch)
(M) 1489 mm (58.62 inch)
(N) 302 mm (11.89 inch)

Ver imagen

g02630037

Illustration 122

g02630056

View P - P
(1) New drop tube assembly
(N) 302 mm (11.89 inch)
(R) 228 mm (8.98 inch)

16. Using a hoist with straps or choke chains raise new drop tube assembly (1) to the bottom of the frame. Support new
drop tube assembly (1) with jacks. Locate new drop tube assembly (1) from the centerlines of the upper hydraulic and
fuel tank brackets. Use the dimensions from Illustration 119, Illustration 120, Illustration 121, and Illustration 122 in
order to position new drop tube assembly (1) correctly.
Note: The weight of new drop tube assembly (1) and associated welded components is approximately 1390 kg (3064
lb). Be sure to use a suitable lifting device rated for this capacity. If using an overhead shop hoist with chains, the use
of a hook insulator is required.
17. Tack weld the assembly into position by using 25 mm (0.98 inch) long, heavy-duty tack welds all the way around each
tube casting.
18. Clean slag from all tack welds and inspect.
Note: No weld overlap or crater cracks allowed.
19. Prepare the weld joints for root passes by feather grinding the ends of the tack welds.

Ver imagen

Illustration 123

g02633339

White arrow shows view of root pass.


(1) New drop tube assembly

20. Weld root pass all the way around each tube casting. Maintain the same direction of weld travel for the fore-aft (side)
weld joints and the transverse (front and rear) weld joints.
21. Remove hoist, clean root passes, and inspect.
Note: Visually inspect subsequent weld passes and repair as needed.

Ver imagen

Illustration 124
Left side view
(1) New drop tube assembly
(W6) A 30 mm (1.18 inch) J-Groove weld
(W7) A 40 mm (1.57 inch) J-Groove weld
(W8) A 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting

Ver imagen

g02633956

Illustration 125

g02633976

Right side view


(1) New drop tube assembly
(W6) A 30 mm (1.18 inch) J-Groove weld
(W7) A 40 mm (1.57 inch) J-Groove weld
(W8) A 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting

22. Use a 30 mm (1.18 inch) J-Groove weld on the front of each tube casting. Weld until 50% full, alternating every two or
three passes from side to side.
Note: Transverse (front and rear) weld passes shall wrap around corners, starting, or terminating in the fore-aft (side)
weld joints.

23. Slag each weld pass.


24. Use a 40 mm (1.57 inch) J-Groove weld on the rear of each tube casting. Weld until 33% full, alternating every two or
three passes from side to side.
Note: Transverse (front and rear) weld passes shall wrap around corners, starting, or terminating in the fore-aft (side)
weld joints.
25. Feather grind the ends of the transverse (front and rear) weld passes.
26. Use a 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting. Weld until 50% full,
alternating every two or three passes from side to side.
27. Slag each weld pass.
28. Clean all welds and prepare joints for finish welding.
29. Use a 30 mm (1.18 inch) J-Groove finish weld on the front of each tube casting. Finish weld the remaining 50%,
alternating every two or three passes from side to side.
Note: Transverse (front and rear) weld passes shall wrap around corners, starting, or terminating in the fore-aft (side)
weld joints.
30. Slag each weld pass.
31. Use a 40 mm (1.57 inch) J-Groove weld on the rear of each tube casting. Weld until 66% full, alternating every two or
three passes from side to side.
Note: Transverse (front and rear) weld passes shall wrap around corners, starting, or terminating in the fore-aft (side)
weld joints.
32. Feather grind the ends of the transverse (front and rear) weld passes.

Ver imagen

Illustration 126
View of finish weld (W8)

g02634336

(1) New drop tube assembly


(W8) A 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting

33. Use a 20 mm (0.79 inch) J-Groove finish weld on the inside and the outside of each tube casting. Finish weld the
remaining 50%, alternating every two or three passes from side to side.
34. Slag each weld pass.
35. Use a 40 mm (1.57 inch) J-Groove finish weld on the rear of each tube casting. Finish weld the remaining 33%,
alternating every two or three passes from side to side.
36. Clean all welds.
37. Inspect and repair the finish welds as needed.

Ver imagen

Illustration 127
Left side view of transverse (front and rear) finish welds
(1) New drop tube assembly
(W6) A 30 mm (1.18 inch) J-Groove weld
(S) Finish grind contour for (W6)
(T) Weld contour before grinding for (W6)
(W7) A 40 mm (1.57 inch) J-Groove weld
(U) Finish grind contour for (W7)
(V) Weld contour before grinding for (W7)

g02635377

38. Grind all transverse (front and rear) finish welds to the contours shown in Illustration 127.
39. Grind the front and rear ends of the fore-aft (side) finish welds flush approximately 75 mm (2.95 inch) from each end.
Blend around each corner to the transverse (front and rear) finish welds.
Note: No sharp corners allowed.
40. Remount the hydraulic tank to the right side of the truck, supporting the bottom of the hydraulic tank with a hydraulic
jack. Snug the mounting bolts and caps.

Ver imagen

Illustration 128

g02635879

(1) New drop tube assembly


(5) Bracket

41. Assemble new bracket (5) to the hydraulic tank with regular mounting hardware.
42. Lower the hydraulic jack allowing bracket (5) to touch the RH side of new drop tube assembly (1) .

Ver imagen

Illustration 129

g02635936

(1) New drop tube assembly


(5) Bracket
(X) Bracket (5) angle as measure from the horizontal is 20 +/- 2 degrees.

43. Check the bracket angle and rotate bracket (5) in order to duplicate the original angle. The angle as measured from the
horizontal should be 20 +/- 2 degrees.

Ver imagen

Illustration 130

g02636016

(1) New drop tube assembly


(5) Bracket
(W9) A tack weld all the way around the inside of the slot in bracket (5).

44. While maintaining angle (X) which is shown in Illustration 129, tack weld bracket (5) to the RH side of new drop tube
assembly (1) .
Note: Tack weld around the inside of the slot in bracket (5) only. Do not tack weld around the perimeter of bracket (5) .

Ver imagen

Illustration 131

g02636039

(1) New drop tube assembly


(5) Bracket
(6) Gusset
(W10) Tack welds attaching gusset (6) to bracket (5) and new drop tube assembly (1).

45. Locate and tack weld gusset (6) to the RH side of new drop tube assembly (1) and to bracket (5). Tack weld both on the
top and on the bottom of gusset (6) .
46. Remove the hydraulic tank from the truck.

Ver imagen

Illustration 132

g02636058

(1) New drop tube assembly


(5) Bracket
(W11) A 25 mm (0.98 inch) weld with 2.5 mm (0.10 inch) root penetration all the way around the inside of the slot in bracket (5).

47. Weld around the inside of the slot in bracket (5) .

Ver imagen

Illustration 133

g02636059

(1) New drop tube assembly


(5) Bracket
(6) Gusset
(W12) A 15 mm (0.59 inch) weld with 2.5 mm (0.10 inch) root penetration on the top and bottom of gusset (6).

48. Weld gusset (6) to the RH side of new drop tube assembly (1) and to bracket (5). Weld both on the top and on the
bottom of gusset (6) .
49. Remount the fuel tank to the left side of the truck, supporting the bottom of the fuel tank with a hydraulic jack. Snug
the mounting bolts and caps.

Ver imagen

Illustration 134

g02637917

(1) New drop tube assembly


(7) Bracket

50. Assemble new bracket (7) to the fuel tank with regular mounting hardware.
51. Lower the hydraulic jack allowing bracket (7) to touch the LH side of new drop tube assembly (1) .

Ver imagen

Illustration 135

g02638139

(1) New drop tube assembly


(7) Bracket
(W13) A tack weld all the way around the inside of the slot in bracket (7).

52. Tack weld bracket (7) to the LH side of new drop tube assembly (1) .
Note: Tack weld around the inside of the slot in bracket (7) only. Do not tack weld around the perimeter of bracket (7) .

Ver imagen

Illustration 136

g02638201

(1) New drop tube assembly


(7) Bracket
(8) Gusset
(W14) Tack welds attaching gusset (8) to bracket (7) and new drop tube assembly (1).

53. Locate and tack weld gusset (8) to the LH side of new drop tube assembly (1) and to bracket (7). Tack weld both on the
top and on the bottom of gusset (8) .
54. Remove the fuel tank from the truck.

Ver imagen

Illustration 137

g02638363

(1) New drop tube assembly


(7) Bracket
(W15) A 25 mm (0.98 inch) weld with 2.5 mm (0.10 inch) root penetration all the way around the inside of the slot in bracket (7).

55. Weld around the inside of the slot in bracket (7) .

Ver imagen

Illustration 138

g02638480

(1) New drop tube assembly


(7) Bracket
(8) Gusset
(W16) A 25 mm (0.98 inch) vertical flare-bevel groove weld which is welded in the upward direction. (W16) welds the inboard side of bracket (7) to the
LH side of new drop tube assembly (1).

56. Weld vertically up along the inside of bracket (7) and the LH side of new drop tube assembly (1) .

Ver imagen

Illustration 139

g02638589

(1) New drop tube assembly


(7) Bracket
(8) Gusset
(W17) A 15 mm (0.59 inch) weld with 2.5 mm (0.10 inch) root penetration on the top and bottom of gusset (8).

57. Weld gusset (8) to the LH side of new drop tube assembly (1) and to bracket (7). Weld both on the top and on the
bottom of gusset (8) .
58. Repaint bare metal areas.
59. Reassemble all of the hardware that was removed prior to the repair.

Updating The A-Frame Mounting Area on the Center Tube for the 793 Truck

Ver imagen

Illustration 140

g00918802

Section view of center tube area


(1) Remove weld
(2) Fillet weld

1.

Begin by removing any existing cracks by grinding or carbon arc gouging. Verify that the crack has been removed by
the use of dye penetrant.

2.

Remove the existing 16 mm (0.63 inch) fillet weld (1) and cut a groove 12 mm (0.47 inch) deep with a 45 degree bevel
as shown in illustration 140.

3.

Clean the prepared weld joint by grinding. Make sure that all of the oil, dirt, and the dye penetrant is cleaned from the
joint.

4.

Weld the groove with small stringer welds. Weld a 16 mm (0.63 inch) fillet (2) over the groove. The toes on the fillet
weld should have a smooth transition with no overlaps.

5.

Visually inspect the welds. The weld should be free from cracks, porosity, undercut, the overlay, and incomplete
fusion.

Suspension A-Frame Field Weld Repair for the Weld Joint for the 785, 785B, 785C, 785D,
789, 789B, 789C, 789D, 793, 793B, 793C and 793D Off-Highway Trucks
Note: For cracks in machined surfaces refer to Special Instruction, REHS2346, "Weld Repair Procedure for the Rear Axle AFrame and Rear Axle Housing on 785, 789, and 793 Off-Highway Trucks".

Ver imagen

Illustration 141

g00659272

Welded joints for the A-Frame

1.

Visually inspect the welded joints of the suspension A-frame for cracks. Also use some liquid dye penetrant in order to
inspect joints that may have cracks. As an alternative, you can use the magnetic particle inspection process to inspect
the welded joints.

2.

Use one of the methods that follows in order to remove cracks.


o Grinding process
o Air carbon arc torch
Note: Cracks that extend completely through the original weld should only be removed by the grinding process.
Completely remove the crack from the base metal. Use some liquid dye penetrant in order to inspect the ground
surfaces of the groove. Also, you can use the magnetic particle inspection process to inspect the ground surfaces of the

groove. When the crack is removed, the bottom of the groove should have an angle of 90 degrees in order to ensure
sufficient penetration. The side walls of the groove should extend upward at an angle of 45 degrees.
3.

Clean the area that will be welded.

4.

Protect the machined surfaces from the weld spatter. Protect the machined surfaces from the sparks.

5.

Attach the welding ground cable directly on the suspension A-frame.

6.

Heat the base metal of the groove to a temperature of 150 C (300 F). Maintain the temperature of the base metal at
150 C (300 F) during the welding process.

7.

Use the SMAW process and "E7018" welding electrode in order to fill the grooves that are left after you remove the
cracks. Remove the slag after every pass of the welding electrode.
Note: The FCAW process can also be used with "E71T-1 H8" welding electrode.

8.

Clean the welds. Inspect the repairs for the following defects:
o Cracks
o Porosity
o Undercut
o Incomplete fusion
Note: Use some liquid dye penetrant in order to inspect the weld. Also, you can use the magnetic particle inspection
process to inspect the weld.

9.

Use a hand grinder to blend the weld flush at the corners to the profile of the casting.

Relocate the Mounting Block on the Suspension A-Frame of 793, 793B, 793C and 793D Off-Highway Trucks
in Order to Prevent Cracks

Ver imagen

Illustration 142

g00659081

Mounting block

Check the location of the mounting block at the front of the suspension A-frame. If the mounting block is located over the weld
bead that joins the center section of the A-frame and the right leg support, the overlap of the welds may cause cracks to develop.
Move the mounting block in order to correct the overlap.
1.

Remove the existing mounting block.

Ver imagen

Illustration 143

g00659082

Fabricated mounting block


(A) 223.5 mm (8.80 inch)
(B) 20 mm (.80 inch)
(C) 45 mm (1.77 inch)
(D) 15 mm (.59 inch)
(E) 193.5 mm (7.62 inch)
(F) 22.5 mm (.89 inch)
(G) 10.53 .10 mm (.415 .004 inch) Diameter

2.

Fabricate a new mounting block from steel that meets ASTM specification "A36". Refer to Illustration 143.

Ver imagen

Illustration 144

g00659083

Moved mounting block


(H) 112 mm (4.4 inch)
(J) 175 mm (6.9 inch)
(K) This is the starting point for the weld.
(L) This is the end point for the weld.

3.

Use the SMAW process with "E7018" welding electrode in order to secure the new mounting block on the suspension
A-frame. Refer to Illustration 144 in order to position the new mounting block.
Note: The FCAW process can also be used with "E71T-1 H8" welding electrode.

Bearing Bore Field Repair for the Suspension A-Frame for 785, 785B, 785C, 785D, 789, 789B, 789C, 789D,
793, 793B, 793C and 793D Off-Highway Trucks

Ver imagen

Illustration 145

g00930332

Typical A-Frame
(A) Refer to Table 22.
(B) Refer to Table 22.

You can install a sleeve in order to salvage the bearing bore at the front of the suspension A-frame.
Note: The only option for wear is a sleeve. The entire a-frame must be replaced if wear is excessive or the a-frame has cracks at
the bolt holes. If the bore cannot be sleeved, the a-frame must be replaced. The nose is not a replacement option due to assembly,
dimensioning, and machining requirements.
Table 22
Dimensions for Machining the Bearing Bore
Sales Model

785B, 785C, 785D

Dimension (A)

32.35 mm (1.27
inch)

Dimension (B)

215.86 .013 mm (8.498 .0005


inch)

Part Number for the


Sleeve
184-6962

789B, 789C

793, 793B, 793C.


793D

1.

32.35 mm (1.27
inch)

21.12 mm (.83 inch)

215.86 .013 mm (8.498 .0005


inch)

184-6962

234.92 .013 mm (9.249 0.0005


inch)

184-6963

Remove the suspension A-frame from the center cross-tube of the truck. Remove the bearing from the bearing bore.

Ver imagen

Illustration 146

g00658984

Bearing bore that does not require welding


(C) Original bearing bore
(D) Worn area
(E) Bore for sleeve

2.

If the largest diameter of the bearing bore that is elongated is less than the outer diameter of the sleeve, machine the
bearing bore to the dimension that is listed in Table 22. Refer to Illustration 146.

Note: If the largest diameter of the bearing bore that is elongated is greater than the outer diameter of the sleeve, you
must replace the A-frame.
3.

Lower the temperature of the sleeve to 45 5C (50 10F).

4.

Install the sleeve in the bearing bore of the suspension A-frame.

5.

Lower the temperature of the bearing to 45 5C (50 10F).

6.

Install the bearing in the bearing bore of the sleeve in the suspension A-frame.

7.

Connect the suspension A-frame to the center cross-tube of the truck.

Control Rod Bores Field Repair on Differential Housing and Main Frame for the 785,
785B, 789, 789B, 789C, 789D, 793, 793B, 793C and 793D Off-Highway Trucks
Repair Procedure

Ver imagen

Illustration 147

g00942194

(A) Main frame bore


(1) 2.5 degree

Ver imagen

Illustration 148

g00942328

(B) Differential housing bore

Begin the repair by cleaning the bore to be welded. Measure the bore so that amount of buildup can be determined. Use small 6
mm (0.24 inch) weld passes. Try to make each pass continuous. Make sure that all weld passes are tied-in and slag each pass.
After welding, bore to the following dimensions as shown in Table 23.
Table 23
785

789

793

Frame Bore
(A)

101.66 mm (4.0024 inch)

101.66 mm (4.0024 inch)

101.66 mm (4.0024 inch)

Differential Housing Bore


B

101.66 mm (4.0024 inch)

101.66 mm (4.0024 inch)

101.66 mm (4.0024 inch)

Field Replacement of the 161-1249 Beam As on the 793C Off-Highway Trucks


Required Parts
Table 24
Required Parts
Item

Qty

Part Number

Description

350-1599 (1) (3) (4) (5)

Support As

350-1598 (1) (3) (4) (5)

Cab Alignment Tool As

161-1249 (3) (4) (5)

Beam As

8X-0514 (3) (4) (5)

Plate

8X-0515 (3) (4) (5)

Plate

8X-1986 (3) (4) (5)

Plates

128-3200 (3) (4) (5)

Plates

8X-1985 (3) (4) (5)

Plates

8X-9176 (3) (4) (5)

Plate

10

125-6974 (3) (4)

Bracket As

11

247-6905 (4) (5)

Bar

12

9R-2613 (3) (4)

Weld Boss

13

091-9284 (4)

Bar

14

8X-6100 (2) (5)

Bracket As

15

9R-1733 (5)

Boss

16

8X-6101 (2) (5)

Bracket As

(1)

A nonserviceable part of the 353-4386 Cab Alignment Tool Gp

(3)

Used on S/N:4AR machines

(4)

Used on S/N:4GZ and ; S/N:ATY machines

(5)

Used on S/N:1HL machines

(2)

This part is canceled. Follow the instructions in this document.

Disassembly

Ver imagen

Illustration 149
(17) Right beam assembly
(18) Transition casting on the right-hand side
(19) Rear pedestal on the right-hand side
(20) 161-1249 Beam As
(21) Rear pedestal on the left-hand side
(22) Holes for the ROPS cab
(23) 8X-0469 Support As
(24) Transition casting on the left-hand side
(25) Left beam assembly
(26) Front suspension cylinder
(27) 8X-0436 Support As

g01956938

(28) Holes for the ROPS cab


(29) Front pedestals

Note: The engine does not need to be removed in order to perform this procedure. Alternate, temporary supports can be
used. This procedure shows the engine removed for clarity.
1.

Disassemble the machine as required in order to allow open access to the 161-1249 Beam As (20). Both front
suspension cylinders (26) will remain in place. The support assembly (27) for the ROPS will remain in place. The
support assembly (23) for the ROPS will be removed. The support assembly (23) will be installed on the new beam
assembly.

2.

Support the frame assembly so that beam assembly (20), beam assembly (25), and beam assembly (17) are reasonably
level.

3.

Document the location of the hardware that will be affected by the tooling on the beam assembly and the
transition casting for the left beam assembly and the right beam assembly.

Temporary Bracing

Ver imagen

Illustration 150

1.

g01956959

Refer to Illustration 150. From steel that has a yield strength of 400 MPa (58015 psi), cut lengths of steel for temporary
bracing. As shown in Illustration 150, install the temporary bracing.
If possible, do not weld the temporary bracing to the corners of the left beam assembly and the right beam assembly or
the corners of the supports for the suspension cylinders. Weld only on the horizontal surfaces toward the center of the
beams or support castings in line with the major axis of the parts. The horizontal bracing will need to clear the jack
clamp on the left beam assembly and the right beam assembly for the locating fixture of the beam assembly.

350-1599 Support As to Check the Height and Squareness of the Beam Assembly

Ver imagen

Illustration 151

Ver imagen

g01956991

Illustration 152

g01956994

(W1) two 6 mm (0.24 inch) fillet welds that are 25 mm (0.98 inch) long, 180 degrees apart on each boss

1.

By using the bases of the two support assemblies (1), mark the location for the two 2J-3507 Full Nuts (30) on the back
side of the left pedestal and the back side of the right pedestal.
Note: The two 2J-3507 Full Nuts (30) are part of the 350-1599 Support As . You will need to replace the nuts after the
procedure is completed.
Note: The approximate weight of each fixture is 890 N (200 lb).

2.

Refer to Illustration 152. Weld the two nuts (30) to the back side of the left pedestal and the back side of the right
pedestal.
Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the FCAW
process can be used with "E71T-1" welding electrode.

3.

Install the top of the two support assemblies to the bases.

4.

Loosen the lock nuts. Adjust the screws on the top of the support assemblies so that each screw barely contacts the
beam assembly. Tighten the lock nuts.

5.

Document the location of the hardware that will be affected by the tooling on the beam assembly and the
transition casting for the left beam assembly and the right beam assembly.

6.

Remove the top of the two support assemblies from the bases. Leave both bases on the pedestals. You will install the
top of the two support assemblies after the new beam assembly has been installed.

The 350-1598 Cab Alignment Tool As to Locate the Beam Assembly

Ver imagen

Illustration 153

g01957001

The 350-1598 Cab Alignment Tool As (2) is used in order to locate the position of the new 161-1249 Beam As (3). The
approximate weight of the fixture is 544 kg (1200 lb).
You can adjust three of the four pins in the 350-1598 Cab Alignment Tool As (2) in order to locate the cab according to the
dimensions that are on the print or you can adjust the fixture to the actual position of the holes in the frame. Set the pin locations
to the actual position of the holes in the frame.
The cab alignment tool assembly contains two bolts (31) that are jacks. One bolt supports the inside rear corner of the fixture near
the beam assembly that will be replaced. You adjust the bolt to the height of the beam assembly on the left side of the machine
after the fixture is in line with the position of the holes in the cab support. The other bolt supports the front of the fixture by the
front left cab support.

Note: The 2 mm (0.08 inch) shim (32) is used to compensate for weld shrinkage in the transverse weld in the beam assembly.
When you establish the location of the bores for the cab supports, the shim should not be in the fixture. The shim must be in the
fixture when you weld the new beam assembly into position.

Ver imagen

Illustration 154

g01957002

1.

By using a suitable lifting device, position the 350-1598 Cab Alignment Tool As (2) over the holes (22), beam
assembly (25), the six holes in the rear cab support (23), the four bores in the front cab support (27) and holes (28) in
the front pedestal. The approximate weight of the cab alignment tool is 544 kg (1200 lb).

2.

Locate and lightly tighten the bolt for the nonadjustable pin that is located in holes (28). This is the pin that goes in the
front pedestal.

3.

Adjust the pin that is in holes (22) on the back, right corner of the fixture. Loosen the two bolts that fasten the bracket
to the frame. Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so the pin slides into the hole.
Tighten the four bolts.

Note: If needed, loosen the locknut on the bolt that is used in order to adjust the height of the fixture. Raise the fixture
to remove the weight from the pin. Tighten the locknut. When the pin is positioned, loosen the locknut and lower the
fixture to the correct height. Tighten the locknut.
4.

Adjust the pin that is over the beam assembly on the back, left corner of the fixture. Loosen the two bolts that fasten the
bracket to the frame. Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so the pin slides into the
hole. Tighten the four bolts.

5.

Adjust the pin that is over the front, left corner of the fixture. Loosen the two bolts that fasten the bracket to the frame.
Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so the pin slides into the hole. Tighten the
four bolts.
Note: If needed, loosen the locknut on the bolt that is used in order to adjust the height of the fixture. Raise the fixture
to remove the weight from the pin. Tighten the locknut. When the pin is positioned, loosen the locknut and lower the
fixture to the correct height. Tighten the locknut.

6.

Verify that contact has been made between the fixture and the spot faces on the bores of the cab supports. Verify that
the bolts for the pins have been tightened.

7.

Remove the 350-1598 Cab Alignment Tool As from the machine. Set the fixture out of the way.

Marking the Transition Casting on the Left Beam Assembly and the Right Beam Assembly

Ver imagen

Illustration 155

g01957005

The transition casting on the new beam assembly is longer than the transition casting that was on the former beam assembly. In
order for the new beam assembly to work on older frames, you must shorten the back end of the right beam assembly 215 mm
(8.5 inch) (A) .

Ver imagen

Illustration 156

g01957336

(B) 363 mm (14.29 inch)


(C) 415 mm (16.33 inch)
(D) The front face of the beam assembly
(E) 90 degrees
(F) Cutting line, all around the left beam assembly, even and square all around
(G) Remove the bracket before you cut the left beam assembly

1.

By using the dimensions that are listed in Illustration 156, mark the cutting line (F) that you will cut on the back end of
the right beam assembly. Use a punch to mark the steel so that the line cannot be erased.

Ver imagen

Illustration 157

2.

g01957354

The cutting line (F) on the left beam assembly is the back side of the weld joint all around the beam. By using an
oxyacetylene torch that is capable of piercing steel that is 30 - 40 mm (1.2 - 1.6 inch) thick, cut the transition casting
along cutting line (F). Cut the steel on the transition casting side of the line. Cut as little steel from the left beam
assembly and the right beam assembly as possible. If a weld joint is present, cut on the side of the weld joint that is
toward the transition casting. This would be away from the two beam assemblies.

Ver imagen

Illustration 158

g01957355

3.

By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (34) from the left end of the pedestal that is
on the left side of the frame. Do not gouge deeply into the pedestal. Gouge into the bottom plate of the beam and gouge
into plate (35) .

4.

By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (33) that is on the front and back of the
beam assembly between the pedestal and the beam assembly on the left side of the frame. Gouge into the bottom plate
of the beam assembly not the pedestal.

Ver imagen

Illustration 159

g01957356

5.

By using an air carbon arc torch, remove the 12 mm (0.47 inch) fillet weld (36) that is between the pedestal and the
beam assembly on the right side of the machine. Gouge into the bottom plate of the beam assembly not the pedestal.

6.

By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (37) that is on the front and back of the
beam assembly between the pedestal and the beam assembly on the right side of the frame. Gouge into the bottom plate
of the beam assembly not the pedestal.

Ver imagen

Illustration 160

g01957357

7.

By using an air carbon arc torch, remove the 12 mm (0.47 inch) fillet welds (38) that are toward the center of the frame
between the pedestals and the beam assembly on both sides of the machine. Gouge into the bottom plate of the beam
assembly not the pedestal.

8.

By using a suitable lifting device, remove the beam assembly from the frame. The beam weighs approximately 1250 kg
(2755 lb).
Note: For S/N:1HL machines, be careful not to damage the 8X-6100 Bracket As (14) and the 8X-6101 Bracket
As (16) that are attached to the beam assembly. You must remove and save both bracket assemblies from the

beam. You cannot order both bracket assemblies through the Cat parts distribution system. You must attach
both bracket assemblies to the new beam assembly (3) .

Ver imagen

Illustration 161

9.

g01957358

Clean the weld joints on both pedestals. When you clean the weld joints, take care in order to preserve as much of the
original edges of both pedestals as possible.

Installation of the New 161-1249 Beam As

Ver imagen

Illustration 162

g01957359

1.

On the left beam assembly, trim the weld joint and the casting so that the faces (39) of the plates and the corners of the
plates are square.

2.

Remove the slag from the trimmed end of the left beam assembly. Smooth both of the end surfaces of the beam
assembly.

Ver imagen

Illustration 163

g01957360

3.

The new transition castings are machined in order to accommodate the designs of the newer left beams and the newer
right beams that contain heavier plate material. You must build up the root (40) of the upper weld joint and the lower
weld joint on both castings with approximately 6 mm (0.24 inch) of weld metal.

4.

Weld the upper weld joint and the lower weld joint on both castings with two passes of weld metal. Grind the edges
smooth in order to provide a good fit with minimal gaps between the transition castings and the left beam and the right
beam. Rotate the beam assembly and position the beam assembly as needed for each weld area.

5.

Clean any paint, grease, or debris from the mounting face, tapped holes, and weld area of the support assembly for the
cab.

Ver imagen

Illustration 164

6.

g01957423

By using an appropriate lifting device, attach support assembly (23) to the left-hand side of the new beam assembly.
Use an impact wrench in order to fasten the bolts. The support assembly weighs approximately 260 kg (573 lb).

Ver imagen

Illustration 165

g01957455

7.

By using a suitable lifting device, install beam assembly (3) to the frame. The beam weighs approximately 1510 kg
(3329 lb). Check the fit of the transition castings on the new beam assembly with the left beam assembly and the right
beam assembly.

8.

Install the 2 mm (0.08 inch) shim (28) into the 350-1598 Cab Alignment Tool As (2) .

9.

By using a suitable lifting device, install the 350-1598 Cab Alignment Tool As (2) into the bores of the beam assembly
(3) and the front pedestal. The approximate weight of the fixture is 544 kg (1200 lb). Snug the pins so that contact is
made with the spot faces of the bores.

10. Check the fit for the transverse weld between the transition casting and the left beam assembly. A minimum root
opening of 3 mm (0.12 inch) is needed. A face gap of 18 mm (0.71 inch) is needed.
11. Install the top of the two 350-1599 Support As (1) to check the height and squareness of the beam assembly. Adjust the
beam as needed.

Tack Welding Procedure

Ver imagen

Illustration 166

g01957514

1.

Apply one tack weld (42) to the outside of the pedestal on the left side of the frame and the new beam assembly and the
back side of the new beam assembly and the pedestal.

2.

Apply one tack weld (41) to the bottom of the joint between the transition casting and the left beam assembly and to the
bottom of the joint between the transition casting and the right beam assembly.

3.

Apply one tack weld (43) to both sides of the inside of both of the pedestals and the new beam assembly.

4.

Apply one tack weld (44) to the front of both sides of the pedestals and the new beam assembly.

Ver imagen

Illustration 167

g01957573

5.

Apply one tack weld (45) to the top of the joint between the transition casting and the left beam assembly and to the top
of the joint between the transition casting and the right beam assembly.

6.

Apply one tack weld (46) to both sides of joint between the transition casting and the left beam assembly and apply one
tack weld to both sides of joint between the transition casting and the right beam assembly.

7.

Remove the 350-1598 Cab Alignment Tool As and the two 350-1599 Support As from the new beam assembly.
Remove the four nuts (26) from the back side of both pedestals.

Finish Welds

Ver imagen

Illustration 168

g01957661

(W2) A 12 mm (0.47 inch) bevel weld

1.

Slag the tack welds and grind the ends of the tack welds.

2.

Refer to (W2) in Illustration 168. Weld the right end of the new beam assembly to the pedestal on the right side of the
frame. Apply three weld passes to the parts. Slag each pass. In order to minimize distortion and residual stress, alternate
from the left side of the pedestal to the right side of the pedestal.

Ver imagen

Illustration 169

g01957663

(W3) A 16 mm (0.63 inch) fillet weld


(W4) A 16 mm (0.63 inch) bevel weld
(W5) A 16 mm (0.63 inch) fillet weld

3.

Refer to Illustration 169. Locate plate (4). Tack the plate to the pedestal on the left side of the frame. Leave enough
space in order to apply a 16 mm (0.63 inch) bevel weld to the plate and to the pedestal.

4.

Refer to (W5) in Illustration 169. Weld the hole in plate (4). Apply four passes. Slag each pass.

5.

Refer to (W3) in Illustration 169. Weld the left side of plate (4) to the left side of the left pedestal. Apply four passes.
Slag each pass.

6.

Refer to (W4) in Illustration 169. Weld the right side of plate (4) to the pedestal. Apply four passes. Slag each pass.

Ver imagen

Illustration 170

g01957669

(W6) A 16 mm (0.63 inch) fillet weld on both ends of the plate (4)
(W7) A 12 mm (0.47 inch) fillet weld on the inside of both pedestals and the beam assembly
(W8) A 16 mm (0.63 inch) fillet weld on the back
(W9) A 16 mm (0.63 inch) fillet weld on the front of both pedestals
(W10) A 16 mm (0.63 inch) fillet weld on the right side of plate (5)
(W11) A 12 mm (0.47 inch) bevel weld on the left side of plate (5)

7.

Locate plate (5). Tack weld the plate into position.

8.

Refer to (W6) in Illustration 170. Weld both ends of plate (4) to the left side of the beam assembly. Apply four passes.
Slag each pass.

9.

Refer to (W10) in Illustration 170. Weld the right side of plate (5) to the left side of plate (4). Apply four passes. Slag
each pass.

10. Refer to (W11) in Illustration 170. Weld the left side of plate (5) to the end of the beam assembly. Apply three passes.
Slag each pass.
Note: For the next three steps, alternate the welds from side to side. Do not weld one item then start the weld on the
opposite side. Balance the welding sequence. This will minimize weld distortion.
11. Refer to (W7) in Illustration 170. Weld the inside of both pedestals to the beam assembly. Apply three passes. Slag
each pass.
12. Refer to (W8) in Illustration 170. Weld the back side of both pedestals. Apply four passes. Slag each pass.
13. Refer to (W9) in Illustration 170. Weld the front side of both pedestals. Apply four passes. Slag each pass.

Ver imagen

Illustration 171

g01957676

(W12) A 20 mm (0.8 inch) j-groove weld


(W13) A 10 mm (0.4 inch) j-groove weld
(W14) A 10 mm (0.4 inch) j-groove weld

14. Prepare the joints between the transition castings and the left beam assembly and the right beam assembly for root
passes. Grind the ends of the tack welds. Slag the welds completely.

15. Refer to (W12) in Illustration 171. By using a j-groove weld, apply the root pass in the four vertical joints between the
transition castings and the left beam assembly and the right beam assembly. Start toward the centerline of the frame,
then move to the outside of the frame. Start on the bottom of the joints.
16. Refer to (W13) in Illustration 171. By using a j-groove weld, apply a root pass between the transition castings and the
left beam assembly and the right beam assembly on the top side. Start the welds toward the center of the frame and
weld toward the outside of the frame.
17. Refer to (W14) in Illustration 171. By using a j-groove weld, apply a root pass between the transition castings and the
left beam assembly and the right beam assembly on the bottom side. Start the welds toward the center of the frame and
weld toward the outside of the frame.
18. Refer to (W12) in Illustration 171. By using a j-groove weld, apply two passes in the four vertical joints between the
transition castings and the left beam assembly and the right beam assembly. Start toward the centerline of the frame.
Start on the bottom of the joints.
19. Refer to (W13) in Illustration 171. By using a j-groove weld, apply one pass between the transition castings and the left
beam assembly and the right beam assembly on the top side. Start the welds toward the center of the frame and weld
toward the outside of the frame.
20. Refer to (W14) in Illustration 171. By using a j-groove weld, apply one pass between the transition castings and the left
beam assembly and the right beam assembly on the bottom side. Start the welds toward the center of the frame and
weld toward the outside of the frame.
21. Repeat Step 18, Step 19, Step 20 until the beams are welded flush.
Note: The welds between the transition castings and the left beam assembly and the right beam assembly are to be
inspected by an ultrasonic flaw detection unit.
22. Clean the welds.

Installation of Hardware on the S/N:4AR Machines


As noted in the illustrations, install the parts that are listed in the following illustrations on the left beam assembly and the right
beam assembly.

Ver imagen

Illustration 172

g01957699

The area of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(W15) An 8 mm (0.32 inch) fillet weld using vertical welding on the outside of the two plates (7) and the two plates (8)
(W16) A 6 mm (0.24 inch) fillet weld on the two sides of both plates (6)
(W17) An 8 mm (0.32 inch) fillet weld using vertical welding on the two ends of plate (9)

As shown in Illustration 173, locate the parts. Tack weld the parts in position. Then, weld the parts in position as shown in
Illustration 172.

Ver imagen

Illustration 173
The top of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(H) 100 mm (3.9 inch)
(J) 326 mm (12.8 inch)
(K) 718 mm (28.27 inch)
(L) 199.5 mm (7.85 inch)
(M) 126.5 mm (5.0inch)
(N) 89 mm (3.5 inch)

g01957707

Illustration 173 shows the location for plates (6), plates (7), plates (8) and plate (9) on the top, right part of beam assembly (3)
and the right beam assembly.

Ver imagen

Illustration 174
A top view of the transition casting and the right beam assembly
(P) 2154.5 mm (84.82 inch)
(R) 194 mm (7.64 inch)

Illustration 174 shows the location of plate (6) from the plate on the front of the right beam assembly.

Ver imagen

g01957714

Illustration 175

g01957716

(S) 15 mm (0.59 inch) at two places

Ver imagen

Illustration 176

g01957806

The inside of the area of the transition casting and the left beam assembly
(10) Bracket assembly
(T) 35 5 mm (1.4 0.2 inch)
(U) 760 mm (29.9 inch)
(W18) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)

Illustration 176 shows the location of one of the two bracket assembly (10). Locate the bracket assembly. Tack weld the bracket
assembly in position. Then, weld the bracket assembly in position.

Ver imagen

Illustration 177

g01957807

The top of the area of the transition casting and the left beam assembly
(10) Bracket assembly
(V) 6 5 mm (0.24 0.20 inch) from the end of the other bracket assembly
(W) 70 5 mm (2.76 0.20 inch) from the center of the boss to the end of bracket assembly (10)
(X) 120 5 mm (4.72 0.20 inch) between the centerline of the bosses and the centerline of bracket assembly (10)
(W19) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)

Illustration 177 shows the position of the second bracket assembly (10) that is positioned on top, left side of the beam assembly
(3). Locate the bracket assembly. Tack weld the bracket assembly in position. Then, weld the bracket assembly in position.
1.

Clean the welds and inspect the welds. As needed, make repairs.

2.

Remove the temporary bracing.

3.

As needed, paint the machine.

4.

Assemble the machine.

Installation of Parts on the S/N:4GZ Machines and the ; S/N:ATY Machines


As noted in the illustrations, install the parts that are listed in the following illustrations on the left beam assembly and the right
beam assembly.

Ver imagen

Illustration 178

g02024180

The inside of the area of the transition casting and the left beam assembly
(10) Bracket assembly
(Y) 35 5 mm (1.4 0.2 inch)
(Z) 760 mm (29.9 inch)
(W20) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)

Illustration 178 shows the location of one of the two bracket assembly (10). Locate the bracket assembly. Tack weld the bracket
assembly in position. Then, weld the bracket assembly in position.

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Illustration 179

g02024181

The top of the area of the transition casting and the left beam assembly
(10) Bracket assembly
(AA) 6 5 mm (0.24 0.20 inch) from the end of the other bracket assembly
(BB) 70 5 mm (2.76 0.20 inch) from the center of the boss to the end of bracket assembly (10)
(CC) 120 5 mm (4.72 0.20 inch) between the centerline of the bosses and the centerline of bracket assembly (10)
(W21) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)

Illustration 179 shows the position of the second bracket assembly (10) that is positioned on top, left side of the beam assembly
(3). Locate the bracket assembly. Tack weld the bracket assembly in position. Then, weld the bracket assembly in position.

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Illustration 180

g02024763

The top of beam assembly (3)


(DD) 70.5 3 mm (2.78 0.12 inch)
(W22) A 5 mm (0.20 inch) skip weld that is 50.0 mm (1.97 inch) long on 200.0 mm (7.87 inch) centers

Ver imagen

Illustration 181
A view of beam assembly (3) from the front
(EE) 871 mm (34.3 inch)

Position bar (11) as shown in Illustration 180 and Illustration 181. Weld the bar to the beam.

Ver imagen

g02024764

Illustration 182
A view of the top of the transition casting and the right beam assembly
(FF) 376 5 mm (14.8 0.2 inch)
(GG) 31 5 mm (1.2 0.2 inch)
(W23) An 8 mm (0.32 inch) fillet weld that is vertical up weld in two places
(W24) An 8 mm (0.32 inch) fillet weld in two places
(W25) A 3 mm (0.12 inch) fillet weld all around the boss
(W26) An 8 mm (0.32 inch) fillet weld that is vertical up in two places
(W27) An 8 mm (0.32 inch) fillet weld in two places
(W28) An 8 mm (0.32 inch) fillet weld that is vertical up in two places

Ver imagen

g02028995

Illustration 183
The top of the transition casting and the right beam assembly
(HH) 391 3 mm (15.40 0.12 inch)
(JJ) 125 5 mm (4.9 0.2 inch)
(KK) 264.5 1 mm (10.40 0.04 inch)
(LL) 712 1 mm (28.03 0.04 inch)
(MM) 126.5 mm (5.0 inch)

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g02029139

Illustration 184

g02029290

(NN) 50.0 mm (1.97 inch)


(PP) 15.0 mm (0.59 inch)

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Illustration 185
The inside of the transition casting and the right beam assembly
(RR) 107 5 mm (4.2 0.2 inch)

g02029295

Refer to Illustration 182. Locate and tack boss (12) to the bottom side of the right transition casting. Weld the boss into position.
Refer Illustration 182, to Illustration 183 and Illustration 184. Locate and tack plate (6) and two gussets (7) into position. Weld all
three parts into position.
Refer to Illustration 182, to Illustration 183 and to Illustration 184. Locate and tack plate (13) and two gussets (8) into position.
Weld all three parts into position.
Refer to Illustration 182, to Illustration 183 and Illustration 185. Locate and tack plate (9) into position. Weld the part into
position.
Clean the welds and inspect the welds. As needed, make repairs.
Remove the temporary bracing.
As needed, paint the machine.
Assemble the machine.

Installation of Parts on the S/N:1HL Machines


As noted in the illustrations, install the parts that are listed in the following illustrations on the left beam assembly and the right
beam assembly.

Ver imagen

Illustration 186
The top of the area of the transition casting and the left beam assembly
(W29) A 6 mm (0.24 inch) fillet weld
(W30) A 6 mm (0.24 inch) fillet weld from the edge of the casting to bracket assembly (16)
(W31) A 6 mm (0.24 inch) fillet weld
(W32) A 6 mm (0.24 inch) fillet weld from bracket assembly (14) to the corner of bracket assembly (16)
(SS) 312.3 3.0 mm (12.30 0.12 inch)
(TT) 81.5 3.0 mm (3.21 0.12 inch)

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g02029440

Illustration 187

g02029461

The inside of the area of the transition casting and the left beam assembly
(UU) 46.0 3.0 mm (1.8 0.12 inch) from the center of the holes for the rops cab
(VV) 111.9 3.0 mm (4.4 0.12 inch)
(WW) 35.0 5.0 mm (1.40 0.20 inch)
(XX) 230.0 5.0 mm (9.06 0.20 inch)
(W33) A 3 mm (0.12 inch) fillet weld all around the boss

Refer to Illustration 186 and Illustration 187. Locate and tack bracket assembly (14), bracket assembly (16), and boss (15) into
position. Weld all three parts into position.

Ver imagen

Illustration 188

g02029475

The top of beam assembly (3)


(YY) 70.5 3 mm (2.78 0.12 inch)
(W34) A 5 mm (0.20 inch) skip weld that is 50.0 mm (1.97 inch) long on 200.0 mm (7.87 inch) centers

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Illustration 189
A view of beam assembly (3) from the front
(ZZ) 871 mm (34.3 inch)

Position bar (11) as shown in Illustration 189 and Illustration 188. Weld the bar to the beam.

Ver imagen

g02029482

Illustration 190

g02029508

A view of the top of the transition casting and the right beam assembly
(AAA) 376 5 mm (14.8 0.2 inch)
(BBB) 31 5 mm (1.2 0.2 inch)
(W35) A 3 mm (0.12 inch) fillet weld all around the boss

Locate and tack boss (12) to the bottom side of the right transition casting. Weld the boss into position.

Ver imagen

Illustration 191

g02029378

The area of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(W36) An 8 mm (0.32 inch) fillet weld using vertical welding on the outside of the two plates (7) and the two plates (8)
(W37) A 6 mm (0.24 inch) fillet weld on the two sides of both plates (6)
(W38) An 8 mm (0.32 inch) fillet weld using vertical welding on the two ends of plate (9)

As shown in Illustration 192, Illustration 193, Illustration, and194 Illustration 195 and locate the parts. Tack weld the parts in
position. Then, weld the parts in position as shown in Illustration 191.

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Illustration 192
The top of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(CCC) 100 mm (3.9 inch)
(DDD) 326 mm (12.8 inch)
(EEE) 718 mm (28.27 inch)
(FFF) 199.5 mm (7.85 inch)
(GGG) 126.5 mm (5.0inch)
(HHH) 89 mm (3.5 inch)

g02029381

Illustration 192 shows the location for plates (6), plates (7), plates (8) and plate (9) on the top, right part of beam assembly (3)
and the right beam assembly.

Ver imagen

Illustration 193
A top view of the transition casting and the right beam assembly
(JJJ) 2154.5 mm (84.82 inch)
(KKK) 194 mm (7.64 inch)

Illustration 193 shows the location of plate (6) from the plate on the front of the right beam assembly.

Ver imagen

g02029382

Illustration 194

g02029384

(LLL) 50.0 mm (1.97 inch)


(MMM) 15.0 mm (0.59 inch)

Illustration 194 shows the position of the two plates (6) from the top of the transition casting.

Ver imagen

Illustration 195
The inside of the transition casting and the right beam assembly
(RR) 107 5 mm (4.2 0.2 inch)

g02029386

Illustration 195 shows the position of plate (9) from the top surface on the transition casting.
Clean the welds and inspect the welds. As needed, make repairs.
Remove the temporary bracing.
As needed, paint the machine.
Assemble the machine.

Procedure to Strengthen the Weld Joint on the Center Tube on 785C and 785D OffHighway Trucks
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

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Illustration 196

g02034341

(1) Tube
(2) Plate

A TIG toe dressing of the weld is now being carried out for the entire circumference of the interface of the Plate (2) and the tube
(1) on the frame assembly. This will provide an improved weld joint on the center tube of the frame assembly. The TIG toe
dressing can be applied to the interface of the Plate (2) and the tube (1) on any machine in order to strengthen the weld.
Refer to the above reference for the procedure to prepare the area for welding and for the procedure to clean the welds and
inspect the welds.
The following two methods can be used in order to strengthen the weld on the center tube of 785C Off-Highway Trucks and
785D Off-Highway Trucks:

TIG dressing of fillet welds for improved fatigue life

Burr grinding of fillet welds for improved fatigue life

The preferred method is TIG dressing. The second method can be performed in an emergency. The second method does not
require an experienced welder or specialized equipment.

TIG Dressing of Fillet Welds for Improved Fatigue Life


Note: The fatigue performance is controlled by the profile of the weld toe. This applies to fabricated structures that have fillet
welded attachments to highly stressed members. The fatigue performance can be improved by altering the original welded toe
profile. This can be achieved by using several post weld treatment options. This procedure describes a method of using an electric
arc to reduce adverse profiles and stress risers. This creates a seamless transition from one component to the next component.
Table 25
Required Equipment
Tool
GTAW (TIG) Power supply and a
torch.
Shielding Gas

Description
The power supply must be capable of producing 225 amps (min. 60% duty cycle) with a
hand control or a foot control.
100% Argon and flow meter
Lanthanated or
Ceriated or
Thoriated Tungsten

Electrode

2.4 mm (0.09 inch) diameter


If needed:
ER70S-2 filler metal
1.5 mm (0.06 inch ) diameter

Grinder
Grinding Wheel
Gauge

Ver imagen

Pneumatic grinder or electric grinder with carbon steel wire wheel attachment
Aluminum oxide
Radius gauges

Illustration 197

g02034397

Preparation of 2.4 mm (0.09 inch) tungsten electrode


(3) Striations or grinding marks
(A) 2 to 3 times the diameter
(B) 1/4 to 1/2 times the diameter

1.

Cleanliness and preparation of tungsten electrode are the first steps in order to ensure that a proper TIG dressing is
achieved. All contaminants must be thoroughly removed from the fillet weld and the surrounding base metal. All rust,
dirt, oil, scale, and silicate islands must be removed. This can be accomplished quickly via a grinder with a carbon steel
wire attachment.

2.

Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 197. The
striatings should run parallel to each other.

3.

Adjust the flow rate of shielding gas to 15 CFH. Adjust the current control to approximately 225 amps. If a ramp down
control is present on the power source, utilize the ramp down control to ensure that proper crater fill control is
achieved.

4.

A number of different techniques exist for TIG dressing. This is due to the variation of the contour of the fillet weld
toe. The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the torch in order to
achieve a smooth radius of the weld. A minimum radius of 5.0 mm (0.20 inch) must exist between the base material
and the weld metal.

Ver imagen

Illustration 198

g02034398

Stringer technique
(C) 0 to 25 degrees work angle

Note: Use a 10 to 15 degrees push angle for the stringer technique.


5.

Illustration 198 represents the stringer technique of welding. The center of the arc needs to be 0.0 to 2.0 mm (0.0 to
0.08 inch) from the weld toe into the base material.

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Illustration 199
Weave technique

g02034399

(D) 0 to 45 degrees work angle


(E) 3 mm (0.1 inch) Weave

Note: Use a 10 to 15 degrees push angle for the weave technique.


6.

Illustration 199 represents the weave technique of welding.

Ver imagen

Illustration 200

7.

g02034401

Illustration 200 represents a cross section view of a proper TIG dressed fillet weld.

Ver imagen

Illustration 201

Ver imagen

g02034404

Illustration 202

g02034405

8.

Illustration 201 and Illustration 202 demonstrate the expected results.

9.

Once the TIG dressing is completed, the area needs to be cleaned and painted in order to prevent pitting due to
corrosion.
Note: Poorly shaped fillet welds with 70 to 90 degrees transition angles will require several overlapping of TIG
dressing runs. Overlapping of the TIG dressing runs is required in order to properly stabilize the weld toe transition
area.
Note: TIG dressing can be conducted in the vertical position when you perform TIG dressing in a downhill
progression.
Note: Some undercuts will require the addition of filler metal. This can be accomplished by hand feeding ER70S-2 1.5
mm (0.06 inch diameter) into the weld pool. You then repeat the TIG dressing in order to achieve the desired toe radius
and the desired profile.

Burr Grinding of the Fillet Welds for Improved Fatigue Life


Note: The profile or geometry of the weld toe controls the fatigue performance of fabricated structures. These fabricated
structures have attachments that are fillet welded to highly stressed members. Fatigue performance improvement can be achieved
through alteration of the original toe profile by several post weld treatment options. This procedure describes a method of using a
mechanical means in order to remove adverse profiles and adverse stress risers. This method creates a smooth transition from one
component to the next component.
Table 26
Required Equipment
Tool
Hand Held Grinder
Compressed Air
Tungsten Carbide Burr
Leather Welding Jacket
Leather Gloves

Description
High speed, pneumatic, rotary, pencil grinder - 20,000 rpm
621 kPa (90 psi) minimum
The burr should be conical shaped with approximate end diameter of
10.0 mm (0.39 inch).

Safety Glasses
Face Shield
Radius Gauge
Bridge Cam Gauge

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Illustration 203
Pneumatic rotary pencil grinder with burr
(4) Preferred shape of burr

1.

Illustration 203 shows the preferred shape of burr.

Ver imagen

g02034414

Illustration 204
(F) 45 degrees
(G) 45 degrees

g02034415

(H) Minimum depth of 0.8 mm (0.03 inch)


(5) Burr tool
(6) Direction of travel
(7) Weld
(8) Plate

2.

The tip of burr should be located over the weld toe. The axis of the tool should be maintained at approximately 45
degrees to the parent plate. The axis of the tool should be inclined at approximately 45 degrees to the direction of
travel. Grinding should extend to a depth of 0.5 mm (0.02 inch) below the last visible traces of the weld toe resulting in
minimum depth of 0.8 mm (0.03 inch) and maximum depth of 1.0 mm (0.04 inch). The resulting ground surface should
be smooth without grinding marks running parallel to the weld, but 90 degrees to the weld. All traces of the original
weld toe should not be visible via the use of a lower powered magnifying glass.

Ver imagen

Illustration 205

3.

g02034416

The finished burr grinding should look like the Illustration 205.

Copyright 1993 - 2015 Caterpillar Inc.


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