Weld Repair Procedure for Field Retrofit of Large Off-Highway Truck Frame Superstructure {7050, 7253} Caterpillar

Off-Highway Truck/Tractor

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: 4AR1-UP)

Introduction

This Special Instruction provides the information that is necessary to perform a field rework procedure of the trucks frame superstructure. The field retrofit will help prevent future structural problems.

The procedures in this publication are used to ensure proper installation of the parts. Perform the procedures and order the parts only after you have completely read this publication.

Suggested tools and equipment should be available for installation. If the tools and the equipment are not available, assembly will be more difficult and more time will be necessary to complete the assembly.

Approximately 210 man hours are needed to complete the procedure. The cab and tires are already removed.

Illustration 1	g00744139
(A) Right side beam (B) Front support (right side) (C) Rear support (right side) (D) Left side beam (E) Front support (left side) (F) Front pedestal (right side)

Table 1

Changes for General Frame Superstructure on the 789 Off-Highway Truck
Item	Description
A	Right Side Beam
B	Front Support (right side)
C	Rear Support (right side)
D	Left Side Beam
E	Front Support (left side)

Table 2

Changes for the General Frame Superstructure on the 793 Off-Highway Truck
Item	Description
A	Right Side Beam
B	Front Support (right side)
C	Rear Support (right side)
D	Left Side Beam
E	Front Support (left side)
F	Front Pedestal (right side)

Illustration 1 and Tables 1 and 2 above show the general changes to the frame.

Weld Specifications and Parameters

Note: Personal breathing protection should be worn by the welders. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator for respiratory protection.

All of the welders must be qualified in Shielded Metal Arc Welding (SMAW). All of the welders must be qualified in either Flux Cored Arc Welding (FCAW) groove welding or Flux Cored Arc Welding (FCAW) fillet welding. Refer to the American National Standards Institute (ANSI)/American Welding Society (AWS) D1.1. Prior to welding, the process must have been used by the welders during the last six months. Welding qualifications must be documented and welding qualifications must be current.

The surrounding area must be a minimum temperature of 16 °C (61 °F) before welding and during welding.

The proper stick welding electrode for Shielded Metal Arc Welding (SMAW) is E7018 American National Standards Institute (ANSI)/American Welding Society (AWS) A5.5. The finished weld will have the following minimum mechanical properties:

• 500 MPa (69,618 psi) Tensile Strength

• 420 MPa (58,015 psi) Yield Strength

• 22 percent elongation in 50 mm (2 inch)

• 27 N·m (20 lb ft) at −29 °C (−20 °F) Impact Toughness

The E7018 electrodes must be stored in an electrode oven at 121 °C (250 °F). Scrap the E7018 electrodes or recondition the E7018 electrodes if the E7018 electrodes get damp. Recondition the E7018 electrodes to the manufacturer's specifications. The following table is the electrode's current settings in relation to the electrode's diameters:

Table 3

Parameters for Welding
Diameter	Amperes
3 mm (0.12 inch)	70-140
4 mm (0.16 inch)	110-180
5 mm (0.20 inch)	190-270

Set the polarity to direct electrode positive (reverse polarity). Use the direct current. Remove the slag after every pass. Do not allow the weld to be larger than the electrode diameter.

Use the Flux Cored Arc Welding (FCAW) with E71T-1 (ANSI/A5.20) welding electrode and the manufacturer's shielding gases that are specified for inside welding. The weld that is deposited by three Flux Cored Arc Welding (FCAW) electrodes will have the following minimum mechanical properties:

Note: The slag system of the E71T-1 (ANSI/A5.20) welding electrode has fast freezing characteristics. There is a chance of trapping gases that are evolving in the weld melt. The weld pass volume should be controlled with caution.

Note: Use the manufacturers recommendation for the correct welding electrodes.

Note: Test for the quality of the weld.

Weld Repair Procedure for the 793 Off-Highway Truck

Remove the Left Side Beam and the Front Support

Show/hide table

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.

Show/hide table

NOTICE
The machine must be parked on a level surface to perform this procedure.

1. Place the wood cribbing blocks under the front of the truck. Remove the front tires.

2. Remove the cab assembly. Refer to the Disassembly and Assembly Manual for removal of the cab assembly.
   Show/hide table

   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.

3. Drain the coolant system.
   Show/hide table

   Illustration 2	g00589306

4. Open the rear hood. Loosen the hose clamps on the coolant line. Remove the coolant line that is connected to the beam.
   Show/hide table

   Illustration 3	g00580576

5. Remove three bolts and three washers on each side of the coolant tank. Remove both covers.
   Show/hide table

   Illustration 4	g00580578

6. Disconnect the coolant lines on each side of the coolant tank.
   Show/hide table

   Illustration 5	g00741547
   (A) Coolant Line (B) Air Conditioning Line

7. Remove four bolts and four washers. Disconnect coolant line (A).

8. Disconnect the air conditioning line (B).

   Note: To prevent contamination, cap the lines.

   Show/hide table

   Illustration 6	g00589324

9. Remove the six bolts and the six washers. The bolts and washers are located on the front of the hood.
   Show/hide table

   Illustration 7	g00589330

10. Remove the two bolts and the two washers. The bolts and washers are located on the inside of the hood.
    Show/hide table

    Illustration 8	g00589338

11. Attach two 138-7573 Link Brackets to the sides of the coolant tank. Attach a suitable lifting device to the hood.
    Show/hide table

    Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

    Show/hide table

    Illustration 9	g00589349

12. Lift the hood assembly from the truck. Place the hood assembly on wood blocks.
    Show/hide table

    Illustration 10	g00589355

13. Remove the steering hose guard.

14. Remove the steering lines from the clamp assembly. Place the lines to the inside of the engine compartment.

15. Detach the air conditioning line from the bracket assembly.

16. Remove any guards on the strut or on the beam.
    Show/hide table

    Illustration 11	g00589358

17. Unscrew the clamp assembly. Place the air lines to the inside of the engine compartment.

    Note: The beam should be free of all guards and of all hose assemblies.

18. Measure the distance from the front cab bore to the rear cab bore. Measure the distance from the front beam outrigger to the rear beam outrigger.

    Note: Record the distances. The distances are compared after the new beam is placed.

19. Make a reference mark on the stub shaft of the strut. Use the bearing to set the height.

20. Measure the distance from the front pedestal to the rear beam. Use this measurement to cut the 101.6 mm (4.0 inch) by 101.6 mm (4.0 inch) by 9.52 mm (0.38 inch) square tubing to the correct length.

21. Cut the square tubing.
    Show/hide table

    Illustration 12	g00589360

22. Lift the square tubing into the correct position. Tack weld the square tubing. The square tubing will help prevent distortion during welding.

23. Secure the beam with chains and a suitable lifting device.
    Show/hide table

    NOTICE
    Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

    Show/hide table

    Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

    Show/hide table

    Illustration 13	g00589391

24. Cut the weld that is holding the beam to the front support.
    Show/hide table

    Illustration 14	g00742316
    (1) 161-2116 Beam

25. Measure 398 mm (15.67 inch) from the rear scab plate. Make a mark on the beam. Make a 90 degree cut into the rear support and into the beam . For the correct cutting dimensions, refer to the following references: Illustration 14 and Table 4.
    Show/hide table

    Table 4

    Dimensions for Illustration 14
    Item	Dimension
    C	398 mm (15.67 inch)
    D	393 mm (15.47 inch)

    Show/hide table

    Illustration 15	g00589403

26. Remove the four front strut mounting bolts. Remove the shims.

27. Lift the beam out of the way.
    Show/hide table

    Illustration 16	g00741946
    (E) Front Support (F) Hood Mount

28. Use an air carbon arc torch to remove the front support. Remove the front hood mount.

Install the Left Side Beam and the Front Support

Table 5

Required Parts for the Installation of 161-2116 Beam and 161-2127 Support
Item	Quantity	Part Number	Description
1	1	161-2116	Beam
2	1	161-2127	Support
3	2	8X-0597	Strip
4	1	7I-5684	Bracket
5	3	9R-2613	Boss
6	1	8X-4711	Boss
7	1	7X-7963	Weld Boss
8	1	7X-7962	Weld Boss
9	1	9R-3845	Boss
10	2	9R-2640	Boss
11	2	8X-4421	Bar
12	1	7I-5072	Plate Assembly

Illustration 17	g00742340
(1) 161-2116 Beam

Table 6

Dimensions for Illustration 17
Item	Dimension
A	398 mm (15.67 inch)
B	393 mm (15.47 inch)

Illustration 18	g00742402
(1) 161-2116 Beam (2) 161-2127 Support (4) 7I-5684 Bracket (6) 8X-4711 Boss (11) 8X-4421 Bar (12) 7I-5072 Plate Assembly

Table 7

Welding Tolerances for Illustration 18
Weld	Tolerances
W1	20 mm (0.79 inch) bevel groove weld (2 Places)
W2	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W3	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Bars) (Both Sides)
W4	20 mm (0.79 inch) bevel groove weld (2 Places)
W5	3 mm (0.12 inch) fillet weld that is 25 mm (0.98 inch) in length with 50 mm (1.97 inch) (center to center)

Table 8

Welding Dimensions for Illustration 18
Item	Dimension
C	48 ± 5 mm (1.90 ± 0.20 inch)
D	894 ± 5 mm (35.20 ± 0.20 inch)
E	547 ± 3 mm (21.54 ± 0.12 inch)
F	275 ± 5 mm (10.83 ± 0.20 inch)
G	120 ± 5 mm (4.72 ± 0.20 inch)
H	70 ± 5 mm (2.76 ± 0.20 inch)
I	950 ± 5 mm (37.40 ± 0.20 inch)
J	475 ± 5 mm (18.70 ± 0.20 inch)
K	537 ± 5 mm (21.14 ± 0.20 inch)
L	468 ± 3 mm (18.42 ± 0.12 inch)
M	100 ± 2 mm (3.94 ± 0.08 inch)

Illustration 19	g00742425
(8) 7X-7962 Weld Boss (9) 9R-3845 Boss (10) 9R-2640 Boss

Table 9

Welding Tolerance for Illustration 19
Weld	Tolerances
W6	3 mm (0.12 inch) fillet weld (3 Bosses)

Table 10

Welding Dimensions for Illustration 19
Item	Dimension
N	215 ± 5 mm (8.46 ± 0.20 inch)
O	40 ± 5 mm (1.57 ± 0.20 inch)
P	10 ± 5 mm (0.39 ± 0.20 inch)
Q	35 ± 5 mm (1.38 ± 0.20 inch)
R	760 mm (29.92 inch)

Illustration 20	g00742433
(5) 9R-2613 Boss (6) 8X-4711 Boss (7) 7X-7963 Weld Boss (12) 7I-5072 Plate Assembly

Table 11

Welding Tolerances for Illustration 20
Weld	Tolerances
W7	3 mm (0.12 inch) fillet weld (3 Bosses)
W8	3 mm (0.12 inch) fillet weld

Table 12

Welding Dimensions for Illustration 20
Item	Dimension
S	165 ± 5 mm (6.50 ± 0.20 inch)
T	230 ± 5 mm (9.06 ± 0.20 inch)
U	105 ± 5 mm (4.13 ± 0.20 inch)
V	139 ± 5 mm (5.47 ± 0.20 inch)
W	248 ± 5 mm (9.76 ± 0.20 inch)
X	247 ± 5 mm (9.72 ± 0.20 inch)
Y	150 ± 5 mm (5.91 ± 0.20 inch)

Illustration 21	g00746447

Table 13

Welding Tolerances for Illustration 21
Weld	Tolerance
W9	5 mm (0.2 inch) fillet weld

Table 14

Welding Dimensions for Illustration 21
Item	Dimension
Z	167 ± 3 mm (6.57 ± 0.12 inch)

Show/hide table

Illustration 22	g00590653

1. Clean the welding area on the pedestal.
   Show/hide table

   Illustration 23	g00588547

2. A 30 degree bevel needs to be cut on the rear support. The finished dimension from the scab plate to the end of the rear support is approximately 393 mm (15.47 inch). Refer to the following references: Illustration 17 and Table 6.
   Show/hide table

   Illustration 24	g00741972

3. Tack weld a 152.40 mm (6 inch) long piece of angle iron to the bottom of the rear support.

   Note: This Step will help with the placement of the beam.

   Show/hide table

   Illustration 25	g00742389
   (1) 161-2116 Beam (3) 8X-0597 Strips

4. Cut 8X-0597 Strips (3). The strips should fit the inside of 161-2116 Beam (1).
   Show/hide table

   Illustration 26	g00742041
   (1) 161-2116 Beam (2) 161-2127 Support (BA) Angle iron

5. Tack weld 161-2127 Support (2) to 161-2116 Beam (1).

6. Cut two pieces of angle iron approximately 1524 mm (60 inch) long.

7. Tack weld angle iron (BA) to the top of the 161-2116 Beam (1) and the 161-2127 Support (2). Tack weld a piece of angle iron (BA) to the bottom of the two pieces.

   Note: Angle iron (BA) is used to help hold the two castings together.

   Show/hide table

   Illustration 27	g00742068
   (BA) Angle iron

8. Cut two holes in top angle iron (BA) for lifting.
   Show/hide table

   Illustration 28	g00742394
   (1) 161-2116 Beam (2) 161-2127 Support

9. Lift (1) and 161-2127 Support (2) with a suitable lifting device.

10. Place 161-2116 Beam (1) and 161-2127 Support (2) into position.
    Show/hide table

    Illustration 29	g00588609

11. Install the same shims. Bolt the strut mount to 161-2116 Beam (1).

12. Use the mark on the stub shaft to set the height.
    Show/hide table

    Illustration 30	g00742389
    (1) 161-2116 Beam (3) 8X-0597 Strip

13. Tack weld the pieces of 8X-0597 Strip (3) to the inside of the rear support and to 161-2116 Beam (1).

14. Cut the tack weld that is holding 161-2127 Support (2) to angle iron (BA).
    Show/hide table

    Illustration 31	g00743406
    (1) 161-2116 Beam (2) 161-2127 Support

15. Locate 161-2127 Support (2). Weld 161-2127 Support (2) to the front pedestal. Refer to the following references: Illustration 18, Tables7 and 8.

16. Unbolt the strut. Move 161-2116 Beam (1) forward by 2 mm (0.08 inch). This step allows tolerance for weld shrinkage.

17. Weld a 6 mm (0.24 inch) bead around the rear joint. The rear joint connects 161-2116 Beam (1) to the rear support.

    Note: The tops of the castings should be level with each other.

18. Weld the joint that is connecting the rear support to 161-2116 Beam (1). Fill the joint completely. Refer to the following references: Illustration 18, Tables7 and 8.

19. Weld the joint that is connecting 161-2127 Support (2) to 161-2116 Beam (1). Fill the joint completely. Refer to the following references: Illustration 18, Tables7 and 8.

20. Install the four front strut mounting bolts. Torque the bolts to 800 ± 100 N·m (590 ± 74 lb ft).
    Show/hide table

    Illustration 32	g00742407
    (1) 161-2116 Beam (2) 161-2127 Support (4) 7I-5684 Bracket

21. Place 7I-5684 Bracket (4). Weld 7I-5684 Bracket (4) to the frame. Refer to the following references: Illustration 21, Tables13 and 14.
    Show/hide table

    Illustration 33	g00746543
    (1) 161-2116 Beam (2) 161-2127 Support (BA) Angle iron

22. Remove angle iron (BA) from the top of 161-2116 Beam (1) and from the bottom of 161-2116 Beam (1).

23. Clean 161-2116 Beam (1) and 161-2127 Support (2).

24. Cut out the 101.6 mm (4.0 inch) by 101.6 mm (4.0 inch) by 9.5 mm (0.38 inch) square tubing.

25. Measure the distance from the front cab bore to the rear cab bore. Measure the distance from the front beam outrigger to the rear beam outrigger.

    Note: The distances should equal the previous measurements.

26. Place three 9R-2613 Bosses (5) on the beam. Refer to the following references: Illustration 20, Tables11 and 12.
    Show/hide table

    Illustration 34	g00742452
    (1) 161-2116 Beam (2) 161-2127 Support (4) 7I-5684 Bracket (6) 8X-4711 Boss (7) 7X-7963 Weld Boss

27. Place 8X-4711 Boss (6) and 7X-7963 Weld Boss (7) on 161-2116 Beam (1). Refer to the following references: Illustration18 , Tables 7, 8, Illustration 20, Tables, 11and 12.

28. Place 7X-7962 Weld Boss (8) on 161-2116 Beam (1). Refer to the following references: Illustration 19, Tables9 and 10.

29. Place 9R-3845 Boss (9) and two 9R-2640 Bosses (10) on 161-2116 Beam (1). Refer to the following references: Illustration 19, Tables9 and 10.
    Show/hide table

    Illustration 35	g00742481
    Completed Frame Assembly (1) 161-2116 Beam (2) 161-2127 Support (4) 7I-5684 Bracket (11) 8X-4421 Bar (12) 7I-5072 Plate Assembly

30. Place two 8X-4421 Bars (11) on 161-2116 Beam (1). Refer to the following references: Illustration 18, Tables7 and 8.

31. Place 7I-5072 Plate Assembly (12) on the underside of the 161-2116 Beam (1). Refer to the following references: Illustration 18, Tables7 and 8.

32. Clean 161-2116 Beam (1) and 161-2127 Support (2).

    Note: Paint 161-2116 Beam (1) and 161-2127 Support (2), as needed.

Remove the Platform

Show/hide table

Illustration 36	g00588966

1. Remove the air intake from the inside of the engine compartment.
   Show/hide table

   Illustration 37	g00588933

2. Remove the air intake under the platform.

3. Remove any intake tubes or any exaust tubes on the right side of the engine compartment.

   Note: Cover the intake and exhaust ports.

   Show/hide table

   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.

4. Drain the steering hydraulic tank into a suitable container.
   Show/hide table

   Illustration 38	g00589008

5. Disconnect the lines on the steering hydraulic tank.
   Show/hide table

   Illustration 39	g00588161

6. Disconnect the lines to the air tank.

   Note: In order to prevent contamination, cap all of the lines.

   Show/hide table

   Illustration 40	g00588882

7. Remove the four bolts that are securing the exhaust to the frame.
   Show/hide table

   Illustration 41	g00588896

8. Remove the mud flap. Remove the old 138-1258 Bracket.
   Show/hide table

   Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

   Show/hide table

   Illustration 42	g00575643
   138-7573 Link Bracket

9. Install three 138-7573 Link Brackets onto the platform.

10. Install a lever puller and a three hook chain.
    Show/hide table

    Illustration 43	g00582395

11. Cover the accumulators before you cut on the platform.
    Show/hide table

    Illustration 44	g00589028

    Show/hide table

    Illustration 45	g00589074

    Show/hide table

    Illustration 46	g00589092

12. Cut the plates and the mounting brackets that are holding the platform to the frame.

13. Remove the three platform mounting bolts.
    Show/hide table

    Illustration 47	g00589136

14. Lift the platform assembly from the truck. Set the platform assembly on a stable stand.

Remove the Front Pedestal

1. Remove any electrical lines and hoses that are attached to the front pedestal.
   Show/hide table

   Illustration 48	g00742614
   (1) Accumulator (2) Hose (3) Bracket

2. Evacuate the accumulators (1). Detach the bottom hoses (2).

3. Remove the brackets (3) that are securing the accumulators (1).

4. Attach a suitable lifting device to accumulators (1). Lift accumulators (1) out of the way.
   Show/hide table

   Illustration 49	g00612867

5. Detach the hydraulic filter from the bracket. Place the filter and the hoses against the engine.
   Show/hide table

   Illustration 50	g00624829
   (A) Lifting device

6. Secure the beam with lifting device (A) and a crane, or secure the beam with a brace (B).

   Note: In order to secure the beam with a brace, measure the distance from the beam to the frame assembly. Use this measurement to cut the 101.60 mm (4.0 inch) by 101.60 mm (4.0 inch) by 9.52 mm (0.38 inch) square tubing to the correct length.

   Note: The beam is left in place in order to place the front pedestal.

7. Use an air carbon arc torch to cut the front of the beam from the pedestal. Cut around the front support. Refer to the arrows in Illustration 50.
   Show/hide table

   Illustration 51	g00633654

8. Remove the bolts that are holding the ROPS brace. Remove the ROPS brace and the shims.

   Note: Keep the shims and the bolts for later installation.

   Show/hide table

   NOTICE
   The radiator support on the 793 and 793B Models is welded to the radiator housing. The radiator may have to be removed. Refer to Dissassembly and Assembly Manual SENR1461 for removal of the radiator.

9. Remove the bolts that are securing the brace on the front pedestal to the radiator support beam.

   Note: The brace on the 793 and 793B Models is cut out with a torch.

   Show/hide table

   Illustration 52	g00612887

10. Cut the plates and the welds that are connecting the front pedestal to the frame with an air carbon arc torch.

11. Wrap a suitable lifting device around the front pedestal.

12. Carefully lift the front pedestal out of the frame assembly.

13. Remove any left over plates from the frame assembly with an air carbon arc torch and a grinder.

14. Clean the areas for a later weld.

Install the New Front Pedestal

Table 15

Required Parts for the Installation of 142-5730 Pedestal
Item	Quantity	Part Number	Description
1	1	142-5730	Pedestal
2	1	142-5713	Tube Assembly
3	1	8X-4061	Plate
4	1	3V-8104	Plate
5	1	8X-0392	Plate
6	1	142-5731	Plate
7	1	8X-0391	Plate
8	11	8T-6911	Weld Boss
9	10	7X-7962	Weld Boss
10	1	138-1216	Tube Assembly
11	1	138-1219	Collar
12	1	8X-0396	Pipe
13	1	8X-4576	Plate
14	1	8X-1985	Plate
15	1	101-6996	Plate
16	1	8X-6780	Block
17	1	6N-5451	Gusset
18	1	130-5686	Plate
19	1	8X-6193	Plate Assembly

Illustration 53	g00743065
(1) 142-5730 Pedestal (2) 142-5713 Tube Assembly (3) 8X-4061 Plate (9) 7X-7962 Weld Boss

Table 16

Welding Tolerances for Illustration 53
Weld	Tolerances
W1	10 mm (0.39 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W2	3 mm (0.1181 inch) fillet weld
W3	12 mm (0.47 inch) fillet weld with a 1.50 mm (0.06 mm) penetration
W4	5 mm (0.20 inch) fillet weld

Table 17

Welding Dimensions for Illustration 53
Item	Dimension
A	372 ± 5 mm (14.65 ± 0.20 inch)
B	167 ± 3 mm (6.57 ± 0.12 inch)
C	2296 ± 4 mm (90.39 ± 0.16 inch)
D	35 ± 2 mm (1.38 ± 0.08 inch)
E	209 ± 5 mm (8.23 ± 0.20 inch)

Illustration 54	g00743074
(4) 3V-8104 Plate (5) 8X-0392 Plate (10) 138-1216 Tube Assembly (11) 138-1219 Collar (13) 8X-0396 Pipe (14) 8X-1985 Plate (15) 6N-5451 Gusset (18) 130-5686 Plate (19) 8X-6193 Plate Assembly

Table 18

Welding Tolerances for Illustration 54
Weld	Tolerances
W5	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W6	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W7	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W8	6 mm (0.24 inch) bevel groove weld (2 Places)

Table 19

Welding Dimensions for Illustration 54
Item	Dimension
F	101 ± 5 mm (3.98 ± 0.20 inch)
G	1068 ± 3 mm (42.05 ± 0.12 inch)
H	60.6 ± 3 mm (2.39 ± 0.12 inch)
I	835 ± 5 mm (32.87 ± 0.20 inch)

Illustration 55	g00743158
(6) 142-5731 Plate (8) 8T-6911 Weld Boss (9) 7X-7962 Weld Boss (13) 8X-4576 Plate (14) 8X-1985 Plate (15) 101-6996 Plate (16) 8X-6780 Block (17) 6N-5451 Gusset (18) 130-5686 Plate (19) 8X-6193 Plate Assembly

Table 20

Welding Tolerances for Illustration 55
Weld	Tolerances
W9	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (Both Sides)
W10	3 mm (0.12 inch) square groove weld
W11	3 mm fillet weld (11 Bosses)

Table 21

Welding Dimensions for Illustration 55
Item	Dimension
J	25 ± 5 mm (0.98 ± 0.20 inch)
K	230 ± 5 mm (9.06 ± 0.20 inch)
L	490 ± 5 mm (19.29 ± 0.20 inch)
M	985 ± 5 mm (38.78 ± 0.20 inch)
N	75 ± 5 mm (2.95 ± 0.20 inch)
O	70 ± 5 mm (2.76 ± 0.20 inch)
P	75 ± 5 mm (2.95 ± 0.20 inch)
Q	430 ± 5 mm (16.93 ± 0.20 inch)
R	50 ± 5 mm (1.97 ± 0.20 inch)
S	135 ± 5 mm (5.31 ± 0.20 inch)
T	225 ± 5 mm (8.86 ± 0.20 inch)
U	93 ± 5 mm (3.66 ± 0.20 inch)

1. Attach a suitable lifting device to 142-5730 Pedestal (1).

2. Lift 142-5730 Pedestal (1). Place 142-5730 Pedestal (1) on the frame.

   Note: Leave the crane and the lifting device attached to 142-5730 Pedestal (1).

3. Use the beam in order to set the height of 142-5730 Pedestal (1). Use 142-5713 Tube Assembly (2) to locate 142-5730 Pedestal (1).

4. Attach 8X-4061 Plate (3) to 142-5713 Tube Assembly (2) with the original bolts.
   Show/hide table

   Illustration 56	g00743073
   (2) 142-5713 Tube Assembly

5. Lift 142-5713 Tube Assembly (2) with a suitable lifting device. Position 142-5713 Tube Assembly (2) in place. Secure 142-5713 Tube Assembly (2) to the left pedestal with the original bolts and the original shims.

6. Tack weld 8X-4061 Plate (3) to 142-5730 Pedestal (1).

7. Tack weld 142-5730 Pedestal (1) to the frame.

8. Tack weld the beam to 142-5730 Pedestal (1).

   Note: The tack welds are removed later and the beam is installed.

   Show/hide table

   Illustration 57	g00743100
   (1) 142-5730 Pedestal (4) 3V-8104 Plate

9. Make two welds on the outside of 142-5730 Pedestal (1) to the frame. Refer to the following references: Illustration 54, Tables18 and 19.

10. Weld 3V-8104 Plate (4) to the front of 142-5730 Pedestal (1) and the frame. Refer to the following references: Illustration 54, Tables18 and 19.
    Show/hide table

    Illustration 58	g00743122
    (1) 142-5730 Pedestal (5) 8X-0392 Plate

11. Weld 8X-0392 Plate (5) to the outside of 142-5730 pedestal (1) and the frame. Refer to the following references: Illustration 54, Tables18 and 19.
    Show/hide table

    Illustration 59	g00743198
    (6) 142-5731 Plate (7) 8X-0391 Plate

12. Weld 142-5731 Plate (6) to the inside of 142-5730 Pedestal (1) and the frame. Refer to the following references: Illustration 55, Tables20 and 21.

13. Weld 8X-0391 Plate (7) to 142-5731 Plate (6), and 8X-0392 Plate (5). Weld 8X-0391 Plate (7) to 142-5730 Pedestal (1) and to the frame.
    Show/hide table

    Illustration 60	g00743148
    (2) 142-5713 Tube Assembly (3) 8X-4061 Plate

14. Weld 8X-4061 Plate (3) to 142-5730 Pedestal (1). Refer to the following references: Illustration 53, Tables16 and 17.

15. Weld 11 8T-6911 Weld Bosses (8) to 142-5730 Pedestal (1). Refer to the following references: Illustration 55, Tables20 and 21.

16. Weld on ten 7X-7962 Weld Bosses (9) to 142-5730 Pedestal (1). Refer to the following references: Illustration 53, Tables 16, 17, Illustration 55, Tables20 and 21.

17. Place any bosses that are remaining onto 142-5730 pedestal (1).
    Show/hide table

    Illustration 61	g00743168
    (10) 138-1216 Tube Assembly (11) 138-1219 Collar (13) 8X-4576 Plate (14) 8X-1985 Plate (15) 101-6996 Plate (16) 8X-6780 Block

18. Locate 138-1216 Tube Assembly (10). Weld 138-1216 Tube Assembly (10) to 138-1219 Collar (11). Weld 138-1219 Collar (11) to 142-5730 Pedestal (1). Refer to the following references: Illustration 54, Tables18 and 19 .

    Note: The following sales models are assembled with different parts: 793 (S/N: 3SJ1-UP), 793B (S/N: 1HL1-UP) and 793C (S/N: 4AR1-UP). Use the parts that are identified to complete the procedure.

19. Weld 8X-0396 Pipe (12) to 142-5730 Pedestal (1) and to the radiator housing.

20. Install the original bolts into 138-1216 Tube Assembly (10) and the front radiator support. Do not tighten the bolts completely.

21. Weld 8X-4576 Plate (13) and 8X-1985 Plate (14) to 142-5730 Pedestal (1).

22. Weld 101-6996 Plate (15) to 8X-4576 Plate (13) and 8X-1985 Plate (14). Refer to the following references: Illustration 53, Tables 16, 17and Illustration 61.

23. Weld 8X-6780 Block (16) to 142-5730 Pedestal (1).
    Show/hide table

    Illustration 62	g00743174
    (17) 6N-5451 Gusset (18) 130-5686 Plate (19) 8X-6193 Plate Assembly

24. Weld 6N-5451 Gusset (17) and 130-5686 Plate (18) to 142-5730 Pedestal (1). Refer to the following references: Illustration 55, Tables20 and 21.

25. Weld 8X-6193 Plate Assembly (19) to 142-5730 Pedestal (1). Refer to the following references: Illustration 54, Tables18 and 19.

26. Measure the distance between the front pedestal and the rear beam. Make a reference mark on the stub shaft of the strut. Use the bearing to set the height.

    Note: Record the distances. The distances are compared after the new beam is placed.

27. Measure the distance from 142-5730 Pedestal (1) to the rear beam. Use this measurement to cut the 101.60 mm (4 inch) by 101.60 mm (4 inch) by 9.52 mm (0.38 inch) square tubing to the correct length.

28. Lift the square tubing into the correct position. Tack weld the square tubing. The square tubing will help prevent distortion during welding.

Remove the Right Side Beam and the Supports

1. Secure the beam with chains and a suitable lifting device.
   Show/hide table

   Illustration 63	g00597919

2. Remove the four front strut mounting bolts and the shims. Retain the bolts and shims for installation of the new beam.

3. Remove the square tubing brace that is holding the beam in place with the frame assembly.

4. Cut the weld that is holding the rear support to the beam.

   Note: Cover all hoses and covers with fire protective material.

   Show/hide table

   Illustration 64	g00636049

5. Lift the beam out of the frame.
   Show/hide table

   Illustration 65	g00590831

6. Use an air carbon arc torch in order to remove the rear support. Remove the scab plate. Remove the platform mount from the rear beam.

Install the New Right Side Beam and the Supports

Table 22

Required Parts for the Installation of 161-1103 Beam, 157-6753 Support, and 171-7691 Support
Item	Quantity	Part Number	Description
1	1	157-6753	Support
2	1	171-7697	Support
3	1	161-1103	Beam
4	1	161-2121	Plate
5	8	7X-7962	Weld Boss
6	2	9R-2613	Boss
7	2	8X-6132	Block

Illustration 66	g00743537
(1) 157-6753 Support (2) 171-7697 Support (3) 161-1103 Beam (4) 161-2121 Plate (5) 7X-7962 Weld Boss

Table 23

Welding Tolerances for Illustration 66
Weld	Tolerances
W1	16 mm (0.63 inch) bevel groove weld (2 Places)
W2	16 mm (0.63 inch) bevel groove weld (2 Places)
W3	10 mm (0.40 inch) fillet over 10 mm (0.40 inch) groove weld (Both Sides)
W4	3 mm fillet weld (6 Bosses)

Table 24

Welding Dimensions for Illustration 66
Item	Dimension
A	65 ± 2 mm (2.56 ± 0.08 inch)
B	73 ± 5 mm (2.87 ± 0.20 inch)
C	250 ± 5 mm (9.84 ± 0.20 inch)
D	35 ± 5 mm (1.38 ± 0.20 inch)
E	798 ± 5 mm (31.42 ± 0.20 inch)

Illustration 67	g00743628
(1) 157-6753 Support (6) 9R-2613 Boss (7) 8X-6132 Blocks

Table 25

Welding Tolerances for Illustration 67
Weld	Tolerances
W5	10 mm (0.39 inch) fillet weld with a 1.50 mm (0.60 inch) penetration
W6	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W7	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (Both Sides)

Table 26

Welding Dimensions for Illustration 67
Item	Dimension
F	119 ± 2 mm (4.68 ± 0.08 inch)
G	300 ± 5 mm (11.81 ± 0.20 inch)
H	376 ± 5 mm (14.80 ± 0.20 inch)
I	31 ± 5 mm (1.22 ± 0.20 inch)

Illustration 68	g00746016
(2) 171-7697 Support (4) 161-2121 Plate

Table 27

Welding Tolerances for Illustration 68
Weld	Tolerance
W8	10 mm (0.39 inch) fillet weld with a 1.5 mm (0.06 inch) penetration

Table 28

Welding Dimensions for Illustration 68
Item	Dimension
J	10 ± 2 mm (0.39 ± 0.08 inch)

1. Clean the welding area.
   Show/hide table

   Illustration 69	g00743519
   (1) 157-6753 Support (2) 171-7697 Support (3) 161-1103 Beam

2. Tack weld 157-6753 Support (1) and 171-7697 Support (2) to 161-1103 Beam (3).

3. Tack weld one or two pieces of angle iron to the top of the assembly. Tack weld four pieces of angle iron to the bottom of the assembly.

4. Cut two holes in the top angle iron for lifting.

5. Place the following hardware into position: 161-1103 Beam (3), 171-7697 Support (2) and 157-6753 Support (1).
   Show/hide table

   Illustration 70	g00590909

6. Install the original shims. Bolt the front strut mounting bolts to 161-1103 Beam (3).

7. Use the mark on the stub shaft in order to set the height.

8. Cut the tack weld that is holding 157-6753 Support (1) to the angle iron.
   Show/hide table

   Illustration 71	g00743531
   (1) 157-6753 Support (2) 161-1103 Beam

9. Locate 157-6753 Support (1) and weld 157-6753 Support (1) to 161-1103 Beam (3). Refer to the following references: Illustration 66, Tables23 and 24.

10. Repeat Step 8 through Step 9 for 171-7697 Support (2). Refer to the following references: Illustration 66, Tables23 and 24.
    Show/hide table

    Illustration 72	g00743533
    (2) 171-7697 Support (4) 161-2121 Plate

11. Weld 161-2121 Plate (4) in place. Refer to the following references: Illustration 68, Tables27 and 28.

12. Remove the four front strut mounting bolts.

13. Move the beam 2 mm (0.08 inch) forward. This step allows tolerance for weld shrinkage.

14. Weld a 6 mm (0.24 inch) bead around the rear joint.

    Note: The tops of the castings should be level with each other.

    Show/hide table

    Illustration 73	g00743534
    (2) 171-7697 Support (3) 161-1103 Beam

15. Weld the joint that is connecting 161-1103 Beam (3) to 171-7697 Support (2). Fill the joints completely. Refer to the following references: Illustration 66, Tables23 and 24.

16. Weld the front joint that is connecting 161-1103 Beam (3) to 157-6753 Support (1). Refer to the following references: Illustration 66, Tables23 and 24.

17. Install the four front strut mounting bolts. Torque the bolts to 800 ± 100 N·m (590.04 ± 73.75 lb ft).

18. Weld two 7X-7962 Bosses (5). Refer to the following references: Illustration 66, Tables23 and 24.

19. Tack weld one 9R-2613 Boss (6) on the 171-7697 Support (2). Refer to the following references: Illustration 67, Tables25 and 26.

20. Weld two 8X-6132 Blocks (7) on 161-1103 Beam (3). Refer to the following references: Illustration 67, Tables25 and 26.

21. Weld six 7X-7962 Bosses (5) on the beam. Tack weld one 9R-2613 Boss (6) on 171-7697 Support (2). Refer to the following references: Illustration 66, Tables 23, 24, Illustration 67, Tables25 and 26.

22. Measure the distance between the front pedestal and the rear beam. The distance should equal the previous measurement.

Install the Exhaust Plate and the Platform Mounts

Table 29

Required Parts for Installation of the Exhaust Plate and the Platform Mounts
Item	Quantity	Part Number	Description
1	1	166-1731	Plate Assembly
2	4	8X-1985	Plate
3	1	101-6564	Plate
4	1	091-9284	Bar
5	1	8X-9176	Plate
6	2	128-3200	Plate
7	1	8X-1986	Plate
8	1	8X-1039	Plate

Illustration 74	g00744415
(1) 166-1731 Plate Assembly

Table 30

Welding Tolerances for Illustration 74
Weld	Tolerances
W1	12 mm (0.47 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (L to W)
W2	12 mm (0.47 inch) fillet weld with a 1.50 mm (0.06 inch) penetration

Illustration 75	g00744502
(1) 166-1731 Plate Assembly

Table 31

Welding Dimensions for Illustration 75
Item	Dimension
A	185 mm (7.28 inch)
B	1066.3 ± 2 mm (41.98 ± 0.08 inch)
C	12 ± 1 mm (0.47 ± 0.04 inch)

Illustration 76	g00744267
(2) 8X-1985 Plate (3) 101-6564 Plate (4) 091-9284 Bar (5) 8X-9176 Plate (6) 128-3200 Plate (7) 8X-1986 Plate (8) 8X-1039 Plate

Table 32

Welding Tolerances for Illustration 76
Weld	Tolerances
W3	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)

Table 33

Welding Dimensions for Illustration 76
Item	Dimension
D	11.4 ± 5 mm (0.45 ± 0.20 inch)
E	8 ± 2 mm (0.32 ± 0.08 inch)
F	1465.5 ± 3 mm (57.69 ± 0.12 inch)
G	264.5 ± 1 mm (10.41 ± 0.04 inch)
H	95 ± 3 mm (3.74 ± 0.12 inch)
I	712 ± 1 mm (28.03 ± 0.04 inch)
J	391 ± 3 mm (15.39 ± 0.12 inch)

Illustration 77	g00744370
(2) 8X-1985 Plate (3) 101-6564 Plate (4) 091-9284 Bar (5) 8X-9176 Plate (6) 128-3200 Plate (7) 8X-1986 Plate

Table 34

Welding Tolerances for Illustration 77
Weld	Tolerances
W4	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W5	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W6	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)
W7	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration (2 Places)

Table 35

Welding Dimensions for Illustration 77
Item	Dimension
K	518 ± 3 mm (20.39 ± 0.12 inch)
L	609 ± 1 mm (23.97 ± 0.04 inch)
M	200 ± 5 mm (7.8740 ± 0.1969 inch)
N	125 ± 5 mm (4.92 ± 0.20 inch)

Illustration 78	g00744381
(7) 8X-1986 Plate (8) 8X-1039 Plate

Table 36

Welding Tolerances for Illustration 78
Weld	Tolerances
W8	10 mm (0.4 inch) fillet weld over 10 mm (0.4 inch) groove weld (Both Sides)

Table 37

Welding Dimensions for Illustration 78
Item	Dimension
O	65 ± 2 mm (2.56 ± 0.08 inch)

1. Use an air carbon arc torch in order to remove the existing exhaust plate from the rear beam.
   Show/hide table

   Illustration 79	g00754941
   166-1731 Plate Assembly

2. Secure the exhaust plate with a 138-7573 Link Bracket and a hoist. Lift the exhaust plate from the rear beam.

3. Clean the mounting surface of the exhaust plate.
   Show/hide table

   Illustration 80	g00591019

4. Fit 166-1731 Plate Assembly (1) to the rear beam. 166-1731 Plate Assembly (1) may not fit up to the rear beam.

   Note: A notch may need to be cut out of the rear beam in order for 166-1731 Plate Assembly (1) to fit properly.

5. Clean the notched out area.

6. Lift 166-1731 Plate (1) with 138-7573 Link Bracket. Tack weld 166-1731 Plate (1) evenly to the rear beam. Refer to the following references: Illustration 75 and Table 31.

7. Weld 166-1731 Plate Assembly (1) in place. Refer to the following references: Illustration 74, Table 30, Illustration75 and Table 31.

8. Weld two 8X-1985 Plates (2) on the outside of the beam. Refer to the following references: Illustration 76, Tables 32, 33, Illustration 77, Tables34 and 35.

9. Weld 101-6564 Plate (3) to the top of two 8X-1985 Plates (2). Refer to the following references: Illustration 76, Tables 32, 33, Illustration 77, Tables34 and 35.
   Show/hide table

   Illustration 81	g00744455
   (2) 8X-1985 Plate (4) 091-9284 Bar

   Show/hide table

   Illustration 82	g00744466
   (2) 8X-1985 Plate (4) 091-9284 Bar (5) 8X-9176 Plate

10. Tack weld two 8X-1985 Plates (2) on the inside of the beam. Weld 091-9284 Bar (4) to 8X-1985 Plates (2). Refer to the following references: Illustration 76, Tables32 and 33.

11. Weld 8X-9176 Plate (5) to the beam and the support. Refer to the following references: Illustration 76, Tables 32, 33, Illustration 77, Tables34 and 35.
    Show/hide table

    Illustration 83	g00744479
    (1) 166-1731 Plate (6) 128-3200 Plate (7) 8X-1986 Plates

12. Weld two 128-3200 Plates (6) to 166-1731 Plate (1). Weld 8X-1986 Plate (7) to two 128-3200 Plates (6). Refer to the following references: Illustration 76, Tables 32, 33, Illustration 77, Tables 34, 35, Illustration 78, Tables36 and 37.
    Show/hide table

    Illustration 84	g00744486
    (1) 166-1731 Plate (2) 8X-1985 Plates (3) 101-6564 Plate (4) 091-9284 Bar (5) 8X-9176 Plate (6) 128-3200 Plate (7) 8X-1986 Plate (8) 8X-1039 Plate

13. Weld 8X-1039 Plate (8) to the support. Refer to the following references: Illustration 76, Tables 32, 33, Illustration 78, Tables36 and 37.

14. Clean the welded areas on the right side of the frame assembly. Paint the areas, as needed.

Prepare the Right Side Platform Group for Installation

Show/hide table

Illustration 85	g00586502
(1) 142-3361 Platform Group

Note: In the following procedures, inspect all parts for wear or damage. Replace the parts, as needed.

1. Remove the floorplates from the old platform group.

2. Rivet the floorplates onto new 142-3361 Platform Group (1).

3. Remove all electrical wires from the old platform group. Install the wiring onto new 142-3361 Platform Group (1).
   Show/hide table

   Illustration 86	g00744869
   (1) 142-3361 Platform Group (2) Installed lights

4. Remove the screws that are securing the two bottom lights. Remove two bottom lights (2) from the old platform group.

5. Install two bottom lights (2) into new 142-3361 Platform Group (1).
   Show/hide table

   Illustration 87	g00744874
   (1) 142-3361 Platform Group

6. Clean the mounting areas for the hydraulic tank and the side exhaust muffler.
   Show/hide table

   Illustration 88	g00744877
   (1) 142-3361 Platform Group (3) Side exhaust muffler

7. Attach a suitable lifting device to the side exhaust muffler (3).

8. Remove the washers and bolts that are securing the side exhaust muffler. Lift the side exhaust muffler (3) off the old platform group.

9. Install side exhaust muffler (3) onto new 142-3361 Platform Group (1). Use the same washers and bolts for installation.

10. Detach the air starting lines from the air tank and from the platform group. Detach the air tank drain valve from the air tank and from the platform group.
    Show/hide table

    Illustration 89	g00744883
    (1) 142-3361 Platform Group (4) Air tank drain valve

11. Reinstall the air tank drain valve (4) to the air tank and 142-3361 Platform Group (1).

12. Attach a suitable lifting device to the air tank.

13. Remove the following items that are securing the air tank: washers, bolts and clamps. Lift the air tank from the old platform group.

14. Secure the air tank to new 142-3361 Platform Group (1) with the same washers, bolts, and clamps.
    Show/hide table

    Illustration 90	g00588161

15. Reinstall the air starting lines to the air tank and to 142-3361 Platform Group (1).
    Show/hide table

    Illustration 91	g00589176

16. Attach a suitable lifting device to the top exhaust muffler.

17. Remove the washers and the bolts that are securing the top exhaust muffler. Lift the top exhaust muffler from the old platform group.

18. Install the top exhaust muffler to the new 142-3361 Platform Group (1). Use the same washers and bolts for installation.

19. Attach a suitable lifting device to the hydraulic tank.
    Show/hide table

    Illustration 92	g00589185

20. Remove the washers and the bolts that are securing the hydraulic tank. Lift the hydraulic tank from the old platform group.

21. Secure the hydraulic tank to new 142-3361 Platform Group (1) with the same washers and the same bolts.
    Show/hide table

    Illustration 93	g00588524

22. Open the two battery compartment access doors. Unhook the four battery cables.

23. Remove the following items that are securing the four batteries: washers, bolts and brackets.

24. Lift the batteries out of the old platform group.

25. Install the batteries inside the new 142-3361 Platform Group (1) with the same washers, the same bolts, and the same brackets.

26. Attach a suitable lifting device to the air breather assembly.

27. Remove the washers and bolts that are securing the air breather assembly to the old platform group. Lift the air breather assembly from the old platform group.
    Show/hide table

    Illustration 94	g00588176

28. Secure the air breather assembly to new 142-3361 Platform Group (1) with the same washers and the same bolts.

29. Remove the washers and the bolts that are securing the bracket assembly to the old platform group. Remove the bracket assembly.
    Show/hide table

    Illustration 95	g00744891
    (1) 142-3361 Platform Group (5) Bracket assembly (6) Support bar

30. Install bracket assembly (5) onto the new 142-3361 Platform Group (1) with the same washers and bolts.

    Note: The rail assembly can be installed before the 142-3361 Platform Group (1) is installed.

31. Remove the washers and the bolts that are securing the support bar (6) under the old platform group. Remove the support bar (6).

32. Install support bar (6) under the new 142-3361 Platform Group (1) with the same washers and the same bolts.

33. Remove the washers and the bolts that are securing the step to the old platform group. Remove the step.
    Show/hide table

    Illustration 96	g00588315

34. Install the step onto the new 142-3361 Platform Group (1) with the same washers and the same bolts.

Install the Right Side Platform Group

Table 38

Required Parts for the Installation of 142-3361 Platform Group
Item	Quantity	Part Number	Description
1	1	142-3361	Platform Group
2	3	8T-4123	Plated Washer
3	3	8T-6430	Bolt
4	1	8X-2052	Plate
5	2	8X-2053	Plate
6	1	101-6564	Plate
7	1	159-8886	Bar
8	2	8X-1991	Plate
9	1	8X-1989	Plate
10	1	8X-1990	Strip
11	1	138-1258	Bracket
12	4	5P-1076	Hard Washer
13	4	8T-4139	Bolt
14	7	7X-7729	Washer
15	7	8T-4136	Bolt

Illustration 97	g00745266
(1) 142-3361 Platform Group (2) 8T-4123 Plated Washer (3) 8T-6430 Bolt (4) 8X-2052 Plate (5) 8X-2053 Plate (6) 101-6564 Plate (7) 159-8886 Bar (8) 8x-1991 Plate (9) 8x-1989 Plate (10) 8x-1990 Strip

Table 39

Welding Tolerances for Illustration 97
Weld	Tolerances
W1	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W2	3 mm (0.12 inch) square groove weld
W3	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W4	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W5	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W6	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W7	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration

Show/hide table

Illustration 98	g00745220
(1) 142-3361 Platform Group

1. Remove the paint from the welding area on the inside edge of 142-3361 Platform Group (1).
   Show/hide table

   Illustration 99	g00745221
   (1) 142-3361 Platform Group

2. Remove the paint from the welding area on the rear edge of 142-3361 Platform Group (1).
   Show/hide table

   Illustration 100	g00745222

3. Remove the paint from the welding areas on the front pedestal.

4. Remove the paint from welding areas on the rear of the beam and the support.
   Show/hide table

   Illustration 101	g00745234
   (1) 142-3361 Platform Group

5. Install three 138-7573 Link Brackets onto 142-3361 Platform Group (1).

6. Install a lever puller and a three hook chain.

7. Lift 142-3361 Platform Group (1) onto the right side of the frame assembly.
   Show/hide table

   Illustration 102	g00745248
   (1) 142-3361 Platform Group

8. Position 142-3361 Platform Group (1) to the frame assembly.
   Show/hide table

   Illustration 103	g00745253
   (2) 8T-4123 Plated Washer (3) 8T-6430 Bolt

   Show/hide table

   Illustration 104	g00745258
   (2) 8T-4123 Plated Washer (3) 8T-6430 Bolt

   Show/hide table

   Illustration 105	g00745259
   (2) 8T-4123 Plated Washer (3) 8T-6430 Bolt

9. Install 142-3361 Platform Group (1) with three 8T-4123 Plated Washers (2) and three 8T-6430 Bolts (3).

10. Torque three 8T-6430 Bolts (3) to 460 ± 60 N·m (340 ± 45 lb ft).
    Show/hide table

    Illustration 106	g00745291
    (4) 8X-2052 Plate (5) 8X-2053 Plates (6) 101-6564 Plate

11. Weld 8X-2052 Plate (4) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.

12. Weld two 8X-2053 Plates (5) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.

13. Weld 101-6564 Plate (6) to the mounting plate on 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.

14. Weld 159-8886 Bar (7) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.

15. Weld two 8X-1991 Plates (8) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.
    Show/hide table

    Illustration 107	g00588475

16. Weld 8X-1989 Plate (9) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.
    Show/hide table

    Illustration 108	g00745304
    (1) 142-3361 Platform Group (2) 8T-4123 Plated Washers (3) 8T-6430 Bolts (10) 8X-1990 Strip

17. Weld 8X-1990 Strip (10) to the frame assembly and to 142-3361 Platform Group (1). Refer to the following references: Illustration 97 and Table 39.
    Show/hide table

    Illustration 109	g00745308
    (11) 138-1258 Bracket (12) 5P-1076 Hard Washers (13) 8T-4139 Bolts (14) 7X-7729 Washers (15) 8T-4136 Bolts

18. Install 138-1258 Bracket (11) to the frame assembly and to 142-3361 Platform Group (1).

19. Use four 5P-1076 Hard Washers (12) and four 8T-4139 Bolts (13) in order to mount 138-1258 Bracket (11) to the frame assembly.

20. Use seven 7X-7729 Washers (14) and seven 8T-4136 Bolts (15) in order to mount 138-1258 Bracket (11) to 142-3361 Platform Group (1).

21. Clean the welding areas. Paint the areas, as needed.

Weld Repair Procedure for the 789 Off-Highway Truck

Note: The following procedures are similar to the procedures of the 793 Off-Highway Truck. Even though the procedures are similar, different parts will be used. Some of the parts in the following procedures will need to be fabricated. These parts will be noted later.

Remove the Left Side Beam and the Front Support

1. Refer to the section"Remove the Left Side Beam and the Front Support" for the 793C Off-Highway Truck for the correct procedure for the 789C Off-Highway Truck.

Install the New Left Side Beam and the New Front Support

Table 40

Required Parts for the Installation of 157-6342 Beam and 161-2127 Support
Item	Quantity	Part Number	Description
1	1	157-6342	Beam
2	1	161-2127	Support
3	3	8X-0597	Strip
4	1	9D-6164	Boss
5	1	9G-0028	Boss Assembly
6	5	9D-6166	Boss
7	5	9D-5659	Boss
8	2	5H-9394	Boss
9	2	8D-3508	Boss
10	4	4D-6267	Block
11	2	4V-1586	Lug
12	1	103-5702	Plate Assembly
13	1	5T-6766	Bracket
14	2	5P-2251	Gusset

Illustration 110	g00742340
(1) 157-6342 Beam

Table 41

Dimensions for Illustration 110
Item	Dimension
A	398 mm (15.67 inch)
B	393 mm (15.47 inch)

Illustration 111	g00745359
(2) 161-2127 Support (4) 9D-6164 Boss (5) 9G-0028 Boss Assembly (6) 9D-6166 Boss (10) 4D-6267 Block (11) 4V-1586 Lug (12) 103-5702 Plate Assembly

Table 42

Welding Dimensions for Illustration 111
Item	Dimension
A	1380 ± 5 mm (54.33 ± 0.20 inch)
B	547 ± 2 mm (21.54 ± 0.08 inch)
C	90 ± 5 mm (3.54 ± 0.20 inch)
D	238 ± 5 mm (9.37 ± 0.20 inch)
E	150 ± 5 mm (5.91 ± 0.20 inch)
F	230 ± 5 mm (9.06 ± 0.20 inch)
G	300 ± 5 mm (11.81 ± 0.20 inch)

Table 43

Welding Tolerances for Illustration 111
Weld	Tolerances
W1	10 mm (0.40 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W2	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W3	6 mm (0.24 inch) fillet weld
W4	20 mm (0.79 inch) bevel groove weld (2 Places)
W5	3 mm (0.12 inch) fillet weld
W6	5 mm (0.20 inch) fillet weld (Both Sides) (2 Lugs)
W7	6 mm (0.24 inch) fillet weld (Both Sides) (2 Blocks)

Illustration 112	g00745429
(12) 103-5702 Plate Assembly (13) 5T-6766 Bracket (14) 5P-2251 Gusset

Table 44

Welding Dimensions for Illustration 112
Item	Dimension
H	48 ± 3 mm (1.20 ± 0.12 inch)
I	547 ± 2 mm (21.54 ± 0.08 inch)
J	488 ± 3 mm (19.21 ± 0.12 inch)
K	335 ± 5 mm (13.20 ± 0.20 inch)
L	75 ± 5 mm (2.95 ± 0.20 inch)
M	205 ± 5 mm (8.07 ± 0.20 inch)
N	75 ± 5 mm (2.95 ± 0.20 inch)
O	290 ± 5 mm (11.42 ± 0.20 inch)

Table 45

Welding Tolerances for Illustration 112
Weld	Tolerances
W8	3 mm (0.12 inch) fillet weld that is 25 mm (1 inch) long with spacing of 50 mm (1.97 inch)
W9	20 mm (0.79 inch) bevel groove weld (2 Places)
W10	10 mm (0.39 inch) fillet weld

Illustration 113	g00745479
(1) 157-6342 Beam (7) 9D-5659 Boss (9) 8D-3508 Boss (12) 103-5702 Plate Assembly

Table 46

Welding Dimensions for Illustration 113
Item	Dimension
P	59 ± 5 mm (2.32 ± 0.20 inch)
Q	210 ± 3 mm (8.27 ± 0.12 inch)
R	75 ± 3 mm (2.95 ± 0.12 inch)

Table 47

Welding Tolerances for Illustration 113
Weld	Tolerances
W11	16 mm (0.63 inch) bevel groove weld (2 Places)
W12	3 mm (0.12 inch) fillet weld
W13	16 mm (0.63 inch) bevel groove weld (2 Places)
W14	3 mm (0.12 inch) fillet weld (5 Bosses)
W15	6 mm (0.24 inch) fillet weld

Illustration 114	g00745496
(7) 9D-5659 Bosses (8) 5H-9394 Bosses

Table 48

Welding Dimensions for Illustration 114
Item	Dimension
S	150 ± 5 mm (5.91 ± 0.20 inch)
T	850 ± 5 mm (33.46 ± 0.20 inch)
U	600 ± 5 mm (23.62 ± 0.20 inch)
V	600 ± 5 mm (23.62 ± 0.20 inch)
W	20 ± 5 mm (0.79 ± 0.20 inch)
X	90 ± 5 mm (3.54 ± 0.20 inch)
Y	40 ± 5 mm (1.57 ± 0.20 inch)
Z	20 ± 5 mm (0.79 ± 0.20 inch)
AB	90 ± 5 mm (3.54 ± 0.20 inch)
AC	210 ± 5 mm (8.27 ± 0.20 inch)

Table 49

Welding Tolerances for Illustration 114
Weld	Tolerances
W16	6 mm (0.24 inch) fillet weld

Illustration 115	g00734084
(11) 4V-1586 Lug

Table 50

Dimensions for Illustration 115
Item	Dimension
AD	10 mm (0.39 inch)
AE	10 mm (0.3937 inch)
AF	140 mm (5.5118 inch)
AG	125 mm (4.9213 inch)
AH	15 mm (0.5906 inch)
AI	20 mm (0.7874 inch)

Illustration 116	g00734118
(12) 103-5702 Plate Assembly

Table 51

Dimensions for Illustration 116
Item	Dimension
AJ	40 mm (1.57 inch)
AK	35 mm (1.38 inch)
AL	100 mm (3.94 inch)
AM	165 mm (6.5 inch)
AN	140 mm (5.51 inch)
AO	30 mm (1.18 inch)
AP	50 mm (1.97 inch)

Illustration 117	g00734132
(13) 5T-6766 Bracket

Table 52

Dimensions for Illustration 117
Item	Dimension
AS	17 ± 1 mm (0.67 ± 0.04 inch)
AT	75 mm (2.95 inch)
AU	25 ± 1 mm (0.98 ± 0.04 inch)
AV	20.5 mm (0.81 inch) (circumference)
AW	125 ± 2 mm (4.92 ± 0.08 inch)
AX	13 ± 1 mm (0.51 ± 0.04 inch)
AY	63 ± 1 mm (2.48 ± 0.04 inch)
AZ	50 ± 1 mm (1.97 ± 0.04 inch)(Radius)
BA	90 ± 1 mm (3.54 ± 0.04 inch)
BB	148 ± 1 mm (5.83 ± 0.04 inch)
BC	90 ± 2 mm (3.54 ± 0.08 inch)
BD	6 ± 1 mm (0.24 ± 0.04 inch)(Radius)
BE	6 mm (0.24 inch)

Illustration 118	g00745519
(13) 5T-6766 Bracket (14) 5P-2251 Gusset

Table 53

Welding Dimensions for Illustration 118
Item	Dimensions
BF	60 ± 3 mm (2.36 ± 0.12 inch)

1. Clean the welding areas.

2. A 30 degree bevel needs to be cut on the rear support. The dimension from the scab plate to the end of the rear support is 393 mm (15.47 inch). Refer to the following references: Illustration 110 and Table 41.

3. Tack weld a 152.40 mm (6 inch) long piece of angle iron to the bottom of the rear support.

   Note: This Step will help with the placement of the beam.

   Show/hide table

   Illustration 119	g00742389
   (1) 157-6342 Beam (3) 8X-0597 Strips

4. Cut 8X-0597 Strips (3). 8X-0597 Strips (3) should fit the inside of 157-6342 Beam (1).

5. Tack weld 161-2127 Support (2) to 157-6342 Beam (1).

6. Cut two pieces of angle iron approximately 1524 mm (60 inch) long.
   Show/hide table

   Illustration 120	g00588545
   (1) 157-6342 Beam (2) 161-2127 Support

7. Tack weld the angle iron to the top of 157-6342 Beam (1) and the 161-2127 Support (2). Tack weld a piece of angle iron to the bottom of the two pieces.

   Note: The angle iron is used in order to help hold the two castings together.

8. Cut two holes in the top angle iron for lifting.
   Show/hide table

   Illustration 121	g00742394
   (1) 157-6342 Beam (2) 161-2127 Support

9. Lift 157-6342 Beam (1) and 161-2127 Support (2) with a suitable lifting device.

10. Place 157-6342 Beam (1) and 161-2127 Support (2) into position.

11. Install the same shims and bolt the strut mount to 157-6342 Beam (1).

12. Use the mark on the stub shaft in order to set the height.

13. Tack weld 8X-0597 Strips (3) to the inside of the rear support and the 157-6342 Beam (1).

14. Cut the tack weld that is holding the 161-2127 Support (2) to the angle iron.
    Show/hide table

    Illustration 122	g00588651
    (1) 157-6342 Beam (2) 161-2127 Support

15. Locate 161-2127 Support (2). Weld 161-2127 Support (2) to the front pedestal. Refer to the following references: Illustration 111, Tables42 and 43.

16. Unbolt the strut. Move 157-6342 Beam (1) up 2 mm (0.08 inch). This step allows tolerance for weld shrinkage.

17. Weld a 6 mm (0.24 inch) bead around the rear joint.

    Note: The tops of the castings should be level with each other.

18. Weld the joint that is connecting the rear support to 157-6342 Beam (1). Fill the joint completely. Refer to the following references: Illustration 111, Tables42 and 43.

19. Weld the joint that is connecting 161-2127 Support (2) to 157-6342 Beam (1). Fill the joint completely. Refer to the following references: Illustration 112, Tables44 and 45.

20. Install the four front strut mounting bolts. Torque the bolts to 900 ± 100 N·m (661.80 ± 73.50 lb ft).

21. Remove the angle iron from the top and bottom of 157-6342 Beam (1).

22. Clean 157-6342 Beam (1) and 161-2127 Support (2).

23. Cut out the 101.60 mm (4 inch) by 101.60 mm (4 inch) by 9.52 mm (0.38 inch) square tubing.

24. Measure the distance from the front cab bore to the rear cab bore. Measure the distance from the front beam outrigger to the rear beam outrigger.

    Note: The distances should equal the previous distances.

25. Place 9D-6164 Boss (4), 9G-0028 Boss Assembly (5), and 9D-6166 Bosses (6) on the top of the beam. Refer to the following references: Illustration 111, Tables 42, 43, Illustration 112, Tables44 and 45.

26. Place 9D-5659 Bosses (7) and 5H-9394 Bosses (8) on the beam. Refer to the following references: Illustration 113, Tables 46, 47, Illustration 114, Tables48 and 49.

27. Place 8D-3508 Boss (9) on the beam. Refer to the following references: Illustration 113, Tables46 and 47.

28. Place two 4V-1586 Lugs (6) on top of 157-6342 Beam (1). Refer to the following references: Illustration 111, Tables 42, 43, Illustration115 and Table 50.

29. Place two 4D-6267 Blocks (7) on the underside of 157-6342 Beam (1). Refer to the following references: Illustration 111, Tables 42, 43, Illustration 112, Tables44 and 45.
    Show/hide table

    Illustration 123	g00745517
    (12) 103-5702 Plate Assembly

30. Weld 103-5702 Plate Assembly (12) on the underside of 157-6342 Beam (1). Refer to the following references: Illustration 111, Tables 42, 43, Illustration 112, Tables 44, 45, Illustration116 and Table 51.

31. Weld 5T-6766 Bracket (13) to 5P-2251 Gusset (14). Refer to the following references: Illustration 117 and Table 52

32. Weld 5T-6766 Bracket (13) and 5P-2251 Gusset (14) to the front frame assembly. Refer to the following references: Illustration 112, Tables 44, 45, Illustration118 and Table 53.

33. Clean 157-6342 Beam (1) and 161-2127 Support (2).

    Note: Paint the new beam and support, as needed.

Remove the Platform and the Support Assembly

Note: The following plates will need to be fabricated in order to perform this procedure.

Table 54

Fabricated Plates for Removal of the Platform and the Support Assembly
Item	Description
1	Beam Plate
2	Platform Plate
3	Middle Plate
4	Front Plate
5	Angle Plate

Note: Use 12.7 mm (0.50 inch) steel plating in order to fabricate the following hardware: Beam Plate (1), Platform Plate (2), Middle Plate (3) and Front Plate (4).

Illustration 124	g00745833
(1) Beam plate

Table 55

Dimensions for Illustration 124
Item	Dimension
A	17 mm (0.67 inch)(Circumference)
B	250 mm (9.84 inch)
C	12.7 mm (0.50 inch)
D	300 mm (11.81 inch)
E	250 mm (9.84 inch)
F	25 mm (0.98 inch)
G	450 mm (17.72 inch)

Illustration 125	g00745855
(2) Platform plate

Table 56

Dimensions for Illustration 125
Item	Dimension
H	450 mm (17.72 inch)
I	17 mm (0.67 inch)(Circumference)
J	350 mm (13.78 inch)
K	260 mm (10.24 inch)
L	25 mm (0.98 inch)
M	90 mm (3.54 inch)
N	12.7 mm (0.50 inch)

Illustration 126	g00745866
(3) Middle plate

Table 57

Dimensions for Illustration 126
Item	Description
O	250 mm (9.84 inch)
P	300 mm (11.81 inch)
Q	12.7 mm (0.50 inch)

Illustration 127	g00745867
(4) Front plate

Table 58

Dimensions for Illustration 127
Item	Dimension
R	63.5 mm (2.50 inch)
S	20.5 mm (0.81 inch)(Circumference)
T	350 mm (13.78 inch)
U	164 mm (6.46 inch)
V	25 mm (0.98 inch)
W	31.75 mm (1.25 inch)
X	12.7 mm (0.50 inch)

Note: Use 50.80 mm (2 inch) by 76.20 mm (3 inch) angle iron in order to fabricate Angle Plate (5).

Illustration 128	g00745872
(5) Angle plate

Table 59

Dimensions for Illustration 128
Item	Dimension
Y	76.2 mm (3.00 inch)
Z	50.8 mm (2.00 inch)
BA	50.8 mm (2.00 inch)

Illustration 129	g00745544
(1) Beam plate (2) Platform plate (3) Middle plate (4) Front plate

Illustration 130	g00745549
(1) Beam plate (2) Platform plate (3) Middle plate

Table 60

Welding Dimensions for Illustration 130
Item	Dimension
BB	50 mm (1.97 inches)
BC	50 mm (1.97 inches)

Table 61

Welding Tolerances for Illustration 130
Weld	Tolerances
W1	8 mm (0.32 inch) fillet weld (Both Sides)

Illustration 131	g00745553
(4) Front plate (5) Angle plate

Table 62

Welding Tolerances for Illustration 131
Weld	Tolerances
W2	6 mm (0.24 inch) fillet weld (Both Sides)

Illustration 132	g00753514
Platform assembly

Table 63

Distances for Illustration 132
Item	Distance
BD	9 mm (0.35 inch)
BE	63.6 mm (2.50 inch)

1. Remove any air intake or any exhaust tubes on the right side of the engine compartment.

   Note: Cover the intake and exhaust ports.

   Show/hide table

   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.

2. Drain the hydraulic tank.

3. Disconnect the lines on the hydraulic tank.

4. Disconnect the lines to the air tank.

   Note: In order to prevent contamination, cap all of the lines.

5. Remove the four bolts that are securing the exhaust to the frame.
   Show/hide table

   Personal injury or death can result from lifting a heavy assembly. The heavy assembly can fall if using an incorrect hoist to lift the load. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

6. Install three 138-7573 Link Brackets onto the platform.

7. Install a lever puller and a three hook chain.
   Show/hide table

   Illustration 133	g00596546

   Show/hide table

   Illustration 134	g00596529

8. Remove the platform mounting bolts.

9. Lift the platform assembly from the truck. Set the platform assembly on a stable stand.
   Show/hide table

   Illustration 135	g00596512

10. Remove the bolts that are securing the steering hydraulic tank. Lift the steering hydraulic tank from the support assembly.

11. Fasten beam plate (1) to the exhaust beam. Refer to Illustration 129.

12. Fasten platform plate (2) to the support assembly. Refer to Illustration 129.

    Note: The gap between beam plate (1) and platform plate (2) is about 12.7 mm (0.50 inch). Refer to the following references: Illustration 130, Tables60 and 61.

13. Place middle plate (3) between beam plate (1) and platform plate (2). Weld middle plate (3) in place. Refer to the following references: Illustration 130, Tables60 and 61.

14. Fasten the front plate (4) to the front pedestal. Measure the distance from the support assembly to the pedestal. The distance should be approximately 63.6 mm (2.50 inch). Refer to the following references: Illustration 131 and Table 62.

15. Weld angle plate (5) to front plate (4) and the support assembly. Refer to the following references: Illustration 131 and Table 62.

16. Measure the distance (BD) from the top of the rear support to the bottom of the platform. Refer to the following references: Illustration 132 and Table 63.

17. Measure the distance (BE) from the top of the front pedestal to the bottom of the support assembly. Refer to the following references: Illustration 132 and Table 63.

18. Record the distances for the reinstallation of the support assembly.

19. Secure the support assembly with the proper lifting equipment.

20. Cover the accumulators before cutting on the platform.
    Show/hide table

    Illustration 136	g00596850
    Tube assemblies

21. Cut the tube assemblies that connect the support assembly to the front beam and the radiator support beam.
    Show/hide table

    Illustration 137	g00635343

22. Cut the plate that is connecting the support assembly to the front beam.
    Show/hide table

    Illustration 138	g00745559

23. Cut the plates that are securing the support assembly to the beam and to the rear support.

24. Remove the fasteners from the exhaust beam and the front pedestal.

25. Lift the support assembly from the frame assembly and set the support assembly on stands.

Remove the Right Side Beam and the Supports

1. Measure the distance between the front beam and the rear beam. Make a reference mark on the stub shaft of the strut. Use the bearing in order to set the height.

   Note: Record the distances. The distances are compared after the new beam is placed.

2. Measure the distance from the front beam to the rear beam. Use this measurement in order to cut the 101.60 mm (4 inch) by 101.60 mm (4 inch) by 9.52 mm (0.38 inch) square tubing to the correct length.

3. Lift the square tubing into the correct position. Tack weld the square tubing. The square tubing will help prevent distortion during welding.

4. Remove the four front strut mounting bolts.
   Show/hide table

   Illustration 139	g00640651

5. Cut the weld that is holding the beam to the front support.

   Note: Cover all hoses and covers with fire protective material.

6. Cut the weld that is holding the beam to the rear support.

7. Secure the beam with chains and a suitable lifting device.

8. Remove the four bolts that are securing the strut mount to the beam. Remove the shims.
   Show/hide table

   Illustration 140	g00640684
   Rear support and scab plate

9. Use a air carbon arc torch in order to remove the rear support. Remove the scab plate.

10. Remove the front support from the front beam.

Install the New Right Side Beam and the New Supports

Table 64

Required Parts for the Installation of 157-2060 Beam, 157-6753 Support, and 171-7697 Support
Item	Quantity	Part Number	Description
1	1	157-2060	Beam
2	1	157-6753	Support
3	1	171-7697	Support
4	1	161-8398	Plate
5	1	3R-4850	Block
6	1	8D-3508	Boss
7	3	9D-6166	Boss
8	1	9D-5659	Boss
9	2	2B-9828	Block
10	2	4D-6267	Block

Illustration 141	g00745724
(2) 157-6753 Support (6) 8D-3508 Boss (7) 9D-6166 Boss (9) 2B-9828 Block

Table 65

Welding Tolerances for Illustration 141
Weld	Tolerances
W1	3 mm (0.12 inch) fillet weld
W2	3 mm (0.12 inch) fillet weld (Both Sides)
W3	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W4	3 mm (0.12 inch) fillet weld (Both Sides)
W5	3 mm (0.12 inch) fillet weld
W6	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration

Table 66

Welding Dimensions for Illustration 141
Item	Dimensions
A	445 ± 5 mm (17.52 ± 0.20 inch)
B	490 ± 5 mm (19.29 ± 0.20 inch)
C	360 ± 5 mm (14.17 ± 0.20 inch)
D	360 ± 5 mm (14.17 ± 0.20 inch)
E	90 ± 5 mm (3.54 ± 0.20 inch)
F	60 ± 5 mm (2.36 ± 0.20 inch)
G	60 ± 5 mm (2.36 ± 0.20 inch)
H	40 ± 5 mm (1.57 ± 0.20 inch)
I	15 ± 2 mm (0.59 ± 0.08 inch)
J	21 ± 2 mm (0.83 ± 0.08 inch)
K	100 ± 1 mm (3.94 ± 0.04 inch)

Illustration 142	g00745947
(1) 157-2060 Beam (2) 157-6753 Support (10) 4D-6267 Block

Table 67

Welding Tolerances for Illustration 142
Weld	Tolerances
W7	10 mm (0.39 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W8	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W9	8 mm (0.32 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W10	20 mm (0.79 inch) bevel groove weld (2 Places)
W11	6 mm (0.24 inch) fillet weld
W12	20 mm (0.79 inch) bevel weld (2 Places)

Table 68

Welding Dimensions for Illustration 142
Item	Dimension
L	290 ± 5 mm (11.42 ± 0.20 inch)
M	75 ± 5 mm (2.95 ± 0.20 inch)
N	691 ± 5 mm (27.20 ± 0.20 inch)

Note: 161-8398 Plate (4) will need to be fabricated in order to perform this procedure. Use 10 mm (0.39 inch) carbon steel plating in order to fabricate 161-8398 Plate (4).

Illustration 143	g00745980
(3) 171-7697 Support (4) 161-8398 Plate

Table 69

Welding Tolerances for Illustration 143
Weld	Tolerances
W13	10 mm (0.39 inch) fillet weld with a 1.5 mm (0.06 inch) penetration
W14	12 mm (0.47 inch) fillet weld with a 1.5 mm (0.06 inch) penetration

Table 70

Welding Dimensions for Illustration 143
Item	Dimension
Y	10 ± 2 mm (0.39 ± 0.08 inch)

Illustration 144	g00745985
(4) 161-8398 Plate (5) 3R-4850 Block

Table 71

Welding Tolerances for Illustration 144
Weld	Tolerances
W15	6 mm (0.24 inch) fillet weld (Both Sides)

Table 72

Welding Dimensions for Illustration 144
Item	Dimension
Z	141 ± 5 mm (5.55 ± 0.2 inch)
BA	270 ± 5 mm (10.63 ± 0.2 inch)

1. Clean the welding areas.

2. Tack weld 157-6753 Support (2) and 171-7697 Support (3) to 157-2060 Beam (1).

3. Tack weld one or two pieces of angle iron to the top of the assembly. Tack weld four pieces of angle iron to the bottom of the assembly.

4. Cut two holes in the top angle iron for lifting.

5. Place the following items into position: 157-2060 Beam (1), 171-7697 Support (3) and 157-6753 Support (2).

6. Install the original shims. Bolt the front strut mounting bolts to 157-2060 Beam (1).

7. Use the mark on the stub shaft in order to set the height.

8. Cut the tack weld that is holding 157-6753 Support (2) to the angle iron.

9. Place 157-6753 Support (2). Weld 157-6753 Support (2) to the front pedestal. Refer to the following references: Illustration 142, Tables 67 and 68.

10. Repeat Step 8 through Step 9 for 171-7697 Support (3). Refer to the following references: Illustration 143, Tables 69 and 70.

11. Place 161-8398 Plate (4) on the rear beam. Weld 161-8398 Plate (4) in place. Refer to the following references: Illustration 143, Tables 69 and 70.

12. Install 3R-4850 Block (5) onto 161-8398 Plate (4). Refer to the following references: Illustration 144, Tables 71 and 72.

13. Remove the four front strut mounting bolts.

14. Move the beam 2 mm (0.08 inch). This step allows tolerance for weld shrinkage.

15. Weld a 6 mm (0.24 inch) bead around the rear joint.

    Note: The tops of the castings should be level with each other.

16. Weld the joint that is connecting 157-2060 Beam (1) to 171-7697 Support (3). Fill the joints completely. Refer to the following references: Illustration 142, Tables 67 and 68.

17. Weld the front joint that is connecting 157-2060 Beam (1) to 157-6753 Support (2). Refer to the following references: Illustration 142 and Table 67.

18. Place 8D-3508 Boss (6) and 9D-6166 Bosses (7) on the inside of the beam. Refer to the following references: Illustration 141, Tables 65 and 66.

19. Place 9D-5659 Boss (8) on the beam. Refer to the following references: Illustration 113, Tables 46 and 47.

20. Place 2B-9828 Blocks (9) on top of the beam. Refer to the following references: Illustration 141, Tables 65 and 66.

21. Place two 4D-6267 Blocks (10) on 157-2060 Beam (10). Refer to the following references: Illustration 142, Tables 67 and 68.

22. Install the four front strut mounting bolts. Torque the bolts to 900 ± 100 N·m (662 ± 74 lb ft).

23. Measure the distance for comparison. The distance should equal the previous measurement.

Install the Support Assembly and the Platform Assembly

Note: The following plates will need to be fabricated in order to perform this procedure.

Table 73

Fabricated Plates for Installation of the Support Assembly and the Platform Assembly
Item	Description
1	Beam Plate
2	Platform Plate
3	Middle Plate
4	Front Plate
5	Angle Plate

Table 74

Required Parts for the Installation of Support Assembly and the Platform Assembly
Item	Quantity	Part Number	Description
6	1	153-1313	Plate
7	1	153-1314	Plate
8	1	5T-6253	Plate

Note: Use 12.7 mm (0.50 inch) steel plating in order to fabricate the following hardware: Beam Plate (1), Platform Plate (2), Middle Plate (3) and Front Plate (4).

Illustration 145	g00745833
(1) Beam plate

Table 75

Dimensions for Illustration 124
Item	Dimension
A	17 mm (0.67 inch)(Circumference)
B	250 mm (9.84 inch)
C	12.7 mm (0.50 inch)
D	300 mm (11.81 inch)
E	250 mm (9.84 inch)
F	25 mm (0.98 inch)
G	450 mm (17.72 inch)

Illustration 146	g00745855
(2) Platform plate

Table 76

Dimensions for Illustration 125
Item	Dimension
H	450 mm (17.72 inch)
I	17 mm (0.67 inch)(Circumference)
J	350 mm (13.78 inch)
K	260 mm (10.24 inch)
L	25 mm (0.98 inch)
M	90 mm (3.54 inch)
N	12.7 mm (0.50 inch)

Illustration 147	g00745866
(3) Middle plate

Table 77

Dimensions for Illustration 126
Item	Description
O	250 mm (9.84 inch)
P	300 mm (11.81 inch)
Q	12.7 mm (0.50 inch)

Illustration 148	g00745867
(4) Front plate

Table 78

Dimensions for Illustration 127
Item	Dimension
R	63.5 mm (2.50 inch)
S	20.5 mm (0.81 inch)(Circumference)
T	350 mm (13.78 inch)
U	164 mm (6.46 inch)
V	25 mm (0.98 inch)
W	31.75 mm (1.25 inch)
X	12.7 mm (0.50 inch)

Note: Use 50.80 mm (2 inch) by 76.20 mm (3 inch) angle iron in order to fabricate Angle Plate (5).

Illustration 149	g00745872
(5) Angle plate

Table 79

Dimensions for Illustration 128
Item	Dimension
Y	76.2 mm (3.00 inch)
Z	50.8 mm (2.00 inch)
BA	50.8 mm (2.00 inch)

Illustration 150	g00745549
(1) Beam plate (2) Platform plate (3) Middle plate

Table 80

Welding Dimensions for Illustration 130
Item	Dimension
BB	50 mm (1.97 inches)
BC	50 mm (1.97 inches)

Table 81

Welding Tolerances for Illustration 130
Weld	Tolerances
W1	8 mm (0.32 inch) fillet weld (Both Sides)

Illustration 151	g00745553
(4) Front plate (5) Angle plate

Table 82

Welding Tolerances for Illustration 151
Weld	Tolerances
W2	6 mm (0.24 inch) fillet weld (Both Sides)

Illustration 152	g00745544
(1) Beam plate (2) Platform plate (3) Middle plate (4) Front plate

Illustration 153	g00745995
(6) 153-1313 Plate

Table 83

Welding Tolerances for Illustration 153
Weld	Tolerance
W3	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration

Illustration 154	g00745993
(7) 153-1314 Plate (8) 5T-6253 Plate

Table 84

Welding Tolerances for Illustration 154
Weld	Tolerances
W4	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W5	16 mm (0.63 inch) bevel weld (2 Places)

Table 85

Welding Dimensions for Illustration 154
Item	Dimension
A	1968 ± 3 mm (77.48± 0.12 inch)
B	195 ± 5 mm (7.68 ± 0.20 inch)

Illustration 155	g00745994
(8) 5T-6253 Plate

Table 86

Welding Tolerances for Illustration 155
Weld	Tolerances
W6	6 mm (0.24 inch) fillet weld with a 1.50 mm (0.06 inch) penetration
W7	5 mm (0.20 inch) fillet weld with a 1.50 mm (0.06 inch) penetration

Note: The following plates will need to be fabricated in order to perform this procedure. Use 10 mm (0.39 inch) steel plating in order to make plate (5), plate (6), and plate (7).

1. Remove the old plates. Clean the welding areas on the support assembly.

2. Clean the tube assembly that is connecting the support assembly to the front pedestal. Clean the tube assembly that is connecting the support assembly to the radiator support beam.

3. Attach a suitable lifting device to the support assembly.

4. Use the previous dimensions in order to position the support assembly on the beam.

5. Use the fabricated plates on the support assembly in order to place the support assembly.

6. Fasten Beam Plate (1) to the exhaust beam.

7. Fasten Front Plate (4) to the front pedestal. Measure the distance from the support assembly to the pedestal.

8. Weld 153-1313 Plate (6) to the inside of the support assembly and the beam. Refer to the following references: Illustration 153 and Table 83.

9. Weld 153-1314 Plate (7) to the inside of the support assembly and the beam. Refer to the following references: Illustration 154, Table 84 and 85.

10. Weld 5T-6253 Plate (8) to the support assembly and the front pedestal. Refer to the following references: Illustration 154, Tables, 84, 85, Illustration 155 and Table 86.

11. Weld the support tube to the front pedestal. Refer to the following references: Illustration 155 and Table 86.

12. Weld the support tube to the radiator support beam. Refer to the following references: Illustration 155 and Table 86.

13. Reinstall a lever puller and a three hook chain onto the platform.
    Show/hide table

    Illustration 156	g00596866

14. Lift the platform assembly. Place the platform assembly on the truck frame.
    Show/hide table

    Illustration 157	g00596546

15. Install the six washers and six bolts into the rear support assembly and the platform assembly. Torque the bolts to 215 ± 40 mm (8.46 ± 1.57 inch).
    Show/hide table

    Illustration 158	g00596529

16. Install the eight washers and eight bolts into the front of the support assembly and the platform assembly. Torque the bolts to 370 ± 50 mm (14.57 ± 1.97 inch).
    Show/hide table

    Illustration 159	g00596739

17. Install the plate with three washers and three bolts.