General Welding Procedures and Updates for Off-Highway Truck HP (High Performance) XL Bodies {0679, 7250, 7258} Caterpillar

Off-Highway Truck/Tractor

793D (S/N: FDB1-1854)

793F (S/N: SSP1-1155; D3T1-143; RBT1-173)

Introduction

This special instruction contains the general welding procedures and updates for large mining truck HP (High Performance) bodies.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

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

Important Safety Information

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

Warnings

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

Notices

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

Notes

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

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

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

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

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

Illustration 1	g00008666

The signal word “WARNING” has the following meanings:

• Pay Attention !

• Become Alert !

• Your Safety Is Involved !

The message that appears under the safety alert symbol explains the hazard.

Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service information.

The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform service work. Special knowledge of the systems and of the components is important. Before you remove 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

Show/hide table

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

Always observe the list of basic precautions that follows:

Safety Signs

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

Protective Equipment

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

Mounting and Dismounting

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

Specifications for Cables, Chains, and Lifting Devices

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

Illustration 2	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 to prevent being sprayed by pressurized liquids. When the machine has been stopped, the danger of hot fluids is greater.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the skin for extended periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor. If there is contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.

Batteries

Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an acid. If there is contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.

Pressurized Items

1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

2. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed. Always make sure that all raised components are blocked correctly. Be alert for possible pressure when you disconnect any device from a system that utilizes pressure.

3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires. 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 the recommended practices that are provided by the manufacturer of the pressure washer.

Approved Inspection Methods

Visual inspection (VT), dye penetrant inspection (PT), magnetic particle inspection (MT), and ultrasonic inspection (UT) are required for certain procedures in this Special Instruction. Each of these inspection methods should be conducted and reported by qualified personnel. Examples of qualified personnel are as follows: VT - AWS CWI (American Welding Society Certified Welding Inspector) or equivalent. MT/PT/ - ASNT (American Society of Nondestructive Testing) Level II (minimum) for each method used. Do not use the magnetic particle inspection process around components that will be affected by magnetism. Do not use the dye penetrant inspection process around components that will be affected by the dye penetrant solution.

Welding Specifications and Qualifications

Show/hide table

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification 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. Attach the clamp for the ground cable as close as possible to the area that is being welded. This process will reduce the likelihood of damage from the welding current to the following components: bearings, hydraulic components, and electrical components. DO NOT weld plates to the frame for grounding/clamping purposes. Use existing blocks, brackets, bosses, and so on, to attach the clamp.

   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 and machine surfaces from sparks and welding spatter.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

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 1

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 table that follows show the recommended parameter range for out of position welding in the field for flux cored welding electrode diameter.

Table 2

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

Note: The settings listed above are recommendations-based on experience from 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. The use of higher parameters than specified for welding in the flat position is acceptable.

Use a polarity setting of DC reverse polarity. Remove the slag after each welding pass. 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 shall be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

Table 3

Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018H4R"
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) when not in use. 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 4

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 shall not exceed two times the electrode diameter.

Weld Inspection and Acceptance Criteria

Table 5

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

General Weld Repair

1. Remove any components that prevent access to the cracked weld.

2. Refer to "Welding Electrodes and Parameters" 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 between 125° C (257° F) and 300° C (572° F) maximum. Welding of attachments (such as blocks and tank mounts) to the inside/outside window plates and subsequent TIG dressing can be completed at 20° C (68° F) is maintained throughout the entire welding procedure.

   Note: The use of heating elements (such as a flexible ceramic pad) is the best method for pre-heat and inter-pass temperature control. If utilizing a gas torch, wait 1 minute after removing the heat source before measuring the base metal temperature.

6. The crack (and sound metal 50 mm (2.00 inch) beyond each end of the crack) shall be removed by gouging and/or grinding. Caution shall 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 PT or 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.

   • Remove the slag after each weld pass

   • Utilize stringer bead technique

   • All vertical welding (SMAW and FCAW) shall be vertical up progression

   • Stagger weld starts and stops when completing multi-pass fillet welds and groove welds

9. Clean the weld area. Inspect the area that was welded. All weld quality shall conform to the criteria specified in the "Weld Inspection and Acceptance Criteria" section in this Special Instruction.

Wear Rate Inspection and Recommended Floor Thickness Guideline

Perform wear rate and floor thickness inspection Every 3000 Hours, starting at 6000 hours.

• Wash the body assembly prior to inspection

• Complete the following inspection procedure

• Visually inspect each numerical location (in the inspection procedure) for cracks or damage and document all findings

• UT inspection, provided all wear measurements for referenced locations

Reference Data

Table 6

Date of Inspection
Mine Site
Parent Company
Inspectors Name
Cat Commercial Contract
Body Serial Number
Body Installation Date
Body Hours (Current)
Body Downtime (Hours)
Machine Serial Number
Machine Hours (Current)
Next Planned Inspection

Visual Inspection Procedure

Show/hide table

Illustration 3	g06295325
View of the inspection points for the front of the body assembly

Show/hide table

Illustration 4	g06295364
View of the inspection points for bottom of the body assembly

Show/hide table

Illustration 5	g06295388
View of the inspection points for the RH side of the body assembly

Note: Check for cracks on the rib ends, and where the ribs are welded to the sidewall. Repeat for both sides. Note location with "L" for left side and "R" for right side, for example L17 or R17.

Show/hide table

Illustration 6	g06295390
View of the inspection points for the rear of the body assembly

1. Perform the visual inspection at the inspection points shown in Illustration 3 through Illustration 6 and document using Table 7.
   Show/hide table

   Table 7

   Inspection Point	Crack Present Yes or NO		Findings/Comments (Issue Details)
   1	Yes	No
   2	Yes	No
   3	Yes	No
   4	Yes	No
   5	Yes	No
   6	Yes	No
   7	Yes	No
   8	Yes	No
   9	Yes	No
   10	Yes	No
   11	Yes	No
   12	Yes	No
   13	Yes	No
   14	Yes	No
   15	Yes	No
   16	Yes	No
   17	Yes	No
   18	Yes	No
   19	Yes	No
   20	Yes	No
   21	Yes	No
   22	Yes	No
   23	Yes	No
   24	Yes	No
   25	Yes	No
   26	Yes	No
   27	Yes	No
   28	Yes	No
   29	Yes	No
   30	Yes	No
   31	Yes	No
   32	Yes	No
   33	Yes	No
   34	Yes	No
   35	Yes	No
   36	Yes	No

Body Floor Wear Measurements and Maintenance

Note: Measured at 6000, 9000, 12000, 15000, and 18000 Service Meter Units (SMU).

Table 8

Phase 1	Add a row of transition bars front and back ( 25 mm (1.00 inch) thick and 150 mm (6.00 inch) apart) if bar thickness is less than 12 mm (0.50 inch).
Phase 2	Add 10 mm (0.40 inch) impact liners when the floor plate thickness is less than 17 mm (0.670 inch).
Phase 3	Add bars ( 25 mm (1.00 inch) thick and 150 mm (6.00 inch) apart) in areas where the floor plate thickness is less than 17 mm (0.670 inch).

Illustration 7	g06295611
View of the body assembly floor (A) Transition bar (D1) 1000 mm (40 inch) (D2) 1000 mm (40 inch)

Table 9

Body Floor Wear Measurements(1)
	A	B	C	D	E	F	G
1
2
3
4
5
6
7
8

(1)	Measure in millimeters (mm).

Front Wall and Front Transition Wear Measurements Layout and Maintenance

Note: Measured at 6000, 9000, 12000, 15000, and 18000 Service Meter Units (SMU).

Table 10

Phase 1

Add 11 mm (0.43 inch) impact liner when large deformations are observed or when plate thickness is less than 10 mm (0.40 inch).

Illustration 8	g06295711
View of the front wall of the body assembly (D1) 2000 mm (80 inch) (D2) 1000 mm (40 inch)

Table 11

Front Wall and Front Transition Wear Measurements(1)
	A	B	C	D
1
2
3

(1)	Measure in millimeters (mm).

LH Sidewall and Transition Wear Measurements Layout and Maintenance

Note: Measured at 6000, 9000, 12000, 15000, and 18000 Service Meter Units (SMU).

Table 12

Phase 1	Add bars ( 12 mm (0.50 inch) thick and spaced 150 mm (6.00 inch) apart) or CAT grid liners when sidewall plate thickness is less than 7 mm (0.30 inch).
Phase 2	Replace transition liners when fully worn.

Illustration 9	g06295801
View of the LH inside the body (A) Sidewall plate (B) Transition liner (C) Transition plate (D) Transition bar (D1) 700 mm (28 inch) (D2) 1300 mm (51 inch)

Table 13

LH Sidewall and Transition Wear Measurements(1)
	A	B	C	D	E	F
1	X
2
3						X

(1)	Measure in millimeters (mm).

RH Sidewall and Transition Wear Measurements Layout and Maintenance

Note: Measured at 6000, 9000, 12000, 15000, and 18000 Service Meter Units (SMU).

Table 14

Phase 1	Add bars ( 12 mm (0.50 inch) thick and spaced 150 mm (6.00 inch) apart) or CAT grid liners when sidewall plate thickness is less than 7 mm (0.30 inch).
Phase 2	Replace transition liners when fully worn.

Illustration 10	g06295863
View of the RH inside the body (A) Sidewall plate (B) Transition liner (C) Transition plate (D) Transition bar (D1) 1300 mm (51 inch) (D2) 700 mm (28 inch)

Table 15

RH Sidewall and Transition Wear Measurements(1)
	A	B	C	D	E	F
1	X
2
3						X

(1)	Measure in millimeters (mm).

Procedure to update the stringer rail on certain 793D and 793F Off-Highway Truck HP-XL Bodies

Repair Option 1 procedure is before crack repair and Repair Option 2 procedure is after crack repair.

Inspection Procedure

Show/hide table

Illustration 11	g06134532

1. Inspect the area outlined in Illustration 11. If no cracking is discovered proceed to "Repair Option 1", if cracking is discovered refer to "Repair Option 2" Section in this Special Instruction.
   Show/hide table

   Illustration 12	g06132754
   View of the area requiring inspection

2. Visually inspect (VT) the areas around the groove welds and adjoining plates for visible cracking.

3. Verify indications with dye penetrant (PT) or magnetic particle (MT) inspection.
   Show/hide table

   Illustration 13	g06132772
   Detailed view of groove weld (AA) 16 mm (0.63 inch) (BB) 30 degree angle (CC) 3 mm (0.12 inch) minimum (DD) 20 mm (0.80 inch)

4. Inspect both groove welds, using ultrasonic testing (UT). Rejected indications will result in removing defective weld material and rewelding the joint. Refer to Illustration 13 for the weld joint geometry for UT reference.
   Show/hide table

   Illustration 14	g06134675
   View tie off point to be inspected

5. Inspect tie off points shown in Illustration 14. Inspect welds and parent material in surrounding areas for any visible cracking. Verify findings with PT or MT.

6. If there is no visible cracking on the fillet welds at the tie off points or surrounding parent material, perform the Post Weld Treatment - TIG Dressing.

   If cracking is present, refer to "Repair Option 2" Section in this Special Instruction.

Required Fabrication

Illustration 15	g06133262
Doubler plate (BB) 10 mm (0.40 inch) (CC) 28 mm (1.10 inch) radius 2X (DD) 60 mm (2.40 inch) radius 2X (EE) 100 mm (4.00 0 inch) radius (FF) 24.5 degree angle (GG) 400 mm (15.75 inch) (HH) 350 mm (13.80 inch) (JJ) 150 mm (5.90 inch) (KK) 48 mm (1.90 inch) 2X (LL) 28 mm (1.10 inch) (MM) 155 mm (6.10 inch) 3X (NN) 282 mm (11.10 inch) (PP) 310 mm (12.20 inch) (RR) 100 mm (4.00 0 inch) diameter 2X (SS) 6 ± 1.5 mm (0.24 ± 0.06 inch) (TT) 60 degree angle

1. Use the dimensions in Illustration 15 and fabricate two doubler plates.

   Use either ASTM A514/A514M Grades B, H, and S or ASTM A656 Grade 80 material for doubler plate fabrication.

   Note: Doubler plates are required for both Repair Option 1 and Repair Option 2.

   Show/hide table

   Illustration 16	g06137165
   Plate (AA) 120 mm (4.72 inch) (BB) 132.5 mm (5.22 inch) (CC) 158 mm (6.22 inch) (DD) 170.5 mm (6.71 inch) (EE) 290 mm (11.42 inch) (FF) 13 mm (0.51 inch) (GG) 12 mm (0.47 inch) (HH) 362 mm (14.25 inch) (JJ) 385.5 mm (15.18 4 inch) (KK) 62 mm (2.44 inch) (LL) 71 mm (2.80 inch) (MM) 95.5 mm (3.76 inch) (NN) 105 mm (4.13 inch) (PP) 9 mm (0.35 inch) (RR) 85 degree angle

   Show/hide table

   Illustration 17	g06137186
   Bevel instructions for plate (SS) 12 mm (0.47 inch) (TT) 45 degree angle

2. Use the dimensions in Illustration 16 to fabricate four plates.

   Note: Two plates will need to beveled inward and two plates need to be beveled outward.

   Use either ASTM A514/A514M Grades B, H, and S or ASTM A656 Grade 80 material for doubler plate fabrication.

   Note: Plates are only used in Repair Option 2.

   Show/hide table

   Illustration 18	g06137207
   Backing strip (AA) 25 mm (1.00 inch) (BB) 387 mm (15.24 inch) (CC) 385 mm (15.16 inch)

3. Use the dimensions in Illustration 18 and fabricate eight backing strips.

   Note: Material for backing strips can be any common structural steel such as ASTM A36.

   Note: Backing strips are only used in Repair Option 2.

   Show/hide table

   Illustration 19	g06138429
   Backing strip for groove weld and run on/off tabs (AA) 430 mm (16.93 inch) (BB) 25 mm (1.00 inch) (CC) 25 mm (1.00 inch) (DD) 60 mm (2.36 inch)

4. Use the dimensions in Illustration 19 and fabricate two backing strips and two sets of run on/off tabs.

   Note: Material for backing strips can be any common structural steel such as ASTM A36.

   Note: Backing strips are only used in Repair Option 2.

Repair Option 1

Repair Option 1 is a repair procedure when there is no cracking discovered at the groove weld on the stringer rail or around the tie off brackets.

Illustration 20	g06132625
View of the bottom side of the body assembly

Illustration 20 indicates the locations for inspection/modification.

Repair Procedure

Show/hide table

Illustration 21	g06320934
View of doubler plate installed on the bottom of the rail (A) fabricated doubler plate

1. Position doubler plate (A). Align the edge surfaces as shown in Illustration 21.
   Show/hide table

   Illustration 22	g06321159
   Cross section of finished weld (A) doubler plate (AA) 6 mm (0.24 inch) (BB) 166 degrees (CC) 24 mm (1.00 inch) minimum

2. With doubler plate (A) in position, weld 10 mm (0.40 inch) V-groove on the front. Extend the weld 6 mm (0.24 inch) beyond the edge of the bevel groove weld. Refer to Illustration 22.

3. Grind completed weld to a smooth transition.
   Show/hide table

   Illustration 23	g06212858
   Welding doubler plate (A) Doubler plate (B) ( C) No weld zone (B) to (C)

4. Use the weld dimensions in Illustration 23 and finish welding doubler plate (A) into position.

   Note: No weld zone (B) to (C).

5. Visually inspect all welds to ensure that the welds conform to the "Weld Inspection and Acceptance Criteria" section.

6. Remove run on/off tabs, and sand area smooth.

Repair Option 2

Illustration 24	g06138443
Areas where cracking may occur

Cracking may occur along the stinger rail wall near the rear of the body. Cracks may propagate through the parent material in the stringer rail.

Repair Option 2 is a repair procedure where there is cracking discovered at the groove weld on the stringer rail or around the tie off brackets.

Existing Cracking

Show/hide table

Illustration 25	g06138511
(AA) 46.7 mm (1.84 inch) (BB) 225 mm (8.86 inch) (CC) 450 mm (17.72 inch) (DD) 450 mm (17.72 inch)

Show/hide table

Illustration 26	g06138762
(EE) 150 mm (5.91 inch) (FF) 150 mm (5.91 inch) (GG) 300 mm (11.81 inch)

1. Use the dimensions in Illustration 25 and Illustration 26 to mark the removal section of the rail.

2. Attach a suitable lifting eye and suitable lifting device to the section/plate being excavated and removed.

3. Back-gouge along the stringer rails in the area marked using air carbon arc torch or Oxy/Fuel to remove weld material shown in Illustration 25.

4. Vertical cuts shown in Illustration 26 shall be perpendicular to cover plate.
   Show/hide table

   Illustration 27	g06139137
   Weld transition areas (HH) 75 mm (2.95 inch)

5. Remove damaged plate from stringer rail.

   Note: There should be 75 mm (2.95 inch) of weld removal on each side of the vertical cuts open to prevent all starts and stops at the corners of the vertical seam. Refer to Illustration 27.

6. Repeat Step 1 through Step 4 on all sides where cracking is present on the body rails.
   Show/hide table

   Illustration 28	g06139164
   View of cross weld to be removed

7. Remove cross stringer welds and backup strips on both rails. Refer to Illustration 28 for weld location.

8. After removing the welds, prepare all edges to be welded, remove any slag/dross from cutting process and sand all surfaces to a smooth transition.

Welding Window Plates

Show/hide table

Illustration 29	g06139218
View of backing strips

1. Position and tack weld backing strips (vertical) for new plate. Illustration 29 shows the vertical backing strips install and the cross seam backing strip with run on/off tabs.

   Note: Only tack weld the backing strips in the weld joint areas. Do not tack weld on the back side of the backing strips.

   Show/hide table

   Illustration 30	g06139231
   View of cross seam backing strip placement (JJ) 12 ± 2 mm (0.47 ± 0.08 inch)

   Show/hide table

   Illustration 31	g06132787
   View of run on/off tabs

2. Use the dimensions in Illustration 30 to install the backing strip on the cross seam. Tack weld backing strip into position and install run on/off tabs.
   Show/hide table

   Illustration 32	g06139247
   View of window plate installed (KK) 12 mm (0.47 inch)

3. Install window plates into position along stringer chamfer side out making a 12 mm (0.47 inch) single bevel. Refer to Illustration 32.

   Note: A minimum of a 5 mm (0.20 inch) root opening will ensure proper access to root of the weld.

4. Tack weld window plates into position.
   Show/hide table

   Illustration 33	g06139309
   View of vertical seam weld

5. Weld the 12 mm (0.47 inch) single bevel vertical seam. Refer to Illustration 33.
   Show/hide table

   Illustration 34	g06139316
   View of the welds at the top and bottom of the rails

6. Weld the 12 mm (0.47 inch) fillet welds along the top and bottom rails
   Show/hide table

   Illustration 35	g06139704
   View of cross seam weld

   Show/hide table

   Illustration 36	g06212859
   View of groove weld

7. Weld the 16 mm (0.63 inch) groove welds on the bottom of the rails. Remove run on/off tabs after completing welds and blend edges to smooth transition.

Installing Doubler Plate

Show/hide table

Illustration 37	g06134632
View of doubler plate installed on the bottom of the rail (A) doubler plate

1. Position doubler plate (A) up against the toe of the 16 mm (0.63 inch) groove weld facing the rear of the body.
   Show/hide table

   Illustration 38	g06321206
   Cross section of finished weld (A) doubler plate (B) Backing strip (AA) 166 degrees (BB) 24 mm (1.00 inch) minimum

   Note: No weld on the back side of backing strip. Tack weld backing strip on the root side of the joint.

2. Grind the tack weld on backing strip (B) to half thickness prior to commencing finish weld.

3. With doubler plate (A) in position, weld 10 mm (0.40 inch) V-groove on the front. Extend the weld 6 mm (0.24 inch) beyond the edge of the bevel groove weld. Refer to Illustration 38.

4. Grind completed weld to a smooth transition.
   Show/hide table

   Illustration 39	g06212858
   Welding doubler plate (A) Doubler plate (B) ( C) No weld zone (B) to (C)

5. Use the weld dimensions in Illustration 39 and finish welding doubler plate (A) into position.

   Note: No weld zone (B) to (C).

6. Visually inspect all welds to ensure that the welds conform to the "Weld Inspection and Acceptance Criteria" section.

Rear Rib Crack Repair

Illustration 40	g06139756

This repair is for through thickness cracks in the base material of the rib near the body pivot. Refer to Illustration 40.

Remove Tie Off Bracket

Show/hide table

Illustration 41	g06140168
View of tie off bracket (A) Tie off bracket

Show/hide table

NOTICE
Tie off bracket will be reused. Use caution not to damage the tie off bracket or parent material when removing the tie off bracket.

1. Prior to repairing the crack, remove and retain tie off bracket (A) assembly.

2. For guide lines on through thickness repair, refer to the "Through Thickness Repair" Section.

The following section assumes that preheat (if required), crack excavation, and NDT verification have been completed and that the crack, which extended through the plate thickness has been removed.

Show/hide table

Illustration 42	g06134736
Gouge/grind dimensions (AA) 60 degree included angle (BB) 0 to 2 mm (0.08 inch) root face (CC) Section thickness (DD) 6 mm (0.23622 inch) or less (varied)

Show/hide table

Illustration 43	g06134879
Finished ground dimensions prior to insertion of backing strip (AA) 60 degree included angle (BB) 0 to 2 mm (0.08 inch) root face (CC) Section thickness (DD) 6 mm (0.23622 inch) or less (varied)

1. Prepare the weld joint requiring a permanent backing using the dimensions in Illustration 42 and Illustration 43.
   Show/hide table

   Illustration 44	g06134914
   Backing strip in place (AA) 60 degree included angle (CC) Section thickness (EE) 6 mm (0.23622 inch) or less (varied)

2. Insert permanent steel backing strip. Attach wire (or other means) to backing strip and insert through the root opening/gap and pull back flush to the insideofthe plate surface.

   The dimensions of the permanent steel backing strip will depend on the configuration of the excavation. Every attempt should be made to accommodate a single, continuous strip that runs the full length of the weld joint.

   A steel backing strip of 6.4 mm (0.25 inch) thick by 38 mm (1.50 inch) wide by the required length are the typical dimensions required for most applications. The steel backing strip material can be any common structural steel such as ASTM A36.

   The thickness of the backing strip should be kept to a minimum to assist with the insertion process. The thicket the backing strip the more difficult it will be to insert.

   A 6.4 mm (0.25 inch) thick backing strip is the minimum that should be used and is sufficient to prevent burn through using the welding parameters specified.

   Select a backing strip width that will ensure a minimum overlap of 6 mm (0.24 inch) of the backing strip to both sides of the weld joint along the entire length. Refer to Illustration 44. Minimize the gap (0 mm if possible) between the backing strip and the inside plate surface.

   Show/hide table

   Illustration 45	g06134933
   Welding complete (CC) Section thickness

3. Tack weld the backing strip into position. Remove wire/rod and grind half the thickness of the tack welds prior to finish welding to ensure proper fusion between tack welds and fill passes.

   Note: Illustration 45 does not represent the number of weld passes required, but only represents the weld bead placement in the weld joint.

   Show/hide table

   Illustration 46	g06134937

4. After completion of welding, blend sand the excess weld material flush with the surrounding plate profile.

After the crack is repaired, the tie off bracket can be relocated.

Note: Only reuse undamaged tie off brackets.

Show/hide table

Illustration 47	g06140243
View of tie off bracket relocated (A) Tie off bracket (AA) 120 mm (4.72 inch) (BB) 150 mm (5.91 inch)

1. Use the dimension in Illustration 47 to locate and orient tie off bracket (A).

2. Secure tie off bracket (A) into position with 8 mm (0.31 inch) fillet welds on all four sides.

Post Weld Treatment - TIG Dressing

The fatigue performance of fabricated structures involving fillet welded attachments to highly stressed members is, among other things, controlled by the profile or geometry of the weld toe. Fatigue performance improvements can be achieved through alteration of the original, as-welded toe profile by several post weld treatment options. This procedure describes a method whereby an electric arc is used to reduce and/or remove unfavorable profiles/stress risers thus creating a smooth, seamless transition from one component to the next component.

Note: Training: Anyone performing this procedure is advised to view the training video “Post Weld Treatment: TIG Dressing Fundamentals”, course number 41737, in the Dealer Learning Management System.

Equipment Requirements

Table 16

Required Equipment
Tool	Description
GTAW (TIG) Power supply and a torch.	The power supply must be able to produce 200 amps (min. 60% duty cycle) with a hand control or a foot control. Polarity - DC negative
Shielding Gas	100% Argon and flow meter
Electrode	Lanthanated or Ceriated or Thoriated Tungsten 2.4 mm (0.09 inch diameter) If needed: ER70S-2 filler metal 1.5 mm (0.06 inch diameter)
Grinder	Pneumatic or electric with carbon steel wire wheel attachment
Grinding Wheel	Aluminum Oxide
Radius gauges

Method

1. The first steps to ensure that proper TIG dressing are cleanliness and tungsten electrode preparation.

   The fillet weld and surrounding base metal must have all contaminants thoroughly removed. It is imperative that all paint, rust, dirt, oil scale, and silicate islands are non-existent, remove by using a grinder with a carbon steel wire attachment.

   Show/hide table

   Illustration 48	g03363246
   2.4 mm (0.09 inch) Tungsten Electrode Preparation (A) Grinding Marks (B) 2 X 3 diameter (C) 1/4 diameter

2. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 48. The grinding marks should run parallel to each other.

3. Adjust the shielding gas flow rate to 15 - 25 CFH. Adjust the current control to approximately 200 amps. If a ramp down control is present on the power source, utilize the ramp down control to ensure that proper crater fill control is achieved.

4. Several different techniques exist for TIG dressing due to the variation of the contour of the fillet weld toe. The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the torch to achieve a smooth radius of the weld. A minimum radius of 5.0 mm (0.20 inch) must exist between the base material and the weld metal.
   Show/hide table

   Illustration 49	g03363256
   Stringer Technique (D) 0 degree work angle

   Note: Use a 10 degree to 15 degree push angle for the stringer technique.

5. Illustration 49 represents the stringer technique of welding. The center of the arc needs to be 0.0 - 2.0 mm (0.0 - 0.08 inch) from the weld toe into the base material.
   Show/hide table

   Illustration 50	g03363260
   Weave Technique (E) 0 degree to 45 degree work angle

   Note: Use a 10 degree to 15 degree push angle for the weave technique.

6. Illustration 50 represents the weave technique of welding.
   Show/hide table

   Illustration 51	g01989613

7. Illustration 51 represents an acid etched, cross section view of a TIG dressed weld toe.
   Show/hide table

   Illustration 52	g01990055

   Show/hide table

   Illustration 53	g01990056

8. Illustration 52 and Illustration 53 demonstrate the expected results.

9. Once TIG dressing is completed, the area needs to be cleaned and painted to prevent pitting due to corrosion.

   Note: Poorly shaped fillet welds with 90 degree to 100 degree transition angles to the base material will require several overlapping TIG dressing runs to smooth out the weld toe transition region.

   Note: TIG dressing can be conducted in the vertical position as long as the TIG dressing is performed in a downhill progression.

   Note: If undercut or other circumstances require the addition of filler metal. Adding filler metal can be accomplished by hand feeding ER70S-2 1.6 mm (0.06 inch) into the weld pool. You then repeat the TIG dressing to achieve the desired toe radius and the desired profile.

10. Inspect using a radius gage to ensure a 5 mm (0.20 inch) minimum radius.

Procedure to update and repair ribs near the stringer rail on the 793F HP-XL Body

This special instruction also contains the necessary instructions to update and repair the ribs near the stringer rail on 793F HP-XL Body.

Inspection/Repair of Existing Saddle Area

Required Fabrication

Show/hide table

Illustration 54	g06151761
View of doubler plate (AA) 323.4 mm (12.73 inch) (BB) 253 mm (10.00 inch) (CC) 115 degree (DD) 193 mm (7.60 inch) (EE) 256.2 mm (10.09 inch) (FF) 100 mm (4.00 inch) (GG) 862 mm (33.94 inch) (HH) 193 mm (7.60 inch) (JJ) 256.2 mm (10.09 inch) (KK) 100 mm (4.00 inch) (LL) 50 mm (2.00 inch) radius 2X (MM) 60 mm (2.36 inch)radius 2X (NN) 50 mm (2.00 inch) radius 2X (PP) 12 mm (0.47 inch) (RR) 45 degree

1. Use the dimensions in Illustration 11 to fabricate doubler plates (as needed), using ASTM A514/A514M Grades B, H, and S or ASTM A656 Grade 80 material.

Saddle Plate Inspection Procedure

Show/hide table

Illustration 55	g06150852
View of areas for inspection

1. Inspect the areas on the ribs for cracking at the locations in Illustration 55.

   Note: There are 8 areas in total to be inspected, both sides of the front two ribs on both stringer rails.

2. If cracking is discovered, remove the paint and verify findings using magnetic particle inspection (MT) or die penetrant inspection (PT).

Crack Repair Procedure

The following section assumes that preheat (if required), crack excavation, and NDT verification have taken place and that the crack has been removed and did not extend through the plate thickness.

Show/hide table

Illustration 56	g06150970
View of excavation profile prior to grinding (A) Gouged profile (AA) Section thickness

1. Excavate the crack.
   Show/hide table

   Illustration 57	g06151009
   Cross sectional view of anticipated grinding (B) 70 degree included angle (AA) Section thickness

   Show/hide table

   Illustration 58	g06151909
   Cross sectional view of prepared joint prior to welding (slight radius at root) (AA) Section thickness (BB) 70 degree (CC) 35 degree

   Show/hide table

   Illustration 59	g06151936
   Longitudinal view of prepared joint (AA) Section thickness (DD) 45 degree

2. Finish grind to achieve a 70 degree included angle (B).

3. Complete welding, blend sand the excess weld material flush with surrounding plate profile.

Doubler Plate Addition

With cracks repaired, the new doubler plate can be installed.

Show/hide table

Illustration 60	g06151943
View of area for paint removal

1. Clean all surfaces using wire wheel/sander to remove all paint in areas where new doubler plate will be installed.
   Show/hide table

   Illustration 61	g06151962
   View of locating new doubler plate (AA) 3 mm (0.12 inch) to 5 mm (0.20 inch) root opening (A) Doubler plate

2. Locate doubler plate (A) onto rib. Ensure that there is at least a 3 mm (0.12 inch) root opening between the toe of fillet weld and bevel on the doubler plate (A).
   Show/hide table

   Illustration 62	g06151971
   Joint cross section (BB) 12 mm (0.47 inch) (CC) 12 mm (0.47 inch) (DD) 12 mm (0.47 inch) (B) Existing weld

3. Illustration 62 shows a cross sectional view of how the V groove weld will be configured. Tack weld plate (A) into position, keep tack welds out of radius and also grind the tack welds before welding over with the fillet welds or the groove root pass.
   Show/hide table

   Illustration 63	g06151981
   Welding specifications (A) Doubler plate

4. Finish welding doubler plate (A) into position using the welding specifications in Illustration 63. Use a balanced welding technique to spread out the heat and minimize distortion.

5. After welding is complete, visually inspect welds using the acceptance criteria in the "Weld Inspection and Acceptance Criteria" section.
   Show/hide table

   Illustration 64	g06151990
   View of doubler plates installed on both sides of the rail

6. This repair process can be performed the same on all 8 doubler plates.

   Note: If the repair is carried out, on one side of the rail, the repair needs to be duplicated on the adjacent side. Refer to Illustration 64.

Procedure to Rework the Floor Rear Rib and Splice Plate on the HP-XL Body

Table 17

Required Parts
Item	Qty	Description
1	4	Splice plate(1)
2	4	Doubler plate(1)
3	1	Doubler plate(1)
4	1	Doubler plate(1)
5	1	Doubler plate(1)
6	1	Doubler plate(1)

(1)	Dealer fabricated part

Illustration 65	g06208550
View of the bottom side of the body assembly (A) Splice plate (B) Gusset

Acceptable Welding Process

• Flux cored arc welding (FCAW), use 40 ± 5 cfh of shielding gas (75% argon and 25% carbon dioxide). Electrode to be used E71T-1MJH8.

• Shielded metal arc welding (SMAW), use E7018–1 electrodes in this DCEP process.

• Air arc gouging (DCEP) use 5/16 inch diameter rods for carbon arc.

• Preheat all repair areas to 100° C (212° F) to 120° C (248° F)

Rear Rib Splice Plate Joint Crack Repair Procedure

Illustration 66	g06208566
View of the rear rib splice plate joints (B) Gusset

1. Remove the welds around gussets (B) remove and discard two gussets (B).

2. Sand excess material flush with adjacent profile.
   Show/hide table

   Illustration 67	g06208661
   View of the rear rib splice plate joints (A) Splice plate

3. Use carbon arc cutting - air (CAC-A) to remove the weld around splice plate (A). Ensure that the entire weld all the way around splice plate (A) is removed.

4. Removed and discard splice plates (A).
   Show/hide table

   Illustration 68	g06208720
   View of the rear rib splice plate joints (AA) 45 degree angle (BB) 20 mm (0.80 inch)

5. Grind/sand the opening to 20 mm (0.80 inch), to accommodate the new splice plate.

6. Bevel both plates to a 45 degree angle to prepare for welding.
   Show/hide table

   Illustration 69	g06208754
   Fabrication details for splicer plate (CC) 61 mm (2.40 inch) (DD) 175 mm (6.90 inch) (EE) (25 degree) (FF) 30 mm (1.20 inch) radius 2 places (GG) 479 mm (18.90 inch) (HH) 594 mm (23.40 inch) (JJ) 655 mm (25.80 inch) (KK) 260 mm (10.24 inch) 2 places (LL) 55 mm (2.20 inch) (MM) 55 mm (2.20 inch) (NN) () (NN) 85 mm (3.35 inch) radius 2 places (PP) 20 mm (0.80 inch) (1) Splice plate

7. Use the dimensions in Illustration 69 to fabricate four splice plates (1).

   Note: Same splice plate to be used at all four locations along the rear rib.

   Show/hide table

   Illustration 70	g06210008
   View of new splice plate in position (AA) 35 mm (1.40 inch) (1) Splice plate

8. Install fabricated splice plates (1) into the 20 mm (0.80 inch) prepared slot, locate splice plate (1) by eye and center. Refer to Illustration 70 for reference dimensions for locating and placement of splice plates (1).

   Note: To avoid interference with welding, trim the edge as needed (indicated by arrow in Illustration 70).

9. Use the weld dimension in Illustration 70 and weld splice plate (1) into position.
   Show/hide table

   Illustration 71	g06210092
   View of doubler plate (2)

   Show/hide table

   Illustration 72	g06210123
   View of doubler plate (3)

   Show/hide table

   Illustration 73	g06210140
   View of doubler plate (4)

   Show/hide table

   Illustration 74	g06210557
   View of doubler plate (5)

   Show/hide table

   Illustration 75	g06210703
   View of doubler plate (6)

10. Use the dimension in Illustrations 71 through Illustration 75 to fabricate the required doubler plates.

    • 4 Doubler plates (2)

    • 1 Doubler plate (3)

    • 1 Doubler plate (4)

    • 1 Doubler plate (5)

    • 1 Doubler plate (6)

    Note: Use ASTM A656/A656M Grade 80 steel and fabricate four doubler plates

    Show/hide table

    Illustration 76	g06211118
    View of doubler plate installation

11. Prior to installing doubler plates, grind excess weld metal to rib profile from C-D.
    Show/hide table

    Illustration 77	g06211121
    View of doubler plate installation (2) Doubler plate (3) Doubler plate (4) Doubler plate (5) Doubler plate (6) Doubler plate

12. Install doubler plates. Refer to Illustration 77 for doubler plate locations.

    Note: Maintain a 5 mm (0.20 inch) root opening between the splice plate surface to each doubler plate chamfered edge.

13. Use the weld dimensions in Illustration 76 to secure doubler plates in position.

    Note: Grind/sand doubler plate ends near (C and D) .

Procedure to Rework the Floor Rib Splice Plates on the HP-XL Body

Table 18

Required Parts
Item	Qty	Description
1	8	Splice plate(1)

(1)	Dealer fabricated part

Show/hide table

Illustration 78	g06211186
View of the floor ribs splice plate locations

1. Perform Step 1 through Step 8 in the "Rear Rib Splice Plate Joint Crack Repair Procedure" Section in this Special Instruction to rework the floor rib splice plates.

   Note: The rib thickness is 10 mm (0.40 inch) thick.