Procedure to Inspect the Support Assembly on Certain 785C, 785D, 789C, and 789D Off-Highway Trucks{3260} Caterpillar

OEM:

CAT WDS (S/N: M4J1-UP)

Off-Highway Truck/Tractor:

785C (S/N: APX1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-UP; SHH1-UP)

Introduction

Illustration 1	g03539177

This special instruction provides the minimum requirements for conducting liquid penetrant testing on the 8X-8919 Support As .

Required Tooling

Important Safety Information

The following information is an explanation of various labels that are found in this document.

Warnings

The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.

Notices

A notice informs the technician that component damage can occur as a result of a condition that exists.

Notes

A note contains general information for the technician about the operation that is being performed.

Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods.

Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information before you perform any repairs or before you perform any maintenance.

Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

The "Safety Alert Symbol" that is followed by a "Signal Word" identifies a hazard. "DANGER", "WARNING", and "CAUTION" are "Signal Words".

Illustration 2	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 or 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. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

Basic Precautions

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Always observe the list of basic precautions that follows:

Safety Signs

Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs on the machine before operating, lubricating, or repairing the machine. Understand all "Safety" signs on the machine before operating, lubricating, or repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.

Protective Equipment

When you work around the machine, always wear protective equipment that is required by the job conditions. Protective equipment includes the items that follow: hard hat, protective glasses and protective shoes. In particular, wear protective glasses when you use a hammer or when you use a sledge hammer. When you weld, use the appropriate protective equipment that is required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.

Mounting and Dismounting

Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a machine. Before you mount the machine, clean any mud or debris from steps, walkways, or work platforms. Always face the machine when you use steps, handholds, and walkways. When you cannot use the accesses on the machine, use ladders, scaffolds, or work platforms to perform safe repair operations.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weights in order 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 in order 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.

Illustration 3	g00629745
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 in order 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. In case of contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.

Batteries

Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an acid. In case of 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. Loose hydraulic lines, loose tubes, and loose hoses 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 of the recommended practices that are provided by the manufacturer of the pressure washer.

Inspection Procedure

The liquid penetrant examination process is applicable to in-process, final, and maintenance (in service) examinations. This process is applicable for the detection of discontinuities, such as lack of fusion, cracks, laps, and cold shuts, that are open to the surface or slightly subsurface of the component under examination.

Qualifications

Personnel performing inspections shall be qualified and certified for magnetic particle testing (MT) and penetrant testing (PT) at a minimum Level I in accordance with ASNT Recommended Practice No. SNT-TC-1A or ASNT CP-189.

Inspection Areas

Illustration 4	g03539378
View of the top of the left-hand side of 8X-8919 Support As (C) 825 mm (32.50 inch) (D) 597 mm (23.50 inch)

Note: The indicated locations apply to the top of the left-hand side support leg and the bottom of the right-hand support leg. The chaplet will be in the center line of the support leg.

Clean and remove the paint 150 mm (6.00 inch) diameter from the center of location (A) and location (B) .

Penetrant Test (PT) Procedure

Illustration 5	g03539441

1. Clean the surface of the inspection area. The surface shall be clean, dry, and free of oil, scale, paint, smeared metal, machining marks, or other contaminates or conditions which might interfere or prevent penetrant from entering discontinuities, suppress dye performance, or produce unacceptable background.

   Note: Magnaflux Spot-check (SKC-S) Cleaner Remover is recommended for oil removal.

2. Remove all coatings and other surface conditions, such as paint, plating, corrosion from the area to be inspected prior to penetrant inspection.

   Note: Grit blasting and wire wheel methods of contamination removal may smear the metal and should not be used.

3. Apply tooling (A) to the entire inspection area, for larger components inspection in sections may be beneficial.

   The component, penetrant, and the ambient temperature shall be in the range from 4° C (39° F) to 52° C (125° F) unless otherwise specified.

4. Allow tooling (A) to dwell for a minimum of 10 minutes. For temperatures between 4° C (39° F) to 10° C (50° F), dwell time should be 20 minutes.

5. Remove tooling A by wiping excess penetrant with a clean, lint free, dry absorbing towel.

6. Remove the remainder of the surface penetrant using a solvent-dampened lint free cloth or towel. The surface of the component shall not be flushed with solvent and the cloth or towel shall not be saturated with solvent.

   Note: Magnaflux Spot-check (SKC-S) Cleaner Remover is recommended for excess penetrant removal.

7. Ensure that the component is dry.

8. Apply tooling (B) ( Non-aqueous developer shall be used unless otherwise stated). Apply tooling (B) using thin even coating over the inspection area.

   Note: If tooling (B) is applied too heavily there is a risk of masking the indications.

9. Allow tooling (B) to dwell for a minimum of 10 minutes and the maximum of 1 hour.

10. Inspection shall start while applying tooling (B), but still allowing tooling (B) to dwell for a minimum of 10 minutes and the maximum of 1 hour.

11. Use visible light when inspecting with a non-fluorescent penetrant. A minimum light intensity of 100 fc (1076 lx) shall be available at the surface of the component being inspected or evaluated. A flash light should meet this minimum.

Grinding of Indications

If, the indications are on the as cast surface or on a machined surface that is not in compliance with the requirements found in ""Acceptance and Rejection Requirements" " section the indications shall be ground /buffed up to 0.5 mm (0.02 inch) and reinspected to ensure accurate inspection results.

Areas that are ground/buffed should not create any sharp corners or edges and the areas should transition smoothly back to the original material.

Acceptance and Rejection Requirements

Relevant linear indications exceeding 16 mm (0.63 inch) shall be considered rejected.

Record of Inspection

1. Record the results of all inspections. Records shall be provided for traceability to the specific component examined and truck serial number.

2. Photos of indications should include a scale for size reference and an overall location of the indications on the component.

3. Examination photos should be sent to the Cat representative.

4. When marking accepted components, marking should be applied in such a manner and location as to be harmless to the components.

Post Cleaning

In some instances the surfaces will need to be cleaned for other operations such as painting.