Documento Cat

Procedure to Repair the Frame on Certain 793 through 793D Off-Highway Trucks
2019/10/22
{7051} (M0086585)
SMCS - 7051 i07816539

Off-Highway Truck/Tractor
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)

793C (S/N: 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
Introduction
Revision History
Revision Summary of Changes
Added Procedure to Replace the Center Support Assembly on the 793D Off-
Highway Truck
06 Added Procedure to Repair the Bracket Assembly (Steering Box) on the 793C and
793D
Added Procedure to Replace the Steering Bracket Assembly
Table 1
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.
Reference: Special Instruction, REHS0541, "Procedure for the Inspection, Repair, and
Component Replacement of the Frames of Certain Off-Highway Trucks"
Reference: Special Instruction, REHS1841, "General Welding Procedures"
Do not perform any procedure in this Special Instruction until you have read the information and
you understand the information.
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, PERJ1017, "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.
Do not operate or work on this product unless you have read

and understood the instruction and warnings in the relevant
Operation and Maintenance Manuals and relevant service
literature. Failure to follow the instructions or heed the warnings
could result in injury or death. Proper care is your responsibility.
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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.
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”.
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 to lift components. Refer to the manufacturer's
weight's 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 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.
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 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. If there is 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. If there is 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 the recommended
practices that are provided by the manufacturer of the pressure washer.
Proper Cleaning for Inspection
To prevent personal injury or death, do not work under the

machine with the body (bed) raised.
When it is necessary to work under the machine with the body

(bed) raised, install the body (bed) retaining cable end through
the rear tow pin at the rear of the machine.
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents,

extreme caution must be exercised when using them. If unsure
about a particular cleaning fluid, refer to the manufacturer's
instructions and directions.
Always wear protective clothing and eye protection when

working with cleaning solvents.
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, PERJ1017, "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.
Before you inspect the area, clean the area with an appropriate high-pressure washer. Be
careful not to damage wires or other components. Use an appropriate degreaser to remove any
oil or grease from the frame assembly. Use a wire brush or a scraper to remove excessive dirt
and grease. Make sure that the substances that follow are removed from the area that will be
inspected.
Oil
Grease
Dirt
Clean drain holes on the steering box. Ensure that any trapped water is drained.
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:
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)
Table 2
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.
Welding Current for Flux Cored Welding Electrode that Is 1.2 mm

(0.045 inch)
Wire Feed Rate Voltage Amperage

7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per
24 to 28 190 to 240
Minute
Table 3
Welding Current for Flux Cored Welding Electrode that Is 1.4 mm

(0.052 inch)
Wire Feed Rate Voltage Amperage

5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute 23 to 27 180 to 220
Table 4
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 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.
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)
Table 5
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.
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
Table 6
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.
Weld Inspection and Acceptance Criteria

ISO 6520
Defect
Defect Name Remarks Defect Limit
Reference
Number
1011, 1012,
Cracks - 1013, 1014,
Longitudinal, 1023, 1024,
Transverse, 1031, 1033,
Radiating, 1034, 1045, -- Not Permitted
Crater, 1046, 1047,
Disconnected, 1051, 1053,
Branching 1054, 1061,
1063, 1064
Crack -
1021 Hard Surfacing Welds Only Permitted
Transverse
Crack -
1021 Joining Welds Not Permitted
Transverse
Maximum Diameter for a Single
1 mm (0.040 inch)
Pore
Maximum Pores in Any 300 mm
6
2011, 2012, (11.81 inch) Length of Weld
Porosity
2014, 2017
Maximum Number of Pores in Any
50 mm (2.0 inch) of Weld Length for
1
Welds Less Than 300 mm
(11.81 inch) in Length
Clustered Maximum Length of Cluster in Any
2013 3 mm (0.120 inch)
Porosity Weld
Maximum Height or Width 3 mm (0.120 inch)
Elongated Maximum Length for Any Single
2015 25 mm (1.00 inch)
Cavities Discontinuity
Maximum Length in Any Weld 10% of Weld Length
Maximum Dimension of Any Single
3 mm (0.120 inch)
Cavity
Elongated
2016 10% of Weld Length
Cavities Maximum Total Length of Affected
Not to Exceed 25 mm
Area in Any Weld
(1.00 inch)
Shrinkage 2021, 2024,
Maximum Diameter or Length 1 mm (0.040 inch)
Cavities 2025
Maximum Height or Width 1mm (0.040 inch)
3011, 3012,
Slag or Flux Maximum Length for Any Single
3014, 3021, 25 mm (1.00 inch)
Inclusions Discontinuity
3022, 3024
Oxide 3031, 3032, Maximum Height or Width 1mm (0.040 inch)
Inclusions 3033
https://sis2.cat.com/#/detail? Maximum Length for Any Single
25 mm (1.00 inch)
Discontinuity
Puckering
(Oxide
3034 -- Not Permitted
Inclusion -
Aluminum)
Metallic 3041, 3042,
-- Not Permitted
Inclusion 3043
Visual (Breaking the Surface) Not Permitted
Subsurface Maximum Height or
1mm (0.040 inch)
Lack of 4011, 4012, Width
Fusion 4013 Subsurface Maximum Length for
25 mm (1.00 inch)
Any Single Discontinuity
10% of Nominal
Penetration Not to
Maximum Reduced Penetration
Lack of Exceed 1mm
402, 4021 (0.040 inch)
Penetration
Maximum Allowed Total Length of
10% of Weld Length
Reduced Penetration
5011, 5012,
Maximum Depth Measured From
Undercut 5013, 5014, 0.5 mm (0.020 inch)
Plate Surface - Any Length
5015
Any Length --
Weld Face Width 5 mm (0.20 inch)
1 mm (0.040 inch)
or Less
Weld Face Width Over 5 mm
(0.20 inch) But Less Than 10 mm 1.5 mm (0.060 inch)
Excess Weld (0.40 inch)
Metal - Groove
Weld 502 Weld Face Width Over 10 mm
Reinforcement (0.40 inch) But Less Than 20 mm 2 mm (0.080 inch)
(Convexity) (0.80 inch)
Weld Face Width Over 20 mm
(0.80 inch) But Less Than 30 mm 3 mm (0.120 inch)
(1.20 inch)
Weld Face Width 30 mm (1.20 inch)
4 mm (0.160 inch)
and Over
Convexity Affects Weld Toe Angle,
90 Degrees
Reducing Fatigue Life
Excess Weld
Metal - Fillet Weld Toe Angles of 135 Degrees
503 --
Weld and More Are Better
Convexity
Defect Limits Expressed as
--
Minimum Toe Angles Allowed
2 mm (0.080 inch)
Without Drawing Limitation
(Any Length)
Excess 5041, 5042, With "Melt - Thru" and "Flush" Weld 1 mm (0.040 inch)
Penetration 5043 Symbols (Any Length)
With "Melt - Thru" and "Grind Flush" Not Permitted (After
Symbols Grinding)
When 1E2995 Applies (Expressed
Incorrect Weld 3 mm (0.120 inch)
505 as a Toe Radius Rather Than a Toe
Toe Minimum Radius
Angle)
Overlap 5061, 5062 Expressed as Minimum Toe Angle 90 Degrees
Applies to Either Weld Leg
--
Measured Independent of the Other
Maximum Undersize 1 mm (0.040 inch)
10% of Total Weld
Fillet Weld Leg Length If At Least 10%
Size - -- of Total Weld Length is
Undersize at Least 1 mm
Maximum Length of Undersize Weld (0.040 inch) Over
Nominal Size,
Otherwise, No
Undersize Length is
Permitted
Fillet Weld Leg -- Applies to Either Weld Leg
--
Size - Measured Independent of the Other
Oversize
+25% (max 3 mm
Maximum Oversize
(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.)
Fillet Weld -
Weld Size ≤ 6.5 mm (0.256 inch) ± 6.5 mm (0.256 inch)
Linear Length
when specified
--
at less than ± 12.5 mm
the length of Weld Size ≥ 6.5 mm (0.256 inch)
(0.492 inch)
the joint
Nominal Size (0.7 x Leg Size) Not
Inclusive of Penetration Beyond the Not Permitted
Weld Root
2 mm (0.080 inch)
Fillet Weld MAX - and Not to
Throat Size - 5213 Exceed 20% of
Undersize Weld Crater Only - Maximum Specified Throat, Not
Undersize Inclusive of
Penetration Beyond
the Weld Root (0.7 x
Leg Size)
Careful Consideration Needs to be
Incompletely Given When Plate Mismatch is Not Permitted
Filled Groove 511 Apparent
Weld Weld Depth Must be Maintained as
--
a Minimum
Root
Maximum Depth measured From
Concavity on
515, 5013 Plate Surface or Tube Inner Surface 0.5 mm (0.020 inch)
Open Root
- Any Length
Groove Welds
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 90 Degrees
Poor Restart Minimum Toe Angles Allowed
5171, 5172
(Tie - In)
Overlap on Groove Welds, Defect
Limits Expressed as Minimum Toe 90 Degrees
Angles Allowed
Lack of Fusion - Visual Maximum
3 mm (0.120 inch)
Length Per Restart
Insufficient Weld Throat Not Permitted
Stray Arc
601 -- Not Permitted
Strike
SMAW, SAW, FCAW, GMAW Not Permitted
Silicon Residue
Slag Residue 615 Permitted Unless
GTAW
Removal Specified by
Drawing Note
Total Maximum Combined Length of
All Imperfections in a Weld,
15%
Expressed as a Percent of Total
Combined Weld Length
--
Discontinuities
(No Single Type of Imperfection Can
Exceed the Limits for That Single --
Type of Imperfection)
Table 7
To verify the quality of the weld, refer to Figure 27 from Caterpillar Specification 1E99 which is
shown above in Table 7.
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) 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 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
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.
Repair of the 793, 793B, 793C, and the 793D

Frame Castings
Tools Needed
Part
Description
Number
9U-7981 Couplant
US-N58L GE/Krautkramer Ultrasonic Flaw Detection Unit
12-4000 GE/Krautkramer Straight Beam Transducer
C-012 GE/Krautkramer Probe Cable
49000500 Cooperheat Thermocouple Wire (Type K)
DMS2 GE/Krautkramer Ultrasonic Thickness Gauge
DA301 GE/Krautkramer Dual-Element Transducer
KB-A533 GE/Krautkramer Probe Cable
13002800 Cooperheat Holding Pin Attachment Unit
26000901
26001101
Cooperheat Flexible Ceramic Pads (FCPs)(1)
26000801
26000701
540-1503 Cooperheat Pins
370-0900 Cooperheat Bulk Insulation
54010702 Cooperheat Washers
Cooperheat Coopermaster 6-Way Power Supply with Local/Remote Control and
09011201
12-Point Recorder
Cooperheat Thermocouple Attachment Unit (TAU) (Capacitive Discharge
13000300
Welder)
222-3076 Right Angle Air Die Grinder
222-3074 Medium Mini Air Die Grinder
174-8911(2) 4 inch electric grinder with 1/8" cutoff disk
9U-6382(3) 5 inch pneumatic grinder with 7" grinding disk
Y-7 Magnaflux AC/DC Portable Magnetic Yoke
K1-5251 Lincoln Electric Surface Tension Transfer (STT) MIG Welder
K1-5601 Lincoln Electric Surface Tension Transfer (STT) Wire Feeder
Table 8
(1)
(2) The specific FCP depends on the size of the area that needing covered. Each FCP part number is a different size.
(3) Use this cutoff disk or an adequate available disk
Use this grinding disk or an adequate available disk
Mapping of the Casting Wall Thickness Using
Ultrasound
Example of a GE/Krautkramer ultrasonic flaw detection unit
Example of a GE/Krautkramer ultrasonic thickness gauge with a dual-element transducer and with a probe cable
Note: For repairs to be done on large castings, knowing the thickness of the parent material
before excavating the defect, will reduce or eliminate the tendency to cut a larger than necessary
opening in the component with the primary material removal method or gouging. This section
outlines the process that is required to determine the thickness of some areas of a component
by using ultrasound from an accessible surface.
Note: Personnel that perform this inspection should be qualified to a minimum of a Level 1 for
ultrasonic testing. Ensure that personnel performing inspections are qualified to perform
calibration and interpretation of the acquired results. An ultrasonic inspection unit capable of
calibration in the thickness range of 10 mm (0.4 inch) to 60 mm (2.4 inch) is needed. A 5 MHz,
dual element transducer is required. The desired diameter is 12.7 mm (0.50 inch), but a large
diameter transducer may be acceptable if the transducer can achieve good contact with the
casting surface in the area. A standard UT flaw detector can be configured to check thickness
with a straight beam transducer, or a flaw detector dedicated to thickness testing can be used.
Refer to Illustrations 3 and 4 to view the inspection units that should be used. If one of these
units is not available, use a comparable unit.
NOTICE
Measurements should not be taken if the temperature of the part
exceeds 200 °F
Note: The instrument shall be calibrated using a two-point calibration. The calibration block shall
have a minimum of 4 steps, with thicknesses that range from 10 mm (0.4 inch) to 12 mm
(0.5 inch) through 50 mm (2.0 inch) to 60 mm (2.4 inch) (a four-step block ( 12 mm
(0.4724 inch), 24 mm (0.9449 inch), 36 mm (1.4173 inch), 50 mm (1.9685 inch) steps). The
block used for the calibration shall have a letter of certification that is traceable through a
serialized number to National Institute of Standards and Technology (NIST). The calibration
procedure should be done according to the instructions in the equipment manual.
Grid setup
1. Identify the casting areas that require rework or repair. Set up a grid pattern surrounding
the discontinuity that will be removed. Start at one end of the crack. Make a point 10 mm
(0.4 inch) on either side of the crack. Add extra points at 15 mm (0.6 inch) centers down
the length of the crack and outward from the first set of points for two to three more rows.
At each end of the crack, place a point 10 mm (0.4 inch) away, and two to three more
points at 15 mm (0.6 inch) centers. Add extra rows of points at each of the crack tips at a
45 degree angle between the last row of points normal/transverse to the crack and the
rows at the ends.
2. Apply couplant to the grid area.
Thickness measurement with UT Transducer
3. Place the transducer firmly on each grid point and observe the reading on the ultrasonic
flaw detection unit. Reading for each grid point must be done in an organized manner.
Thickness at each point can be recorded in the ultrasonic flaw detection unit and traceable
back to the location on the component by labeling the grid rows and columns. The
measurements may be recorded on a graphical representation of the area or the
measurements mat be recorded directly on the component.
Note: Any thickness change that is greater than 2 mm (0.08 inch) between grid points
requires a check between the two points. If there are two questionable readings, then more
readings should be taken to clarify the results.
Welding Specifications
Welding specifications
General Information
793F AC
793F
and 793F
Model Source __________
Command
For
Hauling
Part 277-7950
Supporting WPQR KSS 101-104
Number 279-2003
Steel
Part Name Castings- Description __________
Frame
Joint Preheat
Joint
___Butt - Single V____ Preheat Temp °C (min) ____120____
Design
Root
_________4____mm Method __Electric Pads __
Opening
Root Face ________2_____mm Interpass Temp °C (min) ____120____
Interpass Temp °C
Buttering ________NA_______ ____300____
(max)
Back Gouge Yes___X___ No ______ For
Comments: Thermocouple Controlled
Required Crack Removal
Backing ASTM A36 (see procedure for
Material usage)
Base Materials Post Heat Treatment
Thickness
Group # Material Spec Heating Rate (°C/Hr) ____100____
(mm)
25 mm
1E0627/ASTM (1.0 inch)-
1 Hold Temp/Time °C ____200____
A27 70/40 100 mm
(3.9 inch)
Cooling Rate (°C/Hr) Wrap and Slow Cool
Necessary for hydrogen
Comments:
removal
Filler Materials Gas/Flux Technique
Stringer Weave
Process GMAW / FCAW
Bead______X______ Bead______X______
Restrictions on Weave
Electrode ER70S-6 or E71T-1MH8
Comment: 3X Electrode Dia.
GMAW 0.035 inch / FCAW Initial/Interpass Cleaning: _________Chip / Brush
Size
0.045 inch or 0.052 inch ________
Shielding Back Gouge
75/25 (Ar/CO2) for both
Gas Method:____________________________________
Flow Rate
40 - 45
(CFH)
Electrode GMAW 1/4 to 3/8 inch / FCAW
Other Notes:
Stickout 5/8 to 3/4 inch
Flux N/A Crack/material removal by Arc/Air and grinding
Position Inspection
Position of
Vertical Fillet Method UT, VT, MT (Dry)
Groove
Vertical
Up_X_Down__X_ N/A Comments:
Progression
Table 9
Welding Specifications
welding materials
This procedure is intended for through thickness and partial through thickness repairs of
1E00627 steel castings with access from one side only.
Filler Metals Current
Pass or Weld Volts / Travel Speed
Process Class / Dia. Polarity / Amps
Layer (ipm)
ER70S-6 / 0.035 See detailed See detailed
1 GMAW
inch instructions. instructions.
E71T-1MH8 / 0.045
2 - on FCAW DCEP / 190-240 24-28 / 8-12
inch
E71T-1MH8 / 0.052
2 - on FCAW DCEP / 180-220 23-27 / 10-16
inch
Joint Design
Comments: See specific details for various scenarios.
Table 10
Cleaning
Complete UT thickness mapping of area next to crack. Remove paint and other contaminants by
grinding or sanding with a rotary steel wire wheel. The area to be cleaned should extend at least
152.4 mm (6 inch) on all sides of the crack. Care should be taken when paint is removed so that
minimal base material thickness is affected. Refer to Illustration 7.
Initial Bake and Preheat
Cooperheat Flexible Ceramic Pads (FCPs) secured with holding pins
Cooperheat holding pin attachment unit
1. Attach the flexible ceramic pads (FCPs) and secure (if necessary) by using holding pins
and attachment unit. Casting thickness, crack depth, and proposed joint configuration will
determine placement of the FCP. FCP should be placed a minimum distance of 0.6 times
the casting thickness (plus an extra 75 mm (2.95 inch)) on either side of the crack. FCP
can also be placed above or below a service area if space is available. See Illustrations 8
and 9 to reference the installation of the flexible ceramic pads and holding pins.
Cooperheat thermocouple wire (type K) installed
Cooperheat Thermocouple Attachment Unit (TAU) (Capacitive Discharge Welder)
2. Attach Type K thermocouple using a Thermocouple Attachment Unit (TAU)(Capacitive

Discharge Welder) in a suitable location, unaffected by arc air and grinding debris. A good
location is typically the midpoint of the crack length and midway between one of the FCPs
and the crack. See Illustration 10 for the thermocouple location. See Illustration 11 for a
reference regarding a typical TAU.
Cooperheat bulk insulation, washers, and pins installed
3. Place insulating material over the FCPs and hold in place by using the washers that are
attached to the holding pins. The insulating material will protect personnel from the hot
FCPs and will assist with radiant heat retention. Refer to Illustration 12.
Cooperheat Coopermaster 6-way power supply with local/remote control and 12-point recorder
Close up view the remote control which is on the Cooperheat Coopermaster Coopermaster 6-way power supply
4. Attach the FCPs to main power supply and bring temperature in the designated service
area to 200 °C (392 °F) at a rate of 100 °C (212 °F) per hour. Once 200 °C (392 °F) is
reached, allow the area remain at a constant temperature of 200 °C (392 °F) for 1 hour.
After an hour at 200 °C (392 °F), bring the temperature down to 120 °C (248 °F) (which is
the minimum preheat/interpass temperature). Refer to Illustrations 13 and 14 to view a
typical Cooperheat heating unit and controller.
Alternate Preheat Method
Typical example of a TigerTorch
A TigerTorch can be used to preheat the material that is in the area to be welded. Ensure that
the weld area and 76 mm (3 inch) in each direction from the weld is preheated to the specified
temperature. Verify the preheat temperature with a 164-3310 Infrared Thermometer Gp prior to
welding. Refer to "Welding Specifications and Qualifications" and "Welding Specifications"(Table
9) sections in this document for Preheat Specifications
Crack Removal, Inspection Verification, and Joint

Preparation
Illustration of through thickness crack
(A) The crack
(B) Section thickness
Illustration of gouging profile and depth
(A) The crack
(C) Air carbon arc gouging profile
(D) A minimum of 4.0 mm (0.16 inch)
Prior to final crack removal
1. Excavate the crack by arc air gouging. Be careful not to gouge through the full thickness of
the casting wall. See Illustrations 16 and 17 for guidance on the gouging profile and depth.
Note: Use a depth gauge or a steel ruler to measure gouging depth and maintain a 4 mm
(0.16 inch) minimum amount of material for distance (D).
NOTICE
If the crack "Does Not" extend through the full thickness of the
steel casting wall, skip to the section dealing with partial
through thickness crack repair.
Final crack removal using a cutoff wheel
(D) A minimum of 4.0 mm (0.16 inch)
(E) 3.2 mm (0.125 inch) Cut off wheel
(F) Root opening of about 4.0 mm (0.16 inch)
2. Remove the final portions of the crack. Use a 3.2 mm (0.125 inch) thick abrasive cutoff
disk or wheel to achieve a consistent root opening. Since most cracks do not propagate in
a straight line, the root opening will regularly be larger than the thickness of the cutoff disk.
The objective is to have approximately a 4 mm (0.16 inch) root opening, but the opening
will occasionally be slightly larger than 4 mm (0.16 inch). Illustration 19 shows the
orientation and intent of the cutoff disk for final crack removal.
Cross sectional view of anticipated grinding
(F) Root opening of about 4 mm (0.16 inch)
(G) Finish grind to achieve 70 degree included angle.
(H) A minimum of 2.0 mm (0.08 inch)
Cross sectional view of prepared joint
(F) Root opening of about 4.0 mm (0.16 inch)
(H) A minimum of 2.0 mm (0.08 inch)
(J) is a 70 degree angle
(K) is a 35 degree angle
Longitudinal view of prepared joint
(B) Section Thickness
(H) Root face is a distance of 2.0 mm (0.08 inch).
(L) is a 45 degree angle
View of the prepared joint
Close up view of Illustration 23
127 mm (5 inch) electric grinder
178 mm (7.0 inch) pneumatic grinder with a 178 mm (7.0 inch) disc
3. Grind or sand to achieve the desired weld joint configuration. Refer to Illustrations 20,21,
and 22. The tools used to remove the crack and prepare the weld joint are shown in
Illustrations 25 and 26. Use an 80 grit sanding pad for final grinding the welds.
Note: If the crack extends at severe angles, then consider using a reciprocating saw with
metal cutting blades. Some cases may require the use of both a cutting disk and a
reciprocating saw.
Note: If the root opening is large in areas ( 5 ± .5 mm (0.20 ± 0.02 inch)), then leave a
larger root face ( 2.5 mm (0.1 inch) to 3 mm (0.12 inch)). If the root opening is tight in
areas, then reduce the root face from the nominal 2 mm (0.08 inch) to approximately
1.5 mm (0.06 inch).
Note: If the root opening is too large (greater than 5.5 mm (0.22 inch)) to obtain a good
quality open root weld, then skip to the section which deals with through thickness crack
repair using a permanent backing strip.
Magnaflux AC/DC portable magnetic yoke
4. Verify that the entire crack has been removed utilizing both visual (VT) and magnetic
particle (MT) inspection. Dry, visible magnetic particles with a color contrasting the
component will be used for in-process inspections, while the component being repaired is
preheated for the repair. Refer to Illustration 27 to view a portable magnetic yoke which is
used for the MT inspection.
5. To eliminate false indications, ensure that the area is free of debris, rough edges, and
pockets that will trap magnetic particles.
6. Place one leg of the yoke on each side of the excavated crack. Obtain good contact with
the steel casting component.
7. During the process of energizing the yoke, gently apply the dry magnetic particles with a
bulb type applicator to the crack repair area.
8. Remove the yoke from the area and visually inspect the repair area for particle indications.
9. Energize the yoke down the entire length of the excavation in increments equal to the
distance between the legs of the yoke. Apply extra particles to the area being energized.
Do not wash away the areas previously magnetized.
Note: Continue to excavate and grind the damaged area until the crack has been
removed.
Welding - Root Pass
Lincoln Electric Surface Tension Transfer (STT) MIG welder
Lincoln Electric Surface Tension Transfer (STT ) wire feeder
Note: The Surface Tension Transfer (STT) process was developed by the Lincoln Electric
Company. The STT process has been useful in various applications. One application in
particular has been for open root welding of pipe and plate. This process is achieved through
inverter technology and specially designed waveforms, which allow for heat input and weld
puddle control at relatively low current levels. The following figures provide snapshots of a
typical Invertic STT II power supply and wire feeder that are utilized at Caterpillar.
Note: The following STT welding parameters will provide the necessary heat input and arc
characteristics for good sidewall fusion with minimal root reinforcement when utilized in an open
root joint.
If the root opening is 3 mm (0.12 inch) to 4 mm (0.16 inch), then use the following settings:
Peak Current ... 280 amps
Background Current ... 60 amps
Wire Feed Speed ... 170 ipm
Tailout ... 5
Hot Start ... 5
If the root opening is 4.5 mm (0.18 inch) to 5.5 mm (0.22 inch), then use the following settings:
Peak Current ... 250 amps
Background Current ... 50 amps
Wire Feed Speed ... 150 ipm
Tailout ... 5
Hot Start ... 5
Progression of welding is vertical down utilizing a 25 degree to 45 degree travel angle with a
slight weave as necessary. Welding in a flat position can be accomplished with either the push
or pull technique using a 5 degree to 15 degree travel angle and with a slight weave.
Welding specifications
Electrode ER70S-6 ... 0.89 mm (0.035 inch)
Shielding Gas ... 75/25 (Ar/CO2) @ 40 CFH
Electrical Stickout (ESO) ... 7.938 ± 1.588 mm (.3125 ± .0625 inch)
Note: Ensure that the Voltage Sensing Lead is attached close to the repair area before welding
begins.
Note: If welding of the root pass is interrupted, taper the end (crater) of the weld using the cutoff
disk so that proper fusion of the weld tie-in exists.
STT open root pass
Refer to Illustration 30 to view an example of an STT root pass weld in the vertical position using
all the prior recommendations. The root opening varied between 4 mm (0.16 inch) to 5.5 mm
(0.22 inch) along the length of the joint preparation. The lower amperage and wire feed
parameters were utilized with a slight weave.
Welding-Fill Passes
Refer to Table 9 for guidance related to FCAW.
Placement of FCAW layer 1 weld passes after STT root pass
(A) STT root pass
(B) Fill passes two and three
Placement of FCAW passes over STT root pass
Repair completed using FCAW
Note: As opposed to vertical down welding with STT, all FCAW welds in the vertical position will
be welded with an uphill progression.
Note: Before proceeding to the final bake-out procedure, ensure that all the welding has been
completed. For example, there is adequate weld reinforcement (no underfill or concavity) and
any presence of undercut has been filled in.
1. The first fill layer ( hot pass or passes) should consist of two passes placed at either weld
toe of the root pass. Be careful not to penetrate or blow through the initial root pass.
Illustration 31 demonstrates the STT root pass and the subsequent passes, which will
depend on the thickness of the cast steel wall. Illustrations 32and 33 denote an actual
repair, showing the first layer and the completed joint. Slag shall be removed from each
pass and visually inspected for defects prior to completing the next pass.
2. Perform a final MT inspection with dry visible magnetic particles using the technique
described in the section "Crack Removal, Inspection Verification, and Joint Preparation"
Final Bake
Note: This step is necessary to remove any residual hydrogen left in and next to the weld repair
before allowing to cool to room temperature.
Cover the exposed weld repair area with extra insulating material and raise temperature to
200°C and allow repair area to maintain that same temperature for 1 hour per 25 mm
(0.984 inch) of wall thickness. After the needed time has expired, shut off the power supply and
allow the repair area to cool to room temperature.
If the "Alternate Preheat Method" (TigerTorch) is used, heat repaired area for 1 hour per 25 mm
(1 inch) of the base material thickness to the post heat treatment specification. Refer to the
"Welding Specifications" (Table 9) section in this document for post heat specification. After post
heat requirement has been met cover the repair weld with a thermal blanket to slow the cooling
rate.
Note: Due to the heat generated from welding, the temperature of the repair area may already
be at or above 200°C.
Grind to Profile
1. Remove all the heating equipment (insulation, FCPs, thermocouple, etc.) and visually
inspect area one last time. Grind excess weld metal down to contour of casting profile. Be
cautious not to reduce the casting wall thickness less than the adjacent area. Final grinding
should utilize sanding pads with a grit that will produce a smooth finished surface. Grinding
performed on the repair shown in Illustration 34 utilized 36 grit (sanding pad/disk) first,
followed by 80 grit.
2. Use a suitable tool to remove the pins that secured the flexible ceramic pads (FCP)s. Use
the blend grind technique to remove the arc strikes.
793C and 793D Ski Plate Extension

Note: The Ski Plate Extension is effective in production with machines S/N:FDB1897-UP.
This procedure applies to the extension of the upper internal ski plates to increase the load
transfer effectiveness of the center of the frame.
View of general area of the frame for which this procedure applies
Illustration 35 shows the general area of the frame for which this procedure applies. The
procedure applies to both the left-hand and right-hand side of the frame.
Fabricate Tank Mount Location Fixture for Left-Hand

Side
Note: The material required for tank mount location fixtures can be common structural steel
such as ASTM A36.
View of base plate
(A) Base plate
(AA) 188 mm (7.40 inch)
(BB) 128 mm (5.04 inch)
(CC) 30 mm (1.20 inch)
(DD) 25 mm (1.00 inch)
(EE) 1487.5 mm (58.60 inch)
(FF) 23 mm (0.91 inch) 4 places
(GG) 1537.5 mm (60.53 inch)
(HH) 20 mm (0.80 inch)
1. Use the dimensions in Illustration 36 to fabricate base plate (A).
View of the vertical plate
(B) Vertical plate
(JJ) 50 mm (2.00 inch)
(KK) 160 mm (6.30 inch)
(LL) 10 mm (0.40 inch)
2. Use the dimensions in Illustration 37 to fabricate vertical plate (B).
View of the gusset
(C) Gusset
(MM) 130 mm (5.12 inch)
(NN) 110 mm (4.33 inch)
(PP) 10 mm (0.40 inch)
3. Use the dimensions in Illustration 38 to fabricate gusset (C).
View of semi-completed fixture
(A) Base plate
(B) Vertical plate
(C) Gusset
(RR) 427 mm (16.81 inch)
(SS) 447 mm (17.60 inch)
4. Tack weld vertical plate (B) and gusset (C) to base plate (A) as shown in Illustration39.
5. Attach the semi-completed fixture to the rear tank mount (with mounting hardware) so that
the fixture lies across the front tank mount surface. The holes on the plate may not line up
perfectly with the threaded holes in the front tank mount.
View of rod
(E) Rod
(TT) 375 mm (14.76 inch)
() 25 mm (1.00 inch) diameter
6. Use the dimensions in Illustration 40 to fabricate rod (D).
View of tank mount fixture
(D) Rod
7. Position rod (D) on top of the rail section and against the fixture to capture the height of the
tank mount. Refer to Illustration 41.
8. Tack weld rod (D) fixture.
9. Remove fixture and finish weld rod (D) to the fixture.

The locating fixture will be used to relocate the front tank mount fixture after the repairs
have been completed. Illustration 41 depicts the fabricated fixture on the frame.
10. Remove tooling and set aside until repairs have been completed.
Fabricate Tank Mount Location Fixture for Right-Hand

Side
Note: The material required for tank mount location fixtures can be common structural steel
such as ASTM A36.
View of base plate
(A) Base plate
(AA) 120 mm (4.72 inch)
(BB) 82.6 mm (3.30 inch)
(CC) 18.7 mm (0.74 inch)
(DD) 30 mm (1.20 inch)
(EE) 844 mm (33.23 inch)
(FF) 20 mm (0.80 inch) 4 places
(GG) 904 mm (35.60 inch)
(HH) 20 mm (0.80 inch)
1. Use the dimensions in Illustration 42 to fabricate base plate (A).
View of the vertical plate
(B) Vertical plate
(JJ) 225 mm (8.86 inch)
(KK) 50 mm (2.00 inch)
(LL) 10 mm (0.40 inch)
2. Use the dimensions in Illustration 43 to fabricate vertical plate (B).
View of the gusset
(C) Gusset
(MM) 205 mm (8.10 inch)
(NN) 90 mm (3.54 inch)
(PP) 10 mm (0.40 inch)
3. Use the dimensions in Illustration 44 to fabricate gusset (C).
View of semi-completed fixture
(A) Base plate
(B) Vertical plate
(C) Gusset
(RR) 250 mm (9.84 inch)
(SS) 270 mm (10.63 inch)
4. Tack weld vertical plate (B) and gusset (C) to base plate (A) as shown in Illustration45.
5. Attach the semi-completed fixture to the rear tank mount (with mounting hardware) so that
the fixture lies across the front tank mount surface. The holes on the plate may not line up
perfectly with the threaded holes in the front tank mount.
View of rod
(E) Rod
(TT) 275 mm (10.83 inch)
() 25 mm (1.00 inch) diameter
6. Use the dimensions in Illustration 46 to fabricate rod (D).
View of tank mount fixture
(D) Rod
7. Position rod (D) on top of the rail section and against the fixture to capture the height of the
tank mount. Refer to Illustration 47.
8. Tack weld rod (D) to fixture.
9. Remove fixture and finish weld rod (D) to the fixture.

The locating fixture will be used to relocate the front tank mount fixture after the repairs
have been completed. Illustration 47 depicts the fabricated fixture on the frame.
View of angle iron
(E) Angle iron
(VV) 1200 mm (47.24 inch)
(WW) 32 mm (1.26 inch)
(XX) 40 mm (1.57 inch)
(YY) 56.6 mm (2.23 inch)
(ZZ) 101.6 mm (4.00 inch)
(AB) 12 mm (0.47 inch)
(AC) 101.6 mm (4.00 inch)
View of spacer
(F) Spacer
(AD) 80 mm (3.15 inch)
(AE) 32 mm (1.26 inch)
(AF) 32 mm (1.26 inch)
10. Use the dimensions in Illustration 48 and Illustration 49 to fabricate angle iron (E) and
spacer (F).
View of assembled parts
(E) Angle iron
(F) Spacer
(G) 1B-2721 Bolt
(H) 4K-0684 Hard Washer
(J) 4J-5977 Full Nut
11. Install angle iron (E) as shown in Illustration 50 using bolt (G), spacer (F), two hard
washers (H), and nut (J).
Note: Do not tighten bolt and nut all the way.
View of angle iron rotated upward into position
(E) Angle iron
12. Rotate angle iron (E) upwards until angle iron (E) contacts the bottom of the location
fixture. Tighten bolt (G) and nut (J) to secure angle iron (E) in position. Refer to Illustration
51.
View of angle iron tack welded into position
(A) Base plate
(E) Angel iron
13. Tack weld angle iron (E) to base plate (A).
14. Remove tooling and set aside until repairs have been completed.
Remove Outside Window Plate

Note: The left-hand side of the machine will be shown throughout this document. The right-hand
side is identical except for the external hardware. Both sides are to be completed at the same
time.
Note: The front tank mount has been TIG dressed at the fillet weld toe to prevent fatigue
cracking. To retain the factory TIG dressing, leave the front tank mount attached to the window
plate.
View of the left-hand side of the machine
(A) Front tank mount
(AA) 50 mm (2.00 inch) four places
View of the left-hand side of the machine
(AB) Weld joint
(AC) Weld joint
View of weld joint detail (AB)
( B) Outside window plate
(C) Internal gusset
(BB) 16 mm (0.63 inch)
(CC) 35 mm (1.40 inch)
Illustration 56
https://sis2.cat.com/#/detail? g06239633
View of weld joint detail (AC)
( D) Steel rail
(DD) 16 mm (0.63 inch)
(EE) 50 mm (2.00 inch)
NOTICE
Be cautious when removing the outside window plate. Retain as
much of the outside window plate as possible as the outside
window plate will be reused after the repair is completed.
1. Attach a suitable lifting device to the outside window plate. The approximate weight of
outside window plate with the front tank mount is 200 kg (441 lb).
2. Gouge/excavate welds securing the outside window plate as shown in Illustration 53.
Note: To assist with the removal of the outside window plate, refer to the Illustrations 55
and Illustration 56 to understand the weld joints securing the outside window plate in place.
Note: There is a 35 mm (1.40 inch) thick gusset/plate that is used for backing and
structural purposes. Refer to Illustration 55.
View of the left-hand side with the outside window plate removed
3. Illustration 57 shows the left-hand side of the machine with the outside window plate
removed.
Ski Plate Extension

To reinforce the center structure of the frame, the internal ski plates should be extended on the
top rail sections to match the bottom rail sections.
Note: Only the top left side of the frame undergoing the ski plate extension is shown in this
procedure. Completion of both top ski plate extensions at the same time is recommended.
Note: Once the outside window plate is removed, perform visual inspection and perform any
repairs prior to proceeding with the ski plate extension procedure.
Note: Refer to Special Instruction, REHS0541, "Procedure for the Inspection, Repair, and
Component Replacement of the Frames of Certain Off-Highway Trucks" for lower ski plate
extension procedure for the following machines:
3SJ1-UP
1HL1-UP
4AR1-UP
View of the top ski plate on the left-hand side of the machine
(A) Top ski plate
View of the bottom ski plate on the left-hand side of the machine
(B) Bottom ski plate
1. Illustration 58 and Illustration 59 show the location of top ski plate (A) and bottom ski plate
(B). Illustration 60 indicates top ski plate (A) will extend forward to the internal vertical
gusset plate.
View of the nose of the ski plate to be removed
(AA) Section to be removed
NOTICE
Use Caution when gouging to prevent damage to the underlying
rail section.
2. Remove section (AA) of existing ski plate (A) by gouging and grinding back to the internal
vertical gusset plate. Refer to Illustration 61.
3. Remove the fillet welds around the periphery and the fillet welds connecting ski plate (A) to
the vertical gusset. Refer to Illustration 61.
4. After gouging/grinding, sand the underlying rail surface flush. Fill any craters or divots by
welding and sanding flush.
View of extension plate fabrication
(B) Fabricated extension plate
(BB) 1770 mm (69.70 inch)
(CC) 162 mm (6.37 inch)
(DD) 45 degree angle (both ends)
(EE) 20 mm (0.80 inch)
(FF) 45 degree bevel A to B
5. Use the dimensions in Illustration 62 and fabricate two extension plates (B).
Material for the extension plates is ASTM A572 Grade 42 steel.
View of extension plate in position
(C) Weld joint detail
(D) Weld joint detail
View of weld joint detail (C)
( B) Fabricated extension plate
(E) Rail assembly
(F) 35 mm (1.40 inch) Internal gusset
(G) Existing 16 mm (0.63 inch) fillet weld
(GG) 35 mm (1.40 inch)
(HH) 6 mm (0.24 inch) (minimum)
(JJ) 45 degree angle
View of weld joint detail (D)
( B) Fabricated extension plate
(E) Rail assembly
(H) Existing plate
(J) 35 mm (1.40 inch) Internal gusset
(KK) 6 mm (0.24 inch) (minimum)
(LL) 45 degree angle
(MM) 35 mm (1.40 inch)
6. Use an appropriate lifting device and the information in Illustration 63 through Illustration
65 to position fabricated extension plate (B). The approximate weight of fabricated
extension plate (B) is 35 kg (77 lb).
Note: Install the extension plate with the long square edge facing outward.
7. Preheat is required for the thicker steel plates and castings as identified in Illustration 66.
Minimum preheat/inter-pass temperature of 100° C (212° F) and maximum inter-pass
temperature of 300° C (572° F)
View of weld details
View of weld details
(AB) Detail
(NN) 210 mm (8.30 inch)
View of detail (AB)
8. Tack weld on all four sides of extension plate (B) and then weld according to Illustrations
67 through Illustration 69.
For detail (AB), the weld is to fill the machined pocket on the volcano casting for the length
of the volcano casting. The weld will transition to the 20 mm (0.80 inch) single bevel and
12 mm (0.50 inch) fillet weld at the steel backing for 210 mm (8.30 inch), then to the
20 mm (0.80 inch) single bevel and 8 mm (0.31 inch) fillet weld. Refer to Illustration 67
through Illustration 69.
Note: If the welding is not the same on the bottom extension plate, then add more weld
until the weld is the same as the top. Refer to Illustration 68 and Illustration 69 for the three
weld call outs along the extension plate.
Note: The weld profile is shown as an approximation. The weld profile does not have to be
ground or sanded to match.
9. Inspect all welds visually to ensure that weld quality meets or exceeds the requirements
shown in the "Weld Inspection and Acceptance Criteria" Section.
10. Sand all weld starts and stops.
Install the Outside Window Plates

1. Grind the edges of the outer window plate(s) that were previously removed to clean/bright
base material.
View of the left-hand side window plate in position
(AB) Weld joint detail
(AC) Weld joint detail
View of joint detail (AB)
( A) Outside window plate
(B) Internal gusset
(AA) 16 mm (0.63 inch)
(BB) 45 degree angle
(CC) 6 mm (0.24 inch) minimum
(DD) 35 mm (1.40 inch)
View of joint detail (AC)
( C) Steel rail
(EE) 16 mm (0.63 inch)
(FF) 45 degree angle
(GG) 6 mm (0.24 inch) minimum
(HH) 50 mm (2.00 inch)
2. Use a suitable lifting device and the fabricated fixtures to locate the front tank mounts (on
the window plate), in relation to the rear tank mount (left side will be different). The
approximate weight of outside window plate with the front tank mount is 200 kg (441 lb).
Observe the resulting fit up of the four weld joints and then remove and prepare the edges
of the plate to obtain the weld joints shown in Illustration 71 and Illustration 72.
Note: You can also grind/sand a slight bevel (10 to 15 degree) on the 16 mm (0.63 inch)
window plate to provide better access for weld joint detail (AB).
View of outside window plate tack welded into position
3. Once proper fit up is achieved, secure the outside window plate into position. Weld 6 mm
(0.24 inch) fillet welds ( 50 mm (2.00 inch) length) as shown in Illustration 73.
4. Grind/taper the ends of the 6 mm (0.24 inch) fillet welds. Finish the root pass on all four
sides of the outside window plate by welding 6 mm (0.24 inch) fillet weld between all the
previously deposited 6 mm (0.24 inch) fillet welds.
View of weld completed vertical weld joints
5. Complete the welding of the vertical weld joints as shown in Illustration 74.
View of weld completed horizontal weld joints
6. Complete the welding of the horizontal weld joints as shown in Illustration 75.
7. Inspect all welds visually to ensure that weld quality meets or exceeds the requirements
shown in the "Weld Inspection and Acceptance Criteria" Section.
Note: Ultrasonically test the complete joint groove welds (weld joint details (AB) and (AC).
8. Sand all weld starts and stops and ensure that corners are slightly rounded.
Post Weld Treatment - TIG Dressing

Note: If any hardware is to be fillet welded to the outside window plate, the fillet weld toe must
be TIG dressed to prevent future cracking. The right rear side tank mount will have to be welded
and TIG dressed.
The fatigue performance of fabricated structures involving fillet welded attachments to highly
stressed members is, among other things, controlled by the profile or geometry of the weld toe.
Fatigue performance improvements can be achieved through alteration of the original, as-
welded toe profile by several post weld treatment options. This procedure describes a method
whereby an electric arc is used to reduce and/or remove unfavorable profiles/stress risers thus
creating a smooth, seamless transition from one component to the next component.
Note: Training: Anyone performing this procedure is advised to view the training video
“Post Weld Treatment: TIG Dressing Fundamentals”.
Caterpillar Channel 1 Videos
To provide clarification and details, a video has been created outlining the Post Weld - TIG
Dressing. Reviewing the video prior to performing any Post Weld - TIG Dressing.
Note: A CWS login is required to access Caterpillar Channel 1.
https://channel1.mediaspace.kaltura.com/media/Off-Highway+Truck+Post+Weld+Treatment+-
+TIG+Dressing/1_gmocv9ae
The link above contains the following video:
Post Weld - TIG Dressing
Equipment Requirements
Required Equipment
Tool Description
The power supply must be able to produce 200 amps (min. 60% duty
GTAW (TIG) Power
cycle) with a hand control or a foot control.
supply and a torch.
Polarity - DC negative
Shielding Gas 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 Pneumatic or electric with carbon steel wire wheel attachment
Grinding Wheel Aluminum Oxide
Radius gauges
Table 11
Method
1. The first steps to ensure that proper TIG dressing are cleanliness and tungsten electrode
preparation.
The fillet weld and surrounding base metal must have all contaminants thoroughly
removed. It is imperative that all paint, rust, dirt, oil scale, and silicate islands are non-
existent, remove by using a grinder with a carbon steel wire attachment.
2.4 mm (0.09 inch) Tungsten Electrode Preparation
(A) Striations or grinding marks should be parallel
(B) 2 X 3 diameter
(C) 1/4 to 1/2 diameter
2. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown
in Illustration 77. The grinding marks should run parallel to each other.
3. Adjust the shielding gas flow rate to 15 - 25 CFH. Adjust the current control to
approximately 200 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. Several different techniques exist for TIG dressing 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 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.
Stringer Technique
(D) 0 degree work angle
Note: Use a 10 degree to 15 degree push angle for the stringer technique.
5. Illustration 78 represents the stringer technique of welding. The center of the arc needs to
be 0.0 - 2.0 mm (0.0 - 0.08 inch) from the weld toe into the base material.
Weave Technique
(E) 0 degree to 45 degree work angle
Note: Use a 10 degree to 15 degree push angle for the weave technique.
6. Illustration 79 represents the weave technique of welding.
7. Illustration 80 represents an acid etched, cross section view of a TIG dressed weld toe.
8. Illustration 81 and Illustration 82 demonstrate the expected results.
9. Once TIG dressing is completed, the area needs to be cleaned and painted to prevent
pitting due to corrosion.
Note: Poorly shaped fillet welds with 90 degree to 100 degree transition angles to the base
material will require several overlapping TIG dressing runs to smooth out the weld toe
transition region.
Note: TIG dressing can be conducted in the vertical position as long as the TIG dressing is
performed in a downhill progression.
Note: If undercut or other circumstances require the addition of filler metal. Adding filler
metal can be accomplished by hand feeding ER70S-2 1.6 mm (0.06 inch) into the weld
pool. You then repeat the TIG dressing to achieve the desired toe radius and the desired
profile.
10. Inspect using a radius gage to ensure a 5 mm (0.20 inch) minimum radius.

To provide addition clarification and details, videos have been created outlining the Ultrasonic
(UT) testing process. Reviewing the videos is recommended prior to performing any Ultrasonic
(UT) testing.
Note: A CWS login is required to access Channel 1 Videos.

Media
CATU1247
Number:
Title: Ultrasonic Inspections of Welds
Channel 1 https://channel1.videonitch.com/LearningPrograms/Pass/5006?
URL: CategoryID=456
Table 12
The link referenced in Table 12 contains the following videos:
1. UT Introduction
2. UT Certifications and Safety
3. UT Equipment
4. UT Calibration
5. UT Techniques
6. UT Reporting Results
Requirements for Ultrasonic (UT) Testing

Personnel
Personnel performing and signing off on the inspections will be at least Level II Certified
Technicians in the Ultrasonic Testing method, as defined by ASNT SNT-TC-1A, ASNT CP-189,
or other equivalent international standard.
Personnel performing the inspections will be trained by a Level II or Level III, until the personnel
show proficiency and understanding of procedures and rejection criteria.
Apparatus
Ultrasonic (UT) Instrument
The UT flaw detection instrument shall be capable of generating, receiving, and amplifying high-
frequency ultrasound pulses at such frequencies and energy levels required to perform a
meaningful examination and provide suitable readouts.
Preferred functions/features include but not limited to: inspection program recording, signal
gating system, measurement data display, DAC/TCG recording, and 0 Db Reference.
UT instrument certification/qualification should be performed annually according to ASTM E317

or equivalent. Including the verification of key performance characteristics, such as horizontal
limit and linearity, vertical limit and linearity, resolution - entry surface and far surface, sensitivity
and noise, accuracy of calibrated gain controls.
Straight Beam/Longitudinal Wave Search Unit

The ultrasonic transducer (probe, or search unit) shall be capable of transmitting and receiving
ultrasound at the required frequencies and energy levels necessary for discontinuity detection in
the material being examined. Frequencies of 4 MHz to 5 MHz shall be employed for straight
beam longitudinal wave inspection.
Transducer crystal can be round, square, or rectangular. Crystal size recommended for weld
examination shall be in the range of 9 mm (0.35 inch) to 13 mm (0.50 inch).
Angle Beam/Shear Wave Search Unit

The ultrasonic transducer (probe, or search unit) shall be capable of transmitting and receiving
ultrasound at the required frequencies and energy levels necessary for discontinuity detection in
the material being examined. Frequencies of 2 MHz to 5 MHz shall be employed for angle-beam
shear wave inspection.
Transducer crystal can be round, square, or rectangular. Crystal size recommended for weld
examination shall be in the range of 9 mm (0.35 inch) to 25 mm (1.00 inch). In this procedure a
smaller footprint wedge will be utilized because of limited pull-back, rough surfaces, etc. Ideally
on some welds a .375” diameter transducer with a short approach type angle beam wedge
should be used if available.
Selection of a transducer is determined by testing variables. Testing variables include weld

thickness, testing surface, acceptable flaw size, flaw orientation, and the acoustic properties of
the metal.
In angle-beam inspection, the wedge/shoe is attached to the transducer to generate the desired
incident beam angle and wave mode in the parts. The common beam angles used in weld
inspection are 45°, 60°, and 70°. The refracted angle shall be no greater than ± 2° from normal.
The edge distance shall not exceed 25 mm (1.00 inch). The wedge angles shall be selected
according to information found in the ""Probe Selection" " section
Couplant
Couplant is required between the face of the search unit and the examination surface. Couplant
permits the transmission of ultrasonic waves from the search unit into the material under
examination.
Typical couplants include cellulose gel, glycerin, and light machine oil. Corrosion inhibitors or
wetting agents may be added. Couplants must be selected that are not detrimental to the
product or the process. Special couplant and search unit may be required at elevated
temperatures (above 52° C (125° F).
Distance Calibration Blocks

Refer to ASTM E164 for two options of distance calibration blocks, other suitable blocks may be
used.
Option 1: IIW Type 1 or Type 2 Block
Option 2: DSC Block
Sensitivity Calibration Blocks

Two options for sensitivity calibration blocks are given but other blocks may be used. Minimum
requirements shall meet the requirement determined in the "Sensitivity Calibration" section.
For other sensitivity blocks: 1.5 mm (0.06 inch) side-drilled- holes (SDH) parallel to the
inspection surface and perpendicular to the sound path shall be used as the calibration target.
Option 1: Cat® DAC Block
(A) 340 mm (13.40 inch)
(B) 90 mm (3.55 inch)
(C) 40 mm (1.60 inch)
(D) 1.5 ± 0.05 mm (0.05 ± 0.001 inch) diameter SDH's
(E) 10 ± 0.1 mm (0.40 ± 0.004 inch)
(F) 20 ± 0.1 mm (0.80 ± 0.004 inch)
(G) 30 ± 0.1 mm (1.20 ± 0.004inch)
(H) 40 ± 0.1 mm (1.60 ± 0.004 inch)
(J) 63 ± 0.1 mm (2.50 ± 0.004 inch)
(K) 126 ± 0.1 mm (5.0 ± 0.004 inch)
(L) 189 ± 0.1 mm (7.40 ± 0.004 inch)
(M) 252 ± 0.1 mm (9.90 ± 0.004 inch)
Option 1: Cat® DAC Block 1.5 mm (0.06 inch) SDH's at 10 mm (0.40 inch) steps from the
surface to include all depths over all thickness ranges to be used.
Use the dimensions in Illustration 85 to fabricate Cat® DAC Block use ASTM A572 Grade 42/50
steel.
Option 2: Cat® t Blocks
(N) 200 mm (8.0 inch)
(P) 16 mm (0.60 inch)
(R) 40 mm (1.60 inch)
(S) 1.5 ± 0.05 mm (0.05 ± 0.001 inch) diameter SDH's
(T) 4 ± 0.1 mm (0.16 ± 0.004 inch)
(U) 8 ± 0.1 mm (0.30 ± 0.004 inch)
(V) 20 ± 0.1 mm (0.80 ± 0.004 inch)
(W) 160 ± 0.1 mm (6.30 ± 0.004 inch)
Option 2: Cat® t Blocks
(X) 200 mm (8.0 inch)
(Y) 50 mm (2.0 inch)
(Z) 40 mm (1.60 inch)
(AA) 1.5 ± 0.05 mm (0.05 ± 0.001 inch) diameter SDH's
(BB) 12.5 ± 0.1 mm (0.50 ± 0.004 inch)
(CC) 25 ± 0.1 mm (1.0 ± 0.004 inch)
(DD) 20 ± 0.1 mm (0.80 ± 0.004 inch)
(EE) 160 ± 0.1 mm (6.30 ± 0.004 inch)
Option 2: Cat® t Blocks: Blocks the same material and thickness as the parts to be tested.
Machined 1.5 mm (0.06 inch) SDH's at 1/4t and 1/2t depths. Blocks must be long enough for full
skip path and wide enough for the entire search unit to sit on the scanning surface.
Use the dimensions in Illustration 86 and Illustration 87 to fabricate Cat® t Blocks use ASTM
A572 Grade 42/50 steel.
Sample Preparation
Surface Preparation
The surface must have contour allowing the close coupling between the search unit and
scanning surface.
The inspection surface shall be free of loose scale, loose paint, weld spatter, dirt, excessive
roughness, or other foreign objects that would interfere with the transmission of sound energy
from the search unit into the part. Cleaning and/or grinding may be needed.
Ultrasonic (UT) Testing

Equipment Calibration
In addition to the annual UT equipment certification/qualification, periodical calibration or
standardization is required to verify that UT equipment is performing as intended for day-to-day
usage.
Straight Beam Calibration

Distance Calibration: The distance and sensitivity calibration should be verified by the UT
operator.
Recalibration shall be made a minimum of every 8 hours or process change, such as changing
operator, search unit and/ cable, battery, testing weld, and recouple search unit.
To ensure the accuracy of locating weld discontinuities, the distance shall be calibrated through
the entire sound path used during the specific examination.
The 25 mm (1.00 inch) (position G Illustration 83) and 100 mm (4.00 inch) (position E Illustration
83) thicknesses on the IIW-type reference block are commonly used for distance calibration in
straight beam applications.
Position the UT probe toward the 25 mm (1.00 inch) thickness. Set the proper range in the
instrument to ensure the second reflection from the 100 mm (4.00 inch) thickness can be
displayed.
To obtain meaningful readings, other instrument settings, such as probe angle, gate, and gain
level shall be properly selected.
Sensitivity Calibration
1.5 mm (0.06 inch) side-drilled-holes (SDH) parallel to the inspection surface and perpendicular
to the sound path shall be used as the calibration target.
DAC/TCG - DAC (distance-amplitude-correction) or TCG (time corrected gain): The signal

from the 1.5 mm (0.06 inch) SDH should be calibrated to be 80% FSH (full-screen height) for the
first point of a DAC curve and all points for the TCG. DAC and TCG shall be used to ensure the
same inspection sensitivity at different sound paths across the entire range.
Minimum of three points shall be used to establish the DAC/TCG, over the entire range for the
thickness being tested.
Use Sensitivity Calibration Blocks Option 1 or Option 2 described in the "Sensitivity Calibration
Blocks" section.
Example DAC/TCG set-up for a 50 mm (2.00 inch) thick rail section using straight beam using
the Cat® DAC Block use the 10 mm (0.40 inch), 30 mm (1.20 inch), and 50 mm (2.00 inch)
holes.
Angle Beam Calibration

Distance Calibration: The distance and sensitivity calibration should be verified by the UT
operator.
Recalibration shall be made a minimum of every 8 hours or process change, such as changing
operator, search unit and/ cable, battery, testing weld, and recouple search unit.
Verify the Beam Index Point: (The following example is conducted on a IIW Type Block.)
Position the UT probe toward the 100 mm (4.00 inch) radius on the IIW-type reference block.
Set proper range in the instrument to ensure that the signal from the 100 mm (4.00 inch) radius
is displayed. Scan the search unit back and forth to peak the 100 mm (4.00 inch) signal. The
point on the search unit wedge aligning with the 0 reference line on the calibration block is the
beam index/entry point (position D in Illustration 83).
Verify the Beam Angle: Position the search unit toward the Lucite/open window on the IIW-type
reference block.
Set proper range in the instrument to ensure that the signal from the Lucite/open window is
displayed. Scan the search unit back and forth to peak the signal.
The angle marked on the reference block in line with the search unit index point is the actual
beam angle. The beam angle tolerance shall be within ± 2°. Depending on the beam angle and
the type of reference block, other techniques recognized by related industrial standards may be
used (position B or C in Illustration 83).
Distance Calibration: To ensure the accuracy of locating weld discontinuities, the distance shall
be calibrated through the entire sound path used during the specific examination.
A minimum of two distances will be required to calibrate for distance. 100 mm (4.00 inch) radius
on the IIW-type reference block is commonly used for distance calibration in angle beam
applications (position D in Illustration 83). Depending on the type of IIW block the second radius
could be 25 mm (1.00 inch) machined notch or a 50 mm (2.00 inch) machined notch into the
100 mm (4.00 inch) radius or a straight notch at the 0 reference line. The 0 reference line type
IIW block is described below.
Position the UT probe toward the 100 mm (4.00 inch) radius. (position D in Illustration 83). Set
the proper range in the instrument to ensure the second reflection from the 100 mm (4.00 inch)
radius can be displayed.
To obtain meaningful readings, other instrument settings, such as gate location and gain level
shall be properly selected.
Sensitivity Calibration
1.5 mm (0.06 inch) side-drilled-holes (SDH) parallel to the inspection surface and perpendicular
to the sound path shall be used as the calibration target.
DAC/TCG - DAC (distance-amplitude-correction) or TCG (time corrected gain): The signal

from the 1.5 mm (0.06 inch) SDH should be calibrated to be 80% FSH (full-screen height) for the
first point of a DAC curve and all points for the TCG. DAC and TCG shall be used to ensure the
same inspection sensitivity at different sound paths across the entire range.
Minimum of three points shall be used to establish the DAC/TCG, over the entire range, and a
full skip distance for the material thickness being tested.
Use Sensitivity Calibration Blocks Option 1 or Option 2 described in the "Sensitivity Calibration
Blocks" section.
Example for DAC/TCG set-up for a 16 mm (0.60 inch) thick weld joint using 70° wedge using the
Cat® DAC Block use the 10 mm (0.40 inch), 20 mm (0.80 inch), and 30 mm (1.20 inch) holes.
Example for DAC/TCG set-up for a 16 mm (0.60 inch) weld joint using 70° wedge using the
Cat® t block. Use the 1/4t hole, 3/4t hole, and the 7/4t hole.
Reference Reflector: When, a single 16 mm (0.60 inch) Reference Reflector (refer to AWS
D1.1) is used to attain a horizontal reference-line height indication. The maximum Db level used
to obtain an 80% FSH peak signal shall be recorded as the Reference Gain Level.
An attenuation factor for indication interpretation will have to be used to compensate for
attenuation of the sound beam as the sound beam propagates though the material. An
Indication Rating should be calculated for the basis of Acceptance or Rejection.
Scan Pattern, Scan Distance, and Scan Speed
(FF) Scan distance less than 150 mm (6.0 inch) per second
(GG) First leg
(HH) Second leg
(JJ) Weld center line
(KK) Scan pattern
(LL) Scanning advance (not to exceed 75% of search unit width)
(MM) Oscillating angle ± 15°
(NN) Search unit
The entire volume of weld and HAZ (heat affected zone) shall be examined from each side of
the weld wherever practical. Examination shall be made in first and second leg wherever
possible. Scan speed shall be less than 150 mm (6.0 inch) per second unless the inspection
procedure specifies differently.
The typical inspection configuration for a butt weld is shown in Illustration 88.
To detect longitudinal discontinuities. The search unit shall be oscillated to the left and right with
an angle of approximately ± 15° while continuously scanning perpendicularly to the weld axis.
The lateral movement advancing the search unit shall not exceed 75% of the search unit width.
To ensure full volume coverage. The scan distance shall cover at least 1 full skip path (first and
second leg) back from the weld center line. To detect transverse discontinuities, the sound beam
shall be directed at approximately 15° parallel to the weld axis. The search unit shall be moved
along the weld edge from both sides and from opposite directions.
Initial Surveillance Scanning

For initial scanning, extra gain (6dB or 12dB) may be required to facilitate detection of potential
discontinuities. The evaluation of the indication shall be performed back to the reference
sensitivity.
Probe Selection
Weld Thickness Wedge Angle(1) Range(2)
6 mm (0.25 inch) thru 20 mm (0.80 inch) 70 100
Table 13
(1)
(2) Multiple wedge angles can be used for thicknesses outside guideline.
Range setting should be adjusted accordingly to have a full skip path on the screen.
Acceptance/Rejection Criteria and Sizing
(AB) Search unit
(AC) Search unit
(AD) Search unit
(AE) Distance between (L1) and (L2)
( AF) Signal amplitude
(AG) Amplitude profile
(AH) Threshold
(AJ) 50% threshold
(AK) Search unit position
(L) Length of indication over the threshold
(LR) Length of indication over the 50% threshold
(L1) Longer discontinuity
(L2) Shorter discontinuity
Note: Adjacent discontinuities: when (AE) is smaller than the designated minimum length ( (AE)
< (L1) or a specific length), the two discontinuities shall be regarded as continuous and the
overall length is (L1) + (AE) + (L2).
Subsurface internal weld quality will meet the requirements set forth by Table 13. To determine
the rejectable lengths of indications that meet or exceed the 1.5 mm (0.06 inch) SDH reverence
level:
An indication that meets or exceeds the reference level (DAC, TCG, or 0 Reference Level)
continuously for 25 mm (1.0 inch) or 10% of the weld length whichever is less is rejectable.
Intermittent indications that do not meet the criteria but the aggregate length of the indications
exceed 10% of total weld length is rejectable. Indications below 5 mm (0.20 inch) in length are
not typically included in the aggregate indication length.
In determining the ends of rejectable indications. The 6dB drop method shall be used, with the
flaw detector sensitivity set to the reference level (0dB). Move the search unit parallel to the weld
until the tip of the signal drops to 50% of the DAC height. Mark the weld even with the center of
the search unit. Move the search unit parallel to the weld in the opposite direction until the signal
drops to 50% of the DAC height. Mark the weld even with the center of the search unit.
Acceptability of welds with multiple defective areas. If the space between two defective areas is
less than the largest defect length, the area between the two defective areas shall also be
considered rejectable and should be marked for repair. Refer to Illustration 89.
Procedure to Rework the Belly Pan on the 793D

Off-Highway Truck
This Special Instruction contains general information and procedures that can be referenced to
rework the belly pan bracket assemblies (steering box brackets and the bumper brackets).
Required Parts
Required Parts to Re-Work the Belly Pan
Item Qty Part Number/Description
1 2 295-3031 Plate(1)
2 1 295-3029 Plate(1)
3 1 521-6060 Plate(1)
4 3 521-6061 Plate(1)
5 12 8T-4140 Bolt
6 12 176-5311 Locknut
Table 14
(1)
Dealer Fabricated Part
Required Part Fabrication
View of plate 295-3031 Plate
(1) Plate
1. Use the dimensions in Illustration 90 and fabricate two plates (1).
(2) Plate
2. Use the dimensions in Illustration 91 and fabricate plate (2).
(3) Plate
3. Use the dimensions in Illustration 92 and fabricate plate (3).
(4) Plate
4. Use the dimensions in Illustration 93 and fabricate three plates (4).
Removal Procedure
Top view of the belly pan guards
(A) Guard
(B) Spacer
(C) Hard washer
1. Use a suitable lifting device and remove three guards (A). Retain three guards (A), 12
spacers (B), and 12 hard washers (C).
Note: The approximate weight of guard (A) is 46 kg (101 lb).
View of plates on the steering box and bumper
(D) Plate
(E) Plate
2. Before removing plates (D) and plates (E), use the center two holes on existing plates to
transfer the center of the holes onto the steering box and onto the bumper. These
references will be used to relocate the new brackets. Refer to Illustration 95.
View of plates on the steering box and bumper
(D) Plate
(E) Plate
NOTICE
Use caution to avoid damaging the base material when
removing the plates.
3. Remove the fillet welds and J-groove welds securing three plates (D) to the steering box
and three plates (E) to the bumper.
Note: When removing the plates, favor the plates to avoid damaging the base material.
4. Fill and blend sand any imperfections, back to profile.
Installation Procedure
1. Prep the surface of the bumper and the steering box for the plate installation.
2. Install plate (3) onto the bumper. Align center holes on plate (3) with references transferred
in Step 2 of the "Removal Procedure" 30 mm (1.20 inch) from the bottom of the bumper.
Note: Tack weld plate (3) into position. Only tack weld on the top of plate (3).
View of the plate on the front bumper
(AA) 30 mm (1.20 inch)
(3) Plate
3. Use the weld dimensions in Illustration 98 and weld plate (3) into position.
(BB) 47 ± 3 mm (1.90 ± 0.12 inch)
(CC) 88.5 ± 3 mm (3.50 ± 0.12 inch)
(DD) 47 ± 3 mm (1.90 ± 0.12 inch)
(3) Plate
(4) Plate
(4) Plate
4. Use the dimensions in Illustration 99 to install three plates (4) use the weld dimensions in
Illustration 100 to weld plates (4) into position.

View of the plate on the steering box
(EE) 15 mm (0.60 inch)
(2) Plate
5. Install plate (2) onto the steering box. Align center holes on plate (2) with references
transferred in Step 2 of the "Removal Procedure" 30 mm (1.20 inch) from the bottom of the
bumper.
Note: Tack weld plate (2) into position. Only tack weld on the top of plate (2).

(FF) 299.5 mm (11.80 inch)
(1) Plate
(2) Plate
(1) Plate
(2) Plate
6. Use the dimensions in Illustration 102 to install two plates (1) use the weld dimensions in
Illustration 103 to weld plates (1) and plate (2) into position.
Note: Do not weld on the bottom of plate (2).
7. Use a suitable lifting device and install three guards (A). Secure guards (A) using 12 bolts
(5), 12 locknuts (6), 12 spacers (B), and 12 hard washers (C). Guards (A), spacers (B).
and hard washers (C) were retained in Step 1 of the"Removal Procedure".
Note: The approximate weight of guard (A) is 46 kg (101 lb).
Rear Support Assembly Replacement

Procedure
View of rear support
Required Parts
Required Parts
Qty Part Number/Description
496-3010 Rear Support
1
Approximate Weight 2158 kg (4758 lb)
Table 15
Fabrication (If Required)

Dimensions to fabricate 418-3596 Plate
1. If required use the dimensions in Illustration 106 to fabricate 418-3596 Plate.


Dimensions to fabricate 150-3980 Bar
5. If required use the dimensions in Illustration 110 to fabricate 150-3980 Bar.
General Information
NOTICE
The frame assembly will require bracing and restraint to prevent
movement during removal, installation, and welding.
Note: The new 496-3010 Rear Support has different weld joint geometry.
A 125° C (257° F) minimum preheat/inter-pass temperature is required for any welding on steel
castings, the 50 mm (2.0 inch) top and bottom rail sections, and the rear support. All other
components can be welded at room temperature 20° C (68° F). Maximum inter-pass
temperature is 300° C (572° F).
When preheating by flame, the heat source should be removed for at least 1 minute/inch of
thickness and the temperature should be measured 75 mm (3.0 inch) from the center of the weld
joint.
Weld starts/stops within a multi-pass weld shall be staggered and ground.
Inspection Methods:
VT (Visual Testing)
MT (Magnetic Particle Testing)
UT (Ultrasonic Testing)
Bracing the Frame

Material required for bracing the frame is ASTM A500-Grade B, 4 inch square tubing - 1/4 inch
wall. A combined length of 12 ft of tubing will be required for bracing the frame.

Dimensions for fabrication
(AA) 1760 mm (69.30 inch)
(BB) 15.7 degree angle (2 places)
(CC) 101.6 mm (4.0 inch)
(DD) 101.6 mm (4.0 inch)
1. Use the dimensions in Illustration 111 and fabricate two square tube braces.

View of bracing location dimensions
(A) Vertical weld seam
(EE) 65 mm (2.60 inch)
(FF) 245 mm (9.65 inch)

View of the bracing installed
2. Use the dimensions in Illustration 112 to locate the bracing. The measurements are rough
locations, adjust accordingly to stay away from any hardware on the frame.
Note: The bracing will be installed in an X-configuration towards the rear of the frame to
maintain the distance between the rails while the support assembly is removed. Refer to
Illustration 113.
3. Remove the paint at the locations where the bracing will connect to the frame.
4. Install the bracing in the X-configuration and tack weld into position.

View of weld dimensions for securing braces to the frame
5. Use the weld dimensions in Illustration 114 to secure braces to the frame.
Hardware Removal
View of hardware to be removed and retained (both sides of the frame)
(A) 296-6845 Plate
(B) 150-3980 Bar
1. Remove and retain plate (A) and bar (B) from both the left-hand and right-hand side of the
frame. This hardware is being removed to allow access for the locating device to be
installed.
Note: Use care when removing these parts, so that these parts can be reinstalled later
during the procedure.
Locating Fixture

View of C-Channel
(C) C-Channel
(AA) 2438 mm (96.00 inch)
(BB) 6.4 mm (0.25 inch)
(CC) 45 mm (1.80 inch)
(DD) 200 mm (8.00 inch)
(EE) 100 mm (4.00 inch)
(FF) 12.5 mm (0.50 inch) Radius
(GG) 103.4 mm (4.10 inch)
1. Use the dimensions in Illustration 116 to fabricate two C-Channel locating fixtures.
Note: Use standard 203 mm (8.00 inch) C-Channel (ASTM A36).
View spacer plate
(D) Spacer plate
(HH) 100 mm (4.00 inch)
(JJ) 1200 mm (47.00 inch)
() 8 mm (0.310 inch)
2. Use the dimensions in Illustration 117 to fabricate four spacer plates. The spacer plate will
connect the C-Channel to the frame.
Note: Use ASTM A572 Gr 42/50 or equivalent material.

View of locating fixture pin
(E) Pin
(LL) 25 mm (1.00 inch)
(MM) 335 mm (13.20 inch)
(NN) 47 mm (1.90 inch)
(PP) 10 mm (0.40 inch)
(RR) 200 mm (8.00 inch)
(SS) 131.528 ± 0.07 mm (5.1783 ± 0.0028 inch)
(TT) 25.4 mm (1.00 inch)
(UU) 16.8 mm (0.70 inch) Tap 1/2 - 13
(VV) 2 mm (0.08 inch) Chamfer 3X
3. Use the dimensions in Illustration 118 to machine two pins.

Note: The pin material is AISI 4140 or equivalent material.
Note: The handle on the pin can be made from any available round stock.
Note: 1 inch shoulder x 2 inch shoulder length x 3/4 inch - 10 thread shoulder bolts.

View of spacer
(F) Spacer
(WW) 200 mm (8.00 inch)
(XX) 25 mm (1.00 inch)
(YY) 25 mm (1.00 inch)
(ZZ) 2 mm (0.08 inch) Chamfer 2 places
4. Use the dimensions in Illustration 119 to fabricate two spacers.
Note: Use ASTM A572 Gr 42/50 or equivalent material.

View of locating fixture on the frame
(C) C-Channel
(D) Spacer plate
(E) Pin
(F) Spacer
5. Refer to Illustration 120 for an example of how locating fixture is installed onto the frame.

View of the paint and weld removal
6. Remove the paint in the area where the spacer plate will be welded to the frame as shown
in Illustration 121.
View of weld joint detail
(G) Window plate
(H) Support casting
(AB) 16 mm (0.63 inch)
(AC) 30 degree angle
7. Remove the section of weld on the outside window plate as shown in Illustration 121. Refer
to Illustration 122 for weld joint detail for excavating the joint.

View of pin installed
(E) Pin
8. Use a suitable lifting device to insert pins (E) into both bore holes for the rear support. The
approximate weight of the pin is 39 kg (86 lb).
9. Align spacer and use a suitable lifting device to align the C-Channel and secure with
shoulder bolt. The approximate weight of the C-Channel is 36 kg (80 lb).
Note: Do not tighten shoulder bolts until you are ready to locate the C-Channel onto the
frame.
View of locating the C-Channel
(AD) 200 mm (8.00 inch)
10. Use a suitable lifting device to swing C-Channel (C) to approximately 200 mm (8.00 inch)
onto the frame area that the paint was removed. Refer to Illustration 124.

View of weld dimension for C-Channel and spacer plates
(C) C-Channel
(D) Spacer plate
View of location fixture in position on the RH side of the frame
11. Secure C-Channel (C) in position with spacer plates (D) on the top and the bottom. Weld
spacer plates (D) onto C-Channel (C) and to the frame. Refer to weld dimensions in
Illustration 125.
Note: Illustration 126 shows the locating fixture in position on the RH side of the frame.
Removal of the Rear Support Assembly

View of the vertical weld joint details
(AA) 16 mm (0.63 inch)
(BB) 30 degree angle
(CC) 16 mm (0.63 inch)
(DD) 3 mm (0.12 inch)

View of the J-groove weld joint detail
(EE) 16 mm (0.63 inch)
(FF) 30 degree angle
(GG) 8 mm (0.31 inch) minimum
(HH) 50 mm (2.00 inch)
1. Refer to Illustration 127 and Illustration 128 for the weld joint details for the window plates.
Note: The bevel on the window plate is on both sides.
View of RH side window plate
(A) RH side window plate

View of LH side window plate
(B) LH side window plate
2. Attach a suitable lifting device and remove and retain RH side window plate (A) and LH
side window plate (B) using gouging and grinding. The approximate weight of the window
plates is 37 kg (82 lb).
Note: The window plates will be reused, so use care when removing.
View of internal plates on the LH side
(C) Plate
(D) Plate
3. Remove and retain internal plates by removing the fillet welds securing internal plates (C)
and (D) to the LH side of the frame.

View of internal plates on the RH side
(E) Plate
(F) Plate
4. Remove and retain internal plates by removing the fillet welds securing internal plates (E)
and (F) to the RH side of the frame.
5. Attach a suitable lifting device to support the rear support assembly. The approximate
weight of the rear support assembly is 2158 kg (4758 lb).

View of the internal fillet welds to remove
(JJ) 100 mm (4.00 inch)
NOTICE
Do not gouge too deep into outer window plate when removing
the fillet welds.
6. Remove the internal fillet welds shown in Illustration 133. Remove the fillet weld 100 mm
(4.00 inch) past the edge of the rear support integral backing on the top and bottom.
View of the outside J-Groove welds
Note: Ensure that a suitable lifting device is attached to the rear support assembly,
before removing the outside J-groove welds.
7. Remove the remaining J-groove welds securing the rear support assembly on the outside
of the frame from A to B (on the LH and RH side). Ensure that the welds are excavated
100 mm (4.00 inch) beyond the 50 mm (2.00 inch) groove weld.

View of the 50 mm (2.00 inch) groove welds

View of the 50 mm
https://sis2.cat.com/#/detail? (2.00 inch) groove weld joint detail
(LL) 45 degree angle
(MM) 16 mm (0.63 inch)
NOTICE
Do not cut into the top and bottom rails when cutting the 50 mm
(2.00 inch) groove welds.
8. Cut the four 50 mm (2.00 inch) groove welds beyond center towards the rear support
assembly side of the welds. Refer to Illustration 136 for weld joint detail for all four 50 mm
(2.00 inch) groove welds.

View of the frame with the rear support assembly removed
9. Ensure that a suitable lifting device is attached to the rear support assembly and remove
the shoulder bolts securing the locator pins and spacers, then the rear support assembly
can be removed from the frame. Illustration 137 shows the rear support assembly
removed.

View of the areas to blend
10. Clean the frame rails with grinder/sander removing and filling any imperfections resulting
from the cutting process. Fill all imperfections with weld material and sand back to original
profile.
Locating the New Rear Support Assembly

Required Parts
Required Parts
Item Qty Part Number/Description
496-3010 Rear Support
1 1
Approximate Weight 2158 kg (4758 lb)
Table 16

View of locating the new rear support
(1) 496-3010 Rear Support
1. Attach at suitable lifting device to rear support (1), aligning the rear support to match the
angle of the frame assembly.
Note: The approximate weight of rear support (1) is 2158 kg (4758 lb).
Note: Leave suitable lifting device attached until rear support is secured to the frame.
2. Test fit rear support (1) before installing locator pins. If integral backing has gaps greater
than 2 mm (0.08 inch), remove rear support (1), build up by welding, and blend sand areas
to minimize gaps.

View of rear support in position to be pinned
(E) Pin
(F) Spacer
View of shoulder bolts securing rear support to location fixture
3. With the gaps minimized and rear support in position, use a suitable lifting device to insert
pins (E), spacers (F) and secure to locating fixture using shoulder bolts.
Note: The approximate weight of pins (E) is 39 kg (86 lb).

View of gaps equalized and tack weld locations
4. Equalize the remaining gaps on the integral backing on rear support (1) and tack weld in
the joints identified by the arrows in Illustration 142.
Welding
Examples of run on/run off tabs and a repair in process using run on/run off tabs
Note: For repairs made on plates with open ends (such as the corners), attach run on/run off
tabs to place weld starts on tabs and outside of finished weld. Lack of fusion defects associated
with weld starts and crater cracks associated with weld craters will then be non-existent when
tabs are removed. After welding and inspection have been completed, cut off most the tabs
(about 3 mm (0.12 inch) from the edge of the connection) and sand the remaining to the profile
of the adjacent parts.

View of the internal fillet welds
1. Weld the 12 mm (0.5 inch) fillet welds on the internal side of the frame. Balance the welds
between both sides, top and bottom. Refer to Illustration 144.
View of the top bottom groove welds
2. Install run on/run off tabs onto all four 50 mm (2.00 inch) V-Groove weld joints. Weld each
joint 25% of the final weld volume.
3. Remove the suitable lifting device from the rear support.
4. Finish welding the 50 mm (2.00 inch) V-Groove welds.

View of internal fillet welds
5. Weld the internal 12 mm (0.50 inch) fillet welds as shown in Illustration 146. Weld the
internal welds on both sides of the frame.
6. Visually inspect internal fillet welds to the "Weld Inspection and Acceptance Criteria"
Section in this document.
View of internal plate welds
7. Install and weld the internal plates which were retained in Step 4 of the "Removal of the
Rear Support Assembly" Section. Refer to Illustration 147 for weld details.

View of inside window plate
8. Attach a suitable lifting device and install RH side window plate (A) and LH side window
plate (B) retained in Step 2 of the "Removal of the Rear Support Assembly" Section.
Equalize the root openings all the way around. Refer to Illustration 148 for weld details.
The approximate weight of the window plates is 37 kg (82 lb).
View of locating fixture removed and blend sanded to profile
9. Use a suitable lifting device and remove the locating fixture. The approximate weight of the
C-Channel is 36 kg (80 lb) and the pin is 39 kg (86 lb). Blend sand the window plate to
profile.

View of the rear support in position
10. Finish welding the rear support. Refer to Illustration 150 for weld details.
11. Visually inspect all welds to the "Weld Inspection and Acceptance Criteria" Section in this
document.
Procedure to Inspect, Repair, or Replace the

Engine Cross Tube Assembly
Note: Depending on the location of the crack repair, removal of the engine cross tube assembly
may be required. Leaving the engine cross tube assembled is recommended to aid in
maintaining component dimensional conformance post repair.
View of the engine cross tube location
(A) Engine cross tube assembly
Illustration 151 shows the location of engine cross tube assembly (A).
Cracks may develop on engine cross tube assembly (A) over the life of the component.
Inspection and evaluation are required to determine if engine cross tube assembly (A) can be
repaired or requires replacement, due to trepidation on the durability of the weld repair.

View of cracking locations
If cracks are found during the 500-hour inspection, inspect engine cross tube assembly (A)
before considering whether to repair or replace engine cross tube assembly (A). Inspect the
ends thoroughly where engine cross tube assembly (A) is welded to the end plates. Inspect all
hardware attachments that are welded to engine cross tube assembly (A). Utilize magnetic
particle inspection (MT) or dye penetrant inspection (PT) to verify or validate indications that are
found during visual inspection (VT). Illustration 152 shows examples of cracking that can occur.
Engine Cross Tube Assembly Attachment/Hardware

Weld Repair
View of the engine cross tube assembly and hood support brackets
(B) Hood support brackets
(C) Air intake mounting brackets
1. The larger welded attachments, hood support bracket (B), and air intake mounting
brackets (C) for example, on engine cross tube assembly (A) may experience cracking.
Refer to Illustration153 for the location of hood support bracket (B) and air intake mounting
brackets (C).
Note: The air intake mounting brackets are on the back side of the engine cross tube
assembly.

View of cracking at the fillet weld toe of the hood support bracket ( through engine cross tube assembly wall )
(B) Hood support bracket
(D1) 9.5 mm (0.37 inch)
Note: Applies to all attachments welded to engine cross tube assembly.
2. Illustration 154 shows the likely crack scenario for this type of welded connection. A crack
may initiate at the fillet weld toe on the stressed member, which is the engine cross tube
assembly.
The crack will propagate into the engine cross tube assembly and eventually through the
wall thickness. The engine cross tube assembly is 9.5 mm (0.37 inch) thick. Based on
normal fatigue propagation, if the visible crack at the surface is greater than 25 mm
(1.00 inch), then the depth of the crack is likely through or almost through the wall.
3. Gouge/grind into the crack until all visible traces of the crack have been removed.
4. Use MT or PT to verify crack removal.
5. If the crack propagated through the wall thickness, then repair is not advised. It is
recommended that a new engine cross tube assembly is installed. If the crack does
not propagate through the wall thickness, then repair is advisable, adhere to the following
Steps.

View of crack excavation
(D) Gouged profile
(D2) Section thickness
6. Excavate the crack. The excavated crack should appear as shown in Illustration 155
(depending on crack depth to wall thickness).

(E) 60 degree included angle
7. Finish grind to achieve 60 degree (minimum) included angle. Refer to Illustration 156.

Cross sectional view of prepared joint prior to welding (slight radius at root)
(D3) 60 degree (minimum) angle
(D5) 5 mm (0.20 inch) (minimum) radius
(D6) 45 degree angle
8. Prepare the joint as shown in Illustrations 157 and 158.

View of finish weld and sanded flush
9. After completion of welding, blend sand the excess weld material flush with the
surrounding engine cross tube assembly profile.
Note: If while welding you burn through or blow through the wall thickness of the
engine cross tube assembly, then a new engine cross tube assembly is to be
installed.
10. Remove the remaining portions of the existing fillet weld (adjacent to the crack repair) by
sanding.
11. Reinstate by welding 5 mm (0.20 inch) fillet weld and blend sand weld tie-ins.
12. Visually inspect to ensure conformance to "Weld Inspection and Acceptance Criteria".
13. To prevent cracking a post weld treatment known as TIG dressing should be completed.
Refer to "Post Weld Treatment - TIG Dressing" Section for detailed information regarding
TIG dressing.
View of cracking at the fillet weld toe of the hood support bracket ( through engine cross tube assembly wall )
(D1) 12.7 mm (0.50 inch)
Note: This applies to all attachments welded to the tube.
14. As long as the crack in the weld does not propagate through the thickness of the engine
cross tube assembly, then repair is straight forward.
15. Gouge/grind into the crack until all visible traces of the crack have been removed.
17. Reinstate by welding a 5 mm (0.20 inch) fillet weld and blend sand weld tie-ins.
Note: To prevent recracking, TIG dress weld toe as advised for when there is a crack at
the weld toe.

View of cracking at the fillet weld of the hood support bracket ( through engine cross tube assembly wall )
(D1) 12.7 mm (0.50 inch)
19. As long as the crack is in the weld or hood support (B) and does not propagate through the
thickness of the engine cross tube assembly, then repair is straight forward.
Note: This applies to all attachments welded to the engine cross tube assembly.
20. Gouge/grind into the crack until all visible traces of the crack have been removed. Repair
from both sides if necessary, then sand excess weld metal flush.
sanding.
23. Reinstate by welding a 5 mm (0.20 inch) fillet weld and blend sand weld tie-ins.
Note: To prevent recracking, TIG dress weld toe as advised for when there is a crack at
the weld toe.
Engine Cross Tube Assembly To End Plate Weld

Repair

View of crack at the weld toe on engine cross tube assembly side
(B) End plate
(D1) 9.5 mm (0.37 inch)

View of crack in the weld throat (left) and crack in the weld toe (right) on end plate
(B) End plate
(D1) 9.5 mm (0.37 inch)
If a crack is found at the fillet weld connecting the engine cross tube assembly to the end plates,
the location and extent of cracking will determine if repair is advisable.
The most likely location for cracking is at the fillet weld toe on the engine cross tube assembly as
shown in Illustration 162. A crack may initiate at the fillet weld toe on the stressed member,
which is the engine cross tube assembly. The crack will propagate into the engine cross tube
assembly and eventually through the wall thickness.
The engine cross tube assembly is 9.5 mm (0.37 inch) thick. Based on normal fatigue
propagation, if the visible crack at the surface is (greater than or equal to) 20 mm (0.80 inch),
then the depth of the crack is likely through or almost through the wall.
1. Gouge/grind into the crack until visible traces of the crack have been removed.
2. Use MT and PT to verify crack removal.

Note: If the crack has propagated through the wall thickness, then repair is not
advised. It is recommended that a new engine cross tube assembly is installed.
Note: If the crack does not propagate through the wall thickness, then repair is advisable.

View of crack excavation
(C) Gouged profile
3. Excavate the crack. The excavated crack should appear as shown in Illustration 164
(depending on crack depth to wall thickness).

(D) 60 degree included angle
4. Finish grind to achieve 60 degree (minimum) included angle. Refer to Illustration 165.
Cross sectional view of prepared joint prior to welding (slight radius at root)
(D5) 5 mm (0.20 inch) (minimum) radius

5. Prepare the joint as shown in Illustrations 166 and 167.

View of finish weld and sanded flush
6. After completion of welding, blend sand the excess weld material flush with the
surrounding engine cross tube assembly profile.
Note: If while welding you burn through or blow through the wall thickness of the
engine cross tube assembly, then it is recommended that a new engine cross tube
assembly is installed.
sanding.
8. Reinstate by welding a 12 mm (0.47 inch) (minimum) fillet weld and blend sand weld tie-
ins.
View TIG dressing external weld toes of 3 pass 16 mm (0.63 inch) fillet weld
(B) End plate
(E) Weld toe with smooth radius

Note: To prevent recracking, TIG dress weld toe TIG dress each of the external weld toes
of the 12 mm (0.47 inch) fillet weld.
Note: Illustration 169 assumes a 3 pass 12 mm (0.47 inch) fillet weld. If completed in 4
passes, there will be 4 external weld toes to TIG dress instead of the 3 external weld toes
shown.
Note: In addition, it is recommended to TIG dress the fillet weld toe for all attachments on
the engine cross tube assembly.
Refer to "Post Weld Treatment - TIG Dressing" Section for detailed information regarding
TIG dressing.

View of crack in the weld throat (left) and crack in the weld toe (right) on end plate
(B) End plate
(D1) 9.5 mm (0.37 inch)
10. If a crack exists in the fillet weld either in the throat or weld toe as shown in Illustration 170,
then refer to the "Requirements for Dimensional Conformance After Weld
Repair/Machining" Section.
If the repaired crack was in the weld toe on the engine cross tube assembly side, install
engine cross tube assembly to the chassis, if the engine cross tube assembly had been
previously removed to perform the repair.
Requirements for Dimensional Conformance After
Weld Repair/Machining

Note: The following steps are only required if a weld repair is performed on the throat of the tube
to end plate weld or the fillet weld toe on the end plate.
An ideal bolted joint is required for the ROPS structural system to perform as intended. To
maintain a sound bolted joint, it is critical that the machined end plates retain flatness post weld
repair. The engine cross tube assembly in new condition has the ends machined flat ( 0.25 mm
(0.00984 inch) maximum) after welding and each end plate has to be 20 mm (0.80 inch)
minimum thickness.
1. Remove engine cross tube assembly (A) from the frame.
2. Inspect for dimensional conformance. If engine cross tube confirms, assemble engine
cross tube to the chassis. If non conformance is found, machine the end plate to
specification.
Note: If the repaired engine cross tube assembly does not meet the requirements for
dimensional conformance, it is recommended that a new engine cross tube assembly is
installed.
3. Verify 0.25 mm (0.00984 inch) flatness for each end plate ( 0.5 mm (0.01969 inch)
parallelism between the machined end plate surfaces).
4. Verify 20 mm (0.80 inch) minimum thickness on repaired end plate side post machining.
Procedure to Replace the Center Support

Assembly on the 793D Off-Highway Truck

This section contains general information and procedures that can be used to replace the center
support assembly on 793D Off-Highway Trucks.
Required Parts to Replace the Center Support Assembly

Item Qty Part Number Description
1 1 1B-2721 Bolt
2 1 4J-5977 Full Nut
3 2 4K-0684 Hard Washer
4 1 125-7017 Support As
Table 17
Brace the Frame

The frame will require bracing to be attached by welding to prevent the frame from moving while
the center support assembly is being removed.

View of steel square tube for bracing
(D1) 6.35 mm (0.25 inch)
(D2) 101.6 mm (4.0 inch)
(D3) 101.6 mm (4.0 inch)
(D4) 34 mm (1.34 inch)
(D5) 34 mm (1.34 inch)
(D6) 1795 mm (70.67 inch)
1. Use the dimensions in Illustration 174 to fabricate four braces. Use 4 inch steel square
tubing for braces.
Right-hand side view of the bracing

Left-hand side view of the bracing
NOTICE
Do not weld on top of or across any factory welds or start or
terminate any field welds within 10 mm (0.40 inch) of existing
factory welds and/or plate edges.
2. Weld the square tubing to frame as shown in Illustration 175, lustration 176, and Illustration
177.
Fabricate Locating Fixtures

Left-Hand Side Locating Fixture
Note: The locating fixture will be used to relocate the front tank mount fixture after repairs have
been completed.
Note: Material required for fabricating the fixture can be common structural steel such as ASTM
A36.

Base plate
(D1) 20 mm (0.80 inch)
(D2) 1487.5 mm (58.60 inch)
(D3) 4X 23 mm (0.90 inch)
(D4) 188 mm (7.40 inch)
(D5) 30 mm (1.20 inch)
(D6) 1537.5 mm (60.50 inch)
(D7) 128 mm (5.04 inch)
(D8) 25 mm (1.0 inch)

Vertical plate
(D9) 50 mm (2.0 inch)
(D10) 160 mm (6.30 inch)
(11) 10 mm (0.40 inch)
Gusset
(D12) 110 mm (4.30 inch)
(D13) 130 mm (5.12 inch)
(D14) 10 mm (0.40 inch)
1. Fabricate the parts shown in Illustration 178, Illustration 179, and Illustration 180.
Note: Material required for fabricating the fixture can be common structural steel such as
ASTM A36.

Semi completed fixture
(D15) 250 mm (9.84 inch)
(D16) 270 mm (10.63 inch)
2. Assemble and weld the locating fixture as shown in Illustration 181 and attach the semi
completed locating fixture to the rear tank mount (using existing mounting hardware) so
that the locating fixture lies across the front tank mount surface.
Note: The holes on the plate may not line up perfectly with the threaded holes in the front
tank mount.
Rod
(D17) 375 mm (14.80 inch)
(D18) 25 mm (1.0 inch)
3. Fabricate a rod using the dimensions in Illustration 182.

View of locating fixture in position
4. Position the rod on top of the rail section and against locating fixture to capture the height
of the front tank mount.
5. Tack weld the rod to the locating fixture.
6. Remove the locating fixture and finish weld the rod to the locating fixture. Set locating
fixture aside until repairs have been completed.
Right-Hand Side Locating Fixture

Note: The locating fixture will be used to relocate the front tank mount fixture after repairs have
been completed.
Note: Material required for fabricating the fixture can be common structural steel such as ASTM
A36.
Base plate
(D1) 20 mm (0.80 inch)
(D2) 844 mm (33.23 inch)
(D3) 4X 20 mm (0.80 inch)
(D4) 120 mm (4.70 inch)
(D5) 18.7 mm (0.74 inch)
(D6) 904 mm (35.60 inch)
(D7) 82.6 mm (3.30 inch)
(D8) 30 mm (1.20 inch)

Vertical plate
(D9) 225 mm (8.90 inch)
(D10) 50 mm (2.0 inch)
(D11) 10 mm (0.40 inch)
Gusset
(D12) 205 mm (8.10 inch)
(D13) 90 mm (3.50 inch)
(D14) 10 mm (0.40 inch)
1. Fabricate the parts shown in Illustration 184, Illustration 185, and Illustration 186.
2. Assemble and weld the locating fixture as shown in Illustration 181 and attach the semi
completed locating fixture to the rear tank mount (using existing mounting hardware) so
that the locating fixture lies across the front tank mount surface.
Note: The holes on the plate may not line up perfectly with the threaded holes in the front
tank mount.

Rod
(D19) 275 mm (10.80 inch)
(D20) 25 mm (1.0 inch)
3. Fabricate a rod using the dimensions in Illustration 188.
View of locating fixture in position
4. Position the rod on top of the rail section and against locating fixture to capture the height
of the front tank mount.
5. Tack weld the rod to the locating fixture.

Angle iron and spacer
(D21) 1200 mm (47.20 inch)
(D22) 32 mm (1.30 inch)
(D23) 40 mm (1.60 inch)
(D24) 56.6 mm (2.20 inch)
(D25) 12 mm (0.50 inch)
(D26) 101.6 mm (4.0 inch)
(D27) 101.6 mm (4.0 inch)
(D28) 32 mm (1.30 inch)
(D29) 80 mm (3.10 inch)
(D30) 32 mm (1.30 inch)
6. Use the dimensions in Illustration 190 to fabricate angle iron and spacer.
Assembled parts
(1) 1B-2721 Bolt
(2) 4J-5977 Full Nut
(3) 4K-0684 Hard Washer
7. Secure angle iron and spacer as shown in Illustration 191 using bolt (1), two hard washers
(2), and full nut (3). Do not tighten bolt and nut.
8. Rotate angle iron up until the angle iron touches the bottom of the locating fixture. Tighten
bolt and nut to secure the angle iron in place. Refer to Illustration 192.
9. Tack and weld angle iron to the base plate of the locating fixture.
10. Remove the locating fixture and finish weld the rod to the locating fixture. Set locating
fixture aside until repairs have been completed.
Remove Center Support Assembly and Outside

Window Plates
Remove Center Section of Center Support Assembly
View of the center support assembly
(A) Center support assembly
1. Attach a suitable lifting device to center support assembly (A). The approximate weight of
center support assembly (A) is 1322 kg (2915 lb).
2. Cut center section of center support assembly (A). Cut at the dashed lines and remove the
center section from the frame.
Remove the LH Side Outside Window Plate

View of the LH side outside window plate
(D1) 50 mm (2.0 inch)
(B) Outside window plate
Weld joint cross sections

View of Section A
(D2) 16 mm (0.60 inch)
(D3) 35 mm (1.40 inch)
(B) Outside window plate
(C) Internal gusset
View of Section B
(D4) 16 mm (0.60 inch)
(D5) 50 mm (2.0 inch)
(D) Steel rail
NOTICE
Retain as much of the outside window plate as possible. The
outside window plate will be reused.
1. Attach a suitable lifting device to outside window plate (B). The approximate weight of
outside window plate (B) is 200 kg (441 lb).
2. Arc air gouge the four welds securing outside window plate (B) in position. Do not remove
the bracket assembly. Remove an additional 50 mm (2.0 inch) beyond all four weld
intersections. Refer to Illustration 195.
Refer to Illustration 196, Illustration 197, and Illustration 198 for weld joint cross sections
that will be encountered when removing the outside window plates.
3. Remove and retain outside window plate (B).
Remove the RH Side Outside Window Plate

View of the RH side of the frame
1. Record reference dimensions or scribe location lines for both brackets shown in Illustration
199, then remove and retain the brackets.
View of the RH side outside window plate
(D6) 50 mm (2.0 inch)
(E) Outside window plate
NOTICE
Retain as much of the outside window plate as possible. The
outside window plate will be reused.
2. Attach a suitable lifting device to outside window plate (E). The approximate weight of
outside window plate (E) is 175 kg (386 lb).
3. Arc air gouge the four welds securing outside window plate (E) in position. Do not remove
the bracket assembly or other attachments. Remove an additional 50 mm (2.0 inch)
beyond all four weld intersections. Refer to Illustration 200.
Refer to Illustration 196, Illustration 197, and Illustration 198 for weld joint cross sections
that will be encountered when removing the outside window plates.
4. Remove and retain outside window plate (E).
Remove Support Castings

View of the RH side support casting (outside)
(F) Support casting

View of the RH side support casting (inside)
(F) Support casting
1. Attach a suitable lifting device to support casting (F). The approximate weight of support
casting (F) is 230 kg (507 lb).
2. Gouge/remove internal (both side) welds securing support casting (F). Refer to Illustration
201 and Illustration 202.
Note: Refer to Illustration 197 and Illustration 198 for guidance related to weld joints and
excavation.
3. Clean/grind/sand all slag and debris from the edges of the frame where the center support
assembly was welded into position.
Install the New Center Support Assembly

To install the new center support assembly, the top rails on each side of the frame will need to be
notched out to allow the wider component to fit in between the rails.

Top view of the LH frame rail
(D1) 1128 mm (44.40 inch)
(D2) 25 mm (1.0 inch)

Cross sectional view
(D2) 25 mm (1.0 inch)
(D3) 50 mm (2.0 inch)
1. Notch out each rail using an oxy/fuel torch.

Note: Illustration 203 and Illustration 204 show the approximate minimum dimensions of
the notch required to be removed from the top rail on each side.
2. Clean/grind/sand edges of both rails where the notch was removed.

View of the center support assembly
(4) 125-7017 Center Support As
3. Attach a suitable lifting device to center support assembly (4). The approximate weight of
center support assembly (4) is 1322 kg (2915 lb).
4. Install center support assembly (4) from the top side. Align the machined steel casting
edges with the three existing sides of the rails (bottom and two sides).
Note: Steel backing strips for front vertical weld joint may need to be fabricated and
installed if not retained during the removal process.

View of areas that require preheat
5. Before welding, note the areas in Illustration 206 which require temperature control while
welding. 100° C (212° F) minimum temperature and 300° C (572° F) maximum
temperature.
View outside of box section

View inside of box section
NOTICE
Do not tack weld on sides of loose steel backing strip.
6. Secure center support assembly (4) into position using 6 mm (0.24 inch) fillet welds 50 mm
(2.0 inch) in length at locations shown in Illustration 207 and Illustration 208. Place fillet
welds at each end and the middle of each weld joint, both the LH and RH sides.
Vertical groove welds

View of internal fillet welds
(D4) 1300 mm (51.18100 inch)
Note: Backing strip should only be welded at the top and bottom. Do not weld on the sides.
7. Weld as shown in Illustration 209 and 210 using a balanced welding technique to minimize
distortion.
Weld a root pass in each joint, then weld no more than two passes in each joint before
moving to the next. This applies to both sides (internal and external). Do not weld one
joint complete before starting or moving on to the next.
Note: Due to previous gouging and grinding, it is difficult to express absolute weld callouts
and sizes for the welds shown in Illustration 210. The goal is to attain similar
contours/profiles as shown. The weld on the bottom rail should extend 1300 mm
(51.18100 inch) from the edge of the vertical internal gusset.
View of steel strip
(D5) 25 mm (1.0 inch)
(D7) 50 mm (2.0 inch)
8. There is a large gap that exists where the top rails were notched out. Take measurements
of the width and length of the notch and fabricate a 25 mm (1.0 inch) thick piece of steel
strip (ATSM A572 Grade 42) to minimize the gap.
Grind a 30 degree bevel on the three sides that butt up against the 50 mm (2.0 inch) top
rail section. Refer to Illustration 211 for an approximate cross sectional view.

View of tack welds
(D7) 50 mm (2.0 inch)
9. Secure steel strip into position by tack welding as shown in Illustration 212.
View of ensuring complete weld penetration
(D7) 50 mm (2.0 inch)
10. Weld root pass on the inside and outside joining the steel strip to the casting and rail.
Then, back gouge and/or grind on three sides to ensure complete joint penetration of steel
strip to top rail as shown in Illustration 213.

View of excavation welded and sanded flush
(D7) 50 mm (2.0 inch)
11. Weld excavation (three sides) and sand flush to inside rail surface as shown in Illustration
214.
View of welding continued
(D7) 50 mm (2.0 inch)
12. Weld inside and outside on weld joints until you achieve what is shown in Illustration 215.

View of bottom horizontal groove weld
13. Weld bottom horizontal groove welds (both sides) as shown in Illustration 216.
View of welding the remainder of the opening on top
14. Fill remainder of opening on top as shown in Illustration 217.

View of sanding to profile
15. Sand excess weld metal on top and sides to achieve a consistent profile with the
surrounding area. Refer to Illustration 218.
16. Clean, grind, and sand all weld joint preparations on both outside window plate
connections.
Install Outside Window Plates

Install LH Outside Window Plate
1. Attach a suitable lifting device to LH outside window plate (A). The approximate weight of
outside window plate (A) is 200 kg (441 lb).

View of window plate tacked into position
(A) LH outside window plate
2. Locate and align LH outside window plate (A) that contains connected hardware. Use
locating fixture. Secure LH outside window plate (A) with fillet welds as shown in Illustration
219.
View of vertical welds
3. Weld vertical seams complete alternating back and forth between each. Refer to
Illustration 220.

View of horizontal welds
4. Weld horizontal seams complete alternating back and forth between each. Refer to
Illustration 221.
Install RH Outside Window Plate

1. Attach a suitable lifting device to RH outside window plate (B). The approximate weight of
outside window plate (B) is 175 kg (386 lb).
View of window plate tacked into position
(B) RH outside window plate
2. Locate and align RH outside window plate (B) that contains connected hardware. Use
locating fixture. Secure RH outside window plate (B) with fillet welds as shown in
Illustration 219.

View of vertical welds
3. Weld vertical seams complete alternating back and forth between each. Refer to
Illustration 223.
View of horizontal welds
4. Weld horizontal seams complete alternating back and forth between each. Refer to
Illustration 224.

View of vertical weld flush
5. Sand excess weld metal of vertical weld flush with base metal. Refer to Illustration 225.
View of bracket assembly and plate in position
(C) Bracket assembly
(D) Plate
6. Locate bracket assembly (C) and weld into position using the weld specification in
Illustration 226.
7. Use a suitable lifting device to locate plate (D) and weld into position using the weld
specification in Illustration 226. The approximate weight of plate (D) is 23 kg (50.70626 lb).
TIG Dress the Four Tank Mounts

The four tank mounts on the frame require TIG dressing the fillet weld toe to ensure adequate
fatigue life of the frame. Both rear tank mounts will require TIG dressing prior to putting the
machine back in service. Inspect TIG dressing on front tank mounts and re-TIG dress if needed.
For detailed information regarding TIG dressing refer to "Post Weld Treatment - TIG
Dressing" Section.
Procedure to Repair the Bracket Assembly

(Steering Box) on the 793C 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.

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 228.

View of crack present in the weld joint
Illustration 228 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 228 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.

Cross sectional view of J-groove weld joints
Illustration 229 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.

Cross sectional view of corner joints
Illustration 230 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).
Material Type and Thickness

Part Number Description Material Type Thickness
8X-2272 Bracket ASTM A27 70-40 25 mm (0.98 inch)(1)
8X-2273 Plate ASTM A572 Gr 42 25 mm (0.98 inch)
8X-3566 Support ASTM A27 65-35 Varies
Table 18
(1)
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)
View of probable crack initiation site and propagation path to the surface
(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 229).
2. Verify that the crack has been removed via magnetic particle (MT) or dye penetrant (PT)
testing.

View of crack excavated

View of excavation prepared for welding
(D) 60 degree minimum included angle
(E) 6 mm (0.24 inch) 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.
View run on/off tab examples

View of run on/off tab used in repair process
4. For repairs made on plates with open ends, attach run on/off tabs 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.

View of completed repair
7. Paint repaired area as needed. Illustration 236 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.
Inorder to extend the life of the J-groove weld joints and correct the root gap issues,
access to the inside the bracket assembly (steering box) is required.

View of the front plate on the bracket assembly (steering box)
(B) Front plate
1. Document and scribe lines for all hardware presently 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.

View of front plate
(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 238.
Note: The 30 mm (1.18 inch) is to avoid damaging the integral backing strip of the support
assembly.
View of bracket assembly (steering box) with front plate partially removed
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 239.
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.

View of bracket assembly (steering box) with front plate partially removed
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 240.
8. Once inside, locate the weld root of the J-groove (externally) on three sides
(top/bottom/rear).

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.
View before excavation

View after excavation
10. Back gouge to sound metal (D).

View of prepared area
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.

View of offset
13. Measureoffset (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 245Record the offset dimensions.
Note: Offset will be used to determine fillet weld size.
View of welding progression
14. Weld the root pass as shown in Illustration 246. 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 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.

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 247 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).

View of the internal fillet weld size
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 248. 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.

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 250 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 246.
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.

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 251.
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 252 to fabricate a new front plate. Use ASTM A572
Grade 42 material.

Determine if gap exists
(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 253.
Note: Gaps should be less than 2 mm (0.079 inch)

View of support assembly casting built up
(H) Gap measurement
23. Build up support assembly (B) casting by welding to a dimension slightly higher than gap
measurement (H).
View of support assembly casting sanded to profile
24. Blend sand excess weld material to achieve a smooth J-groove profile with minimal gap.

View of J-groove minimum requirements
(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
256.

View of optional single V groove
(J) Front plate
26. If access to the root is difficult, grind a bevel (15 degree to 20 degree) on front plate (J) to
increase access. Refer to Illustration 257.
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)" Section.
29. Weld the root pass at each of the four weld joints before proceeding with the second and
third weld passes.
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 258. 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.

View of weld sizes
(J) Front plate
31. Finish weld front plate (J) using the weld sizes shown in Illustration 259.
Note: Use a balanced welding technique 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.
Procedure to Replace the Steering Bracket

Assembly
Required Parts
Item Qty Part Number Description
Bracket As
1 1 467-2760
Approximate weight 411 kg (906 lb)
Table 19
Frame bracing
(A) Square steel tubing
1. 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 to extend between the mounting locations
for the front suspension cylinders.
Note: The tubing will need to be cut to fit for each frame. The tube length may vary from
frame to frame. Measure the distances between the front strut support castings, and cut
the tubing to that length.
2. Mark the locations for the two tubes.
3. Prepare the area of the four tube end locations for welding. For the proper procedure, refer
to Preparing the Area for Welding in the above referenced Special Instruction "General
Welding Procedures".
4. Use the information in Illustration 260 to weld both ends of the two tubes (A) in position.
Note: Use the SMAW process and "E7018 H4R" welding electrode for all welds. As an
alternate process, the FCAW process can be used with "E71T-1H8", "E71T-9H8", or
"E71T-12H8" welding electrode.
5. After you have braced the frame, measure the distance from the bore diameters in the
steering bracket assembly to the mounting locations for the front strut support cylinders.
Record these measurements to use as references when you install the new steering
bracket assembly.

Looking down on the steering bracket assembly
(A) Square steel support tubes
(B) Cut lines
6. Layout cut lines (B) all the way around the steering bracket assembly. Stay a minimum of
30 mm (1.2 inch) away from the weld. Do not damage the integral backing of the castings.
7. Use a plasma cutter, or an oxy-fuel torch to remove the center section of the steering
bracket assembly.
8. After the center section of the steering bracket assembly is removed, use carbon arc
cutting to remove the remaining parts of the steering bracket assembly.

Casting profile
(C) 27.0 mm (1.06 inch)
(D) Radius 2.0 mm (0.08 inch)
(E) 25 degrees
(F) 45 +/- 2 degrees
(G) 8 to 15 mm (0.3 to 0.6 inch), 8 mm (0.3 inch) minimum
(H) 22 mm (0.9 inch)
(J) 8 to 15 mm (0.3 to 0.6 inch), 8 mm (0.3 inch) minimum
(K) Radius 2.0 mm (0.08 inch)
(L) 25 degrees
(M) 45 +/- 2 degrees
9. Use the details in Illustration 262 to prepare the joints to accept the new steering bracket
assembly.
10. Magnetic particle inspect all prepared surfaces for cracks. Evaluate and repair the
prepared surfaces as needed.

New steering bracket assembly
(1) 467-2760 Bracket As
(N) Plate
New bracket assembly with plate removed
(1) 467-2760 Bracket As
11. Position the new steering bracket assembly (1) for rework. Use the proper equipment to
remove front plate (N) from the steering bracket assembly. The plate removal will allow the
steering bracket assembly to be installed using the integral backing. The front plate will be
installed at the end of the procedure.
Note: The approximate weight of the plate is 63 kg (139 lb).
Note: The following information provides details about the weld joints and the base
material.

Cross sectional view of J-groove weld joints
12. Illustration 265 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.

Cross sectional view of corner joints
13. Illustration 266 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).
Material Type and Thickness
Part Number Description Material Type Thickness
8X-2272 Bracket ASTM A27 70-40 25 mm (0.98 inch)(1)
Table 20
(1)
Nominal
Note: The cast bracket plate has been quenched and tempered to obtain higher
mechanical properties than listed.
14. Table 20 lists the materials in the steering bracket assembly.

Steering bracket assembly positioned
(1) 467-2760 Bracket As
15. Use the proper equipment to position, and center new steering bracket assembly (1) on the
weld joints. Use the measurements that were saved earlier to position the steering bracket
assembly.
Note: The approximate weight of steering bracket assembly (1) is 353 kg (778 lb).
16. Prepare the ends of the steering bracket assembly for welding. For the proper procedure,
refer to Preparing the Area for Welding in the above referenced Special Instruction
"General Welding Procedures"
17. Use the information in Illustration 268, Illustration 269, Illustration 270, and a balanced
welding sequence to apply groove welds. Blend and sand all corners using 36 grit sanding
pads.
Note: Use the SMAW process and "E7018 H4R" welding electrode for all welds. As an
alternate process, the FCAW process can be used with "E71T-1H8", "E71T-9H8", or
"E71T-12H8" welding electrode.
18. Start at Step 8 in "Advanced Procedure to Repair the Bracket Assembly (Steering Box)".
Perform the procedure from Step 8 to the end of the procedure.
PPI-00074AB6
2021/03/25
18:27:49-05:00
i07156000
© 2021 Caterpillar Inc.
Caterpillar:
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Procedure to Repair the Frame on Certain 793 through 793D Off-Highway Trucks

SMCS - 7051 i07816539

793B (S/N: 1HL1-UP)

Reference: Special Instruction, REHS1841, "General Welding Procedures"

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Do not operate or work on this product unless you have read

When a hoist or jack is used to lift any part or component, stand

Approximate weights of the components are shown. Clean all

Important Safety Information

The signal word “WARNING” has the following meanings:

Your Safety Is Involved !

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

Always observe the list of basic precautions that follows:

Mounting and Dismounting

Specifications for Cables, Chains, and Lifting Devices

Hot Fluids and Parts

Proper Cleaning for Inspection

To prevent personal injury or death, do not work under the

When it is necessary to work under the machine with the body

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents,

Always wear protective clothing and eye protection when

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Welding Specifications and Qualifications

Read and understand the manufacturer's instruction and your

Refer to the American National Standard Z49.1, "Safety in

Proper Welding Procedure on Machines and Engines

4. Protect the wiring harnesses from the welding spatter.

Any fluids or moisture

Welding Electrodes and Parameters

Mechanical Properties from Flux Cored Welding Electrode That Is Classified

Welding Current for Flux Cored Welding Electrode that Is 1.2 mm

Wire Feed Rate Voltage Amperage

Welding Current for Flux Cored Welding Electrode that Is 1.4 mm

Wire Feed Rate Voltage Amperage

Low Hydrogen Electrodes for the SMAW Process

Mechanical Properties of Welds from Low Hydrogen Electrodes That Are

Welding Current for Low Hydrogen Electrodes

Weld Inspection and Acceptance Criteria

General Weld Repair

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

Repair of the 793, 793B, 793C, and the 793D

2. Apply couplant to the grid area.

Initial Bake and Preheat

2. Attach Type K thermocouple using a Thermocouple Attachment Unit (TAU)(Capacitive

Crack Removal, Inspection Verification, and Joint

Welding - Root Pass

Peak Current ... 280 amps

Background Current ... 60 amps

Wire Feed Speed ... 170 ipm

Hot Start ... 5

Peak Current ... 250 amps

Background Current ... 50 amps

Wire Feed Speed ... 150 ipm

Hot Start ... 5

Electrode ER70S-6 ... 0.89 mm (0.035 inch)