Ball Stud Procedure

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ug Gauge on Large Off-Highway Tru…
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Special Instruction
Procedure to Inspect Steering Ball Stud Bores with a Plug Gauge on Large Off-Highway Trucks
{0679, 4303, 4322}
Media Number -M0106381-00 Publication Date -17/06/2019 Date Updated -17/06/2019
i07755559
Procedure to Inspect Steering Ball Stud Bores with a Plug Gauge on

Large Off-Highway Trucks {0679, 4303, 4322}
SMCS - 0679; 4303; 4322
Off-Highway Truck/Tractor
785C (S/N: APX1-UP)
785D (S/N: MSY1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP)
793D (S/N: FDB1-UP)
793F (S/N: RBT1-UP)
795F AC (S/N: ERM1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP)
Introduction
This Special Instruction describes the inspection of tapered bores for the following components:
Steering Arms
Center Arm
Steering Box
Tapered bores that do not pass inspection must not be put back into service. Contact your Caterpillar dealer for
repair options.
This inspection process will provide the procedure to measure the wear patterns on a bore by using a Plug Gauge.
This process also explains the proper process to use Bluing Paste. Refer to Table 2 through Table 4 for the plug
gauge part numbers. This procedure will use a typical steering arm, and a typical steering box to illustrate these
procedures.
Do not perform any procedure in this Special Instruction until you have read the information and you understand
the information.
Reference Section
Reference: Operation and Maintenance Manual, SEBU7173, "784C and 785C Off-Highway Truck/Tractor",
Prepare the Machine for Maintenance
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9/9/2019 Advanced Full Text Search - M0106381 - Procedure to Inspect Steering Ball Stud Bores with a Plug Gauge on Large Off-Highway Tru…
Reference: Operation and Maintenance Manual, SEBU8751, "793F CMD (Command for Hauling) Off-Highway
Truck", Prepare the Machine for Maintenance
Reference: Operation and Maintenance Manual, SEBU8349, "795F AC and 795F AC XQ Off-Highway Truck",
Reference: Operation and Maintenance Manual, SEBU7651, "797B Off-Highway Truck", Prepare the Machine
for Maintenance
Reference: Operation and Maintenance Manual, SEBU8417, "797F and 797F XQ Off-Highway Truck", Prepare
the Machine for Maintenance
Reference: Reuse And Salvage Guidelines, SEBF8271, Salvage of Tapered Steering Bores
Safety Section
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.
Failure to follow all safety guidelines prescribed in this document and by

governing authorities and regulatory agencies may result in severe
injury or death of personnel or machine damage.
When removing a major component or attachment, ensure that it is

properly blocked or secured before removing mounting hardware. An
assembly that is disconnected without proper blocking may shift or fall,
resulting in serious injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance

procedures. To avoid injury or death, follow the procedures exactly as
stated below.
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do
the job.
Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.
Climbing equipment may be required to access this service point. Refer

to the Operation and Maintenance Manual, "Mounting and
Dismounting" topic for safety information.
Before servicing/performing maintenance on the machine, electrical

power must be physically disconnected; battery plugs must be
disconnected from the batteries, or the trailing cable must be unplugged,
and warning tags and padlocks shall be applied by a certified
electrician. Certified electricians shall perform or direct any electrical
work, including any energized testing, repair work in controllers,
motors, or other approved compartments, and shall insure that all
compartments are properly closed and inspected prior to re-
energization. All applicable lock out and tag out procedures must be
followed.
Do not operate the machine if any guards or covers are missing or

inadequately secured. Personnel could be seriously injured or machine
damage may occur.
Observe the safe working load limits of all lifting and blocking devices
and keep a safe distance from suspended/blocked loads. Personnel may
be seriously injured or killed by falling loads.

For the correct procedure, refer to Prepare the Machine for Maintenance in the Operation and Maintenance Manual
for your machine.
Earlier machines will not have a Prepare the Machine for Maintenance procedure. Use the following procedure to
prepare the machines.
1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other
personnel in the sight of the operator.
2. Move the machine to a smooth horizontal location. Move the machine away from any machines that are
working and any personnel. The surface must be solid enough to support the weight of the machine and any
tooling that is used to support the machine.
3. Move the transmission control to the NEUTRAL position.
4. Move the parking brake switch to the ON position to engage the parking brakes. Turn the engine start switch
to the OFF position to stop the engine.
5. Turn the battery disconnect switch to the OFF position. Remove the key.
6. Place chocks in front of the wheels and behind the wheels. Refer to "Use of Wheel Chocks" in the Operation
and Maintenance Manual for your machine for more information.
7. When the use wheel chocks are not possible, ensure that the machine is unable to roll. Turning the wheels
into a suitable bank, or place the wheels in a suitable ditch.
Tooling and Equipment

Table 1
Required Tooling and Equipment
Part Number Description Designation
4C-3386 Spanner Wrench As Lapping

176-6538 Spanner Wrench As Lapping
1 Bottle Lapping Compound

1 Bottle Bluing Paste
Surface
1U-5516 Disc (Coarse) Preparation
/ De-burring
Surface
1U-5519 Holder (Disc Pad) Preparation
/ De-burring
Grinding Wheel (F-Grade) Surface
4C-8515 (2 x 1 inch) Preparation
(120 Grit) / De-burring
Surface
222-3074 Wheel Grinder Group Preparation
/ De-burring
Surface
4C-8521 Wheel Adapter Preparation
/ De-burring
Surface
Die Grinder
222-3076 Preparation
(Right Angle)
/ De-burring
Surface Texture
9A-1593 Comparison Gauge (Surface Texture)
Tester
Specific Tooling for Salvaging Procedures of Steering Components
Table 2
Required Plug Gauge, Lapping Tool, and Ball Stud for 785 Large Off-Highway Truck
Plug Gauge Lapping Oversize Ball
Part Number Part Name Ball Stud
Gp Tool Stud
5T-8728, 8X-6818,
Center Arm
135-5267 217-8419
5T-8597,
8W-5864, 135-5268 Steering Arm 265-9221 226-2378
8X-9619
Bracket
5T-8671, 459-9666 123-6672
Assembly
Table 3
Required Plug Gauge, Lapping Tool, and Ball Stud for 789, 793, and 797 Off-Highway Trucks
Plug Gauge Lapping Oversize Ball
Gp Tool Stud
5T-5730, 8X-6819,
Center Arm
135-5269
5T-6502,
5T-5907, 135-5270 Steering Arm 265-9224 226-2378 123-6672
8X-9620
Bracket
5T-6243
Assembly
Table 4
Required Plug Gauge, Lapping Tool, and Ball Stud for 795F AC, 797B, and 797F Off-Highway Trucks
Plug Lapping Oversize Ball

Gauge Gp Tool Stud
149-0921, 192-5691,
Center Arm
293-8689, 396-8975
151-7289, 192-5692, Steering 156-8136, 192-5702,
265-9227 265-9214 N/A
560-5125, 569-3404 Arm 438-1135
148-9178, 216-1617, Support

292-2185 Assembly
Cleaning Recommendations
Personal injury can result when using cleaner solvents.
To help prevent personal injury, follow the instructions and warnings on

the cleaner solvent container before using.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
Illustration 1 g06427430
Typical burr removal tooling.
(A) Right Angle Die Grinder
(B) Die Grinder
(C) ( D) ( E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft
(F) ( G) Flapper Wheels
Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and
oil.
When you move parts that require cleaning, always use a proper lifting device. This device must protect the
part from damage. For the safety of the operator, all lifting devices must be inspected before use.
During cleaning, do not damage machined surfaces.
Use pressurized air to dry parts.
If the tapered bore cannot be inspected immediately after cleaning, put hydraulic oil on all machined
surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.
Remove the Ball Stud

During every scheduled replacement for the ball stud, inspect the tapered steering bore. Also, when you find
cracks in a ball stud, inspect the tapered steering bore. Refer to Illustration 2 and Table 2 through Table 4 for the
tooling that is required to inspect the tapered bores.
(A) Depth of ball stud inside tapered bore
(B) Overall length of bore
(C) Upper diameter for ball stud
(D) Measurement location for gauge diameter
(E) Gauge diameter
(F) Taper
(G) Surface finish
(H) Straight bore diameter
1. Remove the ball stud from the tapered steering bore. For the removal procedure of ball studs, refer to the
Disassembly and Assembly Manual for your machine.
Remove corrosion from the tapered bore prior to inspection.
2. To inspect the bore properly, the surface must be free of paint or corrosion. If the surface finish is not free of
paint or corrosion, clean the surface. Use a 4C-8515 Flapper Wheel and a 4C-8521 Wheel Adapter to clean
the bore. The lapping procedure that is listed in this document can also be used to clean the tapered bores.
Process for Using the Plug Gauge
The illustration shows a 265-9225 Plug Gauge. This Plug Gauge applies to the 789, 793, and 797 Off Highway Trucks. Refer to Table 2
through Table 4 to select the appropriate Plug Gauge.
Note: Do not add oil to the Bluing Paste.
1. Apply a non-drying high spot indicator Bluing Paste to the taper surface of the Plug Gauge. Make sure that
the Bluing Paste is evenly distributed onto the tapered surface with minimum thickness.
2. Gently insert the Plug Gauge into the tapered bore by using hand pressure. Turn the Plug Gauge by
approximately 180 degrees.
(A) Checking steps.
3. With the Plug Gauge located inside the tapered bore, the steps on the small end of the tapered Plug Gauge
can be used to verify that the length of the tapered bore is correct. The proper length of the tapered bore will
allow the ball stud to seat properly when the ball stud is torqued. See Illustration 7.
On some Plug Gauges the step is machined into the Plug Gauge. Others Plug Gauges contain four color
coded steps in the end of the Plug Gauge. The green marked steps are used to check a standard-size tapered
bore. Use a standard ball stud in this type of tapered bore. The red marked steps are used to check a tapered
bore that has been machined oversize. Use an oversized ball stud in this type of tapered bore.
Note: The 795F AC, 797B, and 797 F Off-Highway Trucks do not have an oversized ball stud option.
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The face of the standard bore or oversize bore that is being inspected should fall within the tolerance that is
machined into the end of the Plug Gauge. This tolerance is indicated by a step between either two green
marks or two red marks. If the steps on the gauge extend beyond the face of the bore, the tapered bore is out
of tolerance. The proper torque on the ball stud cannot be obtained if the bore is outside of the proper
tolerance.
The illustration shows an unacceptable wear pattern.
4. Once you have completed the steps above, remove the Plug Gauge straight. Visually inspect the contact
surface on the bore.
The Bluing Paste must indicate that at least 75 percent of the surface of the gauge contacted the bore. The
Bluing Paste must also indicate solid contact for the full length of the 75 percent contact area. The bore in
Illustration 8 does not meet the 75 percent rule.
Examples of unacceptable wear patterns on a tapered bore
5. Unacceptable wear patterns are shown on the tapered bore in the above illustration. Some of the bores in this
illustration meet the “75 percent rule”. However, these bores fail to meet the “full length of the taper at some
point rule”. DO NOT USE ANY OF THE ABOVE EXAMPLES AGAIN.
Acceptable wear patterns on a tapered bore.
Acceptable wear patterns on a tapered bore.
6. Acceptable wear patterns on a tapered bore are shown in the above illustrations. If the tapered bores have
acceptable wear patterns, no action is required. If the tapered bore did not meet the acceptable wear pattern,
continue to "Lapping Procedure for a Tapered Bore".
Note: The examples in Illustrations 8 through 11 represent the results that may be obtained through the
process of bluing. To be used again, the contact area must be visible across the full length of the taper. The
“full-length” contact area does not include the bottom section that is not tapered. Therefore, the bottom
section should not show any signs of contact.
Lapping Procedure for a Tapered Bore

If the tapered bore did not meet the specifications that were outlined in the "Process for Using the Plug Gauge"
section of this guideline, use the following instructions to recondition the bore. Lapping is the recommended
procedure for the repair of a tapered bore.
After the Lapping Procedure has been completed, the tapered bore must be inspected again with the Plug Gauge
Procedure. If the bore fails to meet the inspection specifications after lapping, contact your Caterpillar dealer for
repair options.
Procedure
The Lapping Tool should be used to lap the tapered bores. Failure to use the appropriate tooling may result in an
unsatisfactory tapered bore and premature failure of the ball stud or tapered bore.
Apply Lapping Compound to the Lapping Tool. Apply Lapping Compound to the area (A) that is shown in Illustration 5.
1. Apply Lapping Compound on the Lapping Tool. The compound should be applied so that the thickness is
approximately 1.5 mm (0.06 inch) thick.
2. Insert the tool into the tapered bore and lightly tap the tool with a rubber mallet. Mark the location of the
tool and the component so the number of rotations can be counted.
3. Use the Spanner Socket to turn the Lapping Tool 12 times in the clockwise direction.
Note: Throughout the Lapping Procedure, apply a downward force. Be sure to keep the Lapping Tool
straight in the tapered bore.
4. Use the Spanner Socket to turn the tool 12 times in the counterclockwise rotation.
5. Remove the Lapping Tool from the bore.
Note: Be sure to remove the Lapping Tool straight out of the bore.
6. Thoroughly clean the bore to remove all Lapping Compound.
7. Inspect the surface texture of the tapered bore. An F surface finish should be maintained after the lapping
procedure. Use the 9A-1593 Surface Texture Comparison Gauge.
8. Inspect the contact pattern on the tapered bore. Refer to the "Process for Using the Plug Gauge" section of
this Reuse and Salvage Guideline.
9. If the bore has passed inspection, clean the tapered bore. Install a new ball stud and tighten to the appropriate
torque. Refer to the appropriate manual for Disassembly and Assembly.
Lapping Tool Usage
The Lapping Tool is hardened to extend the service life. Repeated usage will cause the tool to wear. As the tool is
used, the surface finish will degrade. After repeated usage, the Lapping Compound will score the surface.
Due to the nature of lapping work, a Lapping Tool has a finite life. The Lapping Tool should be able to lap
approximately eight bores before the tool should be replaced.
If the Lapping Tool does not achieve the specified finish and the specified contact pattern, the Lapping Tool should
be discarded and a new tool should be used.
Note: The Lapping Tool may experience uneven wear if the Lapping Tool is used on various sized tapered bores.
If the wear is uneven, the Lapping Tool will not be effective.
Avoid using the Lapping Tool on different-sized bores. Designate an individual tool for each truck model or bore
size.
Copyright 1993 - 2019 Caterpillar Inc. Mon Sep 09 2019 06:50:42 GMT+0800 (Australian Western Standard Time)
All Rights Reserved.
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9/9/2019 Advanced Full Text Search - M0106381 - Procedure to Inspect Steering Ball Stud Bores with a Plug Gauge

ug Gauge on Large Off-Highway Tru…

Procedure to Inspect Steering Ball Stud Bores with a Plug Gauge on

Failure to follow all safety guidelines prescribed in this document and by

When removing a major component or attachment, ensure that it is

Personal injury or death can result from improper maintenance

Personal injury can result from improper handling of chemicals.

Observe all safety precautions recommended by the chemical

Climbing equipment may be required to access this service point. Refer

Before servicing/performing maintenance on the machine, electrical

Do not operate the machine if any guards or covers are missing or

Prepare the Machine for Maintenance

3. Move the transmission control to the NEUTRAL position.

Tooling and Equipment

4C-3386 Spanner Wrench As Lapping

1 Bottle Lapping Compound

Specific Tooling for Salvaging Procedures of Steering Components

Plug Lapping Oversize Ball

148-9178, 216-1617, Support

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and warnings on

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When

During cleaning, do not damage machined surfaces.

Use pressurized air to dry parts.

Remove the Ball Stud

Process for Using the Plug Gauge

Note: Do not add oil to the Bluing Paste.

Lapping Procedure for a Tapered Bore

5. Remove the Lapping Tool from the bore.

6. Thoroughly clean the bore to remove all Lapping Compound.

Lapping Tool Usage

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