REHS0541 - Procedure For The Inspection, Repair, and Component Replacement On The Frames

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Special Instruction
Procedure for the Inspection, Repair, and Component Replacement on the Frames of Certain Off-
Highway Trucks/Tractors {7000, 7051}
Media Number -REHS0541-21 Publication Date -22/09/2014 Date Updated -24/08/2017
i07084987
Procedure for the Inspection, Repair, and Component Replacement on

the Frames of Certain Off-Highway Trucks/Tractors {7000, 7051}
SMCS - 7000-023-CS ; 7051
Off-Highway Truck/Tractor
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
Introduction
This Special Instruction contains general information and procedures that can be referenced when you repair the
chassis of the machines that are listed above. Each repair will be unique. You may need to modify the procedures in
some situations.
Read the entire special instruction. Understand the information before you perform any procedures. Understand the
information before you order any parts.
Note: Some of the components that are necessary to complete procedures in this Special Instruction may not be
available through the normal parts system. Sometimes, special orders are required.
Note: For additional information regarding repairing cracked frames contact the subsidiary service engineer, the
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plant service engineer and the plant product analyst.
Reference: Special Instruction, REHS2346, "Weld Repair Procedure for the Rear Axle A-Frame and Rear Axle
Housing on 785, 789, and 793 Off-Highway Trucks".
When you need to remove components to repair the chassis, refer to the appropriate Disassembly and Assembly
Manual.
Table 1
Disassembly and Assembly Manuals
Sales Model Machine Systems Power Train
784B SENR5678 SENR5677
784C SENR1500 SENR1490
785 SENR4020 SENR4010
785C HAA SENR1500 SENR1490
785D KENR8312 KENR8308
789 SENR3404 SENR3430
789D SENR1534 UENR1065
793 SENR4917 SENR4907
793C (S/N: 4AR) SENR1463 SENR1462
793C (S/N: CBR, ATY, 4GZ) RENR2535 SENR2534
793D RENR8332 RENR8328
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
NOTICE
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Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
Table 2
Approximate Weights of Unloaded Machines
Sales Model Weight
784B, 784C 88.903 kg (196,828 lb)
785, 785B, 785C, 785D 102.965 kg (227,891 lb)
789, 789B, 789C, 789D 130.634 kg (288,728 lb)
793, 793B, 793C, 793D 147.417 kg (325,000 lb)
Table 3
Approximate Weights of Components
Part
Part Name Part Name (Modifier) Weight Sales Model
Number
297 kg
119-4726 Tube Rear Cast Cross-Tube 793, 793B, 793C, 793D
(655 lb)
1370 kg
125-7017 Support Center Cross-Tube 793, 793B, 793C, 793D
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(3020 lb)
819 kg
131-8405 Support As Center Cross-Tube 785C
(1806 lb)
1062 kg
131-1597 Support As Center Cross-Tube 789C
(2341 lb)
8X-0898 Rail Rail - 785, 785B, 785C, 785D
290 kg 789, 789B, 789C, 793, 793B,

8X-2648 Rail Rail
(640 lb) 793C, 793D
382 kg
320-5333 Rail Rail 789D
(842lb)
382 kg
320-5334 Rail Rail 789D
(842lb)
Lower Mounting for the 785, 785B, 785C, 785D, 789,

6G-6499 Shaft (Ball) 93 kg (205 lb)
Hoist Cylinder 789B, 789C, 789D
Lower Mounting for the 110 kg

8X-1213 Shaft (Ball) 793, 793B, 793C, 793D
Hoist Cylinder (245 lb)
1026 kg
120-6765 Support Right Side Tail Casting 793, 793B, 793C, 793D
(2262 lb)
910 kg
120-6764 Support Left Side Tail Casting 793, 793B, 793C, 793D
(2006 lb)
8X-2376 Plate Inside Rear Window Plate 37 kg (82 lb) 793, 793B, 793C, 793D
Bracket 350 kg 784B, 784C, 785, 785B, 785C,

5T-8671 Steering Box
Assembly (775 lb) 785D
Bracket 382 kg
5T-6243 Steering Box 789, 789B, 789C, 789D
Assembly (842 lb)
Bracket 375 kg
8X-2283 Steering Box 793, 793B, 793C, 793D
Assembly (830 lb)
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
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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.
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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.
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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
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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
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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, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
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.
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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
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Rust
Any fluids or moisture
All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6 C
(60 F).
Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum
15.6 C (60 F) requirement.
Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.
Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the
machined surfaces from the welding spatter.
Welding Electrodes and Parameters
Flux Cored Welding Electrode for the FCAW Process
Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's
shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode
is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by
the flux cored welding electrode will have the following minimum mechanical properties:
Table 4
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20
E71T-1 H8"
Tensile Strength 480 MPa (70000 psi)
Yield Strength 400 MPa (58000 psi)
Elongation 22%
Impact Toughness 27 J @ -18 C (20 ft lb @ -0 F)
The tables that follow show the recommended parameter ranges for out of position welding in the field for two
different flux cored welding electrode diameters.
Table 5
Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate Voltage Amperage
7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute 24 to 28 190 to 240
Table 6
Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate Voltage Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute 23 to 27 180 to 220
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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.
Table 7
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1
E7018"
Tensile Strength 480 MPa (70000 psi)
Yield Strength 400 MPa (58000 psi)
Elongation 22%
Impact Toughness 27 J @ -29 C (20 ft lb @ -20 F)
Low hydrogen electrodes must be stored in an electrode oven at 120 C (250 F). If low hydrogen electrodes get
damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer's
specifications.
The table that follows shows the settings for the welding current based on electrode diameter.
Table 8
Welding Current for Low Hydrogen Electrodes
Diameter Amperage Rating
3.2 mm (1/8 inch) 105-155
4.0 mm (5/32 inch) 130-200
4.8 mm (3/16 inch) 200-275
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width
of the weld should not exceed two times the electrode diameter.
Arc Welding Electrodes for the GMAW Process
The table that follows lists the mechanical properties of welds that are deposited by the GMAW Process.
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Table 9
Mechanical Properties of Welds from Gas Metal Arc Welding Electrodes That Are Classified as
"ANSI/AWS A5.18 ER70S-6"
Tensile Strength 480MPa (70,000 psi)
Yield Strength 400 MPa (58,000 psi)
Elongation 22%
Impact Toughness 27J @ -30 C (20 ft lb @ -20 F)
The use of the GMAW process for field repairs is only recommended for certain conditions. Whenever the
GMAW process is appropriate, specific parameters and equipment will be defined.
Weld Inspection and Acceptance Criteria
Table 10
ISO 6520 Defect
Defect Name Reference Remarks Defect Limit
Number
Cracks - 1011, 1012, 1013,

Longitudinal, 1014, 1023, 1024,
Transverse, 1031, 1033, 1034,
-- Not Permitted
Radiating, Crater, 1045, 1046, 1047,
Disconnected, 1051, 1053, 1054,
Branching 1061, 1063, 1064
Crack - Transverse 1021 Hard Surfacing Welds Only Permitted
Crack - Transverse 1021 Joining Welds Not Permitted
Maximum Diameter for a Single

1 mm (0.040 inch)
Pore
Maximum Pores in Any 300 mm

6
2011, 2012, 2014, (11.81 inch) Length of Weld
Porosity
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
Maximum Length of Cluster in Any

Clustered Porosity 2013 3 mm (0.120 inch)
Weld
Maximum Height or Width 3 mm (0.120 inch)
Maximum Length for Any Single

Elongated Cavities 2015 25 mm (1.00 inch)
Discontinuity
Maximum Length in Any Weld 10% of Weld Length
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Maximum Dimension of Any Single

3 mm (0.120 inch)
Cavity
Elongated Cavities 2016 10% of Weld Length Not
Maximum Total Length of Affected
to Exceed 25 mm
Area in Any Weld
(1.00 inch)
Shrinkage Cavities 2021, 2024, 2025 Maximum Diameter or Length 1 mm (0.040 inch)
Maximum Height or Width 1mm (0.040 inch)
Slag or Flux 3011, 3012, 3014, Maximum Length for Any Single
25 mm (1.00 inch)
Inclusions 3021, 3022, 3024 Discontinuity
Maximum Height or Width 1mm (0.040 inch)
Maximum Length for Any Single

Oxide Inclusions 3031, 3032, 3033 25 mm (1.00 inch)
Discontinuity
Puckering (Oxide
Inclusion - 3034 -- Not Permitted
Aluminum)
Metallic Inclusion 3041, 3042, 3043 -- Not Permitted
Visual (Breaking the Surface) Not Permitted
Subsurface Maximum Height or

1mm (0.040 inch)
Width
Lack of Fusion 4011, 4012, 4013
Subsurface Maximum Length for
25 mm (1.00 inch)
Any Single Discontinuity
10% of Nominal
Maximum Reduced Penetration Penetration Not to Exceed
Lack of Penetration 402, 4021 1mm (0.040 inch)
Maximum Allowed Total Length of

10% of Weld Length
Reduced Penetration
5011, 5012, 5013, Maximum Depth Measured From

Undercut 0.5 mm (0.020 inch)
5014, 5015 Plate Surface - Any Length
Any Length --
Excess Weld Metal - Weld Face Width 5 mm (0.20 inch)
Groove Weld 1 mm (0.040 inch)
502 or Less
Reinforcement
(Convexity) Weld Face Width Over 5 mm
(0.20 inch) But Less Than 10 mm 1.5 mm (0.060 inch)
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(0.40 inch)
Weld Face Width Over 10 mm

(0.40 inch) But Less Than 20 mm 2 mm (0.080 inch)
(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 -
Weld Toe Angles of 135 Degrees
Fillet Weld 503 --
and More Are Better
Convexity
Defect Limits Expressed as
--
Minimum Toe Angles Allowed
2 mm (0.080 inch) (Any

Without Drawing Limitation
Length)
With "Melt - Thru" and "Flush" 1 mm (0.040 inch) (Any

Excess Penetration 5041, 5042, 5043
Weld Symbols Length)
With "Melt - Thru" and "Grind Not Permitted (After

Flush" Symbols Grinding)
When 1E2995 Applies (Expressed as

3 mm (0.120 inch)
Incorrect Weld Toe 505 a Toe Radius Rather Than a 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)
Fillet Weld Leg Size 10% of Total Weld Length

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

--
Fillet Weld Leg Size Measured Independent of the Other
--
- Oversize +25% (max 3 mm
Maximum Oversize
(0.120 inch))
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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 - Linear

Weld Size 6.5 mm (0.256 inch) 6.5 mm (0.256 inch)
Length when
specified at less than --
the length of the
Weld Size 6.5 mm (0.256 inch) 12.5 mm (0.492 inch)
joint
Nominal Size (0.7 x Leg Size) Not

Inclusive of Penetration Beyond the Not Permitted
Weld Root
Fillet Weld Throat 2 mm (0.080 inch) MAX -

5213 and Not to Exceed 20% of
Size - 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

Given When Plate Mismatch is Not Permitted
Incompletely Filled Apparent
511
Groove Weld
Weld Depth Must be Maintained as a
--
Minimum
Root Concavity on Maximum Depth measured From

Open Root Groove 515, 5013 Plate Surface or Tube Inner Surface - 0.5 mm (0.020 inch)
Welds Any Length
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,

Poor Restart (Tie - Defect Limits Expressed as 90 Degrees
5171, 5172 Minimum Toe Angles Allowed
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
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Insufficient Weld Throat Not Permitted
Stray Arc Strike 601 -- Not Permitted
SMAW, SAW, FCAW, GMAW Not Permitted
Slag Residue 615 Silicon Residue Permitted

GTAW Unless Removal Specified
by Drawing Note
Total Maximum Combined Length

of All Imperfections in a Weld,
15%
Expressed as a Percent of Total Weld
Combined Length
--
Discontinuities
(No Single Type of Imperfection
Can Exceed the Limits for That --
Single Type of Imperfection)
To verify the quality of the weld, refer to Figure 27 from Caterpillar Specification 1E99 which is shown above in
Table 10.
General Weld Repair
1. Remove any components that prevent access to the cracked weld.
2. Refer to the "Area Preparation" section in this Special Instruction.
3. Use dye penetrant (PT) or magnetic particle (MT) 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.
Walk-Around Inspection of the Frame for the 784B, 784C, 785, 785B,
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785C, 785D, 789, 789B, 789C, 789D, 793, 793B, 793C, and 793D Off-
Highway Trucks
This Special Instruction provides information on the areas of the frame assembly that should be inspected for
cracks. The following areas are covered in this Special Instruction: castings, welded joints, pump and motor
mounts, mounting pads for the fuel tank, mounting hangers for the fuel tank, mounting pads for the hydraulic tank,
mounting hangers for the hydraulic tank and the fabricated assemblies.
Note: The Operation and Maintenance Manual identifies the intervals for maintenance inspection. The conditions
of the site, the payloads, and the haul road conditions may affect the maintenance interval. Site managers should
monitor these intervals accordingly. Site managers should adjust these intervals accordingly.
Typical truck frame
(A) Bracket Assembly (Steering box)
(B) Superstructure
(C) Support (Center cross-tube)
(D) Support (Tail casting)
(E) Support (Rear cross-tube)
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(F) Rear motor mount

(G) The casting that forms the mounting location for the front suspension cylinder
(H) Fuel/hydraulic tank support
(J) Supports for the hoist cylinder
(K) Pin bores for the control rod
Inspect the Support (Rear Cross-Tube)
1. Inspect the welds that are used to hold the rear cross-tube to the tail castings.
2. Inspect the rear of the support (rear cross-tube).
3. If any cracks are found in the rear cross-tube, refer to "General Weld Repair" section in this Special
Instruction. If the crack cannot be repaired, refer to "Rear Cross-Tube Replacement for 793, 793B, 793C, and
793D Off-Highway Trucks" section in this Special Instruction.
Inspect the Tail Casting
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1. Inspect the welds that hold the tail casting to the support (rear center).
2. Inspect the welds that hold the tail casting to the side rails.
3. Inspect the area around the body pin bore for cracks.
4. Inspect the pin bore for the suspension cylinder for wear. This area can only be inspected if the pins have
been removed. Refer to Disassembly and Assembly Manual.
5. Inspect the area around the pin bore for the suspension cylinder for cracks.
6. Inspect the bore and the area around the bore that is for the body retaining pin.
7. Repeat this inspection on the other side of the frame.
8. If any cracks are found in the tail casting, refer to "General Weld Repair" section in this Special Instruction.
If the crack cannot be repaired, refer to "Tail Casting Replacement for 793, 793B, 793C, and 793D Off-
Highway Trucks" section in this Special Instruction.
Inspect the Side Rails
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1. Inspect the welds that hold the frame rails to the tail castings.
2. Inspect the side rails.
3. Inspect the welds that hold the side rails to the support for the suspension cylinders.
4. Inspect the welds that hold the support for the hoist cylinders to the frame rails.
5. Inspect the welds that hold the support for the cab to the frame rails.
6. Inspect the welds that hold the center tube to the frame rails.
7. Inspect the weld on the plates that make up the rails.
8. Inspect the welds that are used on bosses and plates that are attached to the side rails. Carefully inspect the
welds that are used to hold on the brackets for the fuel tank and the hydraulic tank.
9. Inspect the welds that hold the plates that are used for the rear motor mounts.
10. If any cracks are found, refer to the "Frame Rails (Repair)" section in this Special Instruction for the
procedure that is needed to repair the problem.
Inspect the Center Cross-Tube
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1. Inspect the welds that hold the outside brackets to the frame rails. Inspect the welds that hold the center tube
to the two outside brackets.
2. Inspect the center cross-tube.
3. Inspect the welds on any of the bosses, the plates, and/or the brackets that are positioned on the center cross-
tube.
4. If any cracks are found in the center cross-tube, refer to "General Weld Repair" section in this Special
Instruction. If the crack cannot be repaired, refer to the "Center Cross-Tube Support Replacement for the
793C and 793D Off-Highway Trucks" section.
Inspect the Support for the Hoist Cylinders
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1. Inspect the welds that hold the center tube between the two supports.
2. Inspect the support for the hoist cylinder.
3. Inspect the front strut support.
4. Inspect the welds that hold the supports to the frame rails.
5. Inspect the weld that holds the mounting ball to the supports.
6. Inspect the ball for wear.
7. Inspect the welds that are used on any bosses or plates.
8. If any cracks are found, refer to "General Weld Repair" section in this Special Instruction. If the ball cannot
be repaired, refer to "Ball Replacement for the Lower Connection of the Hoist Cylinder" section in this
Special Instruction.
Inspect the Front Strut Support
1. Inspect the weld that holds the side rails to the strut support.
2. Inspect the front strut support.
3. Inspect the welds that are used to hold the center tube to the two strut supports.
4. Inspect the weld that is used on the brackets for the steering cylinders.
5. Inspect the welds that are used on any bosses or plates.
6. If any cracks are found, refer to "General Weld Repair" section in this Special Instruction. If the crack cannot
be repaired, refer to Special Instruction, REHS0172, "Front Strut Frame Casting Replacement" for the
procedure that is needed to repair the problem.
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Inspect the Front Side Rails and the Bumper
1. Inspect the weld that holds the front side rails to the strut supports.
2. Inspect the weld that is used to hold the front side rails to the bumper.
3. Inspect the weld that is used on the front motor mount.
4. Inspect the welds that are used on the vertical supports in the front.
5. Inspect the welds that are used on any bosses or other plates and brackets.
6. If any cracks are found, refer to "General Weld Repair" section in this Special Instruction.
Inspect the Upper Superstructure
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1. Inspect the welds that are used to hold the superstructure to the vertical support.
2. Inspect the welds that are used to hold the superstructure to the side rails in the rear.
3. Inspect the welds that are used to hold the front suspension cylinders to the superstructure.
4. Inspect the welds that hold the superstructure to the frame rails.
5. Inspect the welds that are used on any bosses or other plates.
6. If any cracks are found, refer to "General Weld Repair" section in this Special Instruction. If additional
information is needed, refer to Special Instruction, REHS0452, "Superstructure Repair".
Frame Management/Repair Philosophy

Frame life, as it relates to fatigue, is a function of many variables that include payload, application (condition of
haul roads and load/unload zones), speed, maintenance, and repairs. Frame cracking can be a result of many of
these variables. Over the life of the machine, frame cracking is an expected event in most circumstances.
Understanding and managing all these variables is a part of general machine maintenance. General machine
maintenance is essential to ensuring fully acceptable life of the frame. Proper frame management practice should
include the following: maintenance and repair, documentation, and trending. Local conditions and/or age of
equipment may dictate adjustments to your requirements.
Documentation
1. Any cracks that are identified at inspection or repair should be measured. Any cracks that are identified at
inspection or repair should be documented. This information should be retained for future inspections and
trending. Crack documentation history can show that where cracks are reoccurring, time to propagate, and to
what degree of severity.
2. A crack found at inspection should be marked and dated with paint/etch as to identify any crack growth at
future inspection that is specified by the Operation and Maintenance Manual.
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3. Utilize a crack inspection checklist with identified call out locations on the frame to help in the
documentation process. Table 11 shows an example of a crack inspection checklist. The checklist example
provides a sequential walk-around inspection which includes a table for capturing locations, comments, and
lengths, of cracks.
4. It is important to maintain a database of fleet frame crack status. The repair labor and downtime requirements
for the fleet should be included in this database.
Maintenance and Repair
1. Conduct a full frame inspection as per the inspection requirements listed in this document and your
Operation and Maintenance Manual.
2. Clean the frame prior to inspections.
3. Utilize an inspection diagram. A walk-around inspection diagram with weld joint locations is included in this
document.
4. When evaluating frame cracks for repair, crack documentation and trend history can help in determining
potential crack growth and speed. The sites crack trend data history can determine the priority in completing
the repair. If the sites crack trend data history predicts the crack growth speed to be low risk, then the crack
would then be scheduled for repair at the next scheduled opportunity/preventative maintenance. If the work
sites crack trend data history predicts the crack growth speed to be high risk, then the crack should be
repaired immediately.
Trending
1. Data collected from the crack history documentation reveals crack tendencies.
2. Evaluating tendencies enables site-specific identification and rankings of crack severity/importance.
3. The frequency of crack recurrences can be identified through the trending process.
Table 11
Frame Inspection Checklist
Date
Equipment
Number
SMU
Inspector
Comments - Length -
Item Area OK Cracked
Location
1 RH Front Frame Rail/Support
2 RH Upper Strut Mount
3 K Frame RH
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4 RHR Engine Mount
5 Front Hydraulic Tank Mount
6 Rear Hydraulic Tank Mount
RH Side Torque Tube and Transition to

7
Frame Rail
8 RH Hoist Cylinder Mount
9 RH Rear Frame Rail
10 RH Tail Casting
11 LH Tail Casting
12 LH Rear Frame Rail
13 LH Hoist Cylinder Mount
14 Rear Fuel Tank Mount
15 Front Fuel Tank Mount
LH Side Torque Tube and Transition to

16
Frame Rail
17 A Frame Mount
18 LHR Engine Mount
19 K Frame LH
20 LH Upper Strut Mount
21 LH Front Frame Rail/Support
22 Cross-Tube
23 RH Fore/Aft Rail
24 RH Fore/Aft Transition
25 LH Fore/Aft Transition
26 LH Fore/Aft Rail
Note: Fill in all areas of the checklist and circle cracked areas on the diagrams.
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Inspection Intervals
Inspections of the frame assembly for cracks should be conducted during regular maintenance intervals. Some of
the areas that need to be inspected are blocked by one or more components. If the component that is blocking the
frame is removed, an inspection of that area should be performed. It is therefore important to take advantage of the
opportunity to inspect those parts of the frame assembly that are exposed whenever components are removed. As
an example, when the hydraulic tank is removed, the area behind the hydraulic tank should be cleaned and
inspected. Cracking on one machine may indicate closer focus in that area for the rest of the fleet. Refer to Table 12
for the Operation and Maintenance Manual for the off-highway truck/tractor that is being worked on.
Table 12
Operation and Maintenance Manual
Off-Highway Truck/Tractor Manual Number
784B SEBU6517
784C SEBU7176
785 SEBU6092
785B SEBU6517
785C S/N:(1HW, APX, 2PZ) SEBU7173
785C S/N:(5AZ) SEBU7176
785D SEBU8350
789 SEBU6039
789B SEBU6518
789C SEBU7174
789D SEBU8242
793 SEBU6333
793B SEBU6519
793C S/N:(4AR) SEBU6995
793C XQ S/N:(CBR, ATY, 4GZ) SEBU7175
793D SEBU7792
Prepare the Work Area

1. Before you start to work on the machine, disconnect the battery. Attach a Do Not Operate tag in the operator
compartment.
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2. When possible, make all repairs with the machine parked on a level, hard surface. When you work on the
machine or when you work under the machine, block the machine to prevent the machine from rolling. Select
an appropriate site to repair the chassis. Select an area that is flat, smooth, and drained. Make sure that there
is sufficient space for the items that follow: machine, components, tools, and lifting devices.
3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use hardwood blocks or
jack stands to support the machine before performing any service or disassembly. Always make sure that the
maximum load capacity of the jack stands is greater than the weight of the machine.
4. Make sure that the work area around the machine is made safe. Become aware of hazardous conditions that
may exist. If an engine is started inside an enclosure, make sure that the engine exhaust is properly vented.
5. Before you start a repair, be sure that all protective devices are properly installed and that all protective
devices function correctly. When a guard must be removed or a shield must be removed to perform the repair
work, use extra caution.
6. Always use tools that are in good condition. Before you perform any service work, understand the intended
use of the tools.
7. Replace all fasteners with fasteners of the same part number. Do not use a lesser quality fastener if
replacements are necessary.
8. Prepare to stop an engine that has had a recent overhaul. Prepare to stop an engine that has a fuel system that
has recently been worked on. If the engine has not been assembled correctly, the engine can possibly
overspeed. If the fuel settings are not correct, the engine can possibly overspeed. Overspeeding can cause
bodily injury, death, or property damage. Prepare to shut off the fuel and the air supply to the engine to stop
the engine.
9. Be careful when you remove cover plates. Gradually back off the last two bolts or the last two nuts that are at
opposite sides of the cover or the device. Pry the cover loose to relieve any spring or other pressure, before
you completely remove the last two bolts or the last two nuts.
10. When you make repairs that require welding, have appropriate reference information. Welding should only
be performed by personnel that are adequately trained. Personnel should be knowledgeable in welding
procedures. Make sure that all repairs that require welding comply with the ANSI/AWS standards.
11. Do not damage wiring during removal operations. When you install the wiring, do not damage the wiring.
The wiring can be damaged in operation by the conditions that follow: contact with sharp corners, rubbing
against objects and contact with hot surfaces. Do not connect the wiring to a line that contains fluid.
12. Tighten connections to the correct torque. Make sure that all heat shields, clamps, and guards are installed
correctly to avoid excessive heat, vibration, or rubbing against other parts during operation. Shields that
protect against oil spray onto hot exhaust components in the event of a line, tube, or seal failure must be
installed correctly.
13. Do not operate a machine if any rotating part is damaged or if any rotating part contacts any other part during
operation. Any high speed rotating component that has been damaged or altered should be checked for
balance before reusing. Before you start the engine, make sure that all protective devices are properly
installed. Before you operate the machine, make sure that all protective devices are functioning correctly.
14. Use extra caution when you service the rubber belts. Follow all safety instructions in the appropriate
manuals. Wear protective glasses. Block the machine to prevent the machine from moving.
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15. When you unload components, place the components near the machine. Leave enough space around the
machine to maneuver lifting devices. Carefully inspect the parts. Ensure that all parts are undamaged.
Organize the parts for assembly.
16. The repair of the chassis will be easier if the machine is clean. Use a steam cleaner to clean the truck. Be
careful with the steam cleaner. Do not damage electrical wiring or cab windows.
Casting Replacement that Forms the Mounting Location for the Front
Suspension Cylinder on the Axle Frame for 784B, 785, 785B, 789, 789B,
793, 793B, 793C, and 793D
To replace the casting that forms the mounting location for the front suspension cylinder on the axle frame, refer to
Special Instruction, REHS0172, "Off-Highway Tractor and Truck Front Strut Frame Casting Replacement".
Install the Field Retrofit for the Superstructure of 789, 789B, 789C,
789D, 793, 793B, 793C, and 793D Off-Highway Trucks
To install the field retrofit for the superstructure, refer to Special Instruction, REHS0452, "Weld Repair Procedure
for Field Retrofit of Large Off-Highway Truck Frame Superstructure".
Repair of the Rear Motor Mount Castings

Repair Cracks
1. Remove the necessary components to gain access to the castings for the rear motor mounts.
2. Thoroughly clean the area around the castings for the rear motor mounts .
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Rear motor mount
3. Inspect the welds and castings for the rear motor mounts.
4. If you find a crack, use an air carbon arc to gouge out the crack. Taper the ends of the gouged area to provide
a smooth transition to the base metal. Gouge out at least 50.8 mm (2.0 inch) past the end of the crack. Use a
grinder to smooth the gouged area.
5. Use some liquid dye penetrant to inspect the gouged area to ensure that the crack has been removed.
Note: Use the SMAW process and "E7018" welding electrode for all welds. As an alternate process, the
FCAW process can be used with "E71T-1 H8" welding electrode.
6. Weld the gouged area until you reach the original profile.
Additional Fillet Welding of the Rear Motor Mounts
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(A) 50.8 mm (2.00 inch)
(B) 50.8 mm (2.00 inch)
(C) Additional fillet weld
1. Start at the lower corners of the castings for the rear motor mounts and use an air carbon arc torch to remove
50.8 mm (2.0 inch) of the horizontal 12.0 mm (.47 inch) fillet welds (A) that secure the motor mounts to the
frame. Taper the ends of the gouged area to make a smooth transition into the existing weld.
2. Start at the lower corners of the castings for the rear motor mounts and use an air carbon arc torch to remove
50.8 mm (2.0 inch) of the vertical 12.0 mm (.47 inch) fillet welds (B) that secure the motor mounts to the
frame. Taper the ends of the gouged area to make a smooth transition into the existing weld.
3. Start at the end of the gouged areas and apply a 12.0 mm (.47 inch) fillet weld across the bottom of the motor
mounts. Continue the weld around the corner. Continue the welds into the vertical fillet welds at the sides of
the motor mounts.
Note: Do not start the weld at the bottom corners of the motor mounts and do not stop the weld at the bottom
corners of the motor mounts.
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4. After you have repaired the welds at the corners of the motor mounts, apply an extra fillet weld (D) over the
existing fillet weld. Apply the fillet weld all the way around the motor mount. Refer to Illustration 16 to
determine the profile of the new fillet weld (D).
Note: Ensure that there is at least an 8.0 mm (.32 inch) radius of transition at the toe of the weld. If necessary,
grind the radius.
Center Cross-Tube Support Replacement for the 793C and 793D Off-
Highway Trucks
Prepare the Frame in Order to Remove the Support (Center Cross-Tube)
1. Remove the body from the truck. Remove any components that prevent access to the center cross-tube.
2. Clean the area around the center cross-tube of the items that follow: oil, grease, dirt, and paint.
Note: You must stabilize the area near the center cross-tube before you remove the center cross-tube.
3. Before you stabilize the frame, prepare to take measurements for reference. Record reference dimensions
from the mounting holes for the A-frame to the frame rails. Record reference dimensions to position the tank
support.
(1) Square tubing
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4. Obtain two pieces of 101.6 mm (4.0 inch) square tubing (1) with 6.35 mm (.25 inch) thick walls. The square
tubing should be long enough to extend between the frame rails.
5. Weld the square tubing between the frame rails. Refer to Illustration 17. Weld around each end of the square
tubing (1). Use 8.0 mm (.32 inch) fillet welds.
6. Use the steel bar stock that is 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) wide to make diagonal
braces.
7. Place supports under the front half of the truck and place supports under the back half of the truck. Place the
supports under the frame rails on each side of the truck.
Remove the Existing Support (Center Cross-Tube)
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(A) Top rail
(B) Window plate
(C) Window plate
(D) Window plate
(E) Tank support
(F) Support (Center cross-tube)
1. Cut section (A) from the top rail at each side of the frame. Section (A) should begin at the joint between the
frame rail and the casting for the rear pedestal of the superstructure. Refer to Illustration 18.
Note: Record the length of the opening that remains after you remove section (A).
2. Remove the window plates (B, C, D, and) the tank supports (E) from the sides of the frame rails.
Note: Save the tank supports (E). The tank supports will be used again.
3. Remove the existing center cross-tube (F).
4. Measure approximately 1128 mm (44.4 inch) forward from the rear welded joint of the former center cross-
tube to locate a mark on the inside window plate. The mark will be used to cut an opening for the new
125-7017 Support (Center Cross-Tube).
5. Cut the inside window plates to make an opening for the new center cross-tube.
Install the New Support (Center Cross-Tube)
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(G) New center cross-tube
Note: Use the SMAW process and "E7018" welding electrode for all welds that secure the new cross-tube.
As an alternate process, the FCAW process can be used with "E71T-1 H8" welding electrode .
1. Set the new 125-7017 Support (Center Cross-Tube) (G) in place. Use the reference dimensions that were
recorded earlier to position the center cross-tube.
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8X-2648 Rail
2. Fabricate new top rails. Trim an 8X-2648 Rail. Grind a 30 degree bevel at each end of the 8X-2648 Rail.
Note: Maintain a root opening of 5.0 mm (.20 inch) at each end of the new section of rail.
Support plate
(H) Cut to fit.
(J) 150 mm (5.9 inch)
(K) 300 mm (11.8 inch)
(L) 30 mm (1.2 inch)
(M) 500 mm (19.7 inch)
(N) 10 mm (.4 inches)
3. Use steel that is 20 mm (.79 inch) thick to fabricate a support plate for the new section of frame rail. The
steel must meet ASTM specification "A572". Refer to Illustration 21.
Note: As an alternative, cut the former support plate from the former rail. If the former support plate is
undamaged, use the former support plate again.
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New top rails
(P) 1071.0 mm (42.16 inch)
4. Use 12.0 mm (.47 inch) fillet welds to secure the support plate to the 8X-2648 Rail. Weld along the sides of
the support plate and weld along the angles of the support plate. Do not weld across the end of the support
plate.
5. Tack weld the new top rails in place. Use two 50 mm (2.0 inch) bevel welds (W6) to secure the new sections
of top rail in place.
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6. Tack weld the new center cross-tube in place.
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(G) New center cross-tube
7. Use welds (W1) to secure both rear edges of 125-7017 Support (Center Cross-Tube) to the vertical supports
within the frame rails. Weld to the contour that is shown in Illustration 25.
8. Use 16.0 mm (.63 inch) fillet welds (W2) to join the rear edges of the top rails to both sides of the vertical
supports within the frame rails.
9. Use 12.0 mm (.47 inch) fillet welds (W3) to join the top and bottom edges of the 125-7017 Support (Center
Cross-Tube) to the top and bottom frame rails. Weld from theinsidetheframe rails.
10. Use 16.0 mm (.63 inch) fillet welds (W4) to secure the fore and aft edges of the 125-7017 Support (Center
Cross-Tube) to the inside window plates of the frame rails.
Note: Maintain a 10.0 mm (.40 inch) root opening. Do not extend the weld (W4) into the grooves for the
horizontal welds (W5). The forward edge of the new center support requires an 8X-0597 Backup Strip.
11. Use 16.0 mm (.63 inch) J-groove welds (W5) to secure the top and bottom edges of the 125-7017 Support
(Center Cross-Tube) to the top and bottom frame rails. Weld from the outside of the frame rails.
Window plate (Y)
( R) 669.0 mm (26.34 inch)
(S) 1829.0 mm (72.00 inch)
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Window plate (X)
( U) 669.0 mm (26.34 inch)
(T) 612.0 mm (24.1 inch)
(V) 13.0 mm (.51 inch)
12. Use steel that is 16.0 mm (.63 inch) thick to fabricate two new outside window plates (Y) and (X) for each
frame rail. The steel should meet ASTM specification "A572". Trim the window plates to fit in the frame
rails.
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(E) Tank support
(Y) Window plate
(X) Window plate
13. Position window plate (Y) and window plate (X) on the frame.
14. Use 16.0 mm (.63 inch) J-groove welds (W7) to secure the new outside window plates (Y) and (X) in place.
15. Position the tank supports that were removed earlier.
16. Use 8.0 mm (.32 inch) fillet welds to secure the tank supports to the frame rails. Grind a 5.0 mm (.20 inch)
radius at the toe of the fillet weld. Refer to "Tank Support Field Repair Procedure for the 785, 785B,785C,
785D, 789, 789B, 789C, 789D, 793, 793B, 793C, and 793D Off-Highway Trucks" in this Special Instruction.
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Complete the Installation of the New Support (Center Cross-Tube)
1. Remove the square tubing that was installed to brace the frame.
2. Grind the areas near the intersection of welds to a smooth contour.
3. Paint the areas that were repaired.
4. Install the components that were removed from the truck.
Frame Rails (Repair)

Table 13
Frame Rails
Off-Highway Truck/Tractor Part Number(1)
785 8X-0898
789 8X-2648
793 8X-2648
(1) (Bulk) Must be cut to length.
1. Remove the body of the truck. Refer to Disassembly and Assembly, "Body and Canopy - Remove".
View of the left outside frame
(A) Bevel groove weld
(B) Tank mount
(C) J-groove
(D) Window plate
2. Support the truck frame. Remove the fuel or the hydraulic tank. Use jacks on both sides of the frame rail that
is cracked. Raise the frame until the crack is closed.
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3. Remove all the hardware that will be affected in the area near the center tube. Save all hardware. Record
some reference dimensions from the front mount for the fuel tank to the rear mount for the fuel tank. These
measurements will be used to relocate the front tank mount.
4. Remove bracket (B) for the front fuel tank by using a arc gouge. Angle the cuts toward window plate (D)
away from the tank mount. Use care when cutting as the tank mount will be reused. Remove window plate
(D) by using the carbon arc gouging along the dotted line shown in Illustration 29. Angle the cut toward
window plate (D) away from the top and the bottom rails. The top and bottom weld joints have a backing
plate (C) for the J-groove. When you cut the window, try not to damage the plates. The vertical weld joints
are bevel joints that have a gusset backing. Do not cut into the gusset.
Clean weld joints and prepare weld joints.
(C) J-groove
(E) 45 degree bevel with a 2 mm (0.08 inch) land
5. After window plate (D) is cut and removed, grind off all the old weld. Use a grinder to prepare the joints of
the weld to the original profile. This is shown in illustration 30. Be sure that the weld joints are free of oil,
carbon, slag, or foreign material.
Frame rail
(F) Inside frame rail
(G) Crack
6. Inspect the top and bottom rails (F) for cracks. Refer to Special Instruction, SEHS9091 for a reference. If
cracks are located, cut out the crack from the inside frame rail (F). Weld the cut out areas and grind the area
smooth. Back gouge the repair as shown in Illustration 31. Weld the area that was gouged and grind the area
smooth. Inspection of the rail should be done to ensure that the rail is free of cracks. The Ultrasonic
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inspection procedure should be used to inspect the repair. Use an angle beam transducer that is set up for
mild steel. The weld should be checked from each side. Any internal feature should be repaired.
Inside window plate
(H) Bulkhead
(D) Inside window plate
(I) Backup strip
7. Inspect the center cross-tube for cracks. If the tube is cracked, the tube must be repaired. Refer to "Center
Cross-Tube Support Replacement for the 793C and 793D Off-Highway Trucks" section in this Special
Instruction. Inspect inside window plate (D) in front of the center tube. If the window plate is cracked, the
window plate must be removed. The weld seam to the rear of the truck has a backup strip (I). Remove the
backup strip (I) and all the old weld. For the 785 and 789 trucks, inside window plate (D) will need to be cut
at the gusset (bulkhead) (H) at the location shown in Illustration 32 and a weld seam created. For the 793
truck, cut on the weld seam.
Note: The J-groove seams that run along the frame, top, and bottom of the window plate, will need to be
removed.
Reinforcement plates
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8. Fabricate the required reinforcement plates that are shown in Illustration 33. Use ASTM A572 grade 42 or 40
steel.
Outside window plate
9. Fabricate the required window plates that are shown in Illustration 34. Use ASTM A572 grade 42 or 40 steel.
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Backup strip
10. Fabricate the required backup strips that are shown in Illustration 35. Use ASTM A572 grade 42 or 40 steel.
Inside window plate for 793 Off-Highway Truck
(ZZ) 16.0 mm (0.63 inch)
(ZY) 671.5 mm (26.44 inch) or 677.5 mm (26.67 inch)
(ZX) 669.0 mm (26.34 inch) or 672 mm (26.46 inch)
Note: Measure the length and width of the window plate prior to removal to determine the dimensions that
are appropriate for your truck.
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(ZW) 16.0 mm (0.63 inch)
(ZV) 1735.0 mm (68.31 inch) or 1570.0 mm (61.81 inch)
(ZU) 594.0 mm (23.39 inch) or 597.0 mm (23.50 inch)
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(ZT) 14.0 mm (0.55 inch)
(ZS) 1626.5 mm (64.04 inch) or 1461.5 mm (57.54 inch)
(ZR) 521.0 mm (20.51 inch) or 524.0 mm (20.63 inch)
11. Fabricate the required inside window plates that are shown in Illustration 36, Illustration 37, or Illustration
38. Use ASTM A572 grade 42 or 40 steel.
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Welding the reinforcement plate
(J) Reinforcement plate
(K) 12 mm (0.47 inch) fillet
(L) Weld groove
(M) Existing weld
(N) Groove weld with 12 mm (0.47 inch) fillet
12. After the crack in the bottom rail is repaired, position the plate and tack weld reinforcement plate (J). Weld
reinforcement plate (J) that is shown in illustration 39. Visually inspect the welds. The welds shall be free
from cracks, porosity, undercut, and incomplete fusion. Grind the groove weld flush.
Welding of the inside window plate
(O) 16 mm (0.63 inch) Fillet
(P) Bevel groove
13. Position the plate and tack weld the inside window plate. The root openings on the sides of the plate need to
be a minimum of 6 mm (0.24 inch) to allow for proper fusion of plate corners. Equalize the root opening
between the top and the bottom. Tack weld the window plate. Locate backup strip (I) and tack weld backup
strip (I). Weld the vertical seams (R). Weld the top and bottom J-grooves. After the groove welds are welded
around the window plate, weld a 16 mm (0.63 inch) fillet on the (bulkhead to window) on the inside the rail.
Slag each pass and make sure all tie-ins are complete. The welds around the window plate should be
inspected using ultrasound.
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Welding the outside window plate
(Q) 8 mm (0.32 inch) Fillet tig dressed
(R) Vertical grooves
(S) Bottom grooves
14. Locate and tack weld the outside window plate with a minimum of 6 mm (0.24 inch) root openings on the
sides. Weld the vertical seams (R). Weld the top and bottom horizontal groove weld (S). Slag each pass and
make sure all tie-ins are complete. The welds around the window plate should be inspected with ultrasound.
Locate the bracket for the fuel tank and tack weld the bracket for the fuel tank with the recorded reference
dimensions. Refer to "Tank Support Field Repair Procedure for the 785, 785B,785C, 785D, 789, 789B, 789C,
789D, 793, 793B, 793C, and 793D Off-Highway Trucks" for the correct welding size on the tank supports.
Blend, grind, and paint as needed.
Tank Support Field Repair Procedure for the 785, 785B,785C, 785D,
789, 789B, 789C, 789D, 793, 793B, 793C, and 793D Off-Highway Trucks
This procedure covers the field repair of cracks and to enhance fatigue life of the tank support welds for the 785,
789, 793, Off-Highway Trucks.
Repair Procedure
Table 14
Tank Support
Fuel Tank Bracket Hydraulic Tank Bracket
Front Bracket Rear Bracket Front Bracket Rear Bracket
784 6G-7438 6G-7439 8W-4293 8W-4293
785 6G-7438 6G-7439 8W-4293 8W-4293
789 8W-5359 8W-5354 5T-6465 5T-6464
789D 347-6511 347-6510 5T-6465 5T-6464
793 8X-2571 8X-2572 8X-5936 8X-5936
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass.
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The weld pass shall not exceed two times the electrode diameter.
When the base metal temperature is below 0.0 C (32 F), the base metal shall be preheated to 21 C (70 F) and
this minimum temperature maintained during cutting or welding.
Clean the area to be welded from oil, grease, paint, and dirt. Attach the welding ground cable directly to the center
tube assembly. Protect all machined surfaces from sparks or spatter produced by the welding, chipping and /or
grinding operations.
The weld shall be free from cracks, porosity, undercut and incomplete fusion. All welds quality shall conform to
ANS/AWS 14.3 or Caterpillar Specification 1E99.
Welding parameters will vary due to weld position and the manufacturer of welding electrode. For 1.3 mm
(0.052 inch) diameter electrode typical welding parameters.
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass.
Repair Cracks
Begin the repair by removing any cracks with the carbon arc gouging method, or grinding. Cracks must be removed
to sound metal prior to welding. Verify that the crack has been removed by the use of dye penetrant or magnetic
particle inspection. Be sure to clean the prepared groove before welding. Weld repair the prepared groove by using
passes that do not exceed two times the electrode diameter. If the alternate welding process is selected, the welding
pass size should not exceed 8 mm (0.31 inch) fillet weld volume. Remove the slag after each weld pass to avoid the
possibility of slag inclusions.
Clean and inspect the weld repair. The weld shall be free from cracks, porosity, undercut and incomplete fusion. All
welds quality shall conform to ANS/AWS 14.3 or Caterpillar Specification 1E99.
Tank Support
After the crack has been repaired, weld a small bead 6 mm (0.24 inch) around the toe of the existing weld as shown
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in Illustration 42. Use a small grinder to blend the toe of this weld (B) to approximately a 5 mm (0.2 inch) radius as
shown in Illustration 42. This will create a smooth transition from the weld to the rail, therefore reducing the stress
concentration. Use a small grinder to grind the top of plate (A) to a gradual radius. This will create a smooth
transition from the weld to the tank support.
Outside Window Plates Repair for 784B and 784C Tractors, 785, 785B,
785C, 785D, 789, 789B, 789C, 789D,793, 793B, 793C, and 793D Off-
Highway Trucks
(A) Inside window plate
(B) 100 mm (4.0 inch)
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1. Start at the tail casting and remove the inside window plate (A). Remove an extra 100 mm (4.0 inch) (B)
from the remaining window plate.
Note: When you remove the window plate, do not cut into the tail casting.
2. Locate the crack in the outside window plate. Gouge out the crack from both sides of the plate.
3. Weld one side of the crack. Gouge out the remaining side of the crack. Weld the remaining side of the crack.
Grind the welds down to the original profile.
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4. Add an 8.0 mm (.32 inch) fillet weld (W1) to the toe of the 12.0 mm (.47 inch) fillet weld that joins the
outside window plate and the tail casting. Grind the 8.0 mm (.32 inch) fillet weld to a radius of 5.0 mm
(.20 inch).
Note: You may need to remove the pistol plates to gain access to the 12.0 mm (.47 inch) fillet weld.
5. Position the inside window plate and the backup plate.
Note: If necessary, install the pistol plates first. Use a 12.0 mm (.47 inch) fillet weld to secure the pistol
plates to the frame rail and to the tail casting. Maintain a 3.0 mm (.12 inch) root opening.
6. Apply a 16.0 mm (.63 inch) J-groove weld around the inside window plate from the outside of the frame rail.
Extend the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the bottom of the
frame rail past the vertical joint in the window plates.
7. Use a 16.0 mm (.63 inch) bevel weld to join the inside window plates.
Rear Window Plate Replacement Near the Tail Casting of 784B and
784C Tractors, 785, 785B, 785C, 785D, 789, 789B, 789C, 789D, 793,
793B, 793C, and 793D Off-Highway Trucks
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(A) Outside window plate
(B) 100 mm (4.0 inch)
1. Start at the tail casting and remove a section (A) of the window plate from the outside of the frame rail.
Remove an extra 100 mm (4.0 inch) (B) from the remaining window plate.
Note: The section of window plate that is removed should be the same size as the inside window plate.
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(C) Inside window plate
(D) 100 mm (4.0 inch)
2. Start at the tail casting and remove the inside window plate (C). Remove an extra 100 mm (4.0 inch) (D)
from the remaining window plate.
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(E) New outside window plate
3. Position a new outside window plate (E) and a backup plate.
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4. Use a 12.0 mm (.47 inch) fillet weld (W1) to secure the new outside window plate to the tail casting.
Note: Grind the toe of the 12.0 mm (.47 inch) fillet weld to a 5.0 mm (.20 inch) radius.
Note: Illustration 48 does not show the pistol plates. If necessary, remove the pistol plates to gain access to
weld (W1).
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5. Apply a 16.0 mm (.63 inch) J-groove weld (W2) around the new outside window plate from the outside of
the frame rail. Extend the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the
bottom of the frame rail past the vertical joint in the window plates.
6. Use a 16.0 mm (.63 inch) bevel weld (W3) to join the outside window plates.
7. Position the inside window plate and the backup plate.
Note: If necessary, install the pistol plates. Use a 12.0 mm (.47 inch) fillet weld to secure the pistol plates to
the frame rail and to the tail casting. Maintain a 3.0 mm (.12 inch) root opening.
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8. Apply a 16.0 mm (.63 inch) J-groove weld (W4) around the inside window plate from the outside of the
frame rail. Extend the 16.0 mm (.63 inch) J-groove weld 100 mm (4.0 inch) along the top and along the
bottom of the frame rail past the vertical joint in the window plates.
9. Use a 16.0 mm (.63 inch) bevel weld (W5) to join the inside window plates.
Rear Cross-Tube Replacement for 793, 793B, 793C, and 793D Off-
Highway Trucks
Prepare the Frame in Order to Remove the Rear Cross-Tube
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Note: The rear cross-tube can be replaced with the body on the truck or with the body off the truck. If you leave the
body on the truck, the body must remain in the DOWN position while the cross-tube is replaced.
1. Clean the area around the rear cross-tube of the items that follow: oil, grease, dirt, and paint.
Note: You must stabilize the area near the rear of the frame before you remove the rear cross-tube. Stabilize
the area near the rear frame to maintain the alignment of the bores for the body pins. You can weld braces on
the rails of the frame to stabilize the frame. Do not weld the braces too close to the bores for the body pins to
prevent distortion.
2. Before you stabilize the frame, prepare to take measurements for reference. Use a punch to mark the four
locations that follow:
Mark the rear of the right tail casting directly behind the bore for the body pin.
Mark the rear of the left tail casting directly behind the bore for the body pin.
Mark the rear of the left tail casting directly behind the bore for the pin for the suspension cylinder.
Mark the rear of the right tail casting directly behind the bore for the pin for the suspension cylinder.
3. Record the measurements that follow:
Measure the distance across the tail castings above the bores for the body pins. Measure the distance
from the outside of the castings.
Measure the distance from the top left punch mark to the bottom right punch mark.
Measure the distance from the top right punch mark to the bottom left punch mark.
Measure the distance between the bottom two punch marks.
4. Remove parts that are exposed and remove parts that could be damaged by the repair procedure. Remove the
items that follow: rear lights, backup alarm, lubrication lines, and wiring harnesses. Cut the light bar off the
cross-tube. Save the light bar to install the light bar on the new rear cast cross-tube.
Note: Record measurements for the location of bosses that will be removed.
Brace the Frame When the Body Is Off
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(A) Frame rail
(B) Square tubing
(C) Steel bar stock
1. Weld braces on the frame rails of the truck to maintain the alignment of the pivot pin bores for the body.
Apply one set of braces ahead of the cross-tube. The braces should consist of the material that follows:
Obtain two pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The
square tubing (B) should be long enough to extend across the frame rails.
Obtain two pieces of steel bar stock (C) that are 25.4 mm (1.0 inch) thick and 101.6 mm (4.0 inch) tall.
The steel bar stock should be as long as the square tubing.
2. Place one piece of square tubing (B) across the top of the frame rails. Weld the square tubing (B) in place.
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Start the weld and stop the weld at least 25.4 mm (1.00 inch) away from the edge of the frame rails (A).
3. Place the second piece of square tubing (B) across the bottom of the frame rails (A). Weld the second piece
of square tubing (B) in place directly below the first piece of square tubing (B). Start the weld and stop the
weld at least 25.4 mm (1.00 inch) away from the edge of the frame rails (A).
Note: Adjustable spreader bars can be used in place of the square tubing (B). Refer to Illustration 53. Use the
screw adjustment to adjust the width of the spreader bar. When you use spreader bars, weld the pads to the
inside the frame rails. Start the weld and stop the weld at least 25.4 mm (1.00 inch) away from the weld at the
edge of the frame rails (A).
4. Use the steel bar stock (C) that is 101.6 mm (4 inch) wide to make diagonal braces between the two pieces of
square tubing (B). The diagonal braces are shown in option 1 of Illustration 51.
Note: You can fabricate the diagonal braces from a single plate that is 25.4 mm (1.00 inch) thick. A diagonal
brace that is made from a single piece of plate is shown in option 2 of Illustration 51.
5. Install braces behind the cross-tube. The brace should consist of the material that follows:
Obtain two pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The
square tubing (B) should be long enough to extend across the frame rails.
The material should be as long as the square tubing.
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(A) Frame rail
(E) Square tubing
(F) Steel bar stock
6. Place one piece of square tubing (E) across the top of the tail castings above the pivot pin bores for the body.
Weld the square tubing (E) in place.
7. Place the second piece of square tubing (E) at the bottom of the tail castings between the upper mounts for
the rear suspension cylinders.
8. Use the steel bar stock (F) that is 101.6 mm (4.0 inch) wide to make diagonal braces. Weld the braces on the
tail castings from the pivot pin bores for the body to the upper mounts for the rear suspension cylinder. The
diagonal braces are shown in option 3 of Illustration 52.
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brace that is made from a single plate is shown in option 4 of Illustration 52.
Brace the Frame When the Body Is On
(A) Frame rail
(B) Spreader bar
(C) Steel bar stock
1. Weld braces on the frame rails of the truck to maintain the alignment of the pivot pin bores for the body.
Apply one set of braces ahead of the cross-tube. The brace should consist of the material that follows:
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Obtain four spreader bars (B) with pads for welding. The spreader bars (B) should have a screw
adjustment to extend across the frame rails.
The material should be as long as the spreader bars.
2. Place two spreader bars (B) across the top of the frame rails. Weld the pads of the spreader bars (B) in place.
Start the weld and stop the weld at least 25.4 mm (1.00 inch) away from the weld at the edge of the frame
rails (A).
Note: Use the jam nuts to secure the screw adjustment.
3. Place the second set of spreader bars (B) across the bottom of the frame rails (A). Weld the second set of
spreader bars (B) in place directly below the first set of spreader bars (B). Start the weld and stop the weld at
least 25.4 mm (1.00 inch) away from the weld at the edge of the frame rails (A).
Note: Use the jam nuts to secure the screw adjustment.
4. Use the steel bar stock (C) that is 101.6 mm (4.0 inch) wide to make diagonal braces between the spreader
bars (B). The diagonal braces are shown in option 1 of Illustration 53.
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(A) Frame rail
(B) Spreader bar
(C) Steel bar stock
(H) Shims
5. Install braces behind the cross-tube. The brace should consist of the material that follows:
Obtain a piece of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The
square tubing (B) should be long enough to extend across the frame rails (A).
The material should be as long as the square tubing.
6. Place the shims (H) between the inner flanges of the body for the pivot pin bores and the tail castings. The
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shims will prevent the tail castings from distorting when the new cast cross-tube is installed.
7. Place the piece of square tubing (B) at the bottom of the tail castings between the upper mounts for the rear
suspension cylinders.
Note: Adjustable spreader bars can be used in place of the square tubing (B). Refer to Illustration 54. Use the
screw adjustment to adjust the width of the spreader bar. When you use spreader bars, weld the pads to the
inside the tail castings.
8. Use the steel bar stock (C) that is 101.6 mm (4.0 inch) wide to make diagonal braces. Weld the braces on the
tail castings from the pivot pin bores for the body to the upper mounts for the rear suspension cylinder. Refer
to option 3 of Illustration 54.
Remove the Existing Rear Cross-Tube
New 119-4726 Tube
(J) Length of cross-tube
1. Use a grinder to make the ends of the new 119-4726 Cross-Tube square. Use a grinder to restore the chamfer
at the ends of the 119-4726 Cross-Tube. Measure the length (J) of the new cross-tube. Record the
measurement (J).
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(K) Distance from centerline of frame to cut
(M) Width of opening
2. Establish the center line of the existing cross-tube. Mark a line that is a distance (K) from each side of the
center line of the existing cross-tube. Calculate the distance (K) from the formula that follows.
K = (J 2) + 9.6 mm (.38 inch)
Note: The distance (M) between the outer two lines on the existing cross-tube should be 19.0 mm (.75 inch)
wider than the length (J) of the new cross-tube.
3. Before you cut the cross-tube from the truck, support the existing cross-tube.
4. Cut the existing cross-tube from the truck.
Note: A second cut may be needed on the existing cross-tube to provide clearance for removal.
Note: Make sure that the opening (M) is no more than 19.0 mm (.75 inch) wider than measurement (J).
5. Grind the surface of the transition area until the surface is flush and square. Clean debris away from the
inside surfaces of the casting.
Position the New 119-4726 Cross-Tube for Installation
Prepare The Backup Plates
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Backup plate
1. There are four backup plates that are used with the 119-4726 Cross-Tube. Cut each backup plate into two
pieces along the length of the backup plate.
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(N) 40.0 mm (1.57 inch)
2. Obtain eight pieces of steel that can be used to hold the backup plates in position. The steel should have the
dimensions that follow:
3.0 mm (.12 inch) thick
25.4 mm (1.00 inch) wide
203.20 mm (8.00 inch) long
3. Make a 90 degree bend in the steel. Refer to Illustration 58.
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Backup plate and strip
4. Weld one steel strip to each piece of backup plate. Refer to Illustration 59.
Note: Before you weld the steel strip in place, refer to Illustration 60 to calculate the position of the steel
strip.
(P) Total length of cross-tube and backup plates
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5. Install the backup plates in the new cross-tube. Use the steel strips to hold the backup plates in position.
Note: When the backup plates are positioned in the new cross-tube, the total length (P) of the cross-tube and
backup plates must fit within the opening. When the correct length has been established, tack weld the steel
strips in place.
Prepare the Locator Bars in Order to Hold the New Cross-Tube in Position
1. Obtain eight steel bars to support the new cross-tube. The bars should have the dimensions that follow:
12.7 mm (.50 inch) thick
50.8 mm (2.00 inch) wide
203.2 mm (8.00 inch) long
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Rear cross-tube with backup plates and support bars
2. Weld one locator bar on the top of the new cross-tube at each end of the new cross-tube. Weld the locator
bars centrally on the cross-tube. Allow the locator bars to extend beyond the ends of the new cross-tube. The
end of the locator bar, that extends beyond the end of the cross-tube, will support the cross-tube when the
cross-tube is suspended in position.
3. Weld one locator bar on the back side of the new cross-tube at each end of the new cross-tube. Weld the
locator bars centrally on the cross-tube. Allow the locator bars to extend beyond the ends of the new cross-
tube. The end of the locator bar, that extends beyond the end of the cross-tube, will locate the cross-tube in
the fore and aft position.
Set the New Cross-Tube in Place
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1. Position the new cross-tube in the opening. The new cross-tube should hang from the castings that protrude
from the frame rails. The raised letters on the cross-tube should face toward the front of the machine.
Note: It may be necessary to grind on the locator bars to position the cross-tube centrally in the opening.
Note: The new cross-tube weighs approximately 297 kg (655 lb).
2. After the cross-tube is positioned, weld extra locator bars at the top of the cross-tube. Weld extra locator bars
on the side of the cross-tube. Weld the locator bars on the same side as the existing locator bars. At one end
of the cross-tube, weld the locator bars to the castings. The casting protrudes from the frame rail.
Note: Secure the new cross-tube to the frame rail on only one side. When the secured side is welded, the
opposite end is free to float.
3. On the end of the cross-tube that is secured to the frame, cut the tack welds on the steel strips that hold the
backup plates. Slide the backup plates into position. Tack weld the backup plates to the cross-tube. Remove
the steel strips that held the backup plates.
Weld the New 119-4726 Cross-Tube in Place
1. Use the SMAW process and "E7018" welding electrode to permanently weld the end of the new cross-tube
that is tack welded to the frame. Use two welding operators that start on opposite sides of the secured end of
the cross-tube. Start the welds at the bottom center of the cross-tube and end the welds at the top center of the
cross-tube. Stagger the starts and the stops. Fill the grooved area to a depth of 40.0 mm (1.57 inch). Before
you proceed, complete all welding at the secured end of the cross-tube.
Note: The FCAW process can also be used with "E71T-1 H8" welding electrode.
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2. Allow the welded end of the cross-tube to cool to a temperature of 38 C (100 F). While the welded end
cools, slide the backup plates at the other end of the cross-tube.
3. Use the SMAW and "E7018" welding electrode to weld the four corners on the unsecured end of the cross-
tube. Weld approximately 76.2 mm (3.00 inch) from the center of each corner in both directions. Fill the
corners to a depth of 26.7 mm (1.05 inch).
4. Heat all four corners until the corners are a dull red color. Maintain the dull red color between 2 minutes and
3 minutes. Allow the corners to cool to a temperature of 38 C (100 F).
Note: The heat treat process will minimize the shrinkage of the cross-tube.
5. Gouge out the welds at the corners. Finish welding the cross-tube in place. Fill the grooved area to a depth of
40.0 mm (1.57 inch).
Complete the Installation of the New Rear Cross-Tube
1. Carefully remove the fixtures that braced the frame. Grind excess welds until the welds are flush. Fill any
gouges.
2. Install the light bracket on the new cross-tube. Weld the new bosses on the cross-tube. Refer to the recorded
dimensions.
3. Measure the distances between the punch marks. Compare the measurements to the measurements that were
taken previously.
Note: The distance between the punch marks can be 4.5 mm (.17 inch) shorter than the recorded
measurement. The shorter measurement should not affect the pivot pin bores for the body.
Note: Sometimes, the pivot pin bores may need to be repaired to install the body.
4. Paint the area that was repaired.
5. Install the components that were removed earlier.
Rear Support Assembly Replacement
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1. Start by removing the body and supporting the frame rail with jacks.
2. Next the main rail needs to be braced. Cut two pieces of steel tubing to a length of 102 X 102 X 6 mm
(4 X 4 X 1/4 inch).
3. Weld the two braces (2) between the two frame rails. Weld the brace ends (3) with a 6 mm (0.24 inch) fillet
welds.
4. Make some reference measurements from the rear pivot holes to the rail and scribe a line on the rail. Record
these measurements. The recorded measurements will be used to locate the new rear support assembly.
5. Remove both rear window plates (1) by cutting around the weld seams.
6. Angle the cuts toward the window plate so that minimal damage is done to the rail. Make sure that the
support assembly is safely supported before you cut the assembly loose.
7. Finishing removing the rear support assembly by cutting the inside fillet weld that joins the outside window
to the rear casting.
8. Cut weld joints (5) at the top and bottom of the rails. Also, cut welds (6) that is on the inside on the top and
bottom.
9. After the welds are cut loose, remove the rear support assembly. Prepare the weld joints by grinding the joints
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to the original profile.
10. Be sure to remove all paint, oil, grease, slag, weld metal, and dirt.
11. Position the new rear support assembly near the frame. Use the recorded reference dimensions to locate the
new rear support assembly.
12. Tack weld the assembly into position. Weld the outside window plate to the rear casting on the inside the rail
use a 10 mm (0.4 inch) fillet weld. Weld a 10 mm (0.4 inch) weld on the inside along the rear casting to the
rail on the top and bottom as shown in Illustration 65.
13. Next weld the 29 mm (1.14 inch) top and bottom J-groove welds. Alternate between the top and the bottom.
14. Position and tack weld two 2G-7521 Strips (7) to each window (1).
15. Make strips (7) tack welds from the groove side of assembly.
16. Next tack two 115-3311 Plates to each rail. Weld the vertical 10 mm (0.4 inch) bevel weld joint on both
inside window plates. Weld the outside vertical J-groove joints.
17. Next weld the 10 mm (0.4 inch) J-groove around the inside windows.
Note: Make sure that all welds are tied in properly.
18. Clean and visually inspect all welds. The welds should be free from cracks, porosity, undercut, and
incomplete fusion. Remove the cross bracing and repair the rails.
19. Grind, blend, and paint as needed. All groove welds should be ultrasonically tested for soundness.
Tail Casting Replacement for 793, 793B, 793C, and 793D Off-Highway
Trucks
This procedure shows the replacement of the right side tail casting. Similar procedures are required for the left side
tail casting.
1. Remove the body from the truck. Remove any components that prevent access to the rear body pivot casting.
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2. Support both rear frame rails with jacks.
(A) Square tubing
(B) Square tubing
(C) Inside window plate
3. Obtain two pieces of 101.6 mm (4.0 inch) square tubing (A) with 6.35 mm (.25 inch) thick walls. The square
tubing should be long enough to extend between the frame rails.
4. Obtain two extra pieces of 101.6 mm (4.0 inch) square tubing (B) with 6.35 mm (.25 inch) thick walls. The
square tubing should be 1059 mm (41.7 inch) long. The square tubing will form braces between the rear
cross-tube and the bracing between the frame rails.
5. Refer to Illustration 67 to brace the rear frame rails with the square tubing.
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Note: Position square tubing (A) approximately 140 mm (5.5 inch) from the edge of the inside window plate.
6. Remove the 8X-2376 Window Plate (C) from the inside the frame rail.
(D) Pistol plate
(E) Pistol plate
7. Remove the 8X-2686 Plate (D) and the 8X-0463 Plate (E) from the inside the frame rail.
8. After you make sure that the tail casting is supported, cut the tail casting away from the frame rail and from
the rear cross-tube.
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(F) Backup plate
(G) Backup plate
9. After you remove the damaged tail casting, remove the two 9P-1037 Backup Plates (F) from the frame rail.
Also, remove the four 120-6766 Backup Plates (G) from the rear cross-tube.
10. Clean the edges of the joints at the frame rail. Clean the edges of the joints at the rear cross-tube. Remove
slag and carbon deposits.
11. Position two new 9P-1037 Backup Plates in the frame rail. Tack weld the backup plates in place.
12. Position four new 120-6766 Backup Plates in the rear cross-tube. Tack weld the backup plates in place.
13. Position the new tail casting in place on the frame rail and on the rear cross-tube. Align the unfinished pivot
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pin bore of the new tail casting with the pivot pin bore of the existing tail casting.
Note: The reference dimension between the outer edges of the tail castings is 2085.0 mm (82.09 inch).
14. Tack weld the new tail casting in position.
15. Weld the new tail casting to the rear cross-tube. Alternate the welds between the top of the rear cross-tube
and the bottom of the rear cross-tube to prevent distortion. Also, alternate the welds between the front side of
the rear cross-tube and the back side of the rear cross-tube to prevent distortion.
16. Weld the new tail casting to the top of the frame rail and to the bottom of the frame rail.
17. Install the pistol plates. Position the 8X-2686 Plate (D) and the 8X-0463 Plate (E) inside the frame rail. Use a
4K-7004 Bar to connect the two plates.
Note: Grind the plates to fit the frame rail and the new tail casting. Maintain a 3.0 mm (.12 inch) root
opening.
18. Use a 12.0 mm (.47 inch) fillet weld to secure the 8X-2686 Plate (D) and the 8X-0463 Plate (E) to the frame
rail and to the tail casting. Weld the joint between the plates.
19. Tack weld a new 8X-2688 Backup Plate in the frame rail for the inside window plate.
20. Position the 8X-2376 Window Plate on the inside the frame rail. Use a 16.0 mm (.63 inch) fillet weld to join
the inside window plate to the existing side plate of the frame rail.
21. Use a 16.0 mm (.63 inch) J-groove weld to join the inside window plate to the tail casting and to the frame
rails.
Note: Do not start the weld on the radius and do not stop the weld on the radius. Stagger the starts and stops.
22. Use a 16.0 mm (.63 inch) J-groove weld to join the outside window plate to the tail casting and to the frame
rails.
Note: Do not start the weld on the radius and do not stop the weld on the radius. Stagger the starts and stops.
23. Machine the pivot pin bore of the tail casting to a diameter of 149.93 mm (5.903 inch).
Note: Align the pivot pin bore with the pivot pin bore of the tail casting on the opposite side of the frame.
Procedure to Repair the Bracket Assembly (Steering Box) on the 793C

S/N:ATY and 793D
Note: Removal of the engine is required for performing the Advanced Repair. Refer to Disassembly and
Assembly Manual, SENR1461, "3516B Engine Supplement for 793C Off-Highway Truck" and Disassembly and
Assembly Manual, RENR8334, "793D Off-Highway Truck Engine Supplement" for procedure to remove and
install the engine.
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View of the general area of repair
(A) Bracket assembly (steering box)
(B) Support assembly
The following procedure applies to the repairs of cracks located in the J-groove welds connecting the steering box
to the support castings. Refer to Illustration 71.
View of crack present in the weld joint
Illustration 71 represents a typical crack that can occur in the weld joint between the bracket assembly (steering
box) (A) and support assembly (B). The crack shown in Illustration 71 is a fatigue crack that has initiated from the
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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 72 depicts the J-groove weld joint design that is present on all four sides between bracket assembly
(steering box) (A) and support assembly (B). As shown, support assembly (B) contains an inherent (or integral)
backing for the weld joint.
Cross sectional view of corner joints
Illustration 73 depicts the corner joint connection that is common on all four sides. Fillet welds are specified at this
location ( 12 mm (0.47 inch) x 20 mm (0.79 inch).
Table 15
Material Type and Thickness
Part Number Description Material Type 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-2274 Plate ASTM A572 Gr 42 20 mm (0.79 inch)
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8X-3566 Support ASTM A27 65-35 Varies
8X-3567 Support ASTM A27 65-35 Varies

(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 72).
2. Verify that the crack has been removed via magnetic particle (MT) or dye penetrant (PT) testing.
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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
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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.
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View of completed repair
7. Paint repaired area as needed. Illustration 79 shows a completed repair.
Advanced Procedure to Repair the Bracket Assembly (Steering Box)
Note: Removal of the engine is required for performing the Advanced Repair. Refer to Disassembly and
Assembly Manual, SENR1461, "3516B Engine Supplement for 793C Off-Highway Truck" and Disassembly and
Assembly Manual, RENR8334, "793D Off-Highway Truck Engine Supplement" for procedure to remove and
install the engine.
If required, perform "Basic Repair Procedure for the Bracket Assembly (Steering Box)" before removing
the front plate.
In order to extend the life of the J-groove weld joints and correct the root gap issues, access to the inside 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.
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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 81.
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 82.
5. Gouge/excavate the J-groove welds connecting the remnants of the front plate to the support assembly.
6. Gouge/excavate the corner fillet welds connecting the top and bottom plates to the remaining part of the front
plate.
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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 83.
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.
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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.
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View of offset
13. Measure offset (D) between the inside surface of the adjacent plate of bracket assembly (steering box) and
the inside surface of the integral backing strip on the support assembly. Refer to Illustration 88Record the
offset dimensions.
Note: Offset will be used to determine fillet weld size.
View of welding progression
14. Weld the root pass as shown in Illustration 89. Vertical progression is uphill and no starts or stops are allowed
in the corners. Weld the root pass on one side and then the other side.
Note: Use a balanced welding technique 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.
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View of no weld area previously specified
15. Prior to finishing the weld joint between the support assembly and the bracket assembly (steering box), the
fillet weld that is internal to the bracket assembly (steering box) will need to be modified.
Illustration 90 shows that the internal fillet weld from the factory does not extend all the way to the edge, but
is stopped short by 100 mm (3.94 inch).
View of the internal fillet weld size
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View of the drain hole in the bracket assembly (steering box)
16. Extend the fillet weld until the fillet weld connects at the corners with the previous welds applied. The size of
the fillet weld is 10 mm (0.40 inch) as shown in Illustration 91. Do not weld the drain hole shut.
Note: Grind the existing weld start/stop to minimize lack of fusion before starting the fillet weld that extends
into the corner.
View of full penetration groove weld with fillet weld transition
17. The offset was measured in Step 13. This dimension determines the size of the fillet weld that will be added
over the partial J-groove weld in Step 14, and the fillet weld that was completed in Step 16.
Example: If the offset is 10 mm (0.40 inch), then the fillet weld over the J-groove weld will be a 10 mm
(0.40 inch) by 10 mm (0.40 inch) fillet weld. The fillet weld size will vary depending on the offset.
Illustration 93 depicts the expectation of the full penetration groove weld and fillet weld.
Note: Use the same welding progression and balanced welding technique in reference to Illustration 89.
18. Visually inspect all welding and ensure that all weld quality meets or exceeds the requirements in the "Weld
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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 94.
Dimensions for fabrication of front plate
(E) 1090 mm (42.91 inch)
(F) 355 mm (13.98 inch)
(G) 20 mm (0.79 inch)
21. Use the dimensions in Illustration 95 to fabricate a new front plate. Use ASTM A572 Grade 42 material.
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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 96.
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).
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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 99.

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 100.
27. Secure front plate (J) in place using 6 mm (0.24 inch) by 50 mm (1.97 inch) fillet welds on all four sides.
28. Attach run on/off tabs as discussed in Step 4 in the "Basic Repair Procedure for the Bracket Assembly
(Steering Box)" Section.
29. Weld the root pass at each of the four weld joints before proceeding with the second and third weld passes.
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View of the direction/progression of welding for fillet welds
30. The progression for the J-groove welds will be vertical up. The direction for the top and bottom fillet welds
are shown in Illustration 101. Start each weld pass in the middle and terminate at the end of the joint.
Note: Grind the weld start in the middle to minimize lack of fusion before starting the fillet weld going in the
opposite direction.

View of weld sizes
(J) Front plate
31. Finish weld front plate (J) using the weld sizes shown in Illustration 102.
Note: Use a balanced welding technique 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
NOTICE
Use caution when removing run on/off tabs. Avoid gouging or grinding
adjacent base material.
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33. Remove the run on/off tabs and sand the corners to a generous radius.
34. Locate and reattach all miscellaneous hardware that was document and removed in Step 1 and Step 2.
35. Paint repaired area as needed.
Steering Box Replacement or Replace the Bracket that is on the Steering

Box
The steering box can be replaced or the bracket that is on the steering box can be replaced. To replace the complete
steering box, the engine must be removed. The bracket can be replaced without removing the engine. In either case,
a new steering box is needed to complete the repair.
Table 16
Part Numbers for Replacement of the Steering Box
Model Part Number
784B, 784C, 785, 785B, 785C, 785D 5T-8671
789, 789B, 789C, 789D 5T-6243
793, 793B, 793C, 793D 8X-2283
Complete Steering Box Replacement
1. Remove any components that prevent access to the center steering box.
2. Support both front frame rails with jacks.
3. Measure the distance from the bore diameters in the steering box to the mounting locations for the front
suspension cylinders. Record the measurements to use as a reference when you install the new steering box.
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Typical steering box
(A) Square tubing
(B) Steering box
4. Obtain two pieces of 101.6 mm (4.0 inch) square tubing (A) with 6.35 mm (.25 inch) thick walls. The square
tubing should be long enough to extend between the mounting locations for the front suspension cylinders.
5. Refer to Illustration 103 to place the square tubing (A) between the mounting locations for the front
suspension cylinders.
Note: Use 8.0 mm (.32 inch) fillet welds to secure the square tubing (A) to the mounting locations for the
front suspension cylinders.
6. Use an air carbon arc torch to remove the damaged steering box. Angle the torch toward the steering box to
prevent damage to the mounting locations for the front suspension cylinders.
7. Clean slag and carbon deposits from the J-grooves on the mounting locations for the front suspension
cylinders.
8. Use the reference dimensions to place the new steering box (B) in position.
Note: You may need to remove the cast backup strip on the J-groove to fit the steering box (B) in place. If
you remove the cast backup strip, you will need to use separate backup strips.
9. Ensure that there is a 5.0 mm (0.20 inch) root opening around each end of the steering box (B).
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(B) Steering box
(C) Hardware
10. Start the J-groove welds (W1) at both vertical joints at the front of the steering box (B). Fill the grooves to
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the halfway point.
11. Use J-groove welds (W2) to weld both vertical joints at the rear of the steering box (B). Fill the grooves
completely.
12. Complete the J-groove welds (W1) at both vertical joints at the front of the steering box (B). Fill the grooves
completely.
13. Use J-groove welds (W3) to weld both joints at the bottom of the steering box (B). Fill the grooves
completely.
14. Use J-groove welds (W4) to weld both joints at the top of the steering box (B). Fill the grooves completely.
15. Position any hardware (C) that was removed from the original steering box. Weld the hardware (C) in place.
16. Remove the square tubing (A) that was used to brace the frame. Grind the mounting locations for the front
suspension cylinders to the original profile.
Table 17
Sizes for Welds
Model (W1) (W2) (W3) (W4)
784B, 784C, 785, 785B, 785C, 20.0 mm 25.0 mm 25.0 mm 25.0 mm

785D (.79 inch) (.98 inch) (.98 inch) (.98 inch)
20.0 mm 20.0 mm 25.0 mm 25.0 mm

789, 789B, 789C, 789D
(.79 inch) (.79 inch) (.98 inch) (.98 inch)
20.0 mm 20.0 mm 25.0 mm 25.0 mm

793, 793B, 793C, 793D
(.79 inch) (.79 inch) (.98 inch) (.98 inch)
Replace the Bracket that is on the Steering Bracket
The procedure can be performed without removing the engine. Replace the steering bracket whenever the bores are
not within the specifications. A new steering box is needed to complete the procedure. This procedure consists of
the following procedures: preparation of the new steering bracket, removal of the worn steering bracket, installation
of the new steering bracket and welding of the new steering bracket.
Preparation of the New Steering Bracket
Note: The following trucks need an updated center arm and associated parts to use the steering box part numbers
referenced in Table 18. 785 (S/N: 8GB1-516) and 789 S/N:9ZC1-554. Refer to Service Magazine, SEPD0055,
"New Bearing and Shims Used Between Steering Arm and Frame Bracket" for additional information.
Table 18
Part Numbers for Replacement of the Steering Box
Model Part Number
784B, 784C, 785, 785B, 785C, 785D 5T-8671
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789, 789B, 789C, 789D 5T-6243
793, 793B, 793C, 793D 8X-2283
Table 19
Sizes of Bevels and Sizes of Welds
Model B1 W1 W2 W3 W4 W5
784B,
784C,
785, 10 mm 25.0 mm 10 mm 25.0 mm
12.0 mm (0.47 inch) 12.0 mm (0.47 inch)
785B, (0.4 inch) (0.98 inch) (0.4 inch) (0.98 inch)
785C,
785D
789,
789B, 10 mm 12.0 mm X 20 mm 20 mm 10 mm 12.0 mm X 20 mm 20 mm
789C, (0.4 inch) (0.47 inch X 0.8 inch) (0.8 inch) (0.4 inch) (0.47 inch X 0.8 inch) (0.8 inch)
789D
793,
793B, 10 mm 12.0 mm X 20 mm 20 mm 10 mm 12.0 mm X 20 mm 20 mm
793C, (0.4 inch) (0.47 inch X 0.8 inch) (0.8 inch) (0.4 inch) (0.47 inch X 0.8 inch) (0.8 inch)
793D
1. Order a new steering box. Refer to Table 18.
2. Remove the casting (1). Use air carbon arc to gouge the fillet welds (A) from the outside corners. Gouge the
fillet welds (B) from the inside corners. Protect the bores from sparks or from grinding material during the
removal procedure. Also protect the bores during the cleanup procedure. Refer to Illustration 105. Remove
the bracket from the steering box. Do not cut into the casting with the gouging rod.
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Note: The remaining plate steel will not be needed for this repair.
3. Once the bracket is removed from the steering box, clean the casting by removing all existing weld deposits
with a grinder.
4. Machine the bevel or grind the bevel (B1). The angle of the bevel is 45 degrees. Refer to Table 19 for the size
of the bevels.
Removal of the Worn Bracket from the Existing Steering Box
Note: Be sure to protect all surfaces from sparks and grinding grit.
1. Remove all hydraulic lines and steering cylinders from the area around the existing bracket assembly.
2. The center arm will also need to be removed.
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3. Scribe a line (L1) from the center of the bore across the top of the steering box. Make a center punch on top
of the steering box. This will be used to locate the new bracket.
4. Remove the worn bracket. Cut along line (C1).
Note: For the weld seams (W2), angle the air carbon arc torch straight down to remove the weld deposit. Use
caution so that the cast backup is not cut.
Note: The top and bottom seams are fillet welds (W1). The weld joints on the sides of the bracket are
J-groove welds with a backup casting (W2). Refer to Table 19 for the size of the welds.
5. Clean the J-groove welds that are on the sides of the support castings. Do not gouge the cast backup strip.
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Clean the top of the steering box of slag and bottom of the steering box of slag. Then prepare the square
edge.
Installation of the New Bracket
Note: Ensure that the casting is beveled. Remove all foreign material from the weld joint.
1. Use the scribed line on top of the steering box to locate the center bore. Center the bore with the line. Adjust
the casting so that the top weld seams and bottom weld seams are equal. Locate the new casting.
2. Tack weld the bracket to the steering box and to the support castings.
Weld the New Bracket to the Existing Steering Box
Note: Perform the welding to distribute the heat. This will avoid excessive weld distortion. Complete the groove
welds before you begin the fillet welds. For example, place one pass on the top, one pass on the bottom, one pass of
the right side, and one pass on the left side. Repeat this process until the weld seams are complete. Remove the slag
after each pass and do not allow the interpass temperature to exceed 205 C (400 F).
1. Weld a bevel groove weld (W3) on the top of the casting and on the bottom of the casting. There is a notch
on the bottom of the casting that is designed to drain the casting. Do not weld over the drain hole (DH). Refer
to Table 19 for the size of the welds.
2. Once bevel groove weld (W3) is full, weld a fillet weld (W4) on the top of the casting and on the bottom of
the casting. Again, do not weld over the drain hole (DH). Refer to Table 19 for the size of the welds.
3. Weld J-groove welds (W5) on both sides of the casting. Refer to Table 19 for the size of the welds.
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4. Smooth the welds from the support casting to the steering box. Place the tie-in at the corners. Blend the weld
to match the contour of the support assembly and of the steering box. Grind the welds (G1) at four corners
smooth.
5. Locate any removed hardware. Weld the hardware in place.
6. Visually inspect all welds. The welds shall be free from cracks, porosity, undercut, and incomplete fusion.
Blend the welds. If necessary, paint the components.
7. Reassemble all components that were removed to make the repair.
Ball Replacement for the Lower Connection of the Hoist Cylinder

1. Remove any components that prevent access to the ball.
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View of ball installation

(A) Ball
(B) Refer to Table 20.
(C) Refer to Table 20.
2. Use an air carbon arc torch to remove the worn ball (A). Angle the torch toward the ball to prevent damage to
the drop tube casting.
3. Clean the slag and the carbon from the casting.
4. Locate the new ball (A) in position. Refer to Illustration 111 and Table 20. Use three 8.0 mm (.32 inch) fillet
welds that are equally spaced to tack weld the ball in place. The tack welds should be 50.8 mm (2.0 inch)
long.
5. Use multiple passes to complete the J-groove weld (W1) at the Ball (A). Refer to the Table 20 to determine
the size of the J-groove weld (W1) that is required for your machine. Weld each pass completely around the
ball to minimize distortion.
Note: Cover the ball to protect the machined surfaces from damage due to welding.
6. Use a hand grinder to blend the weld between the ball and the casting. Paint the area around the new ball.
Table 20
Part Number
Sales Model Dimension (B) Dimension (C) Weld (W1)
(A)
785, 785B, 785C, 271 mm 35.0 mm

6G-6499 Ball -
785D (10.67 inch) (1.38 inch)
789, 789B, 789C, 298 mm 35.0 mm

6G-6499 Ball -
789D (11.73 inch) (1.38 inch)
335 mm
793B, 793C, 793D 8X-1213 Shaft - 44 mm (1.73 inch)
(13.19 inch)
Replacing the Drop Tube Assembly on the 793C and 793D Off-Highway
Trucks
Table 21
Required Parts
Item Qty Part Number Description
1 1 125-6968 Support As(1)
2 1 125-6969 Plate As
3 2 284-7988 Plates
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4 1 8X-5939 Block
5 1 135-7627 Bracket
6 1 135-7641 Gusset
7 1 8X-2573 Bracket
8 1 8X-2574 Gusset
(1) Also referred to as "Drop Tube As"
Note: The total combined weight of the components in Table 21 is approximately 1390 kg (3064 lb).
1. Disassemble as required to obtain unrestricted access to the drop tube-to-frame weld joint interfaces. Items to
be removed include the A-frame assembly, drive shaft, hydraulic tank, fuel tank, the hoist cylinders, and any
hoses/tubes that may interfere with welding.
2. Plug all open hose and tube ends.
3. Remove all components from the top of the drop tube.
4. To avoid damage from weld and oxy-fuel cutting torch spatter, protect all exposed machined surfaces, hoses,
tubes, and affected nearby components with flame proof blankets.
5. Support bottom of frame with suitable stands so that the frame is level in the transverse direction.
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(A) 80 mm (3.15 inch)
(B) Existing drop tube assembly
6. Layout cut lines 80 mm (3.15 inch) down from pad casting corner, both sides, two castings. Connect layout
lines across each casting end surface.
7. Using sling straps or choke chains, attach hoist to drop tube castings.
Note: The weight of existing drop tube assembly (B) and associated welded components is approximately
1390 kg (3064 lb). Be sure to use a suitable lifting device rated for this capacity.
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(B) Existing drop tube assembly
8. Using an oxy-fuel cutting torch with a tip capable of penetrating 45 mm (1.77 inch) steel thickness, carefully
cut along the lines laid out in Step 6.
Note: The torch cuts must be parallel with the bottom frame rail surface to prevent damage to the drop tube
mounting pad surfaces.
9. After existing drop tube assembly (B) is free, remove from under truck frame.
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Arrows show the areas on the frame rail pad castings to grind smooth.
10. Remove slag. Then grind the casting faces smooth. Grind the weld metal only. Fill gouges as needed. Then
grind flush.
11. Use a suitable tool to determine the flatness of the frame rail pad castings. Ensure that each frame rail pad
casting is flat to within 5.0 mm (0.20 inch) in both directions.
Note: The casting faces are milled from the factory with a course "N" surface finish. Grind only the areas
affected during the cutting operation. There should be no need to grind the inner, undisturbed casting face
surfaces.
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View of existing drop tube assembly (B) with original components
12. Take note of the original locations of items (C1), (C2), (D), and (E) on existing drop tube assembly (B) using
whatever measurements are necessary. Then use these measurements to locate and weld the new items to new
drop tube assembly (1).
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(1) New drop tube assembly
(2) Plate assembly
(W2) A 20 mm (0.79 inch) flare-bevel groove weld along top of plate assembly (2).
(W3) A 12 mm (0.47 inch) vertical fillet weld with 1.5 mm (0.06 inch) root penetration on both sides of each gusset. Weld in upward
direction.
13. Using the measurements taken in Step 12, locate and weld plate assembly (2) to new drop tube assembly (1).
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(3) Plates
(4) Block
(W4) An 8 mm (0.31 inch) fillet weld with 1.5 mm (0.06 inch) root penetration all the way around each plate (3).
(W5) A 12 mm (0.47 inch) flare-bevel groove weld along the top and bottom of block (4).
14. Using the measurements taken in Step 12, locate and weld plates (3) and block (4) to new drop tube assembly
(1).
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Arrows show where to grind chamfer.
15. Prepare new drop tube assembly (1) by removing paint from casting weld areas. Then grind a 2 mm
(0.08 inch) to 3 mm (0.12 inch), 45 degree chamfer all around the top of both drop tube castings. The arrows
in Illustration 118 show the areas to be ground to a chamfer.
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Left side view
(F) 548 mm (21.57 inch)
(G) 1464 mm (57.64 inch)
(H) 228 mm (8.98 inch)
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View J - J
(H) 228 mm (8.98 inch)
(K) 85 mm (3.35 inch)
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Right side view
(L) 622 mm (24.49 inch)
(M) 1489 mm (58.62 inch)
(N) 302 mm (11.89 inch)
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View P - P
(N) 302 mm (11.89 inch)
(R) 228 mm (8.98 inch)
16. Using a hoist with straps or choke chains raise new drop tube assembly (1) to the bottom of the frame.
Support new drop tube assembly (1) with jacks. Locate new drop tube assembly (1) from the centerlines of
the upper hydraulic and fuel tank brackets. Use the dimensions from Illustration 119, Illustration 120,
Illustration 121, and Illustration 122 to position new drop tube assembly (1) correctly.
Note: The weight of new drop tube assembly (1) and associated welded components is approximately
1390 kg (3064 lb). Be sure to use a suitable lifting device rated for this capacity. If using an overhead shop
hoist with chains, the use of a hook insulator is required.
17. Tack weld the assembly into position by using 25 mm (0.98 inch) long, heavy-duty tack welds all the way
around each tube casting.
18. Clean slag from all tack welds and inspect.
Note: No weld overlap or crater cracks allowed.
19. Prepare the weld joints for root passes by feather grinding the ends of the tack welds.
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White arrow shows view of root pass.
20. Weld root pass all the way around each tube casting. Maintain the same direction of weld travel for the fore-
aft (side) weld joints and the transverse (front and rear) weld joints.
21. Remove hoist, clean root passes, and inspect.
Note: Visually inspect subsequent weld passes and repair as needed.
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Left side view
(W6) A 30 mm (1.18 inch) J-Groove weld
(W8) A 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting
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Right side view
22. Use a 30 mm (1.18 inch) J-Groove weld on the front of each tube casting. Weld until 50% full, alternating
every two or three passes from side to side.
Note: Transverse (front and rear) weld passes shall wrap around corners, starting, or terminating in the fore-
aft (side) weld joints.
23. Slag each weld pass.
24. Use a 40 mm (1.57 inch) J-Groove weld on the rear of each tube casting. Weld until 33% full, alternating
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25. Feather grind the ends of the transverse (front and rear) weld passes.
26. Use a 20 mm (0.79 inch) J-Groove weld on the inside and the outside of each tube casting. Weld until 50%
full, alternating every two or three passes from side to side.
28. Clean all welds and prepare joints for finish welding.
29. Use a 30 mm (1.18 inch) J-Groove finish weld on the front of each tube casting. Finish weld the remaining
50%, alternating every two or three passes from side to side.
31. Use a 40 mm (1.57 inch) J-Groove weld on the rear of each tube casting. Weld until 66% full, alternating
32. Feather grind the ends of the transverse (front and rear) weld passes.

View of finish weld (W8)
( 1) New drop tube assembly
33. Use a 20 mm (0.79 inch) J-Groove finish weld on the inside and the outside of each tube casting. Finish weld
the remaining 50%, alternating every two or three passes from side to side.
35. Use a 40 mm (1.57 inch) J-Groove finish weld on the rear of each tube casting. Finish weld the remaining
33%, alternating every two or three passes from side to side.
36. Clean all welds.
37. Inspect and repair the finish welds as needed.
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Left side view of transverse (front and rear) finish welds
(S) Finish grind contour for (W6)
( T) Weld contour before grinding for (W6)
( W7) A 40 mm (1.57 inch) J-Groove weld
(U) Finish grind contour for (W7)
( V) Weld contour before grinding for (W7)
38. Grind all transverse (front and rear) finish welds to the contours shown in Illustration 127.
39. Grind the front and rear ends of the fore-aft (side) finish welds flush approximately 75 mm (2.95 inch) from
each end. Blend around each corner to the transverse (front and rear) finish welds.
Note: No sharp corners allowed.
40. Remount the hydraulic tank to the right side of the truck, supporting the bottom of the hydraulic tank with a
hydraulic jack. Snug the mounting bolts and caps.
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(5) Bracket
41. Assemble new bracket (5) to the hydraulic tank with regular mounting hardware.
42. Lower the hydraulic jack allowing bracket (5) to touch the RH side of new drop tube assembly (1).

(5) Bracket
(X) Bracket (5) angle as measure from the horizontal is 20 +/- 2 degrees.
43. Check the bracket angle and rotate bracket (5) to duplicate the original angle. The angle as measured from
the horizontal should be 20 +/- 2 degrees.
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(5) Bracket
(W9) A tack weld all the way around the inside the slot in bracket (5).
44. While maintaining angle (X) which is shown in Illustration 129, tack weld bracket (5) to the RH side of new
drop tube assembly (1).
Note: Tack weld around the inside the slot in bracket (5) only. Do not tack weld around the perimeter of
bracket (5).

(5) Bracket
(6) Gusset
(W10) Tack welds attaching gusset (6) to bracket (5) and new drop tube assembly (1).
45. Locate and tack weld gusset (6) to the RH side of new drop tube assembly (1) and to bracket (5). Tack weld
both on the top and on the bottom of gusset (6).
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46. Remove the hydraulic tank from the truck.

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

(5) Bracket
(6) Gusset
(W12) A 15 mm (0.59 inch) weld with 2.5 mm (0.10 inch) root penetration on the top and bottom of gusset (6).
48. Weld gusset (6) to the RH side of new drop tube assembly (1) and to bracket (5). Weld both on the top and on
the bottom of gusset (6).
49. Remount the fuel tank to the left side of the truck, supporting the bottom of the fuel tank with a hydraulic
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jack. Snug the mounting bolts and caps.

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

(7) Bracket
(W13) A tack weld all the way around the inside the slot in bracket (7).
52. Tack weld bracket (7) to the LH side of new drop tube assembly (1).
Note: Tack weld around the inside the slot in bracket (7) only. Do not tack weld around the perimeter of
bracket (7).
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(7) Bracket
(8) Gusset
(W14) Tack welds attaching gusset (8) to bracket (7) and new drop tube assembly (1).
53. Locate and tack weld gusset (8) to the LH side of new drop tube assembly (1) and to bracket (7). Tack weld
both on the top and on the bottom of gusset (8).
54. Remove the fuel tank from the truck.

(7) Bracket
(W15) A 25 mm (0.98 inch) weld with 2.5 mm (0.10 inch) root penetration all the way around the inside the slot in bracket (7).
55. Weld around the inside the slot in bracket (7).
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(7) Bracket
(8) Gusset
(W16) A 25 mm (0.98 inch) vertical flare-bevel groove weld which is welded in the upward direction. (W16) welds the inboard side
of bracket (7) to the LH side of new drop tube assembly (1).
56. Weld vertically up along the inside bracket (7) and the LH side of new drop tube assembly (1).

(7) Bracket
(8) Gusset
(W17) A 15 mm (0.59 inch) weld with 2.5 mm (0.10 inch) root penetration on the top and bottom of gusset (8).
57. Weld gusset (8) to the LH side of new drop tube assembly (1) and to bracket (7). Weld both on the top and on
the bottom of gusset (8).
58. Repaint bare metal areas.
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59. Reassemble all the hardware that was removed prior to the repair.
Updating The A-Frame Mounting Area on the Center Tube for the 793
Truck

Section view of center tube area
(1) Remove weld
(2) Fillet weld
1. Begin by removing any existing cracks by grinding or carbon arc gouging. Verify that the crack has been
removed by the use of dye penetrant.
2. Remove the existing 16 mm (0.63 inch) fillet weld (1) and cut a groove 12 mm (0.47 inch) deep with a 45
degree bevel as shown in illustration 140.
3. Clean the prepared weld joint by grinding. Make sure that all the oil, dirt, and the dye penetrant are cleaned
from the joint.
4. Weld the groove with small stringer welds. Weld a 16 mm (0.63 inch) fillet (2) over the groove. The toes on
the fillet weld should have a smooth transition with no overlaps.
5. Visually inspect the welds. The weld should be free from cracks, porosity, undercut, the overlay, and
incomplete fusion.
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Suspension A-Frame Field Weld Repair for the Weld Joint for the 785,
785B, 785C, 785D, 789, 789B, 789C, 789D, 793, 793B, 793C, and 793D
Off-Highway Trucks
Note: For cracks in machined surfaces refer to Special Instruction, REHS2346, "Weld Repair Procedure for the
Rear Axle A-Frame and Rear Axle Housing on 785, 789, and 793 Off-Highway Trucks".

Welded joints for the A-Frame
1. Visually inspect the welded joints of the suspension A-frame for cracks. Also use some liquid dye penetrant
to inspect joints that may have cracks. As an alternative, you can use the magnetic particle inspection process
to inspect the welded joints.
2. Use one of the methods that follows to remove cracks.
Grinding process
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Air carbon arc torch
Note: Cracks that extend completely through the original weld should only be removed by the grinding
process.
Completely remove the crack from the base metal. Use some liquid dye penetrant to inspect the ground
surfaces of the groove. Also, you can use the magnetic particle inspection process to inspect the ground
surfaces of the groove. When the crack is removed, the bottom of the groove should have an angle of 90
degrees to ensure sufficient penetration. The side walls of the groove should extend upward at an angle of 45
degrees.
3. Clean the area that will be welded.
4. Protect the machined surfaces from the weld spatter. Protect the machined surfaces from the sparks.
5. Attach the welding ground cable directly on the suspension A-frame.
6. Heat the base metal of the groove to a temperature of 150 C (300 F). Maintain the temperature of the base
metal at 150 C (300 F) during the welding process.
7. Use the SMAW process and "E7018" welding electrode to fill the grooves that are left after you remove the
cracks. Remove the slag after every pass of the welding electrode.
8. Clean the welds. Inspect the repairs for the following defects:
Cracks
Porosity
Undercut
Incomplete fusion
Note: Use some liquid dye penetrant to inspect the weld. Also, you can use the magnetic particle inspection
process to inspect the weld.
9. Use a hand grinder to blend the weld flush at the corners to the profile of the casting.
Relocate the Mounting Block on the Suspension A-Frame of 793, 793B, 793C, and 793D Off-
Highway Trucks in Order to Prevent Cracks
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Mounting block
Check the location of the mounting block at the front of the suspension A-frame. If the mounting block is located
over the weld bead that joins the center section of the A-frame and the right leg support, the overlap of the welds
may cause cracks to develop. Move the mounting block to correct the overlap.
1. Remove the existing mounting block.
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Fabricated mounting block
(A) 223.5 mm (8.80 inch)
(B) 20 mm (.80 inch)
(C) 45 mm (1.77 inch)
(D) 15 mm (.59 inch)
(E) 193.5 mm (7.62 inch)
(F) 22.5 mm (.89 inch)
(G) 10.53 .10 mm (.415 .004 inch) Diameter
2. Fabricate a new mounting block from steel that meets ASTM specification "A36". Refer to Illustration 143.
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Moved mounting block
(H) 112 mm (4.4 inch)
(J) 175 mm (6.9 inch)
(K) This is the starting point for the weld.
(L) This is the end point for the weld.
3. Use the SMAW process with "E7018" welding electrode to secure the new mounting block on the suspension
A-frame. Refer to Illustration 144 to position the new mounting block.
Bearing Bore Field Repair for the Suspension A-Frame for 785, 785B, 785C, 785D, 789,
789B, 789C, 789D, 793, 793B, 793C, and 793D Off-Highway Trucks
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Typical A-Frame
(A) Refer to Table 22.
(B) Refer to Table 22.
You can install a sleeve to salvage the bearing bore at the front of the suspension A-frame.
Note: The only option for wear is a sleeve. The entire a-frame must be replaced if wear is excessive or the a-frame
has cracks at the bolt holes. If the bore cannot be sleeved, the a-frame must be replaced. The nose is not a
replacement option due to assembly, dimensioning, and machining requirements.
Table 22
Dimensions for Machining the Bearing Bore
Part Number for the

Sales Model Dimension (A) Dimension (B)
Sleeve
32.35 mm 215.86 .013 mm

785B, 785C, 785D 184-6962
(1.27 inch) (8.498 .0005 inch)
32.35 mm 215.86 .013 mm

789B, 789C, 789D 184-6962
(1.27 inch) (8.498 .0005 inch)
793, 793B, 793C. 21.12 mm 234.92 .013 mm

184-6963
793D (.83 inch) (9.249 0.0005 inch)
1. Remove the suspension A-frame from the center cross-tube of the truck. Remove the bearing from the
bearing bore.
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Bearing bore that does not require welding
(C) Original bearing bore
(D) Worn area
(E) Bore for sleeve
2. If the largest diameter of the bearing bore that is elongated is less than the outer diameter of the sleeve,
machine the bearing bore to the dimension that is listed in Table 22. Refer to Illustration 146.
Note: If the largest diameter of the bearing bore that is elongated is greater than the outer diameter of the
sleeve, you must replace the A-frame.
3. Lower the temperature of the sleeve to 45 5C (50 10F).
4. Install the sleeve in the bearing bore of the suspension A-frame.
5. Lower the temperature of the bearing to 45 5C (50 10F).
6. Install the bearing in the bearing bore of the sleeve in the suspension A-frame.
7. Connect the suspension A-frame to the center cross-tube of the truck.
Control Rod Bores Field Repair on Differential Housing and Main

Frame for the 785, 785B, 789, 789B, 789C, 789D, 793, 793B, 793C, and
793D Off-Highway Trucks
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Repair Procedure

(A) Main frame bore
(1) 2.5 degree

(B) Differential housing bore
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Begin the repair by cleaning the bore to be welded. Measure the bore so that amount of buildup can be determined.
Use small 6 mm (0.24 inch) weld passes. Try to make each pass continuous. Make sure that all weld passes are
tied-in and slag each pass. After welding, bore to the following dimensions as shown in Table 23.
Table 23
785 789 793
Frame Bore
101.66 mm (4.0024 inch) 101.66 mm (4.0024 inch) 101.66 mm (4.0024 inch)
(A)
Differential Housing Bore

101.66 mm (4.0024 inch) 101.66 mm (4.0024 inch) 101.66 mm (4.0024 inch)
B
Field Replacement of the 161-1249 Beam As on the 793C Off-Highway

Trucks
Required Parts
Table 24
Required Parts
Item Qty Part Number Description
1 2 350-1599 (1)(2)(3)(4) Support As
2 1 350-1598 (1)(2)(3)(4) Cab Alignment Tool As
3 1 161-1249 (2)(3)(4) Beam As
4 1 8X-0514 (2)(3)(4) Plate
5 1 8X-0515 (2)(3)(4) Plate
6 2 8X-1986 (2)(3)(4) Plates
7 2 128-3200 (2)(3)(4) Plates
8 2 8X-1985 (2)(3)(4) Plates
9 1 8X-9176 (2)(3)(4) Plate
10 2 125-6974 (2)(3) Bracket As
11 1 247-6905 (3)(4) Bar
12 1 9R-2613 (2)(3) Weld Boss
13 1 091-9284 (3) Bar
14 1 8X-6100 (5)(4) Bracket As
15 1 9R-1733 (4) Boss
16 1 8X-6101 (5)(4) Bracket As
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(1) A nonserviceable part of the 353-4386 Cab Alignment Tool Gp

(2) Used on S/N:4AR machines
(3) Used on S/N:4GZ and ; S/N:ATY machines
(4) Used on S/N:1HL machines
(5) This part is canceled. Follow the instructions in this document.
Disassembly

(17) Right beam assembly
(18) Transition casting on the right-hand side
(19) Rear pedestal on the right-hand side
(20) 161-1249 Beam As
(21) Rear pedestal on the left-hand side
(22) Holes for the ROPS cab
(23) 8X-0469 Support As
(24) Transition casting on the left-hand side
(25) Left beam assembly
(26) Front suspension cylinder
(27) 8X-0436 Support As
(28) Holes for the ROPS cab
(29) Front pedestals
Note: The engine does not need to be removed to perform this procedure. Alternate, temporary supports can
be used. This procedure shows the engine removed for clarity.
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1. Disassemble the machine as required to allow open access to the 161-1249 Beam As (20). Both front
suspension cylinders (26) will remain in place. The support assembly (27) for the ROPS will remain in place.
The support assembly (23) for the ROPS will be removed. The support assembly (23) will be installed on the
new beam assembly.
2. Support the frame assembly so that beam assembly (20), beam assembly (25), and beam assembly (17) are
reasonably level.
3. Document the location of the hardware that will be affected by the tooling on the beam assembly and
the transition casting for the left beam assembly and the right beam assembly.
Temporary Bracing
1. Refer to Illustration 150. From steel that has a yield strength of 400 MPa (58015 psi), cut lengths of steel for
temporary bracing. As shown in Illustration 150, install the temporary bracing.
If possible, do not weld the temporary bracing to the corners of the left beam assembly and the right beam
assembly or the corners of the supports for the suspension cylinders. Weld only on the horizontal surfaces
toward the center of the beams or support castings in line with the major axis of the parts. The horizontal
bracing will need to clear the jack clamp on the left beam assembly and the right beam assembly for the
locating fixture of the beam assembly.
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350-1599 Support As to Check the Height and Squareness of the Beam Assembly

(W1) two 6 mm (0.24 inch) fillet welds that are 25 mm (0.98 inch) long, 180 degrees apart on each boss
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1. By using the bases of the two support assemblies (1), mark the location for the two 2J-3507 Full Nuts (30) on
the back side of the left pedestal and the back side of the right pedestal.
Note: The two 2J-3507 Full Nuts (30) are part of the 350-1599 Support As. You will need to replace the nuts
after the procedure is completed.
Note: The approximate weight of each fixture is 890 N (200 lb).
2. Refer to Illustration 152. Weld the two nuts (30) to the back side of the left pedestal and the back side of the
right pedestal.
FCAW process can be used with "E71T-1" welding electrode.
3. Install the top of the two support assemblies to the bases.
4. Loosen the lock nuts. Adjust the screws on the top of the support assemblies so that each screw barely
contacts the beam assembly. Tighten the lock nuts.
5. Document the location of the hardware that will be affected by the tooling on the beam assembly and
the transition casting for the left beam assembly and the right beam assembly.
6. Remove the top of the two support assemblies from the bases. Leave both bases on the pedestals. You will
install the top of the two support assemblies after the new beam assembly has been installed.
The 350-1598 Cab Alignment Tool As to Locate the Beam Assembly
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The 350-1598 Cab Alignment Tool As (2) is used to locate the position of the new 161-1249 Beam As (3). The
approximate weight of the fixture is 544 kg (1200 lb).
You can adjust three of the four pins in the 350-1598 Cab Alignment Tool As (2) to locate the cab according to the
dimensions that are on the print or you can adjust the fixture to the actual position of the holes in the frame. Set the
pin locations to the actual position of the holes in the frame.
The cab alignment tool assembly contains two bolts (31) that are jacks. One bolt supports the inside rear corner of
the fixture near the beam assembly that will be replaced. You adjust the bolt to the height of the beam assembly on
the left side of the machine after the fixture is in line with the position of the holes in the cab support. The other
bolt supports the front of the fixture by the front left cab support.
Note: The 2 mm (0.08 inch) shim (32) is used to compensate for weld shrinkage in the transverse weld in the beam
assembly. When you establish the location of the bores for the cab supports, the shim should not be in the fixture.
The shim must be in the fixture when you weld the new beam assembly into position.
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1. By using a suitable lifting device, position the 350-1598 Cab Alignment Tool As (2) over the holes (22),
beam assembly (25), the six holes in the rear cab support (23), the four bores in the front cab support (27) and
holes (28) in the front pedestal. The approximate weight of the cab alignment tool is 544 kg (1200 lb).
2. Locate and lightly tighten the bolt for the nonadjustable pin that is located in holes (28). This is the pin that
goes in the front pedestal.
3. Adjust the pin that is in holes (22) on the back, right corner of the fixture. Loosen the two bolts that fasten the
bracket to the frame. Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so the pin
slides into the hole. Tighten the four bolts.
Note: If needed, loosen the locknut on the bolt that is used to adjust the height of the fixture. Raise the fixture
to remove the weight from the pin. Tighten the locknut. When the pin is positioned, loosen the locknut and
lower the fixture to the correct height. Tighten the locknut.
4. Adjust the pin that is over the beam assembly on the back, left corner of the fixture. Loosen the two bolts that
fasten the bracket to the frame. Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so
the pin slides into the hole. Tighten the four bolts.
5. Adjust the pin that is over the front, left corner of the fixture. Loosen the two bolts that fasten the bracket to
the frame. Loosen the two bolts that fasten the pin to the bracket. Adjust the bracket so the pin slides into the
hole. Tighten the four bolts.
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Note: If needed, loosen the locknut on the bolt that is used to adjust the height of the fixture. Raise the fixture
to remove the weight from the pin. Tighten the locknut. When the pin is positioned, loosen the locknut and
lower the fixture to the correct height. Tighten the locknut.
6. Verify that contact has been made between the fixture and the spot faces on the bores of the cab supports.
Verify that the bolts for the pins have been tightened.
7. Remove the 350-1598 Cab Alignment Tool As from the machine. Set the fixture out of the way.
Marking the Transition Casting on the Left Beam Assembly and the Right Beam Assembly
The transition casting on the new beam assembly is longer than the transition casting that was on the former beam
assembly. In order for the new beam assembly to work on older frames, you must shorten the back end of the right
beam assembly 215 mm (8.5 inch) (A).
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(B) 363 mm (14.29 inch)
(C) 415 mm (16.33 inch)
(D) The front face of the beam assembly
(E) 90 degrees
(F) Cutting line, all around the left beam assembly, even and square all around
(G) Remove the bracket before you cut the left beam assembly
1. By using the dimensions that are listed in Illustration 156, mark the cutting line (F) that you will cut on the
back end of the right beam assembly. Use a punch to mark the steel so that the line cannot be erased.
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2. The cutting line (F) on the left beam assembly is the back side of the weld joint all around the beam. By
using an oxyacetylene torch capable of piercing steel that is 30 - 40 mm (1.2 - 1.6 inch) thick, cut the
transition casting along cutting line (F). Cut the steel on the transition casting side of the line. Cut as little
steel from the left beam assembly and the right beam assembly as possible. If a weld joint is present, cut on
the side of the weld joint that is toward the transition casting. This would be away from the two beam
assemblies.
3. By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (34) from the left end of the
pedestal that is on the left side of the frame. Do not gouge deeply into the pedestal. Gouge into the bottom
plate of the beam and gouge into plate (35).
4. By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (33) that is on the front and back
of the beam assembly between the pedestal and the beam assembly on the left side of the frame. Gouge into
the bottom plate of the beam assembly not the pedestal.
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5. By using an air carbon arc torch, remove the 12 mm (0.47 inch) fillet weld (36) that is between the pedestal
and the beam assembly on the right side of the machine. Gouge into the bottom plate of the beam assembly
not the pedestal.
6. By using an air carbon arc torch, remove the 16 mm (0.63 inch) fillet weld (37) that is on the front and back
of the beam assembly between the pedestal and the beam assembly on the right side of the frame. Gouge into
the bottom plate of the beam assembly not the pedestal.
7. By using an air carbon arc torch, remove the 12 mm (0.47 inch) fillet welds (38) that are toward the center of
the frame between the pedestals and the beam assembly on both sides of the machine. Gouge into the bottom
plate of the beam assembly not the pedestal.
8. By using a suitable lifting device, remove the beam assembly from the frame. The beam weighs
approximately 1250 kg (2755 lb).
Note: For S/N:1HL machines, be careful not to damage the 8X-6100 Bracket As (14) and the 8X-6101
Bracket As (16) that are attached to the beam assembly. You must remove and save both bracket
assemblies from the beam. You cannot order both bracket assemblies through the Cat parts
distribution system. You must attach both bracket assemblies to the new beam assembly (3).
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9. Clean the weld joints on both pedestals. When you clean the weld joints, take care to preserve as much of the
original edges of both pedestals as possible.
Installation of the New 161-1249 Beam As
1. On the left beam assembly, trim the weld joint and the casting so that the faces (39) of the plates and the
corners of the plates are square.
2. Remove the slag from the trimmed end of the left beam assembly. Smooth both of the end surfaces of the
beam assembly.
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3. The new transition castings are machined to accommodate the designs of the newer left beams and the newer
right beams that contain heavier plate material. You must build up the root (40) of the upper weld joint and
the lower weld joint on both castings with approximately 6 mm (0.24 inch) of weld metal.
4. Weld the upper weld joint and the lower weld joint on both castings with two passes of weld metal. Grind the
edges smooth to provide a good fit with minimal gaps between the transition castings and the left beam and
the right beam. Rotate the beam assembly and position the beam assembly as needed for each weld area.
5. Clean any paint, grease, or debris from the mounting face, tapped holes, and weld area of the support
assembly for the cab.
6. By using an appropriate lifting device, attach support assembly (23) to the left-hand side of the new beam
assembly. Use an impact wrench to fasten the bolts. The support assembly weighs approximately 260 kg
(573 lb).
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7. By using a suitable lifting device, install beam assembly (3) to the frame. The beam weighs approximately
1510 kg (3329 lb). Check the fit of the transition castings on the new beam assembly with the left beam
assembly and the right beam assembly.
8. Install the 2 mm (0.08 inch) shim (28) into the 350-1598 Cab Alignment Tool As (2).
9. By using a suitable lifting device, install the 350-1598 Cab Alignment Tool As (2) into the bores of the beam
assembly (3) and the front pedestal. The approximate weight of the fixture is 544 kg (1200 lb). Snug the pins
so that contact is made with the spot faces of the bores.
10. Check the fit for the transverse weld between the transition casting and the left beam assembly. A minimum
root opening of 3 mm (0.12 inch) is needed. A face gap of 18 mm (0.71 inch) is needed.
11. Install the top of the two 350-1599 Support As (1) to check the height and squareness of the beam assembly.
Adjust the beam as needed.
Tack Welding Procedure
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1. Apply one tack weld (42) to the outside of the pedestal on the left side of the frame and the new beam
assembly and the back side of the new beam assembly and the pedestal.
2. Apply one tack weld (41) to the bottom of the joint between the transition casting and the left beam assembly
and to the bottom of the joint between the transition casting and the right beam assembly.
3. Apply one tack weld (43) to both sides of the inside both of the pedestals and the new beam assembly.
4. Apply one tack weld (44) to the front of both sides of the pedestals and the new beam assembly.
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5. Apply one tack weld (45) to the top of the joint between the transition casting and the left beam assembly and
to the top of the joint between the transition casting and the right beam assembly.
6. Apply one tack weld (46) to both sides of joint between the transition casting and the left beam assembly and
apply one tack weld to both sides of joint between the transition casting and the right beam assembly.
7. Remove the 350-1598 Cab Alignment Tool As and the two 350-1599 Support As from the new beam
assembly. Remove the four nuts (26) from the back side of both pedestals.
Finish Welds

(W2) A 12 mm (0.47 inch) bevel weld
1. Slag the tack welds and grind the ends of the tack welds.
2. Refer to (W2) in Illustration 168. Weld the right end of the new beam assembly to the pedestal on the right
side of the frame. Apply three weld passes to the parts. Slag each pass. To minimize distortion and residual
stress, alternate from the left side of the pedestal to the right side of the pedestal.
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(W3) A 16 mm (0.63 inch) fillet weld
(W4) A 16 mm (0.63 inch) bevel weld
3. Refer to Illustration 169. Locate plate (4). Tack the plate to the pedestal on the left side of the frame. Leave
enough space to apply a 16 mm (0.63 inch) bevel weld to the plate and to the pedestal.
4. Refer to (W5) in Illustration 169. Weld the hole in plate (4). Apply four passes. Slag each pass.
5. Refer to (W3) in Illustration 169. Weld the left side of plate (4) to the left side of the left pedestal. Apply four
passes. Slag each pass.
6. Refer to (W4) in Illustration 169. Weld the right side of plate (4) to the pedestal. Apply four passes. Slag each
pass.
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(W6) A 16 mm (0.63 inch) fillet weld on both ends of the plate (4)
( W7) A 12 mm (0.47 inch) fillet weld on the inside both pedestals and the beam assembly
(W8) A 16 mm (0.63 inch) fillet weld on the back
(W9) A 16 mm (0.63 inch) fillet weld on the front of both pedestals
(W10) A 16 mm (0.63 inch) fillet weld on the right side of plate (5)
( W11) A 12 mm (0.47 inch) bevel weld on the left side of plate (5)
7. Locate plate (5). Tack weld the plate into position.
8. Refer to (W6) in Illustration 170. Weld both ends of plate (4) to the left side of the beam assembly. Apply
four passes. Slag each pass.
9. Refer to (W10) in Illustration 170. Weld the right side of plate (5) to the left side of plate (4). Apply four
passes. Slag each pass.
10. Refer to (W11) in Illustration 170. Weld the left side of plate (5) to the end of the beam assembly. Apply
three passes. Slag each pass.
Note: For the next three steps, alternate the welds from side to side. Do not weld one item then start the weld
on the opposite side. Balance the welding sequence. This will minimize weld distortion.
11. Refer to (W7) in Illustration 170. Weld the inside both pedestals to the beam assembly. Apply three passes.
Slag each pass.
12. Refer to (W8) in Illustration 170. Weld the back side of both pedestals. Apply four passes. Slag each pass.
13. Refer to (W9) in Illustration 170. Weld the front side of both pedestals. Apply four passes. Slag each pass.

(W12) A 20 mm (0.8 inch) j-groove weld
14. Prepare the joints between the transition castings and the left beam assembly and the right beam assembly for
root passes. Grind the ends of the tack welds. Slag the welds completely.
15. Refer to (W12) in Illustration 171. By using a j-groove weld, apply the root pass in the four vertical joints
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between the transition castings and the left beam assembly and the right beam assembly. Start toward the
centerline of the frame, then move to the outside of the frame. Start on the bottom of the joints.
16. Refer to (W13) in Illustration 171. By using a j-groove weld, apply a root pass between the transition
castings and the left beam assembly and the right beam assembly on the top side. Start the welds toward the
center of the frame and weld toward the outside of the frame.
17. Refer to (W14) in Illustration 171. By using a j-groove weld, apply a root pass between the transition
castings and the left beam assembly and the right beam assembly on the bottom side. Start the welds toward
the center of the frame and weld toward the outside of the frame.
18. Refer to (W12) in Illustration 171. By using a j-groove weld, apply two passes in the four vertical joints
between the transition castings and the left beam assembly and the right beam assembly. Start toward the
centerline of the frame. Start on the bottom of the joints.
19. Refer to (W13) in Illustration 171. By using a j-groove weld, apply one pass between the transition castings
and the left beam assembly and the right beam assembly on the top side. Start the welds toward the center of
the frame and weld toward the outside of the frame.
20. Refer to (W14) in Illustration 171. By using a j-groove weld, apply one pass between the transition castings
and the left beam assembly and the right beam assembly on the bottom side. Start the welds toward the center
of the frame and weld toward the outside of the frame.
21. Repeat Step 18, Step 19, Step 20 until the beams are welded flush.
Note: The welds between the transition castings and the left beam assembly and the right beam assembly are
to be inspected by an ultrasonic flaw detection unit.
22. Clean the welds.
Installation of Hardware on the S/N:4AR Machines
As noted in the illustrations, install the parts that are listed in the following illustrations on the left beam assembly
and the right beam assembly.
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The area of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(W15) An 8 mm (0.32 inch) fillet weld using vertical welding on the outside of the two plates (7) and the two plates (8)
( W16) A 6 mm (0.24 inch) fillet weld on the two sides of both plates (6)
( W17) An 8 mm (0.32 inch) fillet weld using vertical welding on the two ends of plate (9)
As shown in Illustration 173, locate the parts. Tack weld the parts in position. Then, weld the parts in position as
shown in Illustration 172.

The top of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(H) 100 mm (3.9 inch)
(J) 326 mm (12.8 inch)
(K) 718 mm (28.27 inch)
(L) 199.5 mm (7.85 inch)
(M) 126.5 mm (5.0inch)
(N) 89 mm (3.5 inch)
Illustration 173 shows the location for plates (6), plates (7), plates (8) and plate (9) on the top, right part of beam
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assembly (3) and the right beam assembly.

A top view of the transition casting and the right beam assembly
(P) 2154.5 mm (84.82 inch)
(R) 194 mm (7.64 inch)
Illustration 174 shows the location of plate (6) from the plate on the front of the right beam assembly.

(S) 15 mm (0.59 inch) at two places
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The inside the area of the transition casting and the left beam assembly
(10) Bracket assembly
(T) 35 5 mm (1.4 0.2 inch)
(U) 760 mm (29.9 inch)
(W18) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)
Illustration 176 shows the location of one of the two bracket assembly (10). Locate the bracket assembly. Tack weld
the bracket assembly in position. Then, weld the bracket assembly in position.

The top of the area of the transition casting and the left beam assembly
(V) 6 5 mm (0.24 0.20 inch) from the end of the other bracket assembly
(W) 70 5 mm (2.76 0.20 inch) from the center of the boss to the end of bracket assembly (10)
( X) 120 5 mm (4.72 0.20 inch) between the centerline of the bosses and the centerline of bracket assembly (10)
( W19) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)
Illustration 177 shows the position of the second bracket assembly (10) that is positioned on top, left side of the
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beam assembly (3). Locate the bracket assembly. Tack weld the bracket assembly in position. Then, weld the
bracket assembly in position.
1. Clean the welds and inspect the welds. As needed, make repairs.
2. Remove the temporary bracing.
3. As needed, paint the machine.
4. Assemble the machine.
Installation of Parts on the S/N:4GZ Machines and the ; S/N:ATY Machines

(Y) 35 5 mm (1.4 0.2 inch)
(Z) 760 mm (29.9 inch)
(W20) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)
Illustration 178 shows the location of one of the two bracket assembly (10). Locate the bracket assembly. Tack weld
the bracket assembly in position. Then, weld the bracket assembly in position.
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(AA) 6 5 mm (0.24 0.20 inch) from the end of the other bracket assembly
(BB) 70 5 mm (2.76 0.20 inch) from the center of the boss to the end of bracket assembly (10)
( CC) 120 5 mm (4.72 0.20 inch) between the centerline of the bosses and the centerline of bracket assembly (10)
( W21) A 3 mm (0.12 inch) fillet weld on the two sides of bracket assembly (10)
Illustration 179 shows the position of the second bracket assembly (10) that is positioned on top, left side of the
beam assembly (3). Locate the bracket assembly. Tack weld the bracket assembly in position. Then, weld the
bracket assembly in position.
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The top of beam assembly (3)
( DD) 70.5 3 mm (2.78 0.12 inch)
(W22) A 5 mm (0.20 inch) skip weld that is 50.0 mm (1.97 inch) long on 200.0 mm (7.87 inch) centers

A view of beam assembly (3) from the front
(EE) 871 mm (34.3 inch)
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Position bar (11) as shown in Illustration 180 and Illustration 181. Weld the bar to the beam.

A view of the top of the transition casting and the right beam assembly
(FF) 376 5 mm (14.8 0.2 inch)
(GG) 31 5 mm (1.2 0.2 inch)
(W23) An 8 mm (0.32 inch) fillet weld that is vertical up weld in two places
(W24) An 8 mm (0.32 inch) fillet weld in two places
(W25) A 3 mm (0.12 inch) fillet weld all around the boss
(W26) An 8 mm (0.32 inch) fillet weld that is vertical up in two places
(W27) An 8 mm (0.32 inch) fillet weld in two places
(W28) An 8 mm (0.32 inch) fillet weld that is vertical up in two places
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(HH) 391 3 mm (15.40 0.12 inch)
(JJ) 125 5 mm (4.9 0.2 inch)
(KK) 264.5 1 mm (10.40 0.04 inch)
(LL) 712 1 mm (28.03 0.04 inch)
(MM) 126.5 mm (5.0 inch)

(NN) 50.0 mm (1.97 inch)
(PP) 15.0 mm (0.59 inch)

The inside the transition casting and the right beam assembly
(RR) 107 5 mm (4.2 0.2 inch)
Refer to Illustration 182. Locate and tack boss (12) to the bottom side of the right transition casting. Weld the boss
into position.
Refer Illustration 182, to Illustration 183 and Illustration 184. Locate and tack plate (6) and two gussets (7) into
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position. Weld all three parts into position.
Refer to Illustration 182, to Illustration 183 and to Illustration 184. Locate and tack plate (13) and two gussets (8)
into position. Weld all three parts into position.
Refer to Illustration 182, to Illustration 183 and Illustration 185. Locate and tack plate (9) into position. Weld the
part into position.
Clean the welds and inspect the welds. As needed, make repairs.
Remove the temporary bracing.
As needed, paint the machine.
Assemble the machine.
Installation of Parts on the S/N:1HL Machines

(W30) A 6 mm (0.24 inch) fillet weld from the edge of the casting to bracket assembly (16)
( W31) A 6 mm (0.24 inch) fillet weld
(W32) A 6 mm (0.24 inch) fillet weld from bracket assembly (14) to the corner of bracket assembly (16)
( SS) 312.3 3.0 mm (12.30 0.12 inch)
(TT) 81.5 3.0 mm (3.21 0.12 inch)
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(UU) 46.0 3.0 mm (1.8 0.12 inch) from the center of the holes for the rops cab
(VV) 111.9 3.0 mm (4.4 0.12 inch)
(WW) 35.0 5.0 mm (1.40 0.20 inch)
(XX) 230.0 5.0 mm (9.06 0.20 inch)
Refer to Illustration 186 and Illustration 187. Locate and tack bracket assembly (14), bracket assembly (16), and
boss (15) into position. Weld all three parts into position.
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The top of beam assembly (3)
( YY) 70.5 3 mm (2.78 0.12 inch)
(W34) A 5 mm (0.20 inch) skip weld that is 50.0 mm (1.97 inch) long on 200.0 mm (7.87 inch) centers

A view of beam assembly (3) from the front
(ZZ) 871 mm (34.3 inch)
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Position bar (11) as shown in Illustration 189 and Illustration 188. Weld the bar to the beam.

A view of the top of the transition casting and the right beam assembly
(AAA) 376 5 mm (14.8 0.2 inch)
(BBB) 31 5 mm (1.2 0.2 inch)
Locate and tack boss (12) to the bottom side of the right transition casting. Weld the boss into position.
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The area of the transition casting and the right beam assembly
(6) Plates
(7) Plates
(8) Plates
(9) Plate
(W36) An 8 mm (0.32 inch) fillet weld using vertical welding on the outside of the two plates (7) and the two plates (8)
( W37) A 6 mm (0.24 inch) fillet weld on the two sides of both plates (6)
( W38) An 8 mm (0.32 inch) fillet weld using vertical welding on the two ends of plate (9)
As shown in Illustration 192, Illustration 193, Illustration, and194 Illustration 195 and locate the parts. Tack weld
the parts in position. Then, weld the parts in position as shown in Illustration 191.
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(6) Plates
(7) Plates
(8) Plates
(9) Plate
(CCC) 100 mm (3.9 inch)
(DDD) 326 mm (12.8 inch)
(EEE) 718 mm (28.27 inch)
(FFF) 199.5 mm (7.85 inch)
(GGG) 126.5 mm (5.0inch)
(HHH) 89 mm (3.5 inch)
Illustration 192 shows the location for plates (6), plates (7), plates (8) and plate (9) on the top, right part of beam
assembly (3) and the right beam assembly.
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A top view of the transition casting and the right beam assembly
(JJJ) 2154.5 mm (84.82 inch)
(KKK) 194 mm (7.64 inch)
Illustration 193 shows the location of plate (6) from the plate on the front of the right beam assembly.
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(LLL) 50.0 mm (1.97 inch)

(MMM) 15.0 mm (0.59 inch)
Illustration 194 shows the position of the two plates (6) from the top of the transition casting.

The inside the transition casting and the right beam assembly
(RR) 107 5 mm (4.2 0.2 inch)
Illustration 195 shows the position of plate (9) from the top surface on the transition casting.
Clean the welds and inspect the welds. As needed, make repairs.
Remove the temporary bracing.
As needed, paint the machine.
Assemble the machine.
Procedure to Strengthen the Weld Joint on the Center Tube on 785C,

785D, 789B, 789C, 789D, 793, 793B, 793C, and 793D Off-Highway
Trucks
Reference: Special Instruction, REHS1841, "General Welding Procedures"
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(1) Tube
(2) Plate

TIG dressing locations

Detailed TIG dressing location
(AA) minimum 5 mm (0.20 inch) radius
(1) Tube
(2) Plate
TIG toe dressing of the weld is now being carried out for the entire circumference of the interface of plate (2) and
tube (1) on the frame assembly. This will provide an improved weld joint on the center tube of the frame assembly.
The TIG toe dressing can be applied to the interface of plate (2) and tube (1) on any machine to strengthen the
weld.
Apply postweld treatment to the outside 16 mm (0.63 inch) fillet welds connecting plate (2) to tube (1). Refer to
Illustration 197 for the weld locations to be TIG dressed. TIG dress all the way around tube (1).
Illustration 198 is a detailed drawing of the welds that are to TIG dressed. Notice that only the bottom weld toe is
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TIG dressed.
Follow the postweld instructions at the end of this procedure for any questions regarding the postweld treatment
process TIG dressing.
Refer to the above reference for the procedure to prepare the area for welding and for the procedure to clean the
welds and inspect the welds.
The following two methods can be used to strengthen the weld on the center tube of 785C, 785D, 789B, 789C,
789D, 793, 793B, 793C, and 793D Off-Highway Trucks:
TIG dressing of fillet welds for improved fatigue life
Burr grinding of fillet welds for improved fatigue life
The preferred method is TIG dressing. The second method can be performed in an emergency. The second method
does not require an experienced welder or specialized equipment.
TIG Dressing of Fillet Welds for Improved Fatigue Life
Note: The fatigue performance is controlled by the profile of the weld toe. This applies to fabricated structures that
have fillet welded attachments to highly stressed members. The fatigue performance can be improved by altering
the original welded toe profile. This can be achieved by using several post weld treatment options. This procedure
describes a method of using an electric arc to reduce adverse profiles and stress risers. This creates a seamless
transition from one component to the next component.
Table 25
Required Equipment
Tool Description
GTAW (TIG) Power supply The power supply must be capable of producing 225 amps (min. 60% duty
and a torch. cycle) with a hand control or a foot control.
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 grinder or electric grinder with carbon steel wire wheel attachment
Grinding Wheel Aluminum oxide
Gauge Radius gauges
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Preparation of 2.4 mm (0.09 inch) tungsten electrode
(3) Striations or grinding marks
(A) 2 to 3 times the diameter
(B) 1/4 to 1/2 times the diameter
1. Cleanliness and preparation of tungsten electrode are the first steps to ensure that a proper TIG dressing is
achieved. All contaminants must be thoroughly removed from the fillet weld and the surrounding base metal.
All rust, dirt, oil, scale, and silicate islands must be removed. This can be accomplished quickly via a grinder
with a carbon steel wire attachment.
2. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 199.
The striatings should run parallel to each other.
3. Adjust the flow rate of shielding gas to 15 CFH. Adjust the current control to approximately 225 amps. If a
ramp down control is present on the power source, utilize the ramp down control to ensure that proper crater
fill control is achieved.
4. Several different techniques exist for TIG dressing. This is due to the variation of the contour of the fillet
weld toe. The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the
torch 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.
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Stringer technique
(C) 0 degrees to 25 degrees work angle
Note: Use a 10 degrees to 15 degrees push angle for the stringer technique.
5. Illustration 200 represents the stringer technique of welding. The center of the arc needs to be
0.0 mm to 2.0 mm (0.0 inch to 0.08 inch) from the weld toe into the base material.

Weave technique
(D) 0 degrees to 45 degrees work angle
(E) 3 mm (0.1 inch) Weave
Note: Use a 10 degrees to 15 degrees push angle for the weave technique.
6. Illustration 201 represents the weave technique of welding.
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7. Illustration 202 represents a cross section view of a proper TIG dressed fillet weld.
8. Illustration 203 and Illustration 204 demonstrate the expected results.
9. Once the 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 degrees to 100 degrees transition angles will require several
overlapping of TIG dressing runs. Overlapping of the TIG dressing runs is required to properly stabilize the
weld toe transition area.
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Note: TIG dressing can be conducted in the vertical position when you perform TIG dressing in a
downhill progression.
Note: Some undercuts will require the addition of filler metal. This can be accomplished by hand feeding
ER70S-2 1.5 mm (0.06 inch diameter) into the weld pool. You then repeat the TIG dressing to achieve the
desired toe radius and the desired profile.
Inspect using a radius gauge to ensure a minimum 5 mm (0.20 inch) radius.
Burr Grinding of the Fillet Welds for Improved Fatigue Life
Note: The profile or geometry of the weld toe controls the fatigue performance of fabricated structures. These
fabricated structures have attachments that are fillet welded to highly stressed members. Fatigue performance
improvement can be achieved through alteration of the original toe profile by several post weld treatment options.
This procedure describes a method of using a mechanical means to remove adverse profiles and adverse stress
risers. This method creates a smooth transition from one component to the next component.
Table 26
Required Equipment
Tool Description
Hand Held Grinder High speed, pneumatic, rotary, pencil grinder - 20,000 rpm
Compressed Air 621 kPa (90 psi) minimum
The burr should be conical shaped with approximate end diameter of 10.0 mm
Tungsten Carbide Burr
(0.39 inch).
Leather Welding
Jacket
Leather Gloves
Safety Glasses
Face Shield
Radius Gauge
Bridge Cam Gauge
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Pneumatic rotary pencil grinder with burr
(4) Preferred shape of burr
1. Illustration 205 shows the preferred shape of burr.

(F) 45 degrees
(G) 45 degrees
(H) Minimum depth of 0.8 mm (0.03 inch)
(5) Burr tool
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(6) Direction of travel

(7) Weld
(8) Plate
2. The tip of burr should be located over the weld toe. The axis of the tool should be maintained at
approximately 45 degrees to the parent plate. The axis of the tool should be inclined at approximately 45
degrees to the direction of travel. Grinding should extend to a depth of 0.5 mm (0.02 inch) below the last
visible traces of the weld toe resulting in minimum depth of 0.8 mm (0.03 inch) and maximum depth of
1.0 mm (0.04 inch). The resulting ground surface should be smooth without grinding marks running parallel
to the weld, but 90 degrees to the weld. All traces of the original weld toe should not be visible via the use of
a lower powered magnifying glass.
3. The finished burr grinding should look like the Illustration 207.
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REHS0541 - Procedure For The Inspection, Repair, and Component Replacement On The Frames

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Procedure for the Inspection, Repair, and Component Replacement on

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plant service engineer and the plant product analyst.

Sales Model Machine Systems Power Train

784B SENR5678 SENR5677

784C SENR1500 SENR1490

785 SENR4020 SENR4010

785B SENR5678 SENR5677

785C SENR1500 SENR1490

785C HAA SENR1500 SENR1490

785D KENR8312 KENR8308

789 SENR3404 SENR3430

789B SENR5687 SENR5686

789C SENR1534 SENR1524

789D SENR1534 UENR1065

793 SENR4917 SENR4907

793B SENR5692 SENR5691

793C (S/N: 4AR) SENR1463 SENR1462

793C (S/N: CBR, ATY, 4GZ) RENR2535 SENR2534

793D RENR8332 RENR8328

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Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

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

Approximate weights of the components are shown. Clean all surfaces

Sales Model Weight

784B, 784C 88.903 kg (196,828 lb)

785, 785B, 785C, 785D 102.965 kg (227,891 lb)

789, 789B, 789C, 789D 130.634 kg (288,728 lb)

793, 793B, 793C, 793D 147.417 kg (325,000 lb)

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8X-0898 Rail Rail - 785, 785B, 785C, 785D

290 kg 789, 789B, 789C, 793, 793B,

Lower Mounting for the 785, 785B, 785C, 785D, 789,

Lower Mounting for the 110 kg

Bracket 350 kg 784B, 784C, 785, 785B, 785C,

Important Safety Information

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The signal word WARNING has the following meanings:

Your Safety Is Involved !

Improper operation, lubrication, maintenance or repair of this product

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Do not operate or perform any lubrication, maintenance or repair on

Always observe the list of basic precautions that follows:

Mounting and Dismounting

Specifications for Cables, Chains, and Lifting Devices

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Hot Fluids and Parts

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Proper Cleaning for Inspection

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

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme

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particular cleaning fluid, refer to the manufacturer's instructions and

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Welding Specifications and Qualifications

Read and understand the manufacturer's instruction and your

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