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Profissional Documentos
Cultura Documentos
MainAutodataCaterpillar
ProceduretoInspectandRepairtheCenter
SectionFrameonCertain793FOffHighway
Trucks{0679,7051}Caterpillar
Usage:
793FACEMD793FCMDRBT793FXQSND793FSSP
OffHighwayTruck/Tractor:
793FAC(S/N:EMD7677)
793F(S/N:SND1UPSSP1UPRBT1UP)
Introduction
ReferenceSpecialInstruction,REHS4439,"HighVoltageIsolationProcedureforWeldingona
LargeOffHighwayElectricDriveTruck"
ReferenceSpecialInstruction,REHS1841,"GeneralWeldingProcedures"
Thisspecialinstructioncontainsthenecessaryinstructionsforinspectionandrepairofthe
centersectionoftheframeforcertain793FOffHighwayTrucks.
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Note:Thebodydoesnotneedtoberemovedforinspectionorframerepairaslongasretaining
cablesareinserviceableconditionandusedproperly.
Table1
DisassemblyandAssemblyManuals
SalesModel
MachineSystems
PowerTrain
793F
793FXQ
KENR8579
KENR8397
793FCMD(CommandForHauling)
UENR1142
UENR1143
Table2
RequiredTooling
TelescopingMirror
BoreScope
MagneticParticleTestKit
DyePenetrantTestKit
Table3
RequiredParts
(1)
Qty
PartNumber
Description
4317565
Plate(1)
24
4413206
Plate(1)
4413208
Plate(1)
3789104
BracketAs
2953006
BracketAs
Serviceablepartcanbeorderedorfabricated
ThePowerTrainElectricDriveSystemwillcontainhazardousvoltagelevelsduring
machineoperationandforashortperiodoftimeafterengineshutdown.
Donotremoveanycoversthatwillexposeenergizedhighvoltageelectrical
componentswhiletheengineisoperating.
Anytypeofmaintenanceonthefollowingcomponentscanonlybeperformedafterthe
PowerTrainElectricalSystemServiceShutdownprocedurehasbeenfollowed:
Highvoltagecompartmentsintheinvertercabinet
Therearaxlehousingthatcontainstheelectricdrivetractionmotors
Thegenerator
Theretardingresistorgrid,thegridblowermotorandthegridsystemcabling
Theexcitationfieldregulator
Thehighvoltagecablesandconnectionenclosures
Failuretofollowtheseinstructionscouldresultinpersonalinjuryordeath.
NOTICE
Inordertopreventdamagetocomponents.Thepowertrainhighvoltagesystemmust
beshortedtothecabinetgroundbeforeweldinganywhereonthetruck.
NOTICE
Donotallowanydirtorforeignmaterialtogetintothehydraulicsystemduring
assembly,connectionoflines,whencomponentsarefilledwithfluid,orduringany
maintenanceoperation.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduringperformanceof
inspection,maintenance,testing,adjusting,andrepairoftheproduct.Bepreparedto
collectthefluidwithsuitablecontainersbeforeopeninganycompartmentor
disassemblinganycomponentcontainingfluids.
RefertoSpecialPublication,NENG2500,"DealerServiceToolCatalog"fortoolsand
suppliessuitabletocollectandcontainfluidsonCatproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
ImportantSafetyInformation
Thefollowinginformationisanexplanationofvariouslabelsthatarefoundinthisdocument.
Warnings
Thewarninglabelinformsthetechnicianthataninjuryordeathcanoccurasaresultofa
conditionthatmayexist.
Notices
Anoticeinformsthetechnicianthatcomponentdamagecanoccurasaresultofaconditionthat
exists.
Notes
Anotecontainsgeneralinformationforthetechnicianabouttheoperationthatisbeing
performed.
Properrepairisimportanttothesafeoperationandthereliableoperationofthismachine.This
documentoutlinesbasicrecommendedprocedures.Someoftheproceduresrequirespecial
tools,devices,orworkmethods.
Beforeyouperformanyrepairsorbeforeyouperformanymaintenance,readallsafety
information.Understandallsafetyinformationbeforeyouperformanyrepairsorbefore
youperformanymaintenance.
Safetyinformationisprovidedinthisdocumentandonthemachine.Ifthesehazardwarnings
arenotheeded,bodilyinjuryordeathcouldoccurtoyouorotherpersons.
The"SafetyAlertSymbol"thatisfollowedbya"SignalWord"identifiesahazard."DANGER",
"WARNING",and"CAUTION"are"SignalWords".
Illustration1
g00008666
Thesignalword"WARNING"hasthefollowingmeanings:
PayAttention!
BecomeAlert!
YourSafetyIsInvolved!
Themessagethatappearsunderthesafetyalertsymbolexplainsthehazard.
Operationsorconditionsthatmaycauseproductdamageareidentifiedby"NOTICE"labelson
themachineandintheserviceinformation.
Thepersonthatservicesthemachinemaybeunfamiliarwithmanyofthesystemsonthe
machine.Usecautionwhenyouperformservicework.Specialknowledgeofthesystemsand
ofthecomponentsisimportant.Beforeyouremoveordisassembleanycomponent,obtain
knowledgeofthesystemandknowledgeofthecomponent.
Caterpillarcannotanticipateeverypossiblecircumstancethatmightinvolveapotential
hazard.Thesafetyinformationinthisdocumentandthesafetyinformationonthe
machinearenotallinclusive.Determinethatthetools,procedures,workmethods,and
operatingtechniquesaresafe.Determinethattheoperation,lubrication,maintenance,
andrepairprocedureswillnotdamagethemachine.Determinethattheoperation,
lubrication,maintenance,andrepairprocedureswillnotmakethemachineunsafe.
BasicPrecautions
Improperoperation,lubrication,maintenanceorrepairofthisproductcanbe
dangerousandcouldresultininjuryordeath.
Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,until
youhavereadandunderstoodtheoperation,lubrication,maintenanceandrepair
information.
Alwaysobservethelistofbasicprecautionsthatfollows:
SafetySigns
Safetysignsincludetheitemsthatfollow:signs,informationplatesanddecals.Readall
"Safety"signsonthemachinebeforeoperating,lubricating,orrepairingthemachine.
Understandall"Safety"signsonthemachinebeforeoperating,lubricating,orrepairingthe
machine.Replaceanysafetysignsthatareintheconditionsthatfollow:damage,unreadable
andmissing.
ProtectiveEquipment
Whenyouworkaroundthemachine,alwayswearprotectiveequipmentthatisrequiredbythe
jobconditions.Protectiveequipmentincludestheitemsthatfollow:hardhat,protectiveglasses
andprotectiveshoes.Inparticular,wearprotectiveglasseswhenyouuseahammerorwhen
youuseasledgehammer.Whenyouweld,usetheappropriateprotectiveequipmentthatis
requiredbythejobconditions.Protectiveequipmentforweldingincludestheitemsthatfollow:
gloves,weldinghood,gogglesandapron.Donotwearlooseclothingorjewelrythatcancatch
onpartsofthemachine.
MountingandDismounting
Usestepsandhandholdswhenyoumountamachine.Also,usestepsandhandholdswhen
youdismountamachine.Beforeyoumountthemachine,cleananymudordebrisfromsteps,
walkways,orworkplatforms.Alwaysfacethemachinewhenyouusesteps,handholds,and
walkways.Whenyoucannotusetheaccessesonthemachine,useladders,scaffolds,orwork
platformstoperformsaferepairoperations.
SpecificationsforCables,Chains,andLifting
Devices
Useapprovedcables,chains,andliftingdevicesinordertoliftcomponents.Refertothe
manufacturer'sweightsinordertodeterminetheapplicationwhenyouselectthefollowing
items:cable,chainandliftingdevices.Whenyouliftacomponent,theliftangleiscritical.Refer
totheIllustrationthatfollowsinordertoseetheeffectoftheliftangleontheworkingloadlimit.
Note:TheliftingdevicesthatareshowninthispublicationarenotCaterpillarparts.
Note:Ensurethatthehooksareequippedwithasafetylatch.Donotplaceasideloadonthe
liftingeyesduringaliftingoperation.
Illustration2
Liftanglesforliftingslings.
(A)Theloadcapacityis100%oftheworkingloadlimitforthesling.
(B)Theloadcapacityis86%oftheworkingloadlimitforthesling.
(C)Theloadcapacityis70%oftheworkingloadlimitforthesling.
(D)Theloadcapacityis50%oftheworkingloadlimitforthesling.
HotFluidsandParts
g00629745
Toavoidburns,bealertforhotpartsonmachineswhichhavebeenstoppedandhotfluidsin
lines,tubesandcompartments.
Becarefulwhenyouremovefillercaps,breathers,andplugsonthemachine.Holdaragover
thecaporpluginordertopreventbeingsprayedbypressurizedliquids.Whenthemachinehas
beenstopped,thedangerofhotfluidsisgreater.
CorrosionInhibitor
Corrosioninhibitorcontainsalkali.Avoidcontactwiththeeyes.Donotallowcorrosioninhibitor
tocontacttheskinforextendedperiodsoftime.Avoidrepeatedcontactwiththeskin.Donot
drinkcorrosioninhibitor.Incaseofcontact,immediatelywashskinwithsoapandwater.For
contactwiththeeyes,flushtheeyeswithlargeamountsofwaterforatleast15minutes.Seek
medicalattention.
Batteries
Donotsmokewhenaninspectionofthebatteryelectrolytelevelismade.Neverdisconnectany
chargingunitcircuitorbatterycircuitcablefromthebatterywhenthechargingunitisoperating.
Asparkcancauseanexplosionfromtheflammablevapormixtureofhydrogenandoxygenthat
isreleasedfromtheelectrolytethroughthebatteryoutlets.Donotallowbatteryelectrolyteto
contactskinoreyes.Batteryelectrolyteisanacid.Incaseofcontactwithbatteryelectrolyte,
immediatelywashtheskinwithsoapandwater.Forcontactwiththeeyes,flushtheeyeswith
largeamountsofwaterforatleast15minutes.Seekmedicalattention.
PressurizedItems
1.Alwaysuseaboardorapieceofcardboardwhenyoucheckforaleak.Leakingfluid
underpressurecanpenetratebodytissue.Fluidpenetrationcancauseseriousinjuryand
possibledeath.Apinholeleakcancausesevereinjury.Iffluidisinjectedintoyourskin,
youmustgettreatmentimmediately.Seektreatmentfromadoctorthatisfamiliarwiththis
typeofinjury.
2.Relieveallpressureinair,oil,orwatersystemsbeforeanylines,fittings,orrelateditems
aredisconnectedorremoved.Alwaysmakesurethatallraisedcomponentsareblocked
correctly.Bealertforpossiblepressurewhenyoudisconnectanydevicefromasystem
thatutilizespressure.
3.Fuellinesthataredamagedandfuellinesthatareloosecancausefires.Lubricationlines
thataredamagedandlubricationlinesthatareloosecancausefires.Hydrauliclines,
tubes,andhosesthataredamagedcancausefires.Loosehydrauliclines,loosetubes,
andloosehosescancausefires.Donotbendorstrikehighpressurelines.Donotinstall
lineswhichhavebeenbentordamaged.Checklines,tubes,andhosescarefully.Donot
useyourbarehandtocheckforleaks.Iffluidsareinjectedintoyourskin,youmustget
treatmentimmediately.Seektreatmentfromadoctorthatisfamiliarwiththistypeofinjury.
4.Pressureairorwatercancausepersonalinjury.Whenpressureairorwaterisusedfor
cleaning,wearaprotectivefaceshield,protectiveclothing,andprotectiveshoes.The
maximumairpressureforcleaningpurposesmustbebelow205kPa(30psi).Whenyou
useapressurewasher,keepinmindthatthenozzlepressuresarehigh.Thenozzle
pressuresarefrequentlyabove13790kPa(2000psi).Followalloftherecommended
practicesthatareprovidedbythemanufacturerofthepressurewasher.
ApprovedInspectionMethods
Visualinspection(VT),dyepenetrantinspection(PT),magneticparticleinspection(MT)and
ultrasonicinspection(UT)arerequiredforthisrepairprocedure.Eachoftheseinspection
methodsshouldbeconductedandreportedbyqualifiedpersonnel.Examplesofqualified
personnelareasfollows:VTAWSCWI(AmericanWeldingSocietyCertifiedWelding
Inspector)orequivalent.MT/PT/ASNT(AmericanSocietyofNondestructiveTesting)LevelII
(minimum)foreachmethodused.Donotusethemagneticparticleinspectionprocessaround
componentsthatwillbeaffectedbymagnetism.Donotusethedyepenetrantinspection
processaroundcomponentsthatwillbeaffectedbythedyepenetrantsolution.
RequirementsforUltrasonic(UT)Testing
Personnel
PersonnelperformingtheinspectionswillbeatleastLevelIICertifiedTechniciansinthe
UltrasonicTestingmethod,asdefinedbyASNTSNTTC1A,ASNTCP189,orotherequivalent
internationalstandard.
PersonnelperformingtheinspectionswillbetrainedbyaLevelIIorLevelIII,untilthepersonnel
showproficiencyandunderstandingofproceduresandrejectioncriteria.
Apparatus
Ultrasonic(UT)Instrument
TheUTflawdetectioninstrumentshallbecapableofgenerating,receiving,andamplifyinghigh
frequencyelectricalpulsesatsuchfrequenciesandenergylevelsrequiredtoperforma
meaningfulexaminationandprovidesuitablereadouts.
Preferredfunctions/featuresincludebutnotlimitedto:inspectionprogramrecording,signal
gatingsystem,measurementdatadisplay,DAC/TCGrecording,and0DbReference.
UTinstrumentcertification/qualificationshouldbeperformedannuallyaccordingtoASTME317
orequivalent.Includingtheverificationofkeyperformancecharacteristics,suchashorizontal
limitandlinearity,verticallimitandlinearity,resolutionentrysurfaceandfarsurface,sensitivity
andnoise,accuracyofcalibrationgaincontrols.
AngleBeam/ShearwaveSearchUnit
Theultrasonictransducer(probe,orsearchunit)shallbecapableoftransmittingandreceiving
ultrasoundattherequiredfrequenciesandenergylevelsnecessaryfordiscontinuitydetection
inthematerialbeingexamined.Frequenciesof2MHzto5MHzshallbeemployedforangle
beamshearwaveinspection.
Transducercrystalcanberound,square,orrectangular.Crystalsizerecommendedforweld
examinationshallbeintherangeof9mm(0.35inch)to25mm(1.0inch).
Selectionofatransducerisdeterminedbytestingvariables.Testingvariablesincludeweld
thickness,testingsurface,acceptableflawsize,flaworientation,andtheacousticpropertiesof
themetal.
Inanglebeaminspection,thewedge/shoeisattachedtothetransducertogeneratethedesired
incidentbeamangleandwavemodeintheparts.Thecommonbeamanglesusedinweld
inspectionare45,60,and70.Therefractedangleshallbenogreaterthan2fromnormal.
Theedgedistanceshallnotexceed25mm(1.0inch).Thewedgeanglesshallbeselected
accordingtoinformationfoundinthe""ProbeSelection""section.
Couplant
Couplantisrequiredbetweenthefaceofthesearchunitandtheexaminationsurface.Couplant
permitsthetransmissionofultrasonicwavesfromthesearchunitintothematerialunder
examination.
Typicalcouplantsincludecellulosegel,glycerin,andlightmachineoil.Corrosioninhibitorsor
wettingagentsmaybeadded.Couplantsmustbeselectedthatarenotdetrimentaltothe
productortheprocess.Specialcouplantandsearchunitmayberequiredatelevated
temperatures(above52C(125F).
DistanceCalibrationBlocks
RefertoASTME164fortwooptionsofdistancecalibrationblocks,othersuitableblocksmaybe
used.
Illustration3
g03410559
Option1:IIWType1orTypetwoBlock
Illustration4
g03410579
Option2:DSCBlock
SensitivityCalibrationBlocks
Threeoptionsforsensitivitycalibrationblocksaregivenbutotherblocksmaybeused.
Minimumrequirementsshallmeettherequirementdeterminedinthe""SensitivityCalibration""
section.
Forothersensitivityblocks:1.5mm(0.06inch)sidedrilledholes(SDH)paralleltothe
inspectionsurfaceandperpendiculartothesoundpathshallbeusedasthecalibrationtarget.
Illustration5
g03410643
Option1:CatDACBlock
(A)340mm(13.40inch)
(B)90mm(3.55inch)
(C)40mm(1.60inch)
(D)1.50.05mm(0.050.001inch)diameterSDH's
(E)100.1mm(0.400.004inch)
(F)200.1mm(0.800.004inch)
(G)300.1mm(1.200.004inch)
(H)400.1mm(1.600.004inch)
(J)630.1mm(2.500.004inch)
(K)1260.1mm(5.00.004inch)
(L)1890.1mm(7.400.004inch)
(M)2520.1mm(9.900.004inch)
Option1:CatDACBlock1.5mm(0.06inch)SDH'sat10mm(0.40inch)stepsfromthe
surfacetoincludealldepthsoverallthicknessrangestobeused.
UsethedimensionsinIllustration5inordertofabricateCatDACBlockuseASTMA572
Grade42/50steel.
Illustration6
g03410725
Option2:CattBlocks
(N)200mm(8.0inch)
(P)16mm(0.60inch)
(R)40mm(1.60inch)
(S)1.50.05mm(0.050.001inch)diameterSDH's
(T)40.1mm(0.160.004inch)
(U)80.1mm(0.300.004inch)
(V)200.1mm(0.800.004inch)
(W)1600.1mm(6.300.004inch)
Illustration7
g03410752
Option2:CattBlocks
(X)200mm(8.0inch)
(Y)50mm(2.0inch)
(Z)40mm(1.60inch)
(AA)1.50.05mm(0.050.001inch)diameterSDH's
(BB)12.50.1mm(0.500.004inch)
(CC)250.1mm(1.00.004inch)
(DD)200.1mm(0.800.004inch)
(EE)1600.1mm(6.300.004inch)
Option2:CattBlocks:Blocksthesamematerialandthicknessasthepartstobetested.
Machined1.5mm(0.06inch)SDH'sat1/4tand1/2tdepths.Blocksmustbelongenoughfor
fullskippathandwideenoughfortheentiresearchunittositonthescanningsurface.
UsethedimensionsinIllustration6andIllustration7inordertofabricateCattBlocksuse
ASTMA572Grade42/50steel.
Illustration8
g03410827
Option3:IIWType1or2Blocks
Option3:Use1.5mm(0.06inch)SDHpositionArefertoIllustration8.Anattenuationfactorfor
indicationinterpretationwillhavetobeusedtocompensateforattenuationofthesoundbeam
asthesoundbeampropagatesthroughthematerial.ReferenceAWSD1.1orequivalentcode
orstandardforfurtherinstruction.
SamplePreparation
SurfacePreparation
Thesurfacemusthavecontourallowingtheclosecouplingbetweenthesearchunitand
scanningsurface.
Theinspectionsurfaceshallbefreeofloosescale,loosepaint,weldspatter,dirt,excessive
roughness,orotherforeignobjectsthatwouldinterferewiththetransmissionofsoundenergy
fromthesearchunitintothepart.Cleaningand/orgrindingmaybeneeded.
TestProcedure
EquipmentCalibration
InadditiontotheannualUTequipmentcertification/qualification,periodicalcalibrationor
standardizationisrequiredtoverifythatUTequipmentisperformingasintendedfordaytoday
usage.
Foranglebeamapplications,thefollowingkeyparametersshallbechecked:
DistanceCalibration:ThedistanceandsensitivitycalibrationshouldbeverifiedbytheUT
operator.
Recalibrationshallbemadeaminimumofevery4hoursorprocesschange,suchaschanging
operator,searchunitand/cable,battery,testingweld,andrecouplesearchunit.
VerifytheBeamIndexPoint:(ThefollowingexampleisconductedonaIIWTypeBlock.)
PositiontheUTprobetowardthe100mm(4.0inch)radiusontheIIWtypereferenceblock.
Setproperrangeintheinstrumenttoensurethatthesignalfromthe100mm(4.0inch)radius
isdisplayed.Scanthesearchunitbackandforthtopeakthe100mm(4.0inch)signal.The
pointonthesearchunitwedgealigningwiththe0referencelineonthecalibrationblockisthe
beamindex/entrypoint(positionDinIllustration3).
VerifytheBeamAngle:PositionthesearchunittowardtheLucite/openwindowontheIIW
typereferenceblock.
SetproperrangeintheinstrumenttoensurethatthesignalfromtheLucite/openwindowis
displayed.Scanthesearchunitbackandforthtopeakthesignal.
Theanglemarkedonthereferenceblockinlinewiththesearchunitindexpointistheactual
beamangle.Thebeamangletoleranceshallbewithin2.Dependingonthebeamangleand
thetypeofreferenceblock,othertechniquesrecognizedbyrelatedindustrialstandardsmaybe
used(positionBorCinIllustration3).
DistanceCalibration:Inordertoensuretheaccuracyoflocatingwelddiscontinuities,the
distanceshallbecalibratedthroughtheentiresoundpathusedduringthespecificexamination.
100mm(4.0inch)radiusontheIIWtypereferenceblockiscommonlyusedfordistance
calibrationinanglebeamapplications(positionDinIllustration3).
PositiontheUTprobetowardthe100mm(4.0inch)radius.Settheproperrangeinthe
instrumenttoensurethesecondreflectionfromthe100mm(4.0inch)radiuscanbedisplayed.
Inordertoobtainmeaningfulreadings,otherinstrumentsettings,suchasprobeangle,gateand
gainlevelshallbeproperlyselected.
SensitivityCalibration
1.5mm(0.06inch)sidedrilledholes(SDH)paralleltotheinspectionsurfaceandperpendicular
tothesoundpathshallbeusedasthecalibrationtarget.
DAC/TCGDAC(distanceamplitudecorrection)orTCG(timecorrectedgain):Thesignal
fromthe1.5mm(0.06inch)SDHshouldbecalibratedtobe80%FSH(fullscreenheight)for
thefirstpointofaDACcurveandallpointsfortheTCG.DACandTCGshallbeusedtoensure
thesameinspectionsensitivityatdifferentsoundpathsacrosstheentirerange.
MinimumofthreepointsshallbeusedtoestablishtheDAC/TCG,overtheentirerangeanda
fullskipdistanceforthematerialthicknessbeingtested.
UseSensitivityCalibrationBlocksOption1orOption2describedinthe""SensitivityCalibration
Blocks""section.
ExampleforDAC/TCGsetupfora16mm(0.60inch)thickweldjointusing70wedgeusing
theCatDACBlockusethe10mm(0.40inch),20mm(0.80inch),and30mm(1.20inch)
holes.
ExampleforDAC/TCGsetupfora16mm(0.60inch)weldjointusing70wedgeusingthe
Cattblock.Usethe1/4thole,3/4thole,andthe7/4thole.
ReferenceReflector:When,asingle1.5mm(0.06inch)ReferenceReflector(refertoAWS
D1.1)isusedtoattainahorizontalreferencelineheightindication.ThemaximumDblevelused
toobtainan80%FSHpeaksignalshallberecordedastheReferenceGainLevel.
Anattenuationfactorforindicationinterpretationwillhavetobeusedtocompensatefor
attenuationofthesoundbeamasthesoundbeampropagatesthoughthematerial.An
IndicationRatingshouldbecalculatedforthebasisofAcceptanceorRejection.UseSensitivity
CalibrationBlockOption3positionAinIllustration8.
ScanPattern,ScanDistance,andScanSpeed
Illustration9
g03410922
(FF)Scandistancelessthan150mm(6.0inch)persecond
(GG)Firstleg
(HH)Secondleg
(JJ)Weldcenterline
(KK)Scanpattern
(LL)Scanningadvance(nottoexceed75%ofsearchunitwidth)
(MM)Oscillatingangle15
(NN)Searchunit
TheentirevolumeofweldandHAZ(heataffectedzone)shallbeexaminedfromeachsideof
theweldwhereverpractical.Examinationshallbemadeinfirstandsecondlegwherever
possible.Scanspeedshallbelessthan150mm(6.0inch)persecondunlesstheinspection
procedurespecifiesdifferently.
ThetypicalinspectionconfigurationforabuttweldisshowninIllustration9inthe""Sensitivity
CalibrationBlocks""section.
Inordertodetectlongitudinaldiscontinuities.Thesearchunitshallbeoscillatedtotheleftand
rightwithanangleofapproximately15whilecontinuouslyscanningperpendicularlytothe
weldaxis.Thelateralmovementadvancingthesearchunitshallnotexceed75%ofthesearch
unitwidth.
Inordertoensurefullvolumecoverage.Thescandistanceshallcoveratleast1fullskippath
(firstandsecondleg)backfromtheweldcenterline.Todetecttransversediscontinuities,the
soundbeamshallbedirectedatapproximately15paralleltotheweldaxis.Thesearchunit
shallbemovedalongtheweldedgefrombothsidesandfromoppositedirections.
InitialSurveillanceScanning
Forinitialscanning,extragain(6dBor12dB)mayberequiredinordertofacilitatedetectionof
potentialdiscontinuities.Theevaluationoftheindicationshallbeperformedbacktothe
referencesensitivity.
793FUTInspectionAreas
Illustration10
Jointdetailaroundthewindowplate
(PP)Weldseamsaroundthewindowplate
g03411355
Illustration11
g03413338
Viewofacrackwhichpropagatedthroughthebottomrailsection
Refertotherepairproceduresinthisdocumentforspecificinformationforjointtypeand
configuration.
ProbeSelection
Table4
WeldThickness
WedgeAngle(1)
Range(2)
6mm(0.25inch)thru
70
100
20mm(0.80inch)thru
38mm(1.50inch)
70
150
38mm(1.50inch)thru
80mm(3.15inch)
45
200
20mm(0.80inch)
(1)
Multiplewedgeanglescanbeusedforthicknessesoutsideguideline.
(2)
Rangesettingshouldbeadjustedaccordinglytohaveafullskippathonthescreen.
Thewindowplatesare16mm(0.65inch)thick,a70wedgeshallbeusedforlocations(PP)as
showninIllustration10.
The4barlinkcastingtothemainrailweldwillneedUTinspectionafterarepairorthroughwall
crackinthebottomortoprailsection.RefertoIllustration11.Theweld/plateis50mm(2.0
inch)thickanda45wedgeshallbeused.Table4shallbeusedforreferenceifneeded.
Alternateanglescanbeusedformultiplethicknessesifwarrantedbyjointdesignorjoint
preparation.
Accept/RejectCriteriaandSizing
Illustration12
(AB)Searchunit
(AC)Searchunit
(AD)Searchunit
(AE)Distancebetween(L1)and(L2)
(AF)Signalamplitude
(AG)Amplitudeprofile
(AH)Threshold
(AJ)50%threshold
(AK)Searchunitposition
(L)Lengthofindicationoverthethreshold
(LR)Lengthofindicationoverthe50%threshold
(L1)Longerdiscontinuity
(L2)Shorterdiscontinuity
g03411593
Note:Adjacentdiscontinuities:when(AE)issmallerthanthedesignatedminimumlength((AE)
<(L1)oraspecificlength),thetwodiscontinuitiesshallberegardedascontinuousandthe
overalllengthis(L1)+(AE)+(L2).
SubsurfaceinternalweldqualitywillmeettherequirementssetforthbyTable10.Inorderto
determinetherejectablelengthsofindicationsthatmeetorexceedthe1.5mm(0.06inch)SDH
reverencelevel:
Anindicationthatmeetsorexceedsthereferencelevel(DAC,TCG,or0ReferenceLevel)
continuouslyfor25mm(1.0inch)or10%oftheweldlengthwhicheverislessisrejectable.
Intermittentindicationsthatdonotmeetthecriteriabuttheaggregatelengthoftheindications
exceed10%oftotalweldlengthisrejectable.Indicationsbelow5mm(0.20inch)inlengthare
nottypicallyincludedintheaggregateindicationlength.
Indeterminingtheendsofrejectableindications.The6dBdropmethodshallbeused,withthe
flawdetectorsensitivitysettothereferencelevel(0dB).Movethesearchunitparalleltothe
welduntilthetipofthesignaldropsto50%oftheDACheight.Marktheweldevenwiththe
centerofthesearchunit.Movethesearchunitparalleltotheweldintheoppositedirectionuntil
thesignaldropsto50%oftheDACheight.Marktheweldevenwiththecenterofthesearch
unit.Acceptabilityofweldswithmultipledefectiveareas.Ifthespacebetweentwodefective
areasislessthanthelargestdefectlength,theareabetweenthetwodefectiveareasshallalso
beconsideredrejectableandshouldbemarkedforrepair.RefertoIllustration12.
MarkforWeldRepair
Torepairtherejectedweld,additionalexcavationlengthateachendoftherejectable
discontinuityisnormallyrequired.Ageneralguidelineistomarkanadditional25mm(1.0inch)
to50mm(2.0inch)onbothendsofthediscontinuityinordertoensureproperremovalof
defectiveareas.Thisguidelineshallbefollowedwhereverpractical.
Reporting
Aftertheultrasonic(UT)inspectioniscompleted,fillouttheformsprovided.RefertoTable15
andTable16attheendofthisdocument.AcopyshouldbeprovidedtotheCustomer,Dealer,
and/ortheappropriateCaterpillarproductsupportrepresentative.
InspectionIntervals
Inspectionsoftheframeassemblyforcracksshouldbeconductedduringregularmaintenance
intervals.Areastobeinspectedareblockedbyoneormorecomponents.Ifthecomponentthat
isblockingtheframeisremoved,aninspectionofthatareashouldbeperformed.Take
advantageoftheopportunitytoinspectthosepartsoftheframeassemblythatareexposed
whenevercomponentsareremoved.Asanexample,ifthehydraulictankiseverremoved,the
areabehindthehydraulictankshouldbecleanedandinspected.RefertoOperationand
MaintenanceManual,SEBU8406,"793FOffHighwayTruck","FrameClean/Inspect"forthe
properinspectionintervals.
WeldingSpecificationsandQualifications
Protectyourselfandothersreadandunderstandthiswarning.Fumesandgasescan
bedangeroustoyourhealth.Ultravioletraysfromtheweldarccaninjureeyesand
burnskin.Electricshockcankill.
Readandunderstandthemanufacturer'sinstructionandyouremployer'ssafety
practices.Keepyourheadoutofthefumes.Useventilation,exhaustatthearc,or
both,tokeepfumesandgasesfromyourbreathingzoneandthegeneralarea.Wear
correcteye,earandbodyprotection.Donottouchliveelectricparts.
RefertotheAmericanNationalStandardZ49.1,"SafetyinWeldingandCutting"
publishedbytheAmericanWeldingSociety,2501N.W.7thStreet,Miami,Florida
33125:OSHASafetyandHealthStandards,29CFR1910,availablefromU.S.Dept.of
Labor,WashingtonD.C.20210.
Note:Personalbreathingprotectionshouldbewornbythepersonnelthatarewelding.
Personalbreathingprotectionwillpreventfumesfromenteringthelungsofthepersonthatis
welding.Usea2375181Respiratorforbreathingprotection.
Qualifications
Weldersmustbequalifiedfortheappropriatetypeofweldthatisbeingperformed.Welders
mustbequalifiedfortheappropriatepositionofweldthatisbeingperformed.Weldersmustbe
qualifiedfortheweldingprocessthatisbeingutilized:ShieldedMetalArcWelding(SMAW)and
FluxCoredArcWelding(FCAW).RefertoSpecificationANSI/AWSD1.1forinformationthat
regardsqualificationrequirements.Theweldersmusthaveusedtheprocessatsometime
withinthelast6months.Theweldersmustcompletetheprocessofcertificationifthewelders
havenotusedtheweldingprocessesfor6months.
ProperWeldingProcedureonMachinesand
EngineswithElectronicControls
Properprecautionsarenecessarytopreventdamagetoelectroniccontrols.Whenyouweldon
amachinewithelectroniccontrols,usethestepsthatfollow:
1.Turnofftheengine.PutthekeystartswitchintheOFFposition.
2.Ifthemachinehasabatterydisconnectswitch,opentheswitch.Ifthemachinedoesnot
haveabatterydisconnectswitch,disconnectthenegativebatterycableatthebattery.
3.Attachtheclampforthegroundcableascloseaspossibletotheareathatisbeing
welded.Thisprocesswillreducethelikelihoodofdamagefromtheweldingcurrenttothe
followingcomponents:bearings,hydrauliccomponents,andelectricalcomponents.DO
NOTweldplatestotheframeforgrounding/clampingpurposes.Useexisting
blocks,brackets,bosses,andsoon,toattachtheclamp.
Note:DoNOTuseelectricalcomponentsasagroundpointforthewelder.DoNOTuse
groundpointsforelectroniccomponentsasagroundpointforthewelder.
4.Protectthewiringharnessesandmachinesurfacesfromsparksandweldingspatter.
AreaPreparation
Theareatobeweldedshallbeclean,dry,andfreeofthefollowingcontaminants:
Oil
Grease
Paint
Dirt
Rust
Anyfluidsormoisture
Allweldingshallbeconductedonbasematerialheatedandmaintainedataminimum
temperatureof15.6C(60F).
Note:Heatinginstructions(preheat,interpass,andpostheat)foranyspecificrepairshall
overridetheminimum15.6C(60F)requirement.
Note:Heatdistortionofthebasemetalispossiblewhenyouweld.Avoidexcessiveheatingof
thebasemetal.
WeldingElectrodesandParameters
FluxCoredWeldingElectrodefortheFCAWProcess
UsetheFluxCoredArcWelding(FCAW)withE71T1H8(ANSI/A5.20)weldingelectrodeand
themanufacturer'sshieldinggasesthatarespecified(typically75%argonand25%carbon
dioxide).TheH8impliesthattheelectrodeisdesignedtoprovidelessthan8ml/100gof
diffusiblehydrogeninthewelddeposit.Theweldthatisdepositedbythefluxcoredwelding
electrodewillhavethefollowingminimummechanicalproperties:
Table5
MechanicalPropertiesfromFluxCoredWeldingElectrodeThatIsClassifiedas
"ANSI/AWSA5.20E71T1H8"
TensileStrength
480MPa(70000psi)
YieldStrength
400MPa(58000psi)
Elongation
22%
ImpactToughness
27J@18C(20ftlb@0F)
Thetablesthatfollowshowtherecommendedparameterrangesforoutofpositionweldingin
thefieldfortwodifferentfluxcoredweldingelectrodediameters.
Table6
WeldingCurrentforFluxCoredWeldingElectrodethatIs
1.2mm(0.045inch)
WireFeedRate
Voltage
Amperage
7620mm(300inch)PerMinuteto
24to28
190to240
10,160mm(400inch)PerMinute
Table7
WeldingCurrentforFluxCoredWeldingElectrodethatIs
1.4mm(0.052inch)
WireFeedRate
Voltage
Amperage
5080mm(200inch)PerMinuteto
23to27
180to220
6350mm(250inch)PerMinute
Note:Thesettingslistedabovearerecommendationsbasedonexperiencefromweldinginthe
horizontal,verticalup,andoverheadpositions.Slightchangesinthevoltageandamperage
maybenecessaryduetoweldingpositionandvariousformulationsbydifferentelectrode
manufacturers.Theuseofhigherparametersthanspecifiedforweldingintheflatpositionis
acceptable.
UseapolaritysettingofDCreversepolarity.Removetheslagaftereachweldingpass.Thefast
freezingcharacteristicsoffluxcoredweldingelectrodeincreasesthepossibilityofevolvinggas
thatistrappedintheweld.Controlthesizeoftheweldinordertoreducethepossibilityof
evolvinggasthatistrappedintheweld.Themaximumsizeweldperpassshouldbeequivalent
tothatofa8.0mm(.32inch)filletweld.
LowHydrogenElectrodesfortheSMAWProcess
Asanalternativeprocessorwhenwindconditionsareafactor,useSMAWandlowhydrogen
electrodesthatmeetthefollowingrequirements.
Table8
MechanicalPropertiesofWeldsfromLowHydrogenElectrodesThatAreClassifiedas
"ANSI/AWSA5.1E7018H4R"
TensileStrength
480MPa(70000psi)
YieldStrength
400MPa(58000psi)
Elongation
22%
ImpactToughness
27J@29C(20ftlb@20F)
Lowhydrogenelectrodesmustbestoredinanelectrodeovenat120C(250F)whennotin
use.Iflowhydrogenelectrodesgetdamp,scrapthelowhydrogenelectrodesorreconditionthe
lowhydrogenelectrodestothemanufacturer'sspecifications.
Thetablethatfollowsshowsthesettingsfortheweldingcurrentbasedonelectrodediameter.
Table9
WeldingCurrentforLowHydrogenElectrodes
Diameter
AmperageRating
3.2mm(1/8inch)
105155
4.0mm(5/32inch)
130200
4.8mm(3/16inch)
200275
UseapolaritysettingofDCreversepolarity.Removetheslagaftereachpassofthewelding
electrode.Thewidthoftheweldshouldnotexceedtwotimestheelectrodediameter.
WeldInspectionandAcceptanceCriteria
Table10
ISO6520
DefectName
Defect
Reference
Number
Cracks
Longitudinal,
Transverse,
1011,1012,
1013,1014,
1023,1024,
1031,1033,
Remarks
DefectLimit
Radiating,
Crater,
1034,1045,
Disconnected,
1051,1053,
Branching
1054,1061,
1063,1064
Crack
Transverse
Crack
Transverse
NotPermitted
1021
HardSurfacingWeldsOnly
Permitted
1021
JoiningWelds
NotPermitted
1046,1047,
MaximumDiameterforaSingle
Pore
Porosity
2011,2012,
2014,2017
MaximumPoresinAny
300mm(11.81inch)LengthofWeld
MaximumNumberofPoresinAny
50mm(2.0inch)ofWeldLengthfor
WeldsLessThan
1mm(0.040inch)
300mm(11.81inch)inLength
Clustered
Porosity
2013
MaximumLengthofClusterinAny
Weld
MaximumHeightorWidth
3mm(0.120inch)
3mm(0.120inch)
Elongated
Cavities
2015
MaximumLengthforAnySingle
Discontinuity
MaximumLengthinAnyWeld
MaximumDimensionofAnySingle
Cavity
Elongated
Cavities
Shrinkage
2016
2021,2024,
25mm(1.00inch)
10%ofWeld
Length
3mm(0.120inch)
10%ofWeld
MaximumTotalLengthofAffected
LengthNotto
AreainAnyWeld
Exceed
25mm(1.00inch)
MaximumDiameterorLength
1mm(0.040inch)
Cavities
2025
MaximumHeightorWidth
SlagorFlux
Inclusions
1mm(0.040inch)
3011,3012,
3014,3021,
MaximumLengthforAnySingle
3022,3024
Discontinuity
MaximumLengthinAnyWeld
MaximumHeightorWidth
25mm(1.00inch)
10%ofWeld
Length
1mm(0.040inch)
Oxide
3031,3032,
Inclusions
3033
MaximumLengthforAnySingle
Discontinuity
25mm(1.00inch)
MaximumLengthinAnyWeld
10%ofWeld
Length
NotPermitted
NotPermitted
Visual(BreakingtheSurface)
NotPermitted
Puckering
(Oxide
Inclusion
3034
Aluminum)
Metallic
3041,3042,
Inclusion
3043
SubsurfaceMaximumHeightor
Width
1mm(0.040inch)
LackofFusion 4011,4012,
4013
SubsurfaceMaximumLengthfor
AnySingleDiscontinuity
MaximumLengthinAnyWeld
25mm(1.00inch)
10%ofWeld
Length
10%ofNominal
PenetrationNotto
MaximumReducedPenetration
Lackof
Penetration
Exceed
1mm(0.040inch)
402,4021
MaximumAllowedTotalLengthof
ReducedPenetration
10%ofWeld
Length
5011,5012,
Undercut
5013,5014,
5015
MaximumDepthMeasuredFrom
PlateSurfaceAnyLength
AnyLength
0.5mm(0.020
inch)
WeldFaceWidth
5mm(0.20inch)orLess
1mm(0.040inch)
WeldFaceWidthOver
ExcessWeld
Metal
GrooveWeld
502
5mm(0.20inch)ButLessThan
1.5mm(0.060
10mm(0.40inch)
inch)
WeldFaceWidthOver(10mm)
Reinforcement
(0.40inch)ButLessThan
(Convexity)
20mm(0.80inch)
2mm(0.080inch)
WeldFaceWidthOver
20mm(0.80inch)ButLessThan
30mm(1.20inch)
3mm(0.120inch)
WeldFaceWidth
30mm(1.20inch)andOver
ConvexityAffectsWeldToeAngle,
ExcessWeld
MetalFillet
Weld
ReducingFatigueLife
503
Convexity
WeldToeAnglesof135Degrees
andMoreAreBetter
DefectLimitsExpressedas
MinimumToeAnglesAllowed
WithoutDrawingLimitation
4mm(0.160inch)
90Degrees
2mm(0.080inch)
(AnyLength)
Excess
5041,5042,
Penetration
5043
IncorrectWeld
Toe
Overlap
With"MeltThru"and"Flush"Weld
Symbols
1mm(0.040inch)
(AnyLength)
With"MeltThru"and"GrindFlush"
NotPermitted
Symbols
(AfterGrinding)
When1E2995Applies(Expressed
505
5061,5062
asaToeRadiusRatherThanaToe
3mm(0.120inch)
Angle)
MinimumRadius
ExpressedasMinimumToeAngle
90Degrees
AppliestoEitherWeldLeg
MeasuredIndependentoftheOther
MaximumUndersize
FilletWeld
LegSize
1mm(0.040inch)
10%ofTotalWeld
LengthIfAtLeast
Undersize
10%ofTotalWeld
LengthisatLeast
MaximumLengthofUndersizeWeld
1mm(0.040inch)
OverNominalSize,
Otherwise,No
UndersizeLength
isPermitted
AppliestoEitherWeldLeg
MeasuredIndependentoftheOther
MaximumOversize
FilletWeld
LegSize
Oversize
+25%(max
3mm(0.120inch))
ConformancetoDesignFilletWeld
LegSizesMaybeOversized(Within
DefectLimitationsorBeyond)
WithoutCorrectionProvidedthe
ExcessDoesnotInterferewith
SatisfactoryEndUseofthe
Component(i.e.,Distortion,FitUp
Interference,etc.)
FilletWeld
WeldSize
6.5mm(0.256inch)
LinearLength
when
specifiedat
lessthanthe
lengthofthe
joint
6.5mm(0.256
inch)
WeldSize
6.5mm(0.256inch)
12.5mm(0.492
inch)
NominalSize(0.7xLegSize)Not
InclusiveofPenetrationBeyondthe
NotPermitted
WeldRoot
2mm(0.080inch)
FilletWeld
ThroatSize
Undersize
MAXandNotto
5213
Exceed20%of
WeldCraterOnlyMaximum
Undersize
SpecifiedThroat,
NotInclusiveof
Penetration
BeyondtheWeld
Root(0.7xLeg
Size)
CarefulConsiderationNeedstobe
GivenWhenPlateMismatchis
Incompletely
FilledGroove
Weld
511
NotPermitted
Apparent
WeldDepthMustbeMaintainedas
aMinimum
Root
Concavityon
OpenRoot
GrooveWelds
MaximumDepthmeasuredFrom
515,5013
PlateSurfaceorTubeInnerSurface
AnyLength
0.5mm(0.020
inch)
MeasuredinTermsofExcessWeld
Metal(FilletWeldConvexity)or
OverlaponGrooveWelds,Lackof
Fusion,orInsufficientThroat
ExcessWeldMetalonFilletWelds,
DefectLimitsExpressedas
PoorRestart
(TieIn)
5171,5172
90Degrees
MinimumToeAnglesAllowed
OverlaponGrooveWelds,Defect
LimitsExpressedasMinimumToe
90Degrees
AnglesAllowed
LackofFusionVisualMaximum
StrayArc
Strike
601
SlagResidue 615
LengthPerRestart
3mm(0.120inch)
InsufficientWeldThroat
NotPermitted
NotPermitted
SMAW,SAW,FCAW,GMAW
NotPermitted
SiliconResidue
PermittedUnless
GTAW
RemovalSpecified
byDrawingNote
TotalMaximumCombinedLengthof
AllImperfectionsinaWeld,
ExpressedasaPercentofTotal
Combined
Discontinuities
15%
WeldLength
(NoSingleTypeofImperfectionCan
ExceedtheLimitsforThatSingle
TypeofImperfection)
GeneralWeldRepair
1.Removeanycomponentsthatpreventaccesstothecrackedweld.
2.Referto""AreaPreparation""SectioninthisSpecialInstruction.
3.Usedyepenetrant(PT)ormagneticparticle(MT)inordertoidentifytheextentand/or
lengthofthenecessaryrepair.
4.Protectmachinedsurfacesfromsparksandwelddebris.
5.Ensurethatthebasematerialisataminimumtemperatureof15.6C(60F)before
welding.Ensurethataminimumtemperatureof15.6C(60F)ismaintainedthroughout
theentireweldingprocedure.
6.Thecrack(andsoundmetal50mm(2.00inch)beyondeachendofthecrack)shallbe
removedbygougingand/orgrinding.Cautionshouldbeusedtoavoidexcessiveremoval
ofthesurroundingbasematerial.Areasthataregougedbyaircarbonarctorchshallbe
latergroundandcleanedpriortoweldinginordertoremoveallcarbonabsorptionor
contamination.Gougedareasrequiringreweldingshallhavearootradiusofnotlessthan
5mm(0.20inch)andaSingleV60degreeincludedanglejointpreparationtoallowthe
welderreasonableaccesstoreinstatetheweld.
7.UsePTorMTtoinspectthegougedandgroundareainordertoensurethatthecrack
hasbeenremovedbeforeweldingcommences.
8.Repairthepreparedgrooveutilizingtherecommendationsprovidedinthe""Welding
ElectrodesandParameters""SectioninthisSpecialInstruction.
9.Cleantheweldarea.Inspecttheareathatwaswelded.Allweldqualityshallconformto
thecriteriaspecifiedinthe""WeldInspectionandAcceptanceCriteria""sectioninthis
SpecialInstruction.
ProperCleaningforInspection
Whenitisnecessarytoworkunderthemachinewiththebody(bed)raised,attachthe
body(bed)retainingcablestothereartowpoints.Installthereartowpointpins
throughtheendsoftheretainingcables.
Failuretoproperlysecurethebody(bed)mayresultinpersonalinjuryordeath.
Personalinjurycanresultfromworkingwithcleaningsolvent.
Becauseofthevolatilenatureofmanycleaningsolvents,extremecautionmustbe
exercisedwhenusingthem.Ifunsureaboutaparticularcleaningfluid,refertothe
manufacturer'sinstructionsanddirections.
Alwayswearprotectiveclothingandeyeprotectionwhenworkingwithcleaning
solvents.
NOTICE
Caremustbetakentoensurethatfluidsarecontainedduringperformanceof
inspection,maintenance,testing,adjusting,andrepairoftheproduct.Bepreparedto
collectthefluidwithsuitablecontainersbeforeopeninganycompartmentor
disassemblinganycomponentcontainingfluids.
RefertoSpecialPublication,NENG2500,"DealerServiceToolCatalog"fortoolsand
suppliessuitabletocollectandcontainfluidsonCatproducts.
Disposeofallfluidsaccordingtolocalregulationsandmandates.
Illustration13
g03361075
Topviewoftheframeassemblywithcentersectionhighlighted
Cleanthecentersectionoftheframethoroughly,especiallybehindtanks,inordertoensure
visibledetectionofanycracks.RefertoIllustration13forlocationofthecentersection.
Ensurethatthesubstancesthatfollowareremovedfromtheareathatwillbeinspected.
Oil
Grease
Dirt
InspectionProcedure
InspectCenterSectionoftheFrame
Illustration14
g03361127
1.Visualinspectionwillrequireacombinationofatelescopingmirrorand/oraborescopein
ordertoviewsomeoftheareaslisted.
Inmostcases,visualinspectionwillbesatisfactory:howeveranyuncertaintyshouldbe
verifiedviamagneticparticleMTinspection.
Inspect4BarLinkCastingtoMainRailConnection
Illustration15
Topviewoftheframe
g03361135
Illustration16
g03361144
Bottomviewoftheframe
Illustration17
g03361154
Exampleofcornercrackat4barlinkconnection
1.Visuallyinspectthe4barlinkcastingtomainrailconnectionasshowninIllustration15
andIllustration16.
Ifcrackingoccurs,crackswillbemostreadilyvisibleatthecornersoftheweldjointas
showninIllustration17.
Note:Theweldreinforcementhasbeensandedflushwiththeparentmaterialsothe
grooveweldconnectionisnotreadilyidentifiable.
InspectFilletWeldsConnectingTubetoVolcanoPlate
Interior
Illustration18
g03361176
Interiorviewoftubeassembly
(A)Tubeassembly
(B)Plate(volcano)
1.Visuallyinspectthefilletweldsconnectingtubeassembly(A)tovolcanoplate(B)onthe
interiorside.
2.Inspectfilletweld360degreesonbothinteriorsidesofthetruck.RefertoIllustration18
forguidance.
InspectFilletWeldsConnectingTubeAssemblyto
OuterWindowPlateandCoverPlateExterior
Illustration19
g03361203
Exteriorviewoftubeassembly
(A)Tubeassembly
(C)Outerwindowplate
(D)Coverplate
Illustration20
Exampleofafilletweldcrackinthetubeassemblytotheoutsidewindowplatelocation
g03361214
1.Visuallyinspectthefilletweldsconnectingtubeassembly(A)toouterwindowplate(C)
andcoverplate(D)ontheexteriorside.RefertoIllustration19.
2.Inspectfilletwelds360degreesonbothexteriorsidesofthetruck.RefertoIllustration20
forguidance.
InspectGrooveWeldBetweenOuterWindowPlateand
4BarLinkCastingExterior
Illustration21
Exteriorviewoftubeassembly
(C)Outerwindowplate
g03361222
Illustration22
g03361229
Exampleofgrooveweldcrackbetweenouterwindowplateand4barlinkcasting
1.Visuallyinspectthegrooveweldconnectingouterwindowplate(C)tothe4barlink
castingonbothexteriorsides.RefertoIllustration22forguidance.
InspectVerticalGrooveWeldBetweenAdjacent
WindowPlatesExterior
Illustration23
Viewofthelefthandside
(C)Outerwindowplate
(E)Outerwindowplate
g03361246
Illustration24
g03361252
Exampleofacrackinthegrooveweldconnectingtheadjacentouterwindowplates
1.Visuallyinspecttheverticalgrooveweldconnectingadjacentouterwindowplate(E)and
outerwindowplate(C).RefertoIllustration23forguidance.
InspectFilletWeldsAttachingHardwaretoOuter
WindowPlatesExterior
Illustration25
g03361502
Viewoftherighthandsideoftheframe
1.Visuallyinspectthefilletweldsattachingallhardwareonthetwoouterwindowplatesas
showninIllustration25.Inspectbothsidesofthetruck.
Illustration26
g03361516
Exampleoffilletweldcrackaroundhardware
Illustration26showsalargebottomcoolermount.Thelargecoolermountcanbefoundonearliermodel
trucks.LatermodeltruckswillreflectthethreesmallblocksonthebottomasshowninIllustration25.
Illustration27
Viewoftheinsiderighthandsideoftheframe
(F)Pumpbox
g03361525
Illustration28
g03361533
2.Visuallyinspectthefilletweldconnectingpumpbox(F)totheinsidewindowplateonthe
righthandsideoftheframeasshowninIllustration27.
Themainconcernisthetoprighthandcornerofpumpbox(F).RefertoIllustration28.
3.Onceinspectionoftheframeiscompleted,refertoIllustration29inthefollowingsection
inordertodeterminewhatcourseofrepairisrecommended.
Ifnocracksarevisuallydetected,thennorepairisrequired.
DecisionTree
Illustration29
g03361557
RepairOptionAistheleastinvasiverepair,buthasexceptionsattached:
Exception1:Ifthecracklengthintheweldismorethan150mm(6.00inch)inlengthorif
thecrackpropagatesoutintothebasematerialmorethan12mm(0.50inch),callthe
793FProductGroupServiceEngineerforguidance.
Exception2:Ifthecrackgoesthroughthicknessoftheplateorcastingorifthereisaloss
ofbackingmaterial,proceedtoRepairOptionB.
RepairOptionA
Thefollowinginformationpertainstovisualinspectionresultsthatwarrantweld
repairs/modificationstotheoutsideoftheframeandpostweldtreatmentstoexternal
attachments.Thisrepairappliestobothsidesoftheframe.Thisrepairoptionistheleast
invasiverepairanddoesnotrequireaccesstotheinsideoftheframecomponents.
PreHeat:Asaprecautionforthethickersectionsofmaterial(t>=50mm(2.00inch)),maintain
a100C(212F)preheat/interpasstemperatureforthetop/bottomrailtocastingconnections.
Thethinnersidesectionscanbeweldedatroomtemperature20C(68F).
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Table11
DisassemblyandAssemblyManuals
SalesModel
793F
793FXQ
793FCMD(CommandForHauling)
MachineSystems
PowerTrain
KENR8579
KENR8397
UENR1142
UENR1143
Illustration30
Sectionview
(A)Innercurvedplate16mm(0.60inch)to25mm(1.00inch)
(B)Rolledrailplate50mm(2.00inch)
(C)Outerwindow16mm(0.60inch)
g03361777
Illustration31
g03361767
Internalviewofweldjointwithsteelbacking
1.Forvisualcracksdetectedatthe4barlinkcastingtomainrailconnection,asshownin
Illustration17proceedwiththerepairusingthefollowinginformationforguidance.
2.ToassistwithexcavationandrepairseeIllustration30andIllustration31forreference
informationregardingmaterialthickness,weldjointdesign,andgeometricalperspective.
Note:Rolledrailplate(B)is50mm(2.00inch)inthickness.Careshouldbetakennotto
excavatebeyondthesteelbackingstrip.Thecrackshouldbenodeeperthan50mm
(2.00inch)forthebottomweldseam.
Illustration32
Excavatecrackbyarcairgouging
(D)Gougedprofile
g03361816
(E)Sectionthickness
Illustration33
Crosssectionalviewofanticipatedgrinding
(E)Sectionthickness
(F)Finishgrindtoachieve70degreeincludedangle
g03361821
Illustration34
Crosssectionalviewofpreparedjointpriortowelding(slightradiusatroot)
(E)Sectionthickness
(G)70degreeangle
(H)35degreeangle
g03361830
Illustration35
g03361835
Longitudinalviewofpreparedjoint
(E)Sectionthickness
(J)45degreeangle
3.Excavateandremovethecrackandpreparethejointforwelding.
Illustrations32,33,34,and35demonstratethesequenceofstepsnecessarytoobtain
thedesiredjointconfigurationpriortowelding.
Thedepthofexcavationandgrindingwilldependonthedepthofthecrack.
4.Uponcompletionofexcavationandpreparation,refertoweldingprocedureguidelinesand
reinstatebywelding.
Illustration36
g03361861
Viewofcracksatcornersonbottomrailbeforeexcavation
Illustration37
Viewofcracksexcavatedandrunon/offtabsattached
(K)Runon/offtabs
g03361863
Illustration38
g03361879
Viewofcompletedweld,tabsremoved,andsurfacesandedflush
5.AsanexampleIllustration36,37,and38demonstratethepropersequence(before,
during,andafter)forcracksthatdidnotpropagatethroughthethicknessoftheplates.
Note:Forrepairsmadeonplateswithopenends,attachrunon/offtabs(K)inorder
toplaceweldstartsontabsandoutsideoffinishedweld.Lackoffusiondefects
associatedwithstartswillthenbenonexistentwhenrunon/offtabs(K)are
removed.
6.Performvisualinspectioninordertoensurethatallweldqualitymeetsorexceedsthe
requirementsshowninthe""WeldInspectionandAcceptanceCriteria""section.
7.Afterweldinghasbeencompleted,sandflushtoprofileofsurroundingparentmaterial
leavingtheappearancethatnoweldrepairhasbeenconducted.
Illustration39
g03361900
16mm(0.60inch)filletweldbothinteriorendsoftubeassembly
(L)Tubeassembly
(M)Plate(volcano)
8.Forvisualcracksdetectedinthefilletweldsconnectingtubeassembly(L)toplate
(volcano)(M)ontheinteriorside,excavatecompletely,preparejointbygrindingand
reinstatefilletweldtocorrectsize.RefertoIllustration39forminimumweldsize.
Illustration40
g03361910
12mm(0.50inch)filletweldbothexteriorsides
16mm(0.60inch)filletweldovera10mm(0.40inch)bevelgrooveweldbothexteriorsides
(L)Tubeassembly
(N)Outerwindowplate
(P)Coverplate
9.Forvisualcracksdetectedinthefilletweldsconnectingtubeassembly(L)toouterwindow
plate(N)andtocoverplate(P)ontheexteriorside,excavatecompletely,preparejointby
grindingandreinstatefilletweldtocorrectsize.RefertoIllustration40forminimumweld
size.
Illustration41
g03362047
10.Forvisualcracksdetectedattheouterwindowplateto4barlinkcasting,likethatshown
inIllustration41,proceedwiththerepairusingthefollowinginformationforguidance.
Illustration42
g03362049
Jgrooveweldjointwithintegralbacking
(R)16mm(0.60inch)
(S)Windowplate
(T)Steelcasting
11.Illustration42depictsthecrosssectionalviewoftheweldjoint.Followtheexcavationand
preparationguidelinesshowninIllustration32,33,34,and35inordertoreinstateweldto
originalsizeandshape.
Note:Usecautionwhenexcavatingcracks.Steelbackingisincorporatedintothecasting
geometry,retainthesteelbackinginordertoensureacompletejointpenetrationrepair.
ProactivePostWeldTreatment
Inordertopreventcrackingatthefilletweldedattachments,treatmenttothefilletweldtoeis
necessarytoimprovefatiguelife.TIGdressingisthepreferredpostweldtreatmentmethod.
Illustration43
g03361502
Viewoftherighthandexteriorside
Illustration44
Viewofthelefthandexteriorside
g03362315
1.TIGdressthefilletweldtoeoftheattachmentscontainedintherectangleshownin
Illustration43and44.
Note:TIGdresstheentirelengthofthefilletweldtoe,includingaroundtheendsofthe
startandstopsforeachoftheattachments.
Note:Thefilletweldtoeforthetankmountandthetubethroughtheframe(outerweld)
shouldalreadybeTIGdressed.Ifnot,thenTIGdresstheseweldtoes.
Illustration45
g03362320
Viewoftherighthandinteriorside
(U)75mm(3.00inch)
(V)75mm(3.00inch)
2.Inaddition,TIGdresscontinuallyatotaldistanceof150mm(6.00inch)aroundtheright
handcornerofthepumpdrivebracketasshowninIllustration45.
FordetailedinformationregardingTIGdressingrefertothe""PostWeldTreatmentTIG
Dressing""Section.
RepairOptionB
Thefollowinginformationpertainstovisualinspectionresultsthatwarrantweld
repairs/modificationstotheinside/outsideoftheframeandpostweldtreatmentstoexternal
attachments.Thisrepairappliestobothsidesoftheframe.Thisrepairoptionisthemost
invasiverepairanddoesrequireaccesstotheinsideoftheframecomponents.
Note:Bothsidesoftheframecanbeworkedsimultaneously.
PreHeat:Asaprecautionforthethickersectionsofmaterial,maintain100C(212F)
preheat/interpasstemperatureforthetop/bottomrailtocastingconnections.Thethinnerside
sectionscanbeweldedatroomtemperature20C(68F).
Whenyouneedtoremovecomponentsinordertorepairthechassis,refertotheappropriate
DisassemblyandAssemblyManual.
Table12
DisassemblyandAssemblyManuals
SalesModel
MachineSystems
PowerTrain
KENR8579
KENR8397
UENR1142
UENR1143
793F
793FXQ
793FCMD(CommandForHauling)
Table13
RequiredParts
(1)
Item
Qty
PartNumber
Description
4317565
Plate(1)
24
4413206
Plate(1)
4413208
Plate(1)
3789104
BracketAs
2953006
BracketAs
Serviceablepartcanbeorderedorfabricated
FabricateTankMountFixtures
1.Beforeremovinganyhardware,constructlocatingfixturestocapturethelocationofthe
fronttankmountsinrelationtothereartankmountswhichwillremainontheframe.
Note:MaterialrequiredforfixturescanbeacommonstructuralsteelsuchasASTMA36.
FabricatetheRightHandSideTankMountFixture
Illustration46
Baseplate
(A)19mm(0.75inch)
(B)2X874mm(34.40inch)
(C)4X22mm(0.90inch)diameter
(D)120mm(4.70inch)
(E)2X18.725mm(0.74inch)
(F)940mm(37.00inch)
(G)2X82.55mm(3.25inch)
(H)2X33mm(1.30inch)
g03362419
Illustration47
Verticalplate
(J)50mm(2.00inch)
(K)160mm(6.30inch)
(L)9.5mm(0.40inch)
g03362443
Illustration48
g03362447
Gusset
(M)110mm(4.30inch)
(N)130mm(5.10inch)
(P)9.5mm(0.340inch)
Illustration49
Semicompletedrighthandtankmountfixture
(R)135mm(5.30inch)
(S)155.25mm(6.10inch)
(T)110mm(4.30inch)
(U)160mm(6.30inch)
g03362488
Illustration50
g03362500
Rod
(V)275mm(11.00inch)
(W)25mm(1.00inch)
1.Fabricate(tackweld)theplateassemblyshowninIllustration49andattachplate
assemblytothereartankmount(withmountinghardware)sothattheplateassemblylies
acrossthefronttankmountsurface.Theholesontheplateassemblymaynotlineup
perfectlywiththethreadedholesinthefronttankmount.
Illustration51
g03368363
Viewofthetankmountfixturelocation(RHside)
2.PositiontherodshowninIllustration50ontopoftherailsectionandagainstthefixtureto
capturetheheightofthefronttankmount.Tackweldrodtothefixture.Thetankmount
fixturewillbeusedtorelocatethefronttankmountfortherighthandsideafterrepairs
havebeencompleted.RefertoIllustration51foranexampleofthefabricatedfixture
locatedontheframe.
FabricatetheLeftHandSideTankMountFixture
Note:Thesameprocesswillbefollowedforthelefthandsideaswasoutlinedfortheright
handside.
Illustration52
Baseplate
(A)19mm(0.75inch)
(B)2X1487.5mm(58.60inch)
(C)4X26mm(1.00inch)diameter
(D)180mm(7.10inch)
(E)2X26mm(1.00inch)
(F)1540mm(60.60inch)
(G)2X128mm(5.00inch)
(H)2X26.25mm(1.05inch)
g03362507
Illustration53
Verticalplate
(J)50mm(2.00inch)
(K)160mm(6.30inch)
(L)9.5mm(0.40inch)
g03362512
Illustration54
g03362514
Gusset
(M)110mm(4.30inch)
(N)130mm(5.10inch)
(P)9.5mm(0.340inch)
Illustration55
Semicompletedlefthandtankmountfixture
(R)135mm(5.30inch)
(S)155mm(6.10inch)
(T)110mm(4.30inch)
(U)160mm(6.30inch)
g03362515
Illustration56
g03362517
Rod
(V)375mm(15.00inch)
(W)25mm(1.00inch)
1.FabricatethepartsshowninIllustrations52,53,andIllustration54andtackweldtogether
toachievethesemicompletedfixtureshowninIllustration55.
2.Fabricate(tackweld)theplateassemblyshowninIllustration55.Attachtheplate
assemblytothereartankmount(withmountinghardware)sothattheplateassemblylies
acrossthefronttankmountsurface.Theholesontheplateassemblymaynotlineup
perfectlywiththethreadedholesinthefronttankmount.
Illustration57
g03368372
Viewofthetankmountfixturelocation(LHside)
3.PositiontherodshowninIllustration56ontopoftherailsectionandagainstthefixtureto
capturetheheightofthefronttankmount.Tackweldrodtothefixture.Thetankmount
fixturewillbeusedtorelocatethefronttankmountforthelefthandsideafterrepairshave
beencompleted.RefertoIllustration57foranexampleofthefabricatedfixturelocatedon
theframe.
RemoveOuterWindowPlates
Illustration58
Viewoftherighthandside
g03363085
Illustration59
g03363086
Viewofthelefthandside
1.Priortoremovingtheouterwindowplatesremoveandretainallhardwarelocatedonthe
outerwindowplates,refertoIllustration58andIllustration59.
Note:Theapproximateweightofthebracketassembly(fueltankfrontmount)is45kg
(100lb).
Illustration60
Viewoftheouterwindowplateonthelefthandside
(A)Rearouterwindowplate
g03369880
(B)Tubeassembly
2.Accesstotheinsideoftherailassemblyrequiresremovingrearouterwindowplate(A)
showninIllustration60.
Illustration61
g03362574
Viewoftherearwindowjointdetails
(AA)Jointdetail
(AB)Jointdetail
(AC)Jointdetail
(AD)Jointdetail
3.Inordertogainaccesstotheinsideoftherailassemblyremovetheweldsbyairarc
gougingasshowninIllustration61.Excavateweldsconnectingthewindowplatetothe
tubeassemblyandtheframe.
4.Attachasuitableliftingdevicetorearouterwindowplate(A).Theapproximateweightof
rearouterwindowplate(A)is55kg(121lb).
Illustration62
g03362583
Viewofjointdetail(AA)
(A)Rearouterwindowplate
(B)Tubeassembly
(C)16mm(0.60inch)
(D)6mm(0.25inch)
Illustration63
Viewofjointdetail(AB)
(E)8mm(0.30inch)Backingstrip
(F)16mm(0.60inch)
g03362592
Illustration64
g03362598
Viewofjointdetail(AC)
(A)Rearouterwindowplate
(G)16mm(0.60inch)
(H)50mm(2.00inch)
(J)Rail
Illustration65
g03362616
Viewofjointdetail(AD)
(A)Rearouterwindowplate
(K)16mm(0.60inch)
(L)Steelcasting
5.Excavateweldsconnectingrearouterwindowplate(A)totubeassembly(B)andtothe
frame.
Note:RefertoIllustrations62,63,64,and65forguidanceonplatethicknessandjoint
details.
Illustration66
g03387518
Viewofthelefthandsideforwardwindowplate
(E)8mm(0.30inch)Backingstrip
(M)Forwardouterwindowplate
(AE)Jointdetail
(AF)50mm(2.00inch)
Illustration67
Viewofjointdetail(AE)
(M)Forwardouterwindowplate
(N)16mm(0.60inch)
(P)35mm(1.40inch)
(R)Internalstiffener
g03362705
6.Afterrearouterwindowplate(A)hasbeenremoved,attachasuitableliftingdeviceto
forwardouterwindowplate(M)andremoveforwardouterwindowplate(M)asshownin
Illustration66.Theapproximateweightofforwardouterwindowplate(M)is74kg(163
lb).
Illustration67givesguidanceonremainingjointdetailandplatethickness.
7.Removeanadditional50mm(2.00inch)(AF)ofweldmetalbeyondweldjoint(bothtop
andbottom).
InspectionandRepairProcedure
Illustration68
g03362732
Viewoflefthandsidewithbothouterwindowplatesremovedallowingfullaccesstotheinsideoftheframe
Illustration69
g03389545
Viewofthelefthandside
(A)Backingstrip
(B)Plate(volcano)
(C)Tubeassembly
(D)Gusset
1.Visuallyinspecttheinsideofthemainrailforvisiblecracks.Payparticularattentiontotwo
backingstrips(A),plate(volcano)(B),tubeassembly(C),andfivegussets(D).
2.Usedyepenetrant(PT)ormagneticparticle(MT)teststoverifyvisualfinding.
Note:IFTHEREAREANYTHROUGHTHICKNESSCRACKSFOUNDONTUBE
ASSEMBLY(C)ORPLATE(VOLCANO)(B),CONTACTTHEPRODUCTGROUP
SERVICEENGINEERFORGUIDANCE.
Illustration70
g03387739
Viewoflefthandsidegrooveweldinspectionareas
(B)Plate(volcano)
3.Visuallyinspecttheinteriorgrooveweldconnectingthe4barlinkcastingtothevolcano
plate(B).RefertoIllustration70.
Illustration71
Crosssectionalviewofthe4barlinkcastingtotheplate(volcano)connection
g03387792
(BA)Plate(volcano)
(BB)Outsideofrail
(BC)Casting
(BD)Insideofrail
(BE)Castingdimension
(BF)Offset
4.Thecasting(BC)hasaprofiletolerancewhichallowsthepossibilitythatthecasting
surfacemaynotalignwiththesurfaceoftheplate(volcano)(BA)andmayresultinan
offset(BF)betweenthetwosurfacesasshowninIllustration71.
Note:Dimension(BE)variesforeachcasting.
Illustration72
g03388714
Weldprofileand/ortransition
(BA)Plate(volcano)
(BB)Outsideofrail
(BC)Casting
(BD)Insideofrail
(BG)16mm(0.63inch)
(BH)9mm(0.35inch)
5.Ifanoffset(BF)exists,theweldprofileshouldextendortransitionfromplate(volcano)
(BA)surfacetocasting(BC)surface,regardlessoftheoffsetdifference.
6.Multipass(stairstepped)weldsshouldbeusedinordertoprovideagradualtransition
fromthelowersurfacetothehighersurface.RefertoIllustration72.
Note:IfgougingorgrindingofexistingweldmetalisrequiredDONOTexceed10
mm(0.40inch)indepth(asmeasuredfromthesurfaceofplate(volcano)(BA).
Beyondthatdepthisparentmaterial.
Note:Thespacebetweenplate(volcano)(BA)andcasting(BC)welds(indicatedbythe
arrowinIllustration72)isnotconnected.
Illustration73
g03362787
Viewofbackingstrip(A)attached
Illustration74
g03362789
Viewwithbackingstrip(A)removed
7.Severalmodificationsaregoingtoberequiredtotheinsideoftheboxsectionandtube
assembly.Ifbackingstrips(A)arepresentasshowninIllustration73,backingstrips(A)
willneedtoberemoved.Backingstrips(A)arelocatedonboththetopandthebottom.
Note:Fivegussets(D)connectingthetubetothevolcanoplatewillalsoneedtobe
removed.Removegussets(D)priortoremovingbackingstrips(A)inordertoprovide
adequateworkspaceontopandbottom.
NOTICE
Usecautionwhenremovinggussets(D).Avoidremovalofbasematerialonboth
thetubeandthevolcanoplate.Intheeventofbasematerialremoval,filldivots
byweldingandsandsmoothtoprofile(use80gritminimumorfiner).
8.Aftergussets(D)areremoved,steelbackingstrips(A)mustberemoved(ifpresent).
9.Arcairgougemostofsteelbackingstrip(A)andthefilletweldsholdingthesteelbacking
strip(A)intoposition.Donotgougeintotheparentmaterial.
10.Removetheremainderofthematerialbygrinding/sanding(use80gritminimumorfiner).
11.Sandallsurfacessmoothtoprofile.
Note:Theinsidesurfacearea,wheresteelbackingstrip(A)waslocated,shouldbea
seamlesstaperedtransitionbetweenthecastingandthesteelrailsection.Thesurface
shouldbesandedandwithoutsharpgougingandgrindingmarks.RefertoIllustration74.
Illustration75
(AA)Gusset
(AB)126.8mm(5.00inch)
(AC)88.4mm(3.48inch)
g03367738
(AD)14mm(0.55inch)
(AE)180mm(7.10inch)
(AF)14.5mm(0.57inch)
(AG)20mm(0.80inch)
(AH)51mm(0.200.04inch)X45degreebothsides
(AJ)122.5mm(4.82inch)radius
(AK)112mm(4.41inch)radius
12.Fivegussets(D)asshowninIllustration69whichwereremovedwillbereplacedby12
newgussets.RefertoIllustration75fordimensionsforgussetfabricationifneeded.The
materialisASTMA572Grade42/50steel.Ifthepartwasordereduse12newgussets(2)
intherequiredpartslist.
Illustration76
(AL)Spacer
(AM)51.43mm(2.020.12inch)
(AN)755mm(2.950.20inch)
(AP)20+/1degree
g03367764
(AR)12mm(0.47inch)
13.UsethedimensionsinIllustration76andfabricatespacer(AL)usingASTMA36material.
Illustration77
g03389639
(AA)Gusset
(AL)Spacer
NOTICE
Forboththerighthandandlefthandsidesofthetruck,mostGussets(AA)will
alwaysbepositionedonthetubetowardthefrontofthetruck.
14.Insertthefirstgusset(AA)perpendiculartothebottomrailasshowninIllustration77.
Tackweldgusset(AA)intopositionandthenlocatetheadjacentgussetsusingspacer
(AL).
Illustration78
Locationandweldsfor12gussets(AA)
10mm(0.40inch)filletweldover5mm(0.20inch)bevelgrooveweld
(AS)20degree
g03389571
Illustration79
g03368040
Locationofgussetsinrelationtothefirstgusset(AA)thatwasinstalled
15.Illustration78andIllustration79showthelocationof12gussets(AA).Install12gussets
(AA)andtackweldintoposition.
16.Weldgussets(AA)intoposition.Useabalancedweldingtechniquetocontroldistortionby
placingoneweldpassonlyateachlocationforeachgussetworkingyourwayaroundto
thenextgussetinaclockwisefashion.
17.Proceedwithsucceedingweldpassesuntilthefinishedweldsizeisachieved.Avoid
weldingonegussettocompletionateachlocation.
Illustration80
g03389588
18.Removeplatelocatedattheendofthetubeassemblyinordertogainaccesstothe
insideofthetube.
19.Grind/sandtheremainingremnantsofweldmetalontheinsidediameterofthetube
assembly.
20.Visuallyinspectthesurfaceofthetubeassemblyinternaldiametertoadepthof
400mm(15.75inch)fromeachend.Usedyepenetrant(PT)ormagneticparticle
(MT)teststoverifyvisualfindings.
Note:Ifthereareanythroughthicknesscracksfoundonthetube,callthe793F
ProductGroupServiceEngineerforguidance.
Illustration81
g03389023
(AT)363.3mm(14.30inch)
(AU)12mm(0.47inch)
(AV)101mm(0.400.04inch)x45degree
(AW)Plate
21.FabricatetwotubeplatesusingthedimensionsshowninIllustration81usingASTMA572
Grade42/50material.Ifthepartwasorderedusetwonewplates(3)intherequiredparts
list.
Illustration82
Locationofinternalplate
(AW)Plate
(AX)266mm(10.47inch)
g03368113
Illustration83
g03368145
Weldinginternalplate
10mm(0.40inch)filletweldover10mm(0.40inch)bevelgrooveweld
22.UsingthedimensionsinIllustration82insertplate(AW)intothetubeassembly.A90
degreemagnetorsquareshouldbeusedinordertoensurethatplate(AW)is
perpendiculartothetubeassembly.
Note:Usevarioussizesofstickelectrodessuchas(1/16,3/32,or1/8)betweenthe
bottomofplate(AW)andthetubeassemblyinordertoequalizethegaparoundthe
circumferenceofplate(AW)inrelationtotheinsidediameterofthetubeassembly.
Note:Weldingofplate(AW)shouldbedoneinquartersandoppositetoeachotherin
ordertocontroldistortion.Forexample,weldfrom6O'clockto3O'clock,then9O'clockto
12O'clock,then6O'clockto9O'clock,andfinally3O'clockto12O'clock.Weldonepass
ateachlocation,movingontothenextuntilthefinishedweldsizeisobtained.
Illustration84
g03388978
10mm(0.40inch)filletweldover10mm(0.40inch)bevelgrooveweld
(AW)Plate
(AX)27mm(1.06inch)
23.Installplate(AW)ontotheoutsideofthetubeassemblywheretheplatewaspreviously
removed.
Note:Thefrontedgeofplate(AW)shouldbe27mm(1.06inch)infromtheendofthe
tubeassembly.Equalizethegapsandusethesameweldingtechniquesaspreviously
describedinordertoattachplate(AW)tothetubeassembly.
Illustration85
g03362983
Viewofacrackwhichpropagatedthroughthebottomrailsection
24.Ifthereiscrackingintheouterwindowplateandhaspropagatedthroughthebottomrail
sectionand/orthroughtheinsidewindowplatesasshowninIllustration85,refertothe
followingstepsforcrackexcavation,preparation,andrepair.
Note:Ifcrackingislocatedinthebottomortopraildirectlyaboveorbelowthetube
assemblyconnection,thefollowingrepairshouldbecompletedbeforeinstallingthe12
newgussets(AA)aroundthetubeassemblyasshowninIllustration79.Otherwise
gussets(AA)willinterferewiththerepair.
Thefollowingstepsalsoapplytoanythroughthicknesscracksatthe4barlinkcastingto
themainrailconnection.
Note:Userunon/offtabsasshowninIllustration37.
25.Inordertorepairthecracks,adheretothefollowingsteps.Startrepairfrominsideofrail
section.
Illustration86
g03389056
(BJ)Gougedprofile
(BL)Crack
(BK)Sectionthickness
26.Gouge/grindtohalfofsectionthickness.
Illustration87
(BL)Crack
(BK)SectionThickness
(BM)70degree
(BN)35degree
27.Finishgrindtoprofile.
g03389062
Illustration88
g03389067
(BL)Crack
(BK)Sectionthickness
28.Weldpreparedsideandsandflushtoparentmaterial.
Illustration89
g03389068
(BK)Sectionthickness
29.Excavatetheoppositesidetosoundmetal.
30.UsePT(dyepenetranttest)orMT(magneticParticleTest)inordertoverifythatallcracks
havebeenremoved.
Illustration90
g03389072
(BK)Sectionthickness
31.Weldtheoppositeside.
Illustration91
g03389073
(BK)Sectionthickness
32.Weldbothsidescompleteandsandflush.
33.Whenweldingiscomplete,sandbothsidesflushtoprofileofparentmaterial.Evidence
ofarepairshouldnotbevisuallynoticeable.
Note:Visuallyandultrasonicallyinspectweldrepairsusingacceptancecriteriafoundat
thebeginningofthisdocument.Referto""RequirementsforUltrasonic(UT)Testing""
SectionforUTtesting.
Illustration92
g03362988
Viewofpreparededges
34.Clean/grind/sandalljointedgestobeweldedasshowninIllustration92.
Note:Priortoinstallingtheoutsidewindowplateensurethattherearenosmall,cracklike
defectsattheendsofthegrooveweldsconnectingthe4barlinkcastingtothetopand
bottom50mm(2.00inch)railsections.
Illustration93
g03388988
ViewofarearequiringMTinspection
35.Usemagnetparticletesting(MT)inordertotesttheareaidentifiedinIllustration93
(top/bottombothsides).
FabricateandInstallWindowPlate
Illustration94
g03362989
(A)2X260mm(10.25inch)
(B)339.5mm(13.40inch)
(C)410mm(16.10inch)
(D)336mm(13.20inch)
(E)16mm(0.63inch)
(F)45+52
(G)62mm(0.240.08inch)
(H)1445.5mm(56.914inch)
(R)Windowplate
1.UsethedimensionsinIllustration94andfabricateanewwindowplate.UseASTMA572
Grade42/50steelforthenewwindowplate.Ifthepartwasorderedusenewplate(1)in
therequiredparts.
Illustration95
g03362990
(J)Jointdetail
(K)Jointdetail
(L)Jointdetail
(M)Jointdetail
Illustration96
Viewofjointdetail(J)
16mm(0.63inch)Bevelgrooveweld
(N)30degreebevel
(P)6mm(0.24inch)
g03362991
Illustration97
g03362992
Viewofjointdetail(K)
16mm(0.63inch)Jgrooveweld
(R)Windowplate
(S)15mm(0.60inch)minimum
(T)Steelrail
Illustration98
Viewofjointdetail(L)
16mm(0.63inch)filletweldovera10mm(0.40inch)bevelgrooveweld
(U)Tubeassembly
(V)45degreebevel
(W)6mm(0.24inch)
g03362993
(X)Equalizedgaparoundtubeassembly
Illustration99
g03362994
Viewofjointdetail(M)
16mm(0.63inch)Jgrooveweld
(Y)Steelcasting
(Z)15mm(0.60inch)minimum
Note:Builduptheintegralbackingstripforweldjointdetail(M).
Illustration100
Viewofgapcondition1
(R)Windowplate
(Y)Steelcasting
g03362995
Note:Ifthereisavisiblegapbetweentheintegralbackingandwindowplate(R)as
showninIllustration100,buildupthesurfaceasneededandsandtoprofile.
Illustration101
g03362996
Viewofgapcondition2
(R)Windowplate
(Y)Steelcasting
(BA)2mm(0.08inch)maximumgap
2.Ifagapexceedsmorethan2mm(0.08inch)betweentheundersideofwindowplate(R),
andtheintegralbackingasshowninIllustration101buildupthesurfaceandsandto
profileinordertoclosethegap.
Illustration102
Viewofgapcondition3
(R)Windowplate
(BB)Steelrail
g03388994
(BC)2mm(0.08inch)maximumgap
3.IftheoppositeconditionexistsasshowninIllustration102,wherethecastingissetting
higherthansteelrail(BB)andthereisagapgreaterthan2mm(0.08inch)between
windowplate(R)andsteelrail(BB),removematerialfromthecastinginordertoobtaina
gaplessthanorequalto2mm(0.08inch).Theintegralbackingonthecastingshouldnot
bereducedinthicknesslessthan8mm(0.31inch).
4.Useasuitableliftingdeviceinordertopositionfabricatedwindowplate(R)ensuringweld
jointdimensionsasshowninIllustrations96,97,98,andIllustration99.Theapproximate
weightofwindowplate(R)is130kg(287lb).
5.Onceproperfitofwindowplate(R)hasbeenobtained,securewindowplate(R)withtack
welds(6mm(0.24inch)filletweldsby50mm(2.00inch)long)onallsidesandattube
assembly(U).
Minimizeweldingdistortionbyweldingnomorethanonepassateachjointlocationuntil
weldsizeisobtained.
6.Blendsandallweldstartandstops.
7.Visuallyandultrasonicallyinspectallcomplete/fulljointpenetrationgrooveweldsto
ensureconformancetoacceptancecriteriafoundatthebeginningofthisdocument.Refer
to""RequirementsforUltrasonic(UT)Testing""SectionforUTtesting.
8.Visuallyinspectallfilletwelds(andpartialjointpenetrationgroovewelds)toensure
conformancetoacceptancecriteriafoundatthebeginningofthisdocument.
InstallationofHardware
Illustration103
Viewofthelefthandside
8mm(0.30inch)filletweld
g03501284
(4)Bracketassembly(fronttankmount)
1.Locateandattachthelefthandsidebracketassembly(4)inrelationtoreartankmount
usingfixtureassembledbeforeremovingouterwindowplates.
2.Securebracketassembly(4)totheframewithtackwelds.
3.WeldcompleteasshowninIllustration103.
Illustration104
Viewofthelefthandsidehardware
6mm(0.24inch)filletweld2places
(D)8X7415Plate
(W)230mm(9.05inch)
(X)1055mm(41.54inch)
(Y)85mm(3.35inch)
(4)Tankmount
4.Locateplates(D)usingthedimensionsinIllustration104.
5.Secureplates(D)usingtheweldsshowninIllustration105.
g03503857
Illustration105
Viewoftherighthandsidehardwareandwelds
6mm(0.24inch)filletweld4places
8mm(0.30inch)filletweld2places
12mm(0.48inch)filletweld
(5)Bracketassembly(leftreartankmount)
(C)Plate(topcoolermount)
(D)8X7415Plate
(E)2542995Plate
g03501323
Illustration106
g03363117
Viewoftherighthandsidehardware
(F)236.1mm(9.30inch)
(G)80.3mm(3.16inch)
(H)39mm(1.54inch)
(J)125mm(4.92inch)
(K)420.3mm(16.55inch)
(L)116.2mm(4.57inch)
(M)136.2mm(5.36inch)
(N)225mm(8.86inch)
(P)410mm(16.14inch)
(R)85mm(3.35inch)
(S)501.5mm(19.74inch)
(T)85mm(3.35inch)
(U)380.5mm(14.98inch)
6.Locatetopcoolermount(C)usingrightfronttankmount.
7.Locateallotherplates(onrighthandside)usingthedimensionsinIllustration106.
Illustration107
g03368259
Viewof8X7415Plate
(BA)10.5mm(0.41inch)diameterwithM12X1.756GTHD
(BB)20mm(0.80inch)
(BC)60mm(2.40inch)
(BD)80mm(3.20inch)
(BE)20mm(0.80inch)
(BF)40mm(1.60inch)
(BG)25mm(1.00inch)
Illustration108
Viewof2542995Plate
(BH)120mm(4.72inch)
(BJ)100mm(4.00inch)
(BK)20mm(0.80inch)
(BL)10.5mm(0.41inch)diameterwithM12X1.756H
(BM)25mm(1.00inch)
g03368336
Note:Forearliermodeltrucks,the(large)lowercoolermountblock(RHside)hasbeen
replacedwiththreesmallerblocks.Thethreesmallerblocksconsistofone8X7415Plate
andtwo2542995Plate.UsethedimensionsinshowninIllustration107andIllustration
108inordertofabricatetheplates(blocks)ifneeded.
8.SecureallplatesusingtheweldsshowninIllustration105.
ProactivePostWeldTreatment
Inordertopreventcrackingatthefilletweldedattachments,performtreatmenttothefilletweld
toetoimprovefatiguelife.TIGdressingisthepreferredpostweldtreatmentmethod.
Illustration109andIllustration110depicttheattachmentswhichrequireTIGdressingonthe
righthandandlefthandsideoftheframe.
Illustration109
Viewoftherighthandexteriorside
g03361502
Illustration110
g03362315
Viewofthelefthandexteriorside
1.TIGdressthefilletweldtoeoftheattachmentscontainedintherectangleshownin
Illustration109and110.
Note:TIGdresstheentirelengthofthefilletweldtoe,includingaroundtheendsofthe
startandstopsforeachoftheattachments.
Illustration111
Viewoftherighthandinteriorside
(U)75mm(3.00inch)
g03362320
(V)75mm(3.00inch)
2.Inaddition,TIGdresscontinuallyatotaldistanceof150mm(6.00inch)aroundtheright
handcornerofthepumpdrivebracketasshowninIllustration111.
FordetailedinformationregardingTIGdressingrefertothe""PostWeldTreatmentTIG
Dressing""Section.
PostWeldTreatmentTIGDressing
Thefatigueperformanceoffabricatedstructuresinvolvingfilletweldedattachmentstohighly
stressedmembersis,amongotherthings,controlledbytheprofileorgeometryoftheweldtoe.
Fatigueperformanceimprovementscanbeachievedthroughalterationoftheoriginal,as
weldedtoeprofilebyseveralpostweldtreatmentoptions.Thisproceduredescribesamethod
wherebyanelectricarcisusedtoreduceand/orremoveunfavorableprofiles/stressrisersthus
creatingasmooth,seamlesstransitionfromonecomponenttothenextcomponent.
Note:Training:Anyoneperformingthisprocedureisadvisedtoviewthetrainingvideo
"PostWeldTreatment:TIGDressingFundamentals",coursenumber41737,intheDealer
LearningManagementSystem.
EquipmentRequirements
Table14
RequiredEquipment
Tool
GTAW(TIG)Power
supplyandatorch.
ShieldingGas
Description
Thepowersupplymustbeabletoproduce200amps(min.60%
dutycycle)withahandcontrolorafootcontrol.
PolarityDCnegative
100%Argonandflowmeter
Lanthanatedor
Ceriatedor
ThoriatedTungsten
Electrode
2.4mm(0.09inchdiameter)
Ifneeded:
ER70S2fillermetal
1.5mm(0.06inchdiameter)
Grinder
GrindingWheel
Pneumaticorelectricwithcarbonsteelwirewheelattachment
AluminumOxide
Radiusgauges
Method
1.ThefirststepsinordertoensureproperTIGdressingarecleanlinessandtungsten
electrodepreparation.
Thefilletweldandsurroundingbasemetalmusthaveallcontaminantsthoroughly
removed.Itisimperativethatallpaint,rust,dirt,oilscale,andsilicateislandsarenon
existent,removebyusingagrinderwithacarbonsteelwireattachment.
Illustration112
g03363246
2.4mm(0.09inch)TungstenElectrodePreparation
(A)GrindingMarks
(B)2X3diameter
(C)1/4diameter
2.Preparea2.4mm(0.09inch)tungstenelectrode.Refertothedimensionsthatareshown
inIllustration112.Thegrindingmarksshouldrunparalleltoeachother.
3.Adjusttheshieldinggasflowrateto1525CFH.Adjustthecurrentcontrolto
approximately200amps.Ifarampdowncontrolispresentonthepowersource,utilize
therampdowncontroltoensurethatpropercraterfillcontrolisachieved.
4.AnumberofdifferenttechniquesexistforTIGdressingduetothevariationofthecontour
ofthefilletweldtoe.Thecontourofthefilletweldtoemustbereshaped.Useastringeror
weavemanipulationofthetorchinordertoachieveasmoothradiusoftheweld.A
minimumradiusof5.0mm(0.20inch)mustexistbetweenthebasematerialandtheweld
metal.
Illustration113
g03363256
StringerTechnique
(D)0degreeworkangle
Note:Usea10to15degreepushangleforthestringertechnique.
5.Illustration113representsthestringertechniqueofwelding.Thecenterofthearcneeds
tobe0.02.0mm(0.00.08inch)fromtheweldtoeintothebasematerial.
Illustration114
g03363260
WeaveTechnique
(E)0to45degreeworkangle
Note:Usea10to15degreepushanglefortheweavetechnique.
6.Illustration114representstheweavetechniqueofwelding.
Illustration115
g01989613
7.Illustration115representsanacidetched,crosssectionviewofaTIGdressedweldtoe.
Illustration116
g01990055
Illustration117
g01990056
8.Illustration116andIllustration117demonstratetheexpectedresults.
9.OnceTIGdressingiscompleted,theareaneedstobecleanedandpaintedinorderto
preventpittingduetocorrosion.
Note:Poorlyshapedfilletweldswith90degreeto100degreetransitionanglestothe
basematerialwillrequireseveraloverlappingTIGdressingrunstosmoothouttheweld
toetransitionregion.
Note:TIGdressingcanbeconductedintheverticalpositionaslongastheTIGdressing
isperformedinadownhillprogression.
Note:Ifundercutorothercircumstancesrequiretheadditionoffillermetal.Addingfiller
metalcanbeaccomplishedbyhandfeedingER70S21.6mm(0.06inch)intotheweld
pool.YouthenrepeattheTIGdressinginordertoachievethedesiredtoeradiusandthe
desiredprofile.
10.Inspectusingaradiusgagetoensurea5mm(0.20inch)minimumradius.
ReportofUltrasonicInspectionofWelds
Table15
ReportofUltrasonicInspectionofWelds
InspectionCompany:
Date:
Address:
TruckSerialNumber:
PartNumber:
Weld/PartIdentification:
MaterialThickness:
CalibrationBlockType:
WeldJointDesignation:
WeldingProcess:
QualityRequirements:Referto
Table10
Procedure/Rev.:
""RequirementsforUltrasonic(UT)
Couplant:
Testing""
Instrument:
Manufacturer:
Model:
SerialNumber:
CalibrationDate:
Notes:
SearchUnit:
Longitudinal
Shear
Frequency
Size
Manufacturer
Angle
SerialNumber
Table16
ReportofUltrasonicInspectionofWeldsContinued
Line
Number
Indication
SearchUnit
Number
Angle
FromFace
Leg
10
0DbReferenceLevelMethodOnly
Line
Indication
Reference
Attenuation
Indication
Number
Level
Level
Factor(1)(2)
Rating
=d
10
DiscontinuityLocation
Length
Angular
Line
Distance
Distance
DepthFrom
(SoundPath)
Surface
Number
Discontinuity
Evaluation
From
From
10
Remarks:
(1)
Metricequationforangulardistance(soundpath25mm)x.08=C
(2)
Standardequationforangulardistance(soundpath1inch)x2=C
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