AVSpare Createamotion

MainAutodataCaterpillar

ProceduretoInspectandRepairtheCenter
SectionFrameonCertain793FOffHighway
Trucks{0679,7051}Caterpillar
Usage:
793FACEMD793FCMDRBT793FXQSND793FSSP

OffHighwayTruck/Tractor:
793FAC(S/N:EMD7677)
793F(S/N:SND1UPSSP1UPRBT1UP)

Introduction
ReferenceSpecialInstruction,REHS4439,"HighVoltageIsolationProcedureforWeldingona
LargeOffHighwayElectricDriveTruck"
ReferenceSpecialInstruction,REHS1841,"GeneralWeldingProcedures"
Thisspecialinstructioncontainsthenecessaryinstructionsforinspectionandrepairofthe
centersectionoftheframeforcertain793FOffHighwayTrucks.
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Note:Thebodydoesnotneedtoberemovedforinspectionorframerepairaslongasretaining
cablesareinserviceableconditionandusedproperly.
Table1
DisassemblyandAssemblyManuals
SalesModel

MachineSystems

PowerTrain

793F
793FXQ

KENR8579

KENR8397

793FCMD(CommandForHauling)

UENR1142

UENR1143

Table2
RequiredTooling

TelescopingMirror
BoreScope
MagneticParticleTestKit
DyePenetrantTestKit
Table3
RequiredParts

(1)

Qty

PartNumber

Description

4317565

Plate(1)

24

4413206

Plate(1)

4413208

Plate(1)

3789104

BracketAs

2953006

BracketAs

Serviceablepartcanbeorderedorfabricated

ThePowerTrainElectricDriveSystemwillcontainhazardousvoltagelevelsduring
machineoperationandforashortperiodoftimeafterengineshutdown.
Donotremoveanycoversthatwillexposeenergizedhighvoltageelectrical
componentswhiletheengineisoperating.
Anytypeofmaintenanceonthefollowingcomponentscanonlybeperformedafterthe
PowerTrainElectricalSystemServiceShutdownprocedurehasbeenfollowed:
Highvoltagecompartmentsintheinvertercabinet
Therearaxlehousingthatcontainstheelectricdrivetractionmotors
Thegenerator
Theretardingresistorgrid,thegridblowermotorandthegridsystemcabling
Theexcitationfieldregulator
Thehighvoltagecablesandconnectionenclosures
Failuretofollowtheseinstructionscouldresultinpersonalinjuryordeath.

NOTICE
Inordertopreventdamagetocomponents.Thepowertrainhighvoltagesystemmust
beshortedtothecabinetgroundbeforeweldinganywhereonthetruck.

NOTICE
Donotallowanydirtorforeignmaterialtogetintothehydraulicsystemduring
assembly,connectionoflines,whencomponentsarefilledwithfluid,orduringany
maintenanceoperation.

NOTICE
Caremustbetakentoensurethatfluidsarecontainedduringperformanceof
inspection,maintenance,testing,adjusting,andrepairoftheproduct.Bepreparedto
collectthefluidwithsuitablecontainersbeforeopeninganycompartmentor
disassemblinganycomponentcontainingfluids.
RefertoSpecialPublication,NENG2500,"DealerServiceToolCatalog"fortoolsand
suppliessuitabletocollectandcontainfluidsonCatproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.

ImportantSafetyInformation
Thefollowinginformationisanexplanationofvariouslabelsthatarefoundinthisdocument.
Warnings
Thewarninglabelinformsthetechnicianthataninjuryordeathcanoccurasaresultofa
conditionthatmayexist.
Notices
Anoticeinformsthetechnicianthatcomponentdamagecanoccurasaresultofaconditionthat
exists.
Notes

Anotecontainsgeneralinformationforthetechnicianabouttheoperationthatisbeing
performed.
Properrepairisimportanttothesafeoperationandthereliableoperationofthismachine.This
documentoutlinesbasicrecommendedprocedures.Someoftheproceduresrequirespecial
tools,devices,orworkmethods.
Beforeyouperformanyrepairsorbeforeyouperformanymaintenance,readallsafety
information.Understandallsafetyinformationbeforeyouperformanyrepairsorbefore
youperformanymaintenance.
Safetyinformationisprovidedinthisdocumentandonthemachine.Ifthesehazardwarnings
arenotheeded,bodilyinjuryordeathcouldoccurtoyouorotherpersons.
The"SafetyAlertSymbol"thatisfollowedbya"SignalWord"identifiesahazard."DANGER",
"WARNING",and"CAUTION"are"SignalWords".

Illustration1

g00008666

Thesignalword"WARNING"hasthefollowingmeanings:
PayAttention!
BecomeAlert!
YourSafetyIsInvolved!
Themessagethatappearsunderthesafetyalertsymbolexplainsthehazard.
Operationsorconditionsthatmaycauseproductdamageareidentifiedby"NOTICE"labelson
themachineandintheserviceinformation.
Thepersonthatservicesthemachinemaybeunfamiliarwithmanyofthesystemsonthe
machine.Usecautionwhenyouperformservicework.Specialknowledgeofthesystemsand
ofthecomponentsisimportant.Beforeyouremoveordisassembleanycomponent,obtain
knowledgeofthesystemandknowledgeofthecomponent.
Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolveapotential
hazard.Thesafetyinformationinthisdocumentandthesafetyinformationonthe
machinearenotallinclusive.Determinethatthetools,procedures,workmethods,and
operatingtechniquesaresafe.Determinethattheoperation,lubrication,maintenance,
andrepairprocedureswillnotdamagethemachine.Determinethattheoperation,
lubrication,maintenance,andrepairprocedureswillnotmakethemachineunsafe.

BasicPrecautions

Improperoperation,lubrication,maintenanceorrepairofthisproductcanbe
dangerousandcouldresultininjuryordeath.
Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,until
youhavereadandunderstoodtheoperation,lubrication,maintenanceandrepair
information.

Alwaysobservethelistofbasicprecautionsthatfollows:

SafetySigns
Safetysignsincludetheitemsthatfollow:signs,informationplatesanddecals.Readall
"Safety"signsonthemachinebeforeoperating,lubricating,orrepairingthemachine.
Understandall"Safety"signsonthemachinebeforeoperating,lubricating,orrepairingthe
machine.Replaceanysafetysignsthatareintheconditionsthatfollow:damage,unreadable
andmissing.

ProtectiveEquipment
Whenyouworkaroundthemachine,alwayswearprotectiveequipmentthatisrequiredbythe
jobconditions.Protectiveequipmentincludestheitemsthatfollow:hardhat,protectiveglasses
andprotectiveshoes.Inparticular,wearprotectiveglasseswhenyouuseahammerorwhen
youuseasledgehammer.Whenyouweld,usetheappropriateprotectiveequipmentthatis
requiredbythejobconditions.Protectiveequipmentforweldingincludestheitemsthatfollow:
gloves,weldinghood,gogglesandapron.Donotwearlooseclothingorjewelrythatcancatch
onpartsofthemachine.

MountingandDismounting
Usestepsandhandholdswhenyoumountamachine.Also,usestepsandhandholdswhen
youdismountamachine.Beforeyoumountthemachine,cleananymudordebrisfromsteps,
walkways,orworkplatforms.Alwaysfacethemachinewhenyouusesteps,handholds,and
walkways.Whenyoucannotusetheaccessesonthemachine,useladders,scaffolds,orwork
platformstoperformsaferepairoperations.

SpecificationsforCables,Chains,andLifting
Devices

Useapprovedcables,chains,andliftingdevicesinordertoliftcomponents.Refertothe
manufacturer'sweightsinordertodeterminetheapplicationwhenyouselectthefollowing
items:cable,chainandliftingdevices.Whenyouliftacomponent,theliftangleiscritical.Refer
totheIllustrationthatfollowsinordertoseetheeffectoftheliftangleontheworkingloadlimit.
Note:TheliftingdevicesthatareshowninthispublicationarenotCaterpillarparts.
Note:Ensurethatthehooksareequippedwithasafetylatch.Donotplaceasideloadonthe
liftingeyesduringaliftingoperation.

Illustration2
Liftanglesforliftingslings.
(A)Theloadcapacityis100%oftheworkingloadlimitforthesling.
(B)Theloadcapacityis86%oftheworkingloadlimitforthesling.
(C)Theloadcapacityis70%oftheworkingloadlimitforthesling.
(D)Theloadcapacityis50%oftheworkingloadlimitforthesling.

HotFluidsandParts

g00629745

Toavoidburns,bealertforhotpartsonmachineswhichhavebeenstoppedandhotfluidsin
lines,tubesandcompartments.
Becarefulwhenyouremovefillercaps,breathers,andplugsonthemachine.Holdaragover
thecaporpluginordertopreventbeingsprayedbypressurizedliquids.Whenthemachinehas
beenstopped,thedangerofhotfluidsisgreater.

CorrosionInhibitor
Corrosioninhibitorcontainsalkali.Avoidcontactwiththeeyes.Donotallowcorrosioninhibitor
tocontacttheskinforextendedperiodsoftime.Avoidrepeatedcontactwiththeskin.Donot
drinkcorrosioninhibitor.Incaseofcontact,immediatelywashskinwithsoapandwater.For
contactwiththeeyes,flushtheeyeswithlargeamountsofwaterforatleast15minutes.Seek
medicalattention.

Batteries
Donotsmokewhenaninspectionofthebatteryelectrolytelevelismade.Neverdisconnectany
chargingunitcircuitorbatterycircuitcablefromthebatterywhenthechargingunitisoperating.
Asparkcancauseanexplosionfromtheflammablevapormixtureofhydrogenandoxygenthat
isreleasedfromtheelectrolytethroughthebatteryoutlets.Donotallowbatteryelectrolyteto
contactskinoreyes.Batteryelectrolyteisanacid.Incaseofcontactwithbatteryelectrolyte,
immediatelywashtheskinwithsoapandwater.Forcontactwiththeeyes,flushtheeyeswith
largeamountsofwaterforatleast15minutes.Seekmedicalattention.

PressurizedItems
1.Alwaysuseaboardorapieceofcardboardwhenyoucheckforaleak.Leakingfluid
underpressurecanpenetratebodytissue.Fluidpenetrationcancauseseriousinjuryand
possibledeath.Apinholeleakcancausesevereinjury.Iffluidisinjectedintoyourskin,
youmustgettreatmentimmediately.Seektreatmentfromadoctorthatisfamiliarwiththis
typeofinjury.
2.Relieveallpressureinair,oil,orwatersystemsbeforeanylines,fittings,orrelateditems
aredisconnectedorremoved.Alwaysmakesurethatallraisedcomponentsareblocked
correctly.Bealertforpossiblepressurewhenyoudisconnectanydevicefromasystem
thatutilizespressure.
3.Fuellinesthataredamagedandfuellinesthatareloosecancausefires.Lubricationlines
thataredamagedandlubricationlinesthatareloosecancausefires.Hydrauliclines,
tubes,andhosesthataredamagedcancausefires.Loosehydrauliclines,loosetubes,
andloosehosescancausefires.Donotbendorstrikehighpressurelines.Donotinstall
lineswhichhavebeenbentordamaged.Checklines,tubes,andhosescarefully.Donot
useyourbarehandtocheckforleaks.Iffluidsareinjectedintoyourskin,youmustget
treatmentimmediately.Seektreatmentfromadoctorthatisfamiliarwiththistypeofinjury.

4.Pressureairorwatercancausepersonalinjury.Whenpressureairorwaterisusedfor
cleaning,wearaprotectivefaceshield,protectiveclothing,andprotectiveshoes.The
maximumairpressureforcleaningpurposesmustbebelow205kPa(30psi).Whenyou
useapressurewasher,keepinmindthatthenozzlepressuresarehigh.Thenozzle
pressuresarefrequentlyabove13790kPa(2000psi).Followalloftherecommended
practicesthatareprovidedbythemanufacturerofthepressurewasher.

ApprovedInspectionMethods
Visualinspection(VT),dyepenetrantinspection(PT),magneticparticleinspection(MT)and
ultrasonicinspection(UT)arerequiredforthisrepairprocedure.Eachoftheseinspection
methodsshouldbeconductedandreportedbyqualifiedpersonnel.Examplesofqualified
personnelareasfollows:VTAWSCWI(AmericanWeldingSocietyCertifiedWelding
Inspector)orequivalent.MT/PT/ASNT(AmericanSocietyofNondestructiveTesting)LevelII
(minimum)foreachmethodused.Donotusethemagneticparticleinspectionprocessaround
componentsthatwillbeaffectedbymagnetism.Donotusethedyepenetrantinspection
processaroundcomponentsthatwillbeaffectedbythedyepenetrantsolution.

RequirementsforUltrasonic(UT)Testing

Personnel
PersonnelperformingtheinspectionswillbeatleastLevelIICertifiedTechniciansinthe
UltrasonicTestingmethod,asdefinedbyASNTSNTTC1A,ASNTCP189,orotherequivalent
internationalstandard.
PersonnelperformingtheinspectionswillbetrainedbyaLevelIIorLevelIII,untilthepersonnel
showproficiencyandunderstandingofproceduresandrejectioncriteria.

Apparatus
Ultrasonic(UT)Instrument
TheUTflawdetectioninstrumentshallbecapableofgenerating,receiving,andamplifyinghigh
frequencyelectricalpulsesatsuchfrequenciesandenergylevelsrequiredtoperforma
meaningfulexaminationandprovidesuitablereadouts.
Preferredfunctions/featuresincludebutnotlimitedto:inspectionprogramrecording,signal
gatingsystem,measurementdatadisplay,DAC/TCGrecording,and0DbReference.
UTinstrumentcertification/qualificationshouldbeperformedannuallyaccordingtoASTME317
orequivalent.Includingtheverificationofkeyperformancecharacteristics,suchashorizontal
limitandlinearity,verticallimitandlinearity,resolutionentrysurfaceandfarsurface,sensitivity
andnoise,accuracyofcalibrationgaincontrols.

AngleBeam/ShearwaveSearchUnit

Theultrasonictransducer(probe,orsearchunit)shallbecapableoftransmittingandreceiving
ultrasoundattherequiredfrequenciesandenergylevelsnecessaryfordiscontinuitydetection
inthematerialbeingexamined.Frequenciesof2MHzto5MHzshallbeemployedforangle
beamshearwaveinspection.
Transducercrystalcanberound,square,orrectangular.Crystalsizerecommendedforweld
examinationshallbeintherangeof9mm(0.35inch)to25mm(1.0inch).
Selectionofatransducerisdeterminedbytestingvariables.Testingvariablesincludeweld
thickness,testingsurface,acceptableflawsize,flaworientation,andtheacousticpropertiesof
themetal.
Inanglebeaminspection,thewedge/shoeisattachedtothetransducertogeneratethedesired
incidentbeamangleandwavemodeintheparts.Thecommonbeamanglesusedinweld
inspectionare45,60,and70.Therefractedangleshallbenogreaterthan2fromnormal.
Theedgedistanceshallnotexceed25mm(1.0inch).Thewedgeanglesshallbeselected
accordingtoinformationfoundinthe""ProbeSelection""section.

Couplant
Couplantisrequiredbetweenthefaceofthesearchunitandtheexaminationsurface.Couplant
permitsthetransmissionofultrasonicwavesfromthesearchunitintothematerialunder
examination.
Typicalcouplantsincludecellulosegel,glycerin,andlightmachineoil.Corrosioninhibitorsor
wettingagentsmaybeadded.Couplantsmustbeselectedthatarenotdetrimentaltothe
productortheprocess.Specialcouplantandsearchunitmayberequiredatelevated
temperatures(above52C(125F).

DistanceCalibrationBlocks
RefertoASTME164fortwooptionsofdistancecalibrationblocks,othersuitableblocksmaybe
used.

Illustration3

g03410559

Option1:IIWType1orTypetwoBlock

Illustration4

g03410579

Option2:DSCBlock

SensitivityCalibrationBlocks
Threeoptionsforsensitivitycalibrationblocksaregivenbutotherblocksmaybeused.
Minimumrequirementsshallmeettherequirementdeterminedinthe""SensitivityCalibration""

section.
Forothersensitivityblocks:1.5mm(0.06inch)sidedrilledholes(SDH)paralleltothe
inspectionsurfaceandperpendiculartothesoundpathshallbeusedasthecalibrationtarget.

Illustration5

g03410643

Option1:CatDACBlock
(A)340mm(13.40inch)
(B)90mm(3.55inch)
(C)40mm(1.60inch)
(D)1.50.05mm(0.050.001inch)diameterSDH's
(E)100.1mm(0.400.004inch)
(F)200.1mm(0.800.004inch)
(G)300.1mm(1.200.004inch)
(H)400.1mm(1.600.004inch)
(J)630.1mm(2.500.004inch)
(K)1260.1mm(5.00.004inch)
(L)1890.1mm(7.400.004inch)
(M)2520.1mm(9.900.004inch)

Option1:CatDACBlock1.5mm(0.06inch)SDH'sat10mm(0.40inch)stepsfromthe
surfacetoincludealldepthsoverallthicknessrangestobeused.
UsethedimensionsinIllustration5inordertofabricateCatDACBlockuseASTMA572
Grade42/50steel.

Illustration6

g03410725

Option2:CattBlocks
(N)200mm(8.0inch)
(P)16mm(0.60inch)
(R)40mm(1.60inch)
(S)1.50.05mm(0.050.001inch)diameterSDH's
(T)40.1mm(0.160.004inch)
(U)80.1mm(0.300.004inch)
(V)200.1mm(0.800.004inch)
(W)1600.1mm(6.300.004inch)

Illustration7

g03410752

Option2:CattBlocks
(X)200mm(8.0inch)
(Y)50mm(2.0inch)
(Z)40mm(1.60inch)
(AA)1.50.05mm(0.050.001inch)diameterSDH's
(BB)12.50.1mm(0.500.004inch)
(CC)250.1mm(1.00.004inch)
(DD)200.1mm(0.800.004inch)
(EE)1600.1mm(6.300.004inch)

Option2:CattBlocks:Blocksthesamematerialandthicknessasthepartstobetested.
Machined1.5mm(0.06inch)SDH'sat1/4tand1/2tdepths.Blocksmustbelongenoughfor
fullskippathandwideenoughfortheentiresearchunittositonthescanningsurface.
UsethedimensionsinIllustration6andIllustration7inordertofabricateCattBlocksuse
ASTMA572Grade42/50steel.

Illustration8

g03410827

Option3:IIWType1or2Blocks

Option3:Use1.5mm(0.06inch)SDHpositionArefertoIllustration8.Anattenuationfactorfor
indicationinterpretationwillhavetobeusedtocompensateforattenuationofthesoundbeam
asthesoundbeampropagatesthroughthematerial.ReferenceAWSD1.1orequivalentcode
orstandardforfurtherinstruction.

SamplePreparation
SurfacePreparation
Thesurfacemusthavecontourallowingtheclosecouplingbetweenthesearchunitand
scanningsurface.
Theinspectionsurfaceshallbefreeofloosescale,loosepaint,weldspatter,dirt,excessive
roughness,orotherforeignobjectsthatwouldinterferewiththetransmissionofsoundenergy
fromthesearchunitintothepart.Cleaningand/orgrindingmaybeneeded.

TestProcedure
EquipmentCalibration
InadditiontotheannualUTequipmentcertification/qualification,periodicalcalibrationor
standardizationisrequiredtoverifythatUTequipmentisperformingasintendedfordaytoday
usage.
Foranglebeamapplications,thefollowingkeyparametersshallbechecked:
DistanceCalibration:ThedistanceandsensitivitycalibrationshouldbeverifiedbytheUT
operator.
Recalibrationshallbemadeaminimumofevery4hoursorprocesschange,suchaschanging
operator,searchunitand/cable,battery,testingweld,andrecouplesearchunit.
VerifytheBeamIndexPoint:(ThefollowingexampleisconductedonaIIWTypeBlock.)
PositiontheUTprobetowardthe100mm(4.0inch)radiusontheIIWtypereferenceblock.
Setproperrangeintheinstrumenttoensurethatthesignalfromthe100mm(4.0inch)radius
isdisplayed.Scanthesearchunitbackandforthtopeakthe100mm(4.0inch)signal.The
pointonthesearchunitwedgealigningwiththe0referencelineonthecalibrationblockisthe
beamindex/entrypoint(positionDinIllustration3).
VerifytheBeamAngle:PositionthesearchunittowardtheLucite/openwindowontheIIW
typereferenceblock.
SetproperrangeintheinstrumenttoensurethatthesignalfromtheLucite/openwindowis
displayed.Scanthesearchunitbackandforthtopeakthesignal.
Theanglemarkedonthereferenceblockinlinewiththesearchunitindexpointistheactual
beamangle.Thebeamangletoleranceshallbewithin2.Dependingonthebeamangleand
thetypeofreferenceblock,othertechniquesrecognizedbyrelatedindustrialstandardsmaybe
used(positionBorCinIllustration3).
DistanceCalibration:Inordertoensuretheaccuracyoflocatingwelddiscontinuities,the
distanceshallbecalibratedthroughtheentiresoundpathusedduringthespecificexamination.

100mm(4.0inch)radiusontheIIWtypereferenceblockiscommonlyusedfordistance
calibrationinanglebeamapplications(positionDinIllustration3).
PositiontheUTprobetowardthe100mm(4.0inch)radius.Settheproperrangeinthe
instrumenttoensurethesecondreflectionfromthe100mm(4.0inch)radiuscanbedisplayed.
Inordertoobtainmeaningfulreadings,otherinstrumentsettings,suchasprobeangle,gateand
gainlevelshallbeproperlyselected.

SensitivityCalibration
1.5mm(0.06inch)sidedrilledholes(SDH)paralleltotheinspectionsurfaceandperpendicular
tothesoundpathshallbeusedasthecalibrationtarget.
DAC/TCGDAC(distanceamplitudecorrection)orTCG(timecorrectedgain):Thesignal
fromthe1.5mm(0.06inch)SDHshouldbecalibratedtobe80%FSH(fullscreenheight)for
thefirstpointofaDACcurveandallpointsfortheTCG.DACandTCGshallbeusedtoensure
thesameinspectionsensitivityatdifferentsoundpathsacrosstheentirerange.
MinimumofthreepointsshallbeusedtoestablishtheDAC/TCG,overtheentirerangeanda
fullskipdistanceforthematerialthicknessbeingtested.
UseSensitivityCalibrationBlocksOption1orOption2describedinthe""SensitivityCalibration
Blocks""section.
ExampleforDAC/TCGsetupfora16mm(0.60inch)thickweldjointusing70wedgeusing
theCatDACBlockusethe10mm(0.40inch),20mm(0.80inch),and30mm(1.20inch)
holes.
ExampleforDAC/TCGsetupfora16mm(0.60inch)weldjointusing70wedgeusingthe
Cattblock.Usethe1/4thole,3/4thole,andthe7/4thole.
ReferenceReflector:When,asingle1.5mm(0.06inch)ReferenceReflector(refertoAWS
D1.1)isusedtoattainahorizontalreferencelineheightindication.ThemaximumDblevelused
toobtainan80%FSHpeaksignalshallberecordedastheReferenceGainLevel.
Anattenuationfactorforindicationinterpretationwillhavetobeusedtocompensatefor
attenuationofthesoundbeamasthesoundbeampropagatesthoughthematerial.An
IndicationRatingshouldbecalculatedforthebasisofAcceptanceorRejection.UseSensitivity
CalibrationBlockOption3positionAinIllustration8.

ScanPattern,ScanDistance,andScanSpeed

Illustration9

g03410922

(FF)Scandistancelessthan150mm(6.0inch)persecond
(GG)Firstleg
(HH)Secondleg
(JJ)Weldcenterline
(KK)Scanpattern
(LL)Scanningadvance(nottoexceed75%ofsearchunitwidth)
(MM)Oscillatingangle15
(NN)Searchunit

TheentirevolumeofweldandHAZ(heataffectedzone)shallbeexaminedfromeachsideof
theweldwhereverpractical.Examinationshallbemadeinfirstandsecondlegwherever
possible.Scanspeedshallbelessthan150mm(6.0inch)persecondunlesstheinspection
procedurespecifiesdifferently.
ThetypicalinspectionconfigurationforabuttweldisshowninIllustration9inthe""Sensitivity
CalibrationBlocks""section.
Inordertodetectlongitudinaldiscontinuities.Thesearchunitshallbeoscillatedtotheleftand
rightwithanangleofapproximately15whilecontinuouslyscanningperpendicularlytothe
weldaxis.Thelateralmovementadvancingthesearchunitshallnotexceed75%ofthesearch
unitwidth.
Inordertoensurefullvolumecoverage.Thescandistanceshallcoveratleast1fullskippath
(firstandsecondleg)backfromtheweldcenterline.Todetecttransversediscontinuities,the
soundbeamshallbedirectedatapproximately15paralleltotheweldaxis.Thesearchunit
shallbemovedalongtheweldedgefrombothsidesandfromoppositedirections.

InitialSurveillanceScanning
Forinitialscanning,extragain(6dBor12dB)mayberequiredinordertofacilitatedetectionof
potentialdiscontinuities.Theevaluationoftheindicationshallbeperformedbacktothe
referencesensitivity.

793FUTInspectionAreas

Illustration10
Jointdetailaroundthewindowplate
(PP)Weldseamsaroundthewindowplate

g03411355

Illustration11

g03413338

Viewofacrackwhichpropagatedthroughthebottomrailsection

Refertotherepairproceduresinthisdocumentforspecificinformationforjointtypeand
configuration.

ProbeSelection
Table4
WeldThickness

WedgeAngle(1)

Range(2)

6mm(0.25inch)thru

70

100

20mm(0.80inch)thru
38mm(1.50inch)

70

150

38mm(1.50inch)thru
80mm(3.15inch)

45

200

20mm(0.80inch)

(1)

Multiplewedgeanglescanbeusedforthicknessesoutsideguideline.

(2)

Rangesettingshouldbeadjustedaccordinglytohaveafullskippathonthescreen.

Thewindowplatesare16mm(0.65inch)thick,a70wedgeshallbeusedforlocations(PP)as
showninIllustration10.
The4barlinkcastingtothemainrailweldwillneedUTinspectionafterarepairorthroughwall
crackinthebottomortoprailsection.RefertoIllustration11.Theweld/plateis50mm(2.0
inch)thickanda45wedgeshallbeused.Table4shallbeusedforreferenceifneeded.
Alternateanglescanbeusedformultiplethicknessesifwarrantedbyjointdesignorjoint
preparation.

Accept/RejectCriteriaandSizing

Illustration12
(AB)Searchunit
(AC)Searchunit
(AD)Searchunit
(AE)Distancebetween(L1)and(L2)
(AF)Signalamplitude
(AG)Amplitudeprofile
(AH)Threshold
(AJ)50%threshold
(AK)Searchunitposition
(L)Lengthofindicationoverthethreshold
(LR)Lengthofindicationoverthe50%threshold
(L1)Longerdiscontinuity
(L2)Shorterdiscontinuity

g03411593

Note:Adjacentdiscontinuities:when(AE)issmallerthanthedesignatedminimumlength((AE)
<(L1)oraspecificlength),thetwodiscontinuitiesshallberegardedascontinuousandthe
overalllengthis(L1)+(AE)+(L2).
SubsurfaceinternalweldqualitywillmeettherequirementssetforthbyTable10.Inorderto
determinetherejectablelengthsofindicationsthatmeetorexceedthe1.5mm(0.06inch)SDH
reverencelevel:
Anindicationthatmeetsorexceedsthereferencelevel(DAC,TCG,or0ReferenceLevel)
continuouslyfor25mm(1.0inch)or10%oftheweldlengthwhicheverislessisrejectable.
Intermittentindicationsthatdonotmeetthecriteriabuttheaggregatelengthoftheindications
exceed10%oftotalweldlengthisrejectable.Indicationsbelow5mm(0.20inch)inlengthare
nottypicallyincludedintheaggregateindicationlength.
Indeterminingtheendsofrejectableindications.The6dBdropmethodshallbeused,withthe
flawdetectorsensitivitysettothereferencelevel(0dB).Movethesearchunitparalleltothe
welduntilthetipofthesignaldropsto50%oftheDACheight.Marktheweldevenwiththe
centerofthesearchunit.Movethesearchunitparalleltotheweldintheoppositedirectionuntil
thesignaldropsto50%oftheDACheight.Marktheweldevenwiththecenterofthesearch
unit.Acceptabilityofweldswithmultipledefectiveareas.Ifthespacebetweentwodefective
areasislessthanthelargestdefectlength,theareabetweenthetwodefectiveareasshallalso
beconsideredrejectableandshouldbemarkedforrepair.RefertoIllustration12.

MarkforWeldRepair
Torepairtherejectedweld,additionalexcavationlengthateachendoftherejectable
discontinuityisnormallyrequired.Ageneralguidelineistomarkanadditional25mm(1.0inch)
to50mm(2.0inch)onbothendsofthediscontinuityinordertoensureproperremovalof
defectiveareas.Thisguidelineshallbefollowedwhereverpractical.

Reporting
Aftertheultrasonic(UT)inspectioniscompleted,fillouttheformsprovided.RefertoTable15
andTable16attheendofthisdocument.AcopyshouldbeprovidedtotheCustomer,Dealer,
and/ortheappropriateCaterpillarproductsupportrepresentative.

InspectionIntervals
Inspectionsoftheframeassemblyforcracksshouldbeconductedduringregularmaintenance
intervals.Areastobeinspectedareblockedbyoneormorecomponents.Ifthecomponentthat
isblockingtheframeisremoved,aninspectionofthatareashouldbeperformed.Take
advantageoftheopportunitytoinspectthosepartsoftheframeassemblythatareexposed
whenevercomponentsareremoved.Asanexample,ifthehydraulictankiseverremoved,the
areabehindthehydraulictankshouldbecleanedandinspected.RefertoOperationand

MaintenanceManual,SEBU8406,"793FOffHighwayTruck","FrameClean/Inspect"forthe
properinspectionintervals.

WeldingSpecificationsandQualifications

Protectyourselfandothersreadandunderstandthiswarning.Fumesandgasescan
bedangeroustoyourhealth.Ultravioletraysfromtheweldarccaninjureeyesand
burnskin.Electricshockcankill.
Readandunderstandthemanufacturer'sinstructionandyouremployer'ssafety
practices.Keepyourheadoutofthefumes.Useventilation,exhaustatthearc,or
both,tokeepfumesandgasesfromyourbreathingzoneandthegeneralarea.Wear
correcteye,earandbodyprotection.Donottouchliveelectricparts.
RefertotheAmericanNationalStandardZ49.1,"SafetyinWeldingandCutting"
publishedbytheAmericanWeldingSociety,2501N.W.7thStreet,Miami,Florida
33125:OSHASafetyandHealthStandards,29CFR1910,availablefromU.S.Dept.of
Labor,WashingtonD.C.20210.

Note:Personalbreathingprotectionshouldbewornbythepersonnelthatarewelding.
Personalbreathingprotectionwillpreventfumesfromenteringthelungsofthepersonthatis
welding.Usea2375181Respiratorforbreathingprotection.

Qualifications
Weldersmustbequalifiedfortheappropriatetypeofweldthatisbeingperformed.Welders
mustbequalifiedfortheappropriatepositionofweldthatisbeingperformed.Weldersmustbe
qualifiedfortheweldingprocessthatisbeingutilized:ShieldedMetalArcWelding(SMAW)and
FluxCoredArcWelding(FCAW).RefertoSpecificationANSI/AWSD1.1forinformationthat
regardsqualificationrequirements.Theweldersmusthaveusedtheprocessatsometime
withinthelast6months.Theweldersmustcompletetheprocessofcertificationifthewelders
havenotusedtheweldingprocessesfor6months.

ProperWeldingProcedureonMachinesand
EngineswithElectronicControls
Properprecautionsarenecessarytopreventdamagetoelectroniccontrols.Whenyouweldon
amachinewithelectroniccontrols,usethestepsthatfollow:
1.Turnofftheengine.PutthekeystartswitchintheOFFposition.

2.Ifthemachinehasabatterydisconnectswitch,opentheswitch.Ifthemachinedoesnot
haveabatterydisconnectswitch,disconnectthenegativebatterycableatthebattery.
3.Attachtheclampforthegroundcableascloseaspossibletotheareathatisbeing
welded.Thisprocesswillreducethelikelihoodofdamagefromtheweldingcurrenttothe
followingcomponents:bearings,hydrauliccomponents,andelectricalcomponents.DO
NOTweldplatestotheframeforgrounding/clampingpurposes.Useexisting
blocks,brackets,bosses,andsoon,toattachtheclamp.
Note:DoNOTuseelectricalcomponentsasagroundpointforthewelder.DoNOTuse
groundpointsforelectroniccomponentsasagroundpointforthewelder.
4.Protectthewiringharnessesandmachinesurfacesfromsparksandweldingspatter.

AreaPreparation
Theareatobeweldedshallbeclean,dry,andfreeofthefollowingcontaminants:
Oil
Grease
Paint
Dirt
Rust
Anyfluidsormoisture
Allweldingshallbeconductedonbasematerialheatedandmaintainedataminimum
temperatureof15.6C(60F).
Note:Heatinginstructions(preheat,interpass,andpostheat)foranyspecificrepairshall
overridetheminimum15.6C(60F)requirement.
Note:Heatdistortionofthebasemetalispossiblewhenyouweld.Avoidexcessiveheatingof
thebasemetal.

WeldingElectrodesandParameters
FluxCoredWeldingElectrodefortheFCAWProcess
UsetheFluxCoredArcWelding(FCAW)withE71T1H8(ANSI/A5.20)weldingelectrodeand
themanufacturer'sshieldinggasesthatarespecified(typically75%argonand25%carbon
dioxide).TheH8impliesthattheelectrodeisdesignedtoprovidelessthan8ml/100gof
diffusiblehydrogeninthewelddeposit.Theweldthatisdepositedbythefluxcoredwelding
electrodewillhavethefollowingminimummechanicalproperties:
Table5
MechanicalPropertiesfromFluxCoredWeldingElectrodeThatIsClassifiedas

"ANSI/AWSA5.20E71T1H8"
TensileStrength

480MPa(70000psi)

YieldStrength

400MPa(58000psi)

Elongation

22%

ImpactToughness

27J@18C(20ftlb@0F)

Thetablesthatfollowshowtherecommendedparameterrangesforoutofpositionweldingin
thefieldfortwodifferentfluxcoredweldingelectrodediameters.
Table6
WeldingCurrentforFluxCoredWeldingElectrodethatIs
1.2mm(0.045inch)
WireFeedRate

Voltage

Amperage

7620mm(300inch)PerMinuteto

24to28

190to240

10,160mm(400inch)PerMinute
Table7
WeldingCurrentforFluxCoredWeldingElectrodethatIs
1.4mm(0.052inch)
WireFeedRate

Voltage

Amperage

5080mm(200inch)PerMinuteto

23to27

180to220

6350mm(250inch)PerMinute
Note:Thesettingslistedabovearerecommendationsbasedonexperiencefromweldinginthe
horizontal,verticalup,andoverheadpositions.Slightchangesinthevoltageandamperage
maybenecessaryduetoweldingpositionandvariousformulationsbydifferentelectrode
manufacturers.Theuseofhigherparametersthanspecifiedforweldingintheflatpositionis
acceptable.
UseapolaritysettingofDCreversepolarity.Removetheslagaftereachweldingpass.Thefast
freezingcharacteristicsoffluxcoredweldingelectrodeincreasesthepossibilityofevolvinggas
thatistrappedintheweld.Controlthesizeoftheweldinordertoreducethepossibilityof
evolvinggasthatistrappedintheweld.Themaximumsizeweldperpassshouldbeequivalent
tothatofa8.0mm(.32inch)filletweld.

LowHydrogenElectrodesfortheSMAWProcess

Asanalternativeprocessorwhenwindconditionsareafactor,useSMAWandlowhydrogen
electrodesthatmeetthefollowingrequirements.
Table8
MechanicalPropertiesofWeldsfromLowHydrogenElectrodesThatAreClassifiedas
"ANSI/AWSA5.1E7018H4R"
TensileStrength

480MPa(70000psi)

YieldStrength

400MPa(58000psi)

Elongation

22%

ImpactToughness

27J@29C(20ftlb@20F)

Lowhydrogenelectrodesmustbestoredinanelectrodeovenat120C(250F)whennotin
use.Iflowhydrogenelectrodesgetdamp,scrapthelowhydrogenelectrodesorreconditionthe
lowhydrogenelectrodestothemanufacturer'sspecifications.
Thetablethatfollowsshowsthesettingsfortheweldingcurrentbasedonelectrodediameter.
Table9
WeldingCurrentforLowHydrogenElectrodes
Diameter

AmperageRating

3.2mm(1/8inch)

105155

4.0mm(5/32inch)

130200

4.8mm(3/16inch)

200275

UseapolaritysettingofDCreversepolarity.Removetheslagaftereachpassofthewelding
electrode.Thewidthoftheweldshouldnotexceedtwotimestheelectrodediameter.

WeldInspectionandAcceptanceCriteria
Table10
ISO6520
DefectName

Defect

Reference
Number

Cracks
Longitudinal,
Transverse,

1011,1012,
1013,1014,
1023,1024,
1031,1033,

Remarks

DefectLimit

Radiating,
Crater,

1034,1045,

Disconnected,

1051,1053,

Branching

1054,1061,
1063,1064

Crack
Transverse
Crack
Transverse

NotPermitted

1021

HardSurfacingWeldsOnly

Permitted

1021

JoiningWelds

NotPermitted

1046,1047,

MaximumDiameterforaSingle
Pore

Porosity

2011,2012,
2014,2017

MaximumPoresinAny
300mm(11.81inch)LengthofWeld
MaximumNumberofPoresinAny
50mm(2.0inch)ofWeldLengthfor
WeldsLessThan

1mm(0.040inch)

300mm(11.81inch)inLength
Clustered
Porosity

2013

MaximumLengthofClusterinAny
Weld

MaximumHeightorWidth

3mm(0.120inch)

3mm(0.120inch)

Elongated
Cavities

2015

MaximumLengthforAnySingle
Discontinuity
MaximumLengthinAnyWeld

MaximumDimensionofAnySingle
Cavity
Elongated
Cavities

Shrinkage

2016

2021,2024,

25mm(1.00inch)
10%ofWeld
Length

3mm(0.120inch)

10%ofWeld

MaximumTotalLengthofAffected

LengthNotto

AreainAnyWeld

Exceed
25mm(1.00inch)

MaximumDiameterorLength

1mm(0.040inch)

Cavities

2025

MaximumHeightorWidth
SlagorFlux
Inclusions

1mm(0.040inch)

3011,3012,
3014,3021,

MaximumLengthforAnySingle

3022,3024

Discontinuity
MaximumLengthinAnyWeld

MaximumHeightorWidth

25mm(1.00inch)
10%ofWeld
Length

1mm(0.040inch)

Oxide

3031,3032,

Inclusions

3033

MaximumLengthforAnySingle
Discontinuity

25mm(1.00inch)

MaximumLengthinAnyWeld

10%ofWeld
Length

NotPermitted

NotPermitted

Visual(BreakingtheSurface)

NotPermitted

Puckering
(Oxide
Inclusion

3034

Aluminum)
Metallic

3041,3042,

Inclusion

3043

SubsurfaceMaximumHeightor
Width

1mm(0.040inch)

LackofFusion 4011,4012,

4013

SubsurfaceMaximumLengthfor
AnySingleDiscontinuity
MaximumLengthinAnyWeld

25mm(1.00inch)
10%ofWeld
Length
10%ofNominal
PenetrationNotto

MaximumReducedPenetration
Lackof
Penetration

Exceed
1mm(0.040inch)

402,4021

MaximumAllowedTotalLengthof
ReducedPenetration

10%ofWeld
Length

5011,5012,
Undercut

5013,5014,
5015

MaximumDepthMeasuredFrom
PlateSurfaceAnyLength
AnyLength

0.5mm(0.020
inch)

WeldFaceWidth
5mm(0.20inch)orLess

1mm(0.040inch)

WeldFaceWidthOver
ExcessWeld
Metal
GrooveWeld

502

5mm(0.20inch)ButLessThan

1.5mm(0.060

10mm(0.40inch)

inch)

WeldFaceWidthOver(10mm)

Reinforcement

(0.40inch)ButLessThan

(Convexity)

20mm(0.80inch)

2mm(0.080inch)

WeldFaceWidthOver
20mm(0.80inch)ButLessThan
30mm(1.20inch)

3mm(0.120inch)

WeldFaceWidth
30mm(1.20inch)andOver
ConvexityAffectsWeldToeAngle,
ExcessWeld
MetalFillet
Weld

ReducingFatigueLife
503

Convexity

WeldToeAnglesof135Degrees
andMoreAreBetter
DefectLimitsExpressedas
MinimumToeAnglesAllowed

WithoutDrawingLimitation

4mm(0.160inch)
90Degrees

2mm(0.080inch)
(AnyLength)

Excess

5041,5042,

Penetration

5043

IncorrectWeld
Toe
Overlap

With"MeltThru"and"Flush"Weld
Symbols

1mm(0.040inch)
(AnyLength)

With"MeltThru"and"GrindFlush"

NotPermitted

Symbols

(AfterGrinding)

When1E2995Applies(Expressed
505

5061,5062

asaToeRadiusRatherThanaToe

3mm(0.120inch)

Angle)

MinimumRadius

ExpressedasMinimumToeAngle

90Degrees

AppliestoEitherWeldLeg
MeasuredIndependentoftheOther

MaximumUndersize
FilletWeld
LegSize

1mm(0.040inch)
10%ofTotalWeld

LengthIfAtLeast

Undersize

10%ofTotalWeld
LengthisatLeast
MaximumLengthofUndersizeWeld

1mm(0.040inch)
OverNominalSize,
Otherwise,No
UndersizeLength
isPermitted

AppliestoEitherWeldLeg
MeasuredIndependentoftheOther

MaximumOversize
FilletWeld
LegSize

Oversize

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

ConformancetoDesignFilletWeld
LegSizesMaybeOversized(Within
DefectLimitationsorBeyond)
WithoutCorrectionProvidedthe
ExcessDoesnotInterferewith

SatisfactoryEndUseofthe
Component(i.e.,Distortion,FitUp
Interference,etc.)
FilletWeld

WeldSize
6.5mm(0.256inch)

LinearLength
when
specifiedat
lessthanthe
lengthofthe
joint

6.5mm(0.256
inch)

WeldSize
6.5mm(0.256inch)

12.5mm(0.492
inch)

NominalSize(0.7xLegSize)Not
InclusiveofPenetrationBeyondthe

NotPermitted

WeldRoot

2mm(0.080inch)

FilletWeld
ThroatSize
Undersize

MAXandNotto
5213

Exceed20%of
WeldCraterOnlyMaximum
Undersize

SpecifiedThroat,
NotInclusiveof
Penetration
BeyondtheWeld
Root(0.7xLeg
Size)

CarefulConsiderationNeedstobe
GivenWhenPlateMismatchis

Incompletely
FilledGroove
Weld

511

NotPermitted

Apparent
WeldDepthMustbeMaintainedas
aMinimum

Root
Concavityon
OpenRoot
GrooveWelds

MaximumDepthmeasuredFrom
515,5013

PlateSurfaceorTubeInnerSurface
AnyLength

0.5mm(0.020
inch)

MeasuredinTermsofExcessWeld
Metal(FilletWeldConvexity)or
OverlaponGrooveWelds,Lackof

Fusion,orInsufficientThroat
ExcessWeldMetalonFilletWelds,
DefectLimitsExpressedas
PoorRestart
(TieIn)

5171,5172

90Degrees

MinimumToeAnglesAllowed
OverlaponGrooveWelds,Defect
LimitsExpressedasMinimumToe

90Degrees

AnglesAllowed
LackofFusionVisualMaximum

StrayArc
Strike

601

SlagResidue 615

LengthPerRestart

3mm(0.120inch)

InsufficientWeldThroat

NotPermitted

NotPermitted

SMAW,SAW,FCAW,GMAW

NotPermitted
SiliconResidue
PermittedUnless

GTAW

RemovalSpecified
byDrawingNote
TotalMaximumCombinedLengthof
AllImperfectionsinaWeld,
ExpressedasaPercentofTotal

Combined
Discontinuities

15%

WeldLength
(NoSingleTypeofImperfectionCan
ExceedtheLimitsforThatSingle

TypeofImperfection)

GeneralWeldRepair
1.Removeanycomponentsthatpreventaccesstothecrackedweld.
2.Referto""AreaPreparation""SectioninthisSpecialInstruction.
3.Usedyepenetrant(PT)ormagneticparticle(MT)inordertoidentifytheextentand/or
lengthofthenecessaryrepair.
4.Protectmachinedsurfacesfromsparksandwelddebris.
5.Ensurethatthebasematerialisataminimumtemperatureof15.6C(60F)before
welding.Ensurethataminimumtemperatureof15.6C(60F)ismaintainedthroughout
theentireweldingprocedure.
6.Thecrack(andsoundmetal50mm(2.00inch)beyondeachendofthecrack)shallbe
removedbygougingand/orgrinding.Cautionshouldbeusedtoavoidexcessiveremoval
ofthesurroundingbasematerial.Areasthataregougedbyaircarbonarctorchshallbe
latergroundandcleanedpriortoweldinginordertoremoveallcarbonabsorptionor
contamination.Gougedareasrequiringreweldingshallhavearootradiusofnotlessthan
5mm(0.20inch)andaSingleV60degreeincludedanglejointpreparationtoallowthe
welderreasonableaccesstoreinstatetheweld.
7.UsePTorMTtoinspectthegougedandgroundareainordertoensurethatthecrack
hasbeenremovedbeforeweldingcommences.
8.Repairthepreparedgrooveutilizingtherecommendationsprovidedinthe""Welding
ElectrodesandParameters""SectioninthisSpecialInstruction.
9.Cleantheweldarea.Inspecttheareathatwaswelded.Allweldqualityshallconformto
thecriteriaspecifiedinthe""WeldInspectionandAcceptanceCriteria""sectioninthis
SpecialInstruction.

ProperCleaningforInspection

Whenitisnecessarytoworkunderthemachinewiththebody(bed)raised,attachthe
body(bed)retainingcablestothereartowpoints.Installthereartowpointpins
throughtheendsoftheretainingcables.
Failuretoproperlysecurethebody(bed)mayresultinpersonalinjuryordeath.

Personalinjurycanresultfromworkingwithcleaningsolvent.
Becauseofthevolatilenatureofmanycleaningsolvents,extremecautionmustbe
exercisedwhenusingthem.Ifunsureaboutaparticularcleaningfluid,refertothe
manufacturer'sinstructionsanddirections.
Alwayswearprotectiveclothingandeyeprotectionwhenworkingwithcleaning
solvents.

NOTICE
Caremustbetakentoensurethatfluidsarecontainedduringperformanceof
inspection,maintenance,testing,adjusting,andrepairoftheproduct.Bepreparedto
collectthefluidwithsuitablecontainersbeforeopeninganycompartmentor
disassemblinganycomponentcontainingfluids.
RefertoSpecialPublication,NENG2500,"DealerServiceToolCatalog"fortoolsand
suppliessuitabletocollectandcontainfluidsonCatproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.

Illustration13

g03361075

Topviewoftheframeassemblywithcentersectionhighlighted

Cleanthecentersectionoftheframethoroughly,especiallybehindtanks,inordertoensure
visibledetectionofanycracks.RefertoIllustration13forlocationofthecentersection.
Ensurethatthesubstancesthatfollowareremovedfromtheareathatwillbeinspected.
Oil
Grease
Dirt

InspectionProcedure

InspectCenterSectionoftheFrame

Illustration14

g03361127

1.Visualinspectionwillrequireacombinationofatelescopingmirrorand/oraborescopein
ordertoviewsomeoftheareaslisted.
Inmostcases,visualinspectionwillbesatisfactory:howeveranyuncertaintyshouldbe
verifiedviamagneticparticleMTinspection.

Inspect4BarLinkCastingtoMainRailConnection

Illustration15
Topviewoftheframe

g03361135

Illustration16

g03361144

Bottomviewoftheframe

Illustration17

g03361154

Exampleofcornercrackat4barlinkconnection

1.Visuallyinspectthe4barlinkcastingtomainrailconnectionasshowninIllustration15
andIllustration16.

Ifcrackingoccurs,crackswillbemostreadilyvisibleatthecornersoftheweldjointas
showninIllustration17.
Note:Theweldreinforcementhasbeensandedflushwiththeparentmaterialsothe
grooveweldconnectionisnotreadilyidentifiable.

InspectFilletWeldsConnectingTubetoVolcanoPlate
Interior

Illustration18

g03361176

Interiorviewoftubeassembly
(A)Tubeassembly
(B)Plate(volcano)

1.Visuallyinspectthefilletweldsconnectingtubeassembly(A)tovolcanoplate(B)onthe
interiorside.
2.Inspectfilletweld360degreesonbothinteriorsidesofthetruck.RefertoIllustration18
forguidance.

InspectFilletWeldsConnectingTubeAssemblyto
OuterWindowPlateandCoverPlateExterior

Illustration19

g03361203

Exteriorviewoftubeassembly
(A)Tubeassembly
(C)Outerwindowplate
(D)Coverplate

Illustration20
Exampleofafilletweldcrackinthetubeassemblytotheoutsidewindowplatelocation

g03361214

1.Visuallyinspectthefilletweldsconnectingtubeassembly(A)toouterwindowplate(C)
andcoverplate(D)ontheexteriorside.RefertoIllustration19.
2.Inspectfilletwelds360degreesonbothexteriorsidesofthetruck.RefertoIllustration20
forguidance.

InspectGrooveWeldBetweenOuterWindowPlateand
4BarLinkCastingExterior

Illustration21
Exteriorviewoftubeassembly
(C)Outerwindowplate

g03361222

Illustration22

g03361229

Exampleofgrooveweldcrackbetweenouterwindowplateand4barlinkcasting

1.Visuallyinspectthegrooveweldconnectingouterwindowplate(C)tothe4barlink
castingonbothexteriorsides.RefertoIllustration22forguidance.

InspectVerticalGrooveWeldBetweenAdjacent
WindowPlatesExterior

Illustration23
Viewofthelefthandside
(C)Outerwindowplate
(E)Outerwindowplate

g03361246

Illustration24

g03361252

Exampleofacrackinthegrooveweldconnectingtheadjacentouterwindowplates

1.Visuallyinspecttheverticalgrooveweldconnectingadjacentouterwindowplate(E)and
outerwindowplate(C).RefertoIllustration23forguidance.

InspectFilletWeldsAttachingHardwaretoOuter
WindowPlatesExterior

Illustration25

g03361502

Viewoftherighthandsideoftheframe

1.Visuallyinspectthefilletweldsattachingallhardwareonthetwoouterwindowplatesas
showninIllustration25.Inspectbothsidesofthetruck.

Illustration26

g03361516

Exampleoffilletweldcrackaroundhardware
Illustration26showsalargebottomcoolermount.Thelargecoolermountcanbefoundonearliermodel
trucks.LatermodeltruckswillreflectthethreesmallblocksonthebottomasshowninIllustration25.

Illustration27
Viewoftheinsiderighthandsideoftheframe
(F)Pumpbox

g03361525

Illustration28

g03361533

2.Visuallyinspectthefilletweldconnectingpumpbox(F)totheinsidewindowplateonthe
righthandsideoftheframeasshowninIllustration27.
Themainconcernisthetoprighthandcornerofpumpbox(F).RefertoIllustration28.
3.Onceinspectionoftheframeiscompleted,refertoIllustration29inthefollowingsection
inordertodeterminewhatcourseofrepairisrecommended.
Ifnocracksarevisuallydetected,thennorepairisrequired.

DecisionTree

Illustration29

g03361557

RepairOptionAistheleastinvasiverepair,buthasexceptionsattached:
Exception1:Ifthecracklengthintheweldismorethan150mm(6.00inch)inlengthorif
thecrackpropagatesoutintothebasematerialmorethan12mm(0.50inch),callthe
793FProductGroupServiceEngineerforguidance.
Exception2:Ifthecrackgoesthroughthicknessoftheplateorcastingorifthereisaloss
ofbackingmaterial,proceedtoRepairOptionB.

RepairOptionA
Thefollowinginformationpertainstovisualinspectionresultsthatwarrantweld
repairs/modificationstotheoutsideoftheframeandpostweldtreatmentstoexternal
attachments.Thisrepairappliestobothsidesoftheframe.Thisrepairoptionistheleast
invasiverepairanddoesnotrequireaccesstotheinsideoftheframecomponents.
PreHeat:Asaprecautionforthethickersectionsofmaterial(t>=50mm(2.00inch)),maintain
a100C(212F)preheat/interpasstemperatureforthetop/bottomrailtocastingconnections.
Thethinnersidesectionscanbeweldedatroomtemperature20C(68F).
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Table11
DisassemblyandAssemblyManuals
SalesModel
793F
793FXQ
793FCMD(CommandForHauling)

MachineSystems

PowerTrain

KENR8579

KENR8397

UENR1142

UENR1143

Illustration30
Sectionview
(A)Innercurvedplate16mm(0.60inch)to25mm(1.00inch)
(B)Rolledrailplate50mm(2.00inch)
(C)Outerwindow16mm(0.60inch)

g03361777

Illustration31

g03361767

Internalviewofweldjointwithsteelbacking

1.Forvisualcracksdetectedatthe4barlinkcastingtomainrailconnection,asshownin
Illustration17proceedwiththerepairusingthefollowinginformationforguidance.
2.ToassistwithexcavationandrepairseeIllustration30andIllustration31forreference
informationregardingmaterialthickness,weldjointdesign,andgeometricalperspective.
Note:Rolledrailplate(B)is50mm(2.00inch)inthickness.Careshouldbetakennotto
excavatebeyondthesteelbackingstrip.Thecrackshouldbenodeeperthan50mm
(2.00inch)forthebottomweldseam.

Illustration32
Excavatecrackbyarcairgouging
(D)Gougedprofile

g03361816

(E)Sectionthickness

Illustration33
Crosssectionalviewofanticipatedgrinding
(E)Sectionthickness
(F)Finishgrindtoachieve70degreeincludedangle

g03361821

Illustration34
Crosssectionalviewofpreparedjointpriortowelding(slightradiusatroot)
(E)Sectionthickness
(G)70degreeangle
(H)35degreeangle

g03361830

Illustration35

g03361835

Longitudinalviewofpreparedjoint
(E)Sectionthickness
(J)45degreeangle

3.Excavateandremovethecrackandpreparethejointforwelding.
Illustrations32,33,34,and35demonstratethesequenceofstepsnecessarytoobtain
thedesiredjointconfigurationpriortowelding.
Thedepthofexcavationandgrindingwilldependonthedepthofthecrack.
4.Uponcompletionofexcavationandpreparation,refertoweldingprocedureguidelinesand
reinstatebywelding.

Illustration36

g03361861

Viewofcracksatcornersonbottomrailbeforeexcavation

Illustration37
Viewofcracksexcavatedandrunon/offtabsattached
(K)Runon/offtabs

g03361863

Illustration38

g03361879

Viewofcompletedweld,tabsremoved,andsurfacesandedflush

5.AsanexampleIllustration36,37,and38demonstratethepropersequence(before,
during,andafter)forcracksthatdidnotpropagatethroughthethicknessoftheplates.
Note:Forrepairsmadeonplateswithopenends,attachrunon/offtabs(K)inorder
toplaceweldstartsontabsandoutsideoffinishedweld.Lackoffusiondefects
associatedwithstartswillthenbenonexistentwhenrunon/offtabs(K)are
removed.
6.Performvisualinspectioninordertoensurethatallweldqualitymeetsorexceedsthe
requirementsshowninthe""WeldInspectionandAcceptanceCriteria""section.
7.Afterweldinghasbeencompleted,sandflushtoprofileofsurroundingparentmaterial
leavingtheappearancethatnoweldrepairhasbeenconducted.

Illustration39

g03361900

16mm(0.60inch)filletweldbothinteriorendsoftubeassembly
(L)Tubeassembly
(M)Plate(volcano)

8.Forvisualcracksdetectedinthefilletweldsconnectingtubeassembly(L)toplate
(volcano)(M)ontheinteriorside,excavatecompletely,preparejointbygrindingand
reinstatefilletweldtocorrectsize.RefertoIllustration39forminimumweldsize.

Illustration40

g03361910

12mm(0.50inch)filletweldbothexteriorsides
16mm(0.60inch)filletweldovera10mm(0.40inch)bevelgrooveweldbothexteriorsides
(L)Tubeassembly
(N)Outerwindowplate
(P)Coverplate

9.Forvisualcracksdetectedinthefilletweldsconnectingtubeassembly(L)toouterwindow
plate(N)andtocoverplate(P)ontheexteriorside,excavatecompletely,preparejointby
grindingandreinstatefilletweldtocorrectsize.RefertoIllustration40forminimumweld
size.

Illustration41

g03362047

10.Forvisualcracksdetectedattheouterwindowplateto4barlinkcasting,likethatshown
inIllustration41,proceedwiththerepairusingthefollowinginformationforguidance.

Illustration42

g03362049

Jgrooveweldjointwithintegralbacking
(R)16mm(0.60inch)
(S)Windowplate
(T)Steelcasting

11.Illustration42depictsthecrosssectionalviewoftheweldjoint.Followtheexcavationand
preparationguidelinesshowninIllustration32,33,34,and35inordertoreinstateweldto
originalsizeandshape.
Note:Usecautionwhenexcavatingcracks.Steelbackingisincorporatedintothecasting
geometry,retainthesteelbackinginordertoensureacompletejointpenetrationrepair.

ProactivePostWeldTreatment
Inordertopreventcrackingatthefilletweldedattachments,treatmenttothefilletweldtoeis
necessarytoimprovefatiguelife.TIGdressingisthepreferredpostweldtreatmentmethod.

Illustration43

g03361502

Viewoftherighthandexteriorside

Illustration44
Viewofthelefthandexteriorside

g03362315

1.TIGdressthefilletweldtoeoftheattachmentscontainedintherectangleshownin
Illustration43and44.
Note:TIGdresstheentirelengthofthefilletweldtoe,includingaroundtheendsofthe
startandstopsforeachoftheattachments.
Note:Thefilletweldtoeforthetankmountandthetubethroughtheframe(outerweld)
shouldalreadybeTIGdressed.Ifnot,thenTIGdresstheseweldtoes.

Illustration45

g03362320

Viewoftherighthandinteriorside
(U)75mm(3.00inch)
(V)75mm(3.00inch)

2.Inaddition,TIGdresscontinuallyatotaldistanceof150mm(6.00inch)aroundtheright
handcornerofthepumpdrivebracketasshowninIllustration45.
FordetailedinformationregardingTIGdressingrefertothe""PostWeldTreatmentTIG
Dressing""Section.

RepairOptionB
Thefollowinginformationpertainstovisualinspectionresultsthatwarrantweld
repairs/modificationstotheinside/outsideoftheframeandpostweldtreatmentstoexternal
attachments.Thisrepairappliestobothsidesoftheframe.Thisrepairoptionisthemost
invasiverepairanddoesrequireaccesstotheinsideoftheframecomponents.
Note:Bothsidesoftheframecanbeworkedsimultaneously.

PreHeat:Asaprecautionforthethickersectionsofmaterial,maintain100C(212F)
preheat/interpasstemperatureforthetop/bottomrailtocastingconnections.Thethinnerside
sectionscanbeweldedatroomtemperature20C(68F).
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Table12
DisassemblyandAssemblyManuals
SalesModel

MachineSystems

PowerTrain

KENR8579

KENR8397

UENR1142

UENR1143

793F
793FXQ
793FCMD(CommandForHauling)
Table13

RequiredParts

(1)

Item

Qty

PartNumber

Description

4317565

Plate(1)

24

4413206

Plate(1)

4413208

Plate(1)

3789104

BracketAs

2953006

BracketAs

Serviceablepartcanbeorderedorfabricated

FabricateTankMountFixtures
1.Beforeremovinganyhardware,constructlocatingfixturestocapturethelocationofthe
fronttankmountsinrelationtothereartankmountswhichwillremainontheframe.
Note:MaterialrequiredforfixturescanbeacommonstructuralsteelsuchasASTMA36.

FabricatetheRightHandSideTankMountFixture

Illustration46
Baseplate
(A)19mm(0.75inch)
(B)2X874mm(34.40inch)
(C)4X22mm(0.90inch)diameter
(D)120mm(4.70inch)
(E)2X18.725mm(0.74inch)
(F)940mm(37.00inch)
(G)2X82.55mm(3.25inch)
(H)2X33mm(1.30inch)

g03362419

Illustration47
Verticalplate
(J)50mm(2.00inch)
(K)160mm(6.30inch)
(L)9.5mm(0.40inch)

g03362443

Illustration48

g03362447

Gusset
(M)110mm(4.30inch)
(N)130mm(5.10inch)
(P)9.5mm(0.340inch)

Illustration49
Semicompletedrighthandtankmountfixture
(R)135mm(5.30inch)
(S)155.25mm(6.10inch)
(T)110mm(4.30inch)
(U)160mm(6.30inch)

g03362488

Illustration50

g03362500

Rod
(V)275mm(11.00inch)
(W)25mm(1.00inch)

1.Fabricate(tackweld)theplateassemblyshowninIllustration49andattachplate
assemblytothereartankmount(withmountinghardware)sothattheplateassemblylies
acrossthefronttankmountsurface.Theholesontheplateassemblymaynotlineup
perfectlywiththethreadedholesinthefronttankmount.

Illustration51

g03368363

Viewofthetankmountfixturelocation(RHside)

2.PositiontherodshowninIllustration50ontopoftherailsectionandagainstthefixtureto
capturetheheightofthefronttankmount.Tackweldrodtothefixture.Thetankmount
fixturewillbeusedtorelocatethefronttankmountfortherighthandsideafterrepairs
havebeencompleted.RefertoIllustration51foranexampleofthefabricatedfixture
locatedontheframe.

FabricatetheLeftHandSideTankMountFixture
Note:Thesameprocesswillbefollowedforthelefthandsideaswasoutlinedfortheright
handside.

Illustration52
Baseplate
(A)19mm(0.75inch)
(B)2X1487.5mm(58.60inch)
(C)4X26mm(1.00inch)diameter
(D)180mm(7.10inch)
(E)2X26mm(1.00inch)
(F)1540mm(60.60inch)
(G)2X128mm(5.00inch)
(H)2X26.25mm(1.05inch)

g03362507

Illustration53
Verticalplate
(J)50mm(2.00inch)
(K)160mm(6.30inch)
(L)9.5mm(0.40inch)

g03362512

Illustration54

g03362514

Gusset
(M)110mm(4.30inch)
(N)130mm(5.10inch)
(P)9.5mm(0.340inch)

Illustration55
Semicompletedlefthandtankmountfixture
(R)135mm(5.30inch)
(S)155mm(6.10inch)
(T)110mm(4.30inch)
(U)160mm(6.30inch)

g03362515

Illustration56

g03362517

Rod
(V)375mm(15.00inch)
(W)25mm(1.00inch)

1.FabricatethepartsshowninIllustrations52,53,andIllustration54andtackweldtogether
toachievethesemicompletedfixtureshowninIllustration55.
2.Fabricate(tackweld)theplateassemblyshowninIllustration55.Attachtheplate
assemblytothereartankmount(withmountinghardware)sothattheplateassemblylies
acrossthefronttankmountsurface.Theholesontheplateassemblymaynotlineup
perfectlywiththethreadedholesinthefronttankmount.

Illustration57

g03368372

Viewofthetankmountfixturelocation(LHside)

3.PositiontherodshowninIllustration56ontopoftherailsectionandagainstthefixtureto
capturetheheightofthefronttankmount.Tackweldrodtothefixture.Thetankmount
fixturewillbeusedtorelocatethefronttankmountforthelefthandsideafterrepairshave
beencompleted.RefertoIllustration57foranexampleofthefabricatedfixturelocatedon
theframe.

RemoveOuterWindowPlates

Illustration58
Viewoftherighthandside

g03363085

Illustration59

g03363086

Viewofthelefthandside

1.Priortoremovingtheouterwindowplatesremoveandretainallhardwarelocatedonthe
outerwindowplates,refertoIllustration58andIllustration59.
Note:Theapproximateweightofthebracketassembly(fueltankfrontmount)is45kg
(100lb).

Illustration60
Viewoftheouterwindowplateonthelefthandside
(A)Rearouterwindowplate

g03369880

(B)Tubeassembly

2.Accesstotheinsideoftherailassemblyrequiresremovingrearouterwindowplate(A)
showninIllustration60.

Illustration61

g03362574

Viewoftherearwindowjointdetails
(AA)Jointdetail
(AB)Jointdetail
(AC)Jointdetail
(AD)Jointdetail

3.Inordertogainaccesstotheinsideoftherailassemblyremovetheweldsbyairarc
gougingasshowninIllustration61.Excavateweldsconnectingthewindowplatetothe
tubeassemblyandtheframe.
4.Attachasuitableliftingdevicetorearouterwindowplate(A).Theapproximateweightof
rearouterwindowplate(A)is55kg(121lb).

Illustration62

g03362583

Viewofjointdetail(AA)
(A)Rearouterwindowplate
(B)Tubeassembly
(C)16mm(0.60inch)
(D)6mm(0.25inch)

Illustration63
Viewofjointdetail(AB)
(E)8mm(0.30inch)Backingstrip
(F)16mm(0.60inch)

g03362592

Illustration64

g03362598

Viewofjointdetail(AC)
(A)Rearouterwindowplate
(G)16mm(0.60inch)
(H)50mm(2.00inch)
(J)Rail

Illustration65

g03362616

Viewofjointdetail(AD)
(A)Rearouterwindowplate
(K)16mm(0.60inch)
(L)Steelcasting

5.Excavateweldsconnectingrearouterwindowplate(A)totubeassembly(B)andtothe
frame.
Note:RefertoIllustrations62,63,64,and65forguidanceonplatethicknessandjoint
details.

Illustration66

g03387518

Viewofthelefthandsideforwardwindowplate
(E)8mm(0.30inch)Backingstrip
(M)Forwardouterwindowplate
(AE)Jointdetail
(AF)50mm(2.00inch)

Illustration67
Viewofjointdetail(AE)
(M)Forwardouterwindowplate
(N)16mm(0.60inch)
(P)35mm(1.40inch)
(R)Internalstiffener

g03362705

6.Afterrearouterwindowplate(A)hasbeenremoved,attachasuitableliftingdeviceto
forwardouterwindowplate(M)andremoveforwardouterwindowplate(M)asshownin
Illustration66.Theapproximateweightofforwardouterwindowplate(M)is74kg(163
lb).
Illustration67givesguidanceonremainingjointdetailandplatethickness.
7.Removeanadditional50mm(2.00inch)(AF)ofweldmetalbeyondweldjoint(bothtop
andbottom).

InspectionandRepairProcedure

Illustration68

g03362732

Viewoflefthandsidewithbothouterwindowplatesremovedallowingfullaccesstotheinsideoftheframe

Illustration69

g03389545

Viewofthelefthandside
(A)Backingstrip
(B)Plate(volcano)
(C)Tubeassembly
(D)Gusset

1.Visuallyinspecttheinsideofthemainrailforvisiblecracks.Payparticularattentiontotwo
backingstrips(A),plate(volcano)(B),tubeassembly(C),andfivegussets(D).
2.Usedyepenetrant(PT)ormagneticparticle(MT)teststoverifyvisualfinding.
Note:IFTHEREAREANYTHROUGHTHICKNESSCRACKSFOUNDONTUBE
ASSEMBLY(C)ORPLATE(VOLCANO)(B),CONTACTTHEPRODUCTGROUP
SERVICEENGINEERFORGUIDANCE.

Illustration70

g03387739

Viewoflefthandsidegrooveweldinspectionareas
(B)Plate(volcano)

3.Visuallyinspecttheinteriorgrooveweldconnectingthe4barlinkcastingtothevolcano
plate(B).RefertoIllustration70.

Illustration71
Crosssectionalviewofthe4barlinkcastingtotheplate(volcano)connection

g03387792

(BA)Plate(volcano)
(BB)Outsideofrail
(BC)Casting
(BD)Insideofrail
(BE)Castingdimension
(BF)Offset

4.Thecasting(BC)hasaprofiletolerancewhichallowsthepossibilitythatthecasting
surfacemaynotalignwiththesurfaceoftheplate(volcano)(BA)andmayresultinan
offset(BF)betweenthetwosurfacesasshowninIllustration71.
Note:Dimension(BE)variesforeachcasting.

Illustration72

g03388714

Weldprofileand/ortransition
(BA)Plate(volcano)
(BB)Outsideofrail
(BC)Casting
(BD)Insideofrail
(BG)16mm(0.63inch)
(BH)9mm(0.35inch)

5.Ifanoffset(BF)exists,theweldprofileshouldextendortransitionfromplate(volcano)
(BA)surfacetocasting(BC)surface,regardlessoftheoffsetdifference.

6.Multipass(stairstepped)weldsshouldbeusedinordertoprovideagradualtransition
fromthelowersurfacetothehighersurface.RefertoIllustration72.
Note:IfgougingorgrindingofexistingweldmetalisrequiredDONOTexceed10
mm(0.40inch)indepth(asmeasuredfromthesurfaceofplate(volcano)(BA).
Beyondthatdepthisparentmaterial.
Note:Thespacebetweenplate(volcano)(BA)andcasting(BC)welds(indicatedbythe
arrowinIllustration72)isnotconnected.

Illustration73

g03362787

Viewofbackingstrip(A)attached

Illustration74

g03362789

Viewwithbackingstrip(A)removed

7.Severalmodificationsaregoingtoberequiredtotheinsideoftheboxsectionandtube
assembly.Ifbackingstrips(A)arepresentasshowninIllustration73,backingstrips(A)

willneedtoberemoved.Backingstrips(A)arelocatedonboththetopandthebottom.
Note:Fivegussets(D)connectingthetubetothevolcanoplatewillalsoneedtobe
removed.Removegussets(D)priortoremovingbackingstrips(A)inordertoprovide
adequateworkspaceontopandbottom.

NOTICE
Usecautionwhenremovinggussets(D).Avoidremovalofbasematerialonboth
thetubeandthevolcanoplate.Intheeventofbasematerialremoval,filldivots
byweldingandsandsmoothtoprofile(use80gritminimumorfiner).

8.Aftergussets(D)areremoved,steelbackingstrips(A)mustberemoved(ifpresent).
9.Arcairgougemostofsteelbackingstrip(A)andthefilletweldsholdingthesteelbacking
strip(A)intoposition.Donotgougeintotheparentmaterial.
10.Removetheremainderofthematerialbygrinding/sanding(use80gritminimumorfiner).
11.Sandallsurfacessmoothtoprofile.
Note:Theinsidesurfacearea,wheresteelbackingstrip(A)waslocated,shouldbea
seamlesstaperedtransitionbetweenthecastingandthesteelrailsection.Thesurface
shouldbesandedandwithoutsharpgougingandgrindingmarks.RefertoIllustration74.

Illustration75
(AA)Gusset
(AB)126.8mm(5.00inch)
(AC)88.4mm(3.48inch)

g03367738

(AD)14mm(0.55inch)
(AE)180mm(7.10inch)
(AF)14.5mm(0.57inch)
(AG)20mm(0.80inch)
(AH)51mm(0.200.04inch)X45degreebothsides
(AJ)122.5mm(4.82inch)radius
(AK)112mm(4.41inch)radius

12.Fivegussets(D)asshowninIllustration69whichwereremovedwillbereplacedby12
newgussets.RefertoIllustration75fordimensionsforgussetfabricationifneeded.The
materialisASTMA572Grade42/50steel.Ifthepartwasordereduse12newgussets(2)
intherequiredpartslist.

Illustration76
(AL)Spacer
(AM)51.43mm(2.020.12inch)
(AN)755mm(2.950.20inch)
(AP)20+/1degree

g03367764

(AR)12mm(0.47inch)

13.UsethedimensionsinIllustration76andfabricatespacer(AL)usingASTMA36material.

Illustration77

g03389639

(AA)Gusset
(AL)Spacer

NOTICE
Forboththerighthandandlefthandsidesofthetruck,mostGussets(AA)will
alwaysbepositionedonthetubetowardthefrontofthetruck.

14.Insertthefirstgusset(AA)perpendiculartothebottomrailasshowninIllustration77.
Tackweldgusset(AA)intopositionandthenlocatetheadjacentgussetsusingspacer
(AL).

Illustration78
Locationandweldsfor12gussets(AA)
10mm(0.40inch)filletweldover5mm(0.20inch)bevelgrooveweld
(AS)20degree

g03389571

Illustration79

g03368040

Locationofgussetsinrelationtothefirstgusset(AA)thatwasinstalled

15.Illustration78andIllustration79showthelocationof12gussets(AA).Install12gussets
(AA)andtackweldintoposition.
16.Weldgussets(AA)intoposition.Useabalancedweldingtechniquetocontroldistortionby
placingoneweldpassonlyateachlocationforeachgussetworkingyourwayaroundto
thenextgussetinaclockwisefashion.
17.Proceedwithsucceedingweldpassesuntilthefinishedweldsizeisachieved.Avoid
weldingonegussettocompletionateachlocation.

Illustration80

g03389588

18.Removeplatelocatedattheendofthetubeassemblyinordertogainaccesstothe
insideofthetube.
19.Grind/sandtheremainingremnantsofweldmetalontheinsidediameterofthetube
assembly.
20.Visuallyinspectthesurfaceofthetubeassemblyinternaldiametertoadepthof
400mm(15.75inch)fromeachend.Usedyepenetrant(PT)ormagneticparticle
(MT)teststoverifyvisualfindings.
Note:Ifthereareanythroughthicknesscracksfoundonthetube,callthe793F
ProductGroupServiceEngineerforguidance.

Illustration81

g03389023

(AT)363.3mm(14.30inch)
(AU)12mm(0.47inch)
(AV)101mm(0.400.04inch)x45degree
(AW)Plate

21.FabricatetwotubeplatesusingthedimensionsshowninIllustration81usingASTMA572
Grade42/50material.Ifthepartwasorderedusetwonewplates(3)intherequiredparts
list.

Illustration82
Locationofinternalplate
(AW)Plate
(AX)266mm(10.47inch)

g03368113

Illustration83

g03368145

Weldinginternalplate
10mm(0.40inch)filletweldover10mm(0.40inch)bevelgrooveweld

22.UsingthedimensionsinIllustration82insertplate(AW)intothetubeassembly.A90
degreemagnetorsquareshouldbeusedinordertoensurethatplate(AW)is
perpendiculartothetubeassembly.
Note:Usevarioussizesofstickelectrodessuchas(1/16,3/32,or1/8)betweenthe
bottomofplate(AW)andthetubeassemblyinordertoequalizethegaparoundthe
circumferenceofplate(AW)inrelationtotheinsidediameterofthetubeassembly.
Note:Weldingofplate(AW)shouldbedoneinquartersandoppositetoeachotherin
ordertocontroldistortion.Forexample,weldfrom6O'clockto3O'clock,then9O'clockto
12O'clock,then6O'clockto9O'clock,andfinally3O'clockto12O'clock.Weldonepass
ateachlocation,movingontothenextuntilthefinishedweldsizeisobtained.

Illustration84

g03388978

10mm(0.40inch)filletweldover10mm(0.40inch)bevelgrooveweld
(AW)Plate
(AX)27mm(1.06inch)

23.Installplate(AW)ontotheoutsideofthetubeassemblywheretheplatewaspreviously
removed.
Note:Thefrontedgeofplate(AW)shouldbe27mm(1.06inch)infromtheendofthe
tubeassembly.Equalizethegapsandusethesameweldingtechniquesaspreviously
describedinordertoattachplate(AW)tothetubeassembly.

Illustration85

g03362983

Viewofacrackwhichpropagatedthroughthebottomrailsection

24.Ifthereiscrackingintheouterwindowplateandhaspropagatedthroughthebottomrail
sectionand/orthroughtheinsidewindowplatesasshowninIllustration85,refertothe
followingstepsforcrackexcavation,preparation,andrepair.
Note:Ifcrackingislocatedinthebottomortopraildirectlyaboveorbelowthetube
assemblyconnection,thefollowingrepairshouldbecompletedbeforeinstallingthe12
newgussets(AA)aroundthetubeassemblyasshowninIllustration79.Otherwise
gussets(AA)willinterferewiththerepair.
Thefollowingstepsalsoapplytoanythroughthicknesscracksatthe4barlinkcastingto
themainrailconnection.
Note:Userunon/offtabsasshowninIllustration37.
25.Inordertorepairthecracks,adheretothefollowingsteps.Startrepairfrominsideofrail
section.

Illustration86

g03389056

(BJ)Gougedprofile
(BL)Crack
(BK)Sectionthickness

26.Gouge/grindtohalfofsectionthickness.

Illustration87
(BL)Crack
(BK)SectionThickness
(BM)70degree
(BN)35degree

27.Finishgrindtoprofile.

g03389062

Illustration88

g03389067

(BL)Crack
(BK)Sectionthickness

28.Weldpreparedsideandsandflushtoparentmaterial.

Illustration89

g03389068

(BK)Sectionthickness

29.Excavatetheoppositesidetosoundmetal.
30.UsePT(dyepenetranttest)orMT(magneticParticleTest)inordertoverifythatallcracks
havebeenremoved.

Illustration90

g03389072

(BK)Sectionthickness

31.Weldtheoppositeside.

Illustration91

g03389073

(BK)Sectionthickness

32.Weldbothsidescompleteandsandflush.
33.Whenweldingiscomplete,sandbothsidesflushtoprofileofparentmaterial.Evidence
ofarepairshouldnotbevisuallynoticeable.
Note:Visuallyandultrasonicallyinspectweldrepairsusingacceptancecriteriafoundat
thebeginningofthisdocument.Referto""RequirementsforUltrasonic(UT)Testing""
SectionforUTtesting.

Illustration92

g03362988

Viewofpreparededges

34.Clean/grind/sandalljointedgestobeweldedasshowninIllustration92.
Note:Priortoinstallingtheoutsidewindowplateensurethattherearenosmall,cracklike
defectsattheendsofthegrooveweldsconnectingthe4barlinkcastingtothetopand
bottom50mm(2.00inch)railsections.

Illustration93

g03388988

ViewofarearequiringMTinspection

35.Usemagnetparticletesting(MT)inordertotesttheareaidentifiedinIllustration93
(top/bottombothsides).

FabricateandInstallWindowPlate

Illustration94

g03362989

(A)2X260mm(10.25inch)
(B)339.5mm(13.40inch)
(C)410mm(16.10inch)
(D)336mm(13.20inch)
(E)16mm(0.63inch)
(F)45+52
(G)62mm(0.240.08inch)
(H)1445.5mm(56.914inch)
(R)Windowplate

1.UsethedimensionsinIllustration94andfabricateanewwindowplate.UseASTMA572
Grade42/50steelforthenewwindowplate.Ifthepartwasorderedusenewplate(1)in
therequiredparts.

Illustration95

g03362990

(J)Jointdetail
(K)Jointdetail
(L)Jointdetail
(M)Jointdetail

Illustration96
Viewofjointdetail(J)
16mm(0.63inch)Bevelgrooveweld
(N)30degreebevel
(P)6mm(0.24inch)

g03362991

Illustration97

g03362992

Viewofjointdetail(K)
16mm(0.63inch)Jgrooveweld
(R)Windowplate
(S)15mm(0.60inch)minimum
(T)Steelrail

Illustration98
Viewofjointdetail(L)
16mm(0.63inch)filletweldovera10mm(0.40inch)bevelgrooveweld
(U)Tubeassembly
(V)45degreebevel
(W)6mm(0.24inch)

g03362993

(X)Equalizedgaparoundtubeassembly

Illustration99

g03362994

Viewofjointdetail(M)
16mm(0.63inch)Jgrooveweld
(Y)Steelcasting
(Z)15mm(0.60inch)minimum

Note:Builduptheintegralbackingstripforweldjointdetail(M).

Illustration100
Viewofgapcondition1
(R)Windowplate
(Y)Steelcasting

g03362995

Note:Ifthereisavisiblegapbetweentheintegralbackingandwindowplate(R)as
showninIllustration100,buildupthesurfaceasneededandsandtoprofile.

Illustration101

g03362996

Viewofgapcondition2
(R)Windowplate
(Y)Steelcasting
(BA)2mm(0.08inch)maximumgap

2.Ifagapexceedsmorethan2mm(0.08inch)betweentheundersideofwindowplate(R),
andtheintegralbackingasshowninIllustration101buildupthesurfaceandsandto
profileinordertoclosethegap.

Illustration102
Viewofgapcondition3
(R)Windowplate
(BB)Steelrail

g03388994

(BC)2mm(0.08inch)maximumgap

3.IftheoppositeconditionexistsasshowninIllustration102,wherethecastingissetting
higherthansteelrail(BB)andthereisagapgreaterthan2mm(0.08inch)between
windowplate(R)andsteelrail(BB),removematerialfromthecastinginordertoobtaina
gaplessthanorequalto2mm(0.08inch).Theintegralbackingonthecastingshouldnot
bereducedinthicknesslessthan8mm(0.31inch).
4.Useasuitableliftingdeviceinordertopositionfabricatedwindowplate(R)ensuringweld
jointdimensionsasshowninIllustrations96,97,98,andIllustration99.Theapproximate
weightofwindowplate(R)is130kg(287lb).
5.Onceproperfitofwindowplate(R)hasbeenobtained,securewindowplate(R)withtack
welds(6mm(0.24inch)filletweldsby50mm(2.00inch)long)onallsidesandattube
assembly(U).
Minimizeweldingdistortionbyweldingnomorethanonepassateachjointlocationuntil
weldsizeisobtained.
6.Blendsandallweldstartandstops.
7.Visuallyandultrasonicallyinspectallcomplete/fulljointpenetrationgrooveweldsto
ensureconformancetoacceptancecriteriafoundatthebeginningofthisdocument.Refer
to""RequirementsforUltrasonic(UT)Testing""SectionforUTtesting.
8.Visuallyinspectallfilletwelds(andpartialjointpenetrationgroovewelds)toensure
conformancetoacceptancecriteriafoundatthebeginningofthisdocument.

InstallationofHardware

Illustration103
Viewofthelefthandside
8mm(0.30inch)filletweld

g03501284

(4)Bracketassembly(fronttankmount)

1.Locateandattachthelefthandsidebracketassembly(4)inrelationtoreartankmount
usingfixtureassembledbeforeremovingouterwindowplates.
2.Securebracketassembly(4)totheframewithtackwelds.
3.WeldcompleteasshowninIllustration103.

Illustration104
Viewofthelefthandsidehardware
6mm(0.24inch)filletweld2places
(D)8X7415Plate
(W)230mm(9.05inch)
(X)1055mm(41.54inch)
(Y)85mm(3.35inch)
(4)Tankmount

4.Locateplates(D)usingthedimensionsinIllustration104.
5.Secureplates(D)usingtheweldsshowninIllustration105.

g03503857

Illustration105
Viewoftherighthandsidehardwareandwelds
6mm(0.24inch)filletweld4places
8mm(0.30inch)filletweld2places
12mm(0.48inch)filletweld
(5)Bracketassembly(leftreartankmount)
(C)Plate(topcoolermount)
(D)8X7415Plate
(E)2542995Plate

g03501323

Illustration106

g03363117

Viewoftherighthandsidehardware
(F)236.1mm(9.30inch)
(G)80.3mm(3.16inch)
(H)39mm(1.54inch)
(J)125mm(4.92inch)
(K)420.3mm(16.55inch)
(L)116.2mm(4.57inch)
(M)136.2mm(5.36inch)
(N)225mm(8.86inch)
(P)410mm(16.14inch)
(R)85mm(3.35inch)
(S)501.5mm(19.74inch)
(T)85mm(3.35inch)
(U)380.5mm(14.98inch)

6.Locatetopcoolermount(C)usingrightfronttankmount.
7.Locateallotherplates(onrighthandside)usingthedimensionsinIllustration106.

Illustration107

g03368259

Viewof8X7415Plate
(BA)10.5mm(0.41inch)diameterwithM12X1.756GTHD
(BB)20mm(0.80inch)
(BC)60mm(2.40inch)
(BD)80mm(3.20inch)
(BE)20mm(0.80inch)
(BF)40mm(1.60inch)
(BG)25mm(1.00inch)

Illustration108
Viewof2542995Plate
(BH)120mm(4.72inch)
(BJ)100mm(4.00inch)
(BK)20mm(0.80inch)
(BL)10.5mm(0.41inch)diameterwithM12X1.756H
(BM)25mm(1.00inch)

g03368336

Note:Forearliermodeltrucks,the(large)lowercoolermountblock(RHside)hasbeen
replacedwiththreesmallerblocks.Thethreesmallerblocksconsistofone8X7415Plate
andtwo2542995Plate.UsethedimensionsinshowninIllustration107andIllustration
108inordertofabricatetheplates(blocks)ifneeded.
8.SecureallplatesusingtheweldsshowninIllustration105.

ProactivePostWeldTreatment
Inordertopreventcrackingatthefilletweldedattachments,performtreatmenttothefilletweld
toetoimprovefatiguelife.TIGdressingisthepreferredpostweldtreatmentmethod.
Illustration109andIllustration110depicttheattachmentswhichrequireTIGdressingonthe
righthandandlefthandsideoftheframe.

Illustration109
Viewoftherighthandexteriorside

g03361502

Illustration110

g03362315

Viewofthelefthandexteriorside

1.TIGdressthefilletweldtoeoftheattachmentscontainedintherectangleshownin
Illustration109and110.
Note:TIGdresstheentirelengthofthefilletweldtoe,includingaroundtheendsofthe
startandstopsforeachoftheattachments.

Illustration111
Viewoftherighthandinteriorside
(U)75mm(3.00inch)

g03362320

(V)75mm(3.00inch)

2.Inaddition,TIGdresscontinuallyatotaldistanceof150mm(6.00inch)aroundtheright
handcornerofthepumpdrivebracketasshowninIllustration111.
FordetailedinformationregardingTIGdressingrefertothe""PostWeldTreatmentTIG
Dressing""Section.

PostWeldTreatmentTIGDressing
Thefatigueperformanceoffabricatedstructuresinvolvingfilletweldedattachmentstohighly
stressedmembersis,amongotherthings,controlledbytheprofileorgeometryoftheweldtoe.
Fatigueperformanceimprovementscanbeachievedthroughalterationoftheoriginal,as
weldedtoeprofilebyseveralpostweldtreatmentoptions.Thisproceduredescribesamethod
wherebyanelectricarcisusedtoreduceand/orremoveunfavorableprofiles/stressrisersthus
creatingasmooth,seamlesstransitionfromonecomponenttothenextcomponent.
Note:Training:Anyoneperformingthisprocedureisadvisedtoviewthetrainingvideo
"PostWeldTreatment:TIGDressingFundamentals",coursenumber41737,intheDealer
LearningManagementSystem.

EquipmentRequirements
Table14
RequiredEquipment
Tool
GTAW(TIG)Power
supplyandatorch.
ShieldingGas

Description
Thepowersupplymustbeabletoproduce200amps(min.60%
dutycycle)withahandcontrolorafootcontrol.
PolarityDCnegative
100%Argonandflowmeter
Lanthanatedor
Ceriatedor
ThoriatedTungsten

Electrode

2.4mm(0.09inchdiameter)
Ifneeded:
ER70S2fillermetal
1.5mm(0.06inchdiameter)

Grinder
GrindingWheel

Pneumaticorelectricwithcarbonsteelwirewheelattachment
AluminumOxide

Radiusgauges

Method
1.ThefirststepsinordertoensureproperTIGdressingarecleanlinessandtungsten
electrodepreparation.
Thefilletweldandsurroundingbasemetalmusthaveallcontaminantsthoroughly
removed.Itisimperativethatallpaint,rust,dirt,oilscale,andsilicateislandsarenon
existent,removebyusingagrinderwithacarbonsteelwireattachment.

Illustration112

g03363246

2.4mm(0.09inch)TungstenElectrodePreparation
(A)GrindingMarks
(B)2X3diameter
(C)1/4diameter

2.Preparea2.4mm(0.09inch)tungstenelectrode.Refertothedimensionsthatareshown
inIllustration112.Thegrindingmarksshouldrunparalleltoeachother.

3.Adjusttheshieldinggasflowrateto1525CFH.Adjustthecurrentcontrolto
approximately200amps.Ifarampdowncontrolispresentonthepowersource,utilize
therampdowncontroltoensurethatpropercraterfillcontrolisachieved.
4.AnumberofdifferenttechniquesexistforTIGdressingduetothevariationofthecontour
ofthefilletweldtoe.Thecontourofthefilletweldtoemustbereshaped.Useastringeror
weavemanipulationofthetorchinordertoachieveasmoothradiusoftheweld.A
minimumradiusof5.0mm(0.20inch)mustexistbetweenthebasematerialandtheweld
metal.

Illustration113

g03363256

StringerTechnique
(D)0degreeworkangle

Note:Usea10to15degreepushangleforthestringertechnique.
5.Illustration113representsthestringertechniqueofwelding.Thecenterofthearcneeds
tobe0.02.0mm(0.00.08inch)fromtheweldtoeintothebasematerial.

Illustration114

g03363260

WeaveTechnique
(E)0to45degreeworkangle

Note:Usea10to15degreepushanglefortheweavetechnique.
6.Illustration114representstheweavetechniqueofwelding.

Illustration115

g01989613

7.Illustration115representsanacidetched,crosssectionviewofaTIGdressedweldtoe.

Illustration116

g01990055

Illustration117

g01990056

8.Illustration116andIllustration117demonstratetheexpectedresults.
9.OnceTIGdressingiscompleted,theareaneedstobecleanedandpaintedinorderto
preventpittingduetocorrosion.
Note:Poorlyshapedfilletweldswith90degreeto100degreetransitionanglestothe
basematerialwillrequireseveraloverlappingTIGdressingrunstosmoothouttheweld
toetransitionregion.
Note:TIGdressingcanbeconductedintheverticalpositionaslongastheTIGdressing
isperformedinadownhillprogression.
Note:Ifundercutorothercircumstancesrequiretheadditionoffillermetal.Addingfiller
metalcanbeaccomplishedbyhandfeedingER70S21.6mm(0.06inch)intotheweld
pool.YouthenrepeattheTIGdressinginordertoachievethedesiredtoeradiusandthe
desiredprofile.
10.Inspectusingaradiusgagetoensurea5mm(0.20inch)minimumradius.

ReportofUltrasonicInspectionofWelds

Table15
ReportofUltrasonicInspectionofWelds

InspectionCompany:
Date:
Address:
TruckSerialNumber:

PartNumber:

Weld/PartIdentification:

MaterialThickness:

CalibrationBlockType:

WeldJointDesignation:

WeldingProcess:
QualityRequirements:Referto
Table10

Procedure/Rev.:
""RequirementsforUltrasonic(UT)

Couplant:

Testing""

Instrument:
Manufacturer:

Model:

SerialNumber:

CalibrationDate:

Notes:

SearchUnit:

Longitudinal

Shear

Frequency

Size

Manufacturer

Angle

SerialNumber

Table16
ReportofUltrasonicInspectionofWeldsContinued
Line
Number

Indication

SearchUnit

Number

Angle

FromFace

Leg

10

0DbReferenceLevelMethodOnly
Line

Indication

Reference

Attenuation

Indication

Number

Level

Level

Factor(1)(2)

Rating

=d

10

DiscontinuityLocation

Length

Angular

Line

Distance

Distance

DepthFrom

(SoundPath)

Surface

Number

Discontinuity
Evaluation

From

From

10

Remarks:

(1)

Metricequationforangulardistance(soundpath25mm)x.08=C

(2)

Standardequationforangulardistance(soundpath1inch)x2=C

RECENT
2885611CATERPILLAR
5011826HITACHI
4654476HITACHI
4669416HITACHI
2958691CATERPILLAR

PARTS
Caterpillar
Hitachi
Volvopro

AUTODATA

Accept/Reject

 Caterpillar
VolvoImpact
VolvoProsis
HitachiHOP
BoschESPI
Partlist

|
Spareparts
ThenamesCat,Caterpillar,JohnDeere,Komatsu,Volvo,Hitachi,Doosan,JCB,Hyundaior
anyotheroriginalequipmentmanufacturersareregisteredtrademarksoftherespectiveoriginal
equipmentmanufacturers.Allnames,descriptions,numbersandsymbolsareusedfor
referencepurposesonly.