Procedure To Inspect The Frame of 773E Off

Advanced Full Text Search - M0074926 - Procedure to Inspect the Frame... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Welcome: j210es
Product: NO EQUIPMENT SELECTED
Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED
Special Instruction
Procedure to Inspect the Frame of 773E Off-Highway Trucks {0374, 0679, 7051}
Media Number -M0074926-00 Publication Date -18/08/2016 Date Updated -18/08/2016
i06755439
Procedure to Inspect the Frame of 773E Off-Highway Trucks {0374,

0679, 7051}
SMCS - 0374; 0679; 7051
Off-Highway Truck/Tractor
773E (S/N: KEG1-UP; ASK1-UP)
Introduction
This Special Instruction contains general information for inspecting the frame of 773E Off-Highway Truck.
Do not perform any procedure in this Special Instruction until you have read the information and you
understand the information.
Safety Section
When it is necessary to work under the machine with the body (bed)
raised, attach the body (bed) retaining cables to the rear tow points.
Install the rear tow point pins through the ends of the retaining cables.
Failure to properly secure the body (bed) may result in personal injury
or death.
1 of 22 9/6/2017, 12:24 PM
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents, extreme

caution must be exercised when using them. If unsure about a
particular cleaning fluid, refer to the manufacturer's instructions and
directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
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 !
2 of 22 9/6/2017, 12:24 PM
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.
You must determine that the tools, procedures, work methods, and operating techniques are safe. You
must determine that the operation, lubrication, maintenance, and repair procedures will not damage
the machine. Also, you must determine that the operation, lubrication, maintenance, and repair
procedures will not make the machine unsafe.
Basic Precautions
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
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
3 of 22 9/6/2017, 12:24 PM
or jewelry that can catch on parts of the machine.
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and
compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug
in order to prevent being sprayed by pressurized liquids. When the machine has been stopped, the danger of
hot fluids is greater.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact
the skin for extended periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor.
In case of contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with
large amounts of water for at least 15 minutes. Seek medical attention.
Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit
circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an
explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte
through the battery outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an
acid. In case of contact with battery electrolyte, immediately wash the skin with soap and water. For contact
with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure
can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type of injury.
2. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are
disconnected or removed. Always make sure that all raised components are blocked correctly. Be alert
for possible pressure when you disconnect any device from a system that utilizes pressure.
3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are
damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are
damaged can cause fires. Loose hydraulic lines, loose tubes, and loose hoses can cause fires. Do not
bend or strike high-pressure lines. Do not install lines which have been bent or damaged. Check lines,
tubes, and hoses carefully. Do not use your bare hand to check for leaks. If fluids are injected into your
skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of
injury.
4. Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a
protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning
4 of 22 9/6/2017, 12:24 PM
purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in mind that the
nozzle pressures are high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all
of the recommended practices that are provided by the manufacturer of the pressure washer.
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.
Proper Cleaning for Inspection
When it is necessary to work under the machine with the body (bed)
raised, attach the body (bed) retaining cables to the rear tow points.
Install the rear tow point pins through the ends of the retaining cables.
Failure to properly secure the body (bed) may result in personal injury
or death.
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents, extreme

caution must be exercised when using them. If unsure about a
particular cleaning fluid, refer to the manufacturer's instructions and
directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
5 of 22 9/6/2017, 12:24 PM
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Before you inspect the area, clean the area with an appropriate high-pressure washer. Be careful not to
damage wires or other components. Use an appropriate degreaser to remove any oil or grease from the frame
assembly. A wire brush or a scraper to remove excessive dirt and grease may also be needed. Make sure that
the substances that follow are removed from the area that will be inspected.
Oil
Grease
Dirt
Frame Inspection Procedure

Frame Management/Repair Philosophy
Frame life, as it relates to fatigue, is a function of many variables that include payload, application (condition
of haul roads and load/unload zones), speed, maintenance, and repairs. Frame cracking can be a result of
many of these variables. Over the life of the machine, frame cracking is an expected event in most
circumstances. Understanding and managing all these variables is a part of general machine maintenance.
General machine maintenance is essential to ensuring fully acceptable life of the frame. Proper frame
management practice should include the following: maintenance and repairs, documentation, and trending,
Local conditions and/or age of equipment may dictate adjustments to your requirements.
Documentation
1. Any cracks that are identified at inspection or repair should be measured. Any cracks that are identified
at inspection or repair should be documented. This information should be retained for future inspections
and trending. Crack documentation history can show that where cracks are reoccurring, time to
propagate, and to what degree of severity.
2. A crack found at inspection should be marked and dated with paint/etch as to identify any crack growth
at future inspection that is specified by the Operation and Maintenance Manual.
3. Utilize a crack inspection checklist with identified call out locations on the frame to help in the
documentation process. Table 1 shows an example of a crack inspection checklist. The check list
example provides a sequential walk-around inspection which includes a table for capturing locations,
comments, and lengths, of cracks.
4. It is important to maintain a database of fleet frame crack status. The repair labor and downtime
requirements for the fleet should be included in this database.
6 of 22 9/6/2017, 12:24 PM
Maintenance and Repair

1. Conduct a full frame inspection as per the inspection requirements listed in this document and the
Operation and Maintenance Manual.
2. Clean the frame prior to inspection.
3. Utilize an inspection diagram. A walk-around diagram with weld joint locations is included in this
document.
4. When evaluating frame cracks for repair, crack documentation and trend history can help determining
potential crack growth and speed. The sites crack trend data history can determine the priority in
completing the repair. If the sites crack trend data history predicts the crack growth speed to be low risk,
then the crack would then be scheduled for repair at the next scheduled opportunity/preventive
maintenance. If the work sites crack trend data history predicts the crack growth speed to be high risk,
then the crack should be repaired immediately.
Trending
1. Data collected from the crack history documentation reveals crack tendencies.
2. Evaluating tendencies enables site-specific identification and ranking of crack severity/importance.
3. The frequency of crack recurrences can be identified through the trending process.
Frame Component Identification
7 of 22 9/6/2017, 12:24 PM
View of the frame components
(A) Bumper assembly
(B) Support assemblies (Pedestals)
(C) Support assemblies (Fore/Aft Beam)
(D) Plate assemblies (Upper Suspension Mounts)
(E) Support assembly (Main Beam)
(F) Support assembly (Center Tube)
(G) Rail assemblies (Frame Rails)
(H) Support assembly (Tail Casting)
(J) Support assembly (Drop Tube)
(K) Ball (Hoist Ball Trunnions)
(L) Support assembly (Suspension Mounts)
(M) Box assembly (Steering Box)
Fillet Weld Toe Crack Examples
8 of 22 9/6/2017, 12:24 PM
Fillet Weld Through Throat Crack Examples
9 of 22 9/6/2017, 12:24 PM
Inspection by Zones
10 of 22 9/6/2017, 12:24 PM
View of the left-hand side of the frame
(A) Zone 1
(B) Zone 2
(C) Zone 3
View of the support assembly (tail casting)
( D) Zone 4
11 of 22 9/6/2017, 12:24 PM
View of the right-hand side of the frame
(E) Zone 5
(F) Zone 6
(G) Zone 7
12 of 22 9/6/2017, 12:24 PM
View of top of frame
(H) Zone 8
Zone 1 left -hand side front suspension mount
(1) Front pedestal
(2) Cab mount
(3) Follow along fore/aft beam
(4) Upper suspension mounts (outside and inside)
(5) Welds along suspension mount
(6) Welds at the steering box
(7) Engine mount
13 of 22 9/6/2017, 12:24 PM
Zone 2 left-hand side behind suspension mount
(9) Cab mount
(10) Rear pedestal
(11) Front of fuel tank mount (outside) / engine mount (inside)
(12) Center tube
(13) Welds at the steering box
(14) Filter bracket (outside) / engine mount (inside)
14 of 22 9/6/2017, 12:24 PM
Zone 3 left-hand side behind the fuel tank
(15) Rear fuel tank mount
(16) Window plate welds (inside and outside)
(17) Drop tube welds
(18) Hoist cylinder trunnion welds / inside drop tube / lower fuel tank mount
(19) Center tube / A-frame king pin
15 of 22 9/6/2017, 12:24 PM
Zone 4 tail casting
(20) Left-hand body pivot bores/suspension cylinder mounts
(21) Tail casting center tube
(22) Sway arm radius and bore
(23) Right-hand body pivot bores/suspension cylinder mounts
16 of 22 9/6/2017, 12:24 PM
Zone 5 right-hand side behind the hydraulic tank
(24) Window plate (inside and outside)
(25) Hydraulic tank rear mount
(26) Drop tube welds
(27) Hoist cylinder trunnion welds / inside drop tube
(28) Center tube / A-frame king pin
Zone 6 right-hand side behind the suspension mount
(29) Hydraulic tank front mount
(30) Air dryer mount
(31) Rear pedestal
( 33) Suspension mounts (outside) / engine mount (inside)
( 34) Welds at steering box
17 of 22 9/6/2017, 12:24 PM
Zone 7 right-hand side front of suspension mount
(36) Rear fore/aft beam welds
(37) Front fore/aft beam welds
(38) Front pedestal
(39) Window plate welds (inside) / engine mounts (outside)
(40) Window plate welds at suspension mount
(41) Welds at steering box
18 of 22 9/6/2017, 12:24 PM
Zone 8 top view of the frame
(42) Main beam
(43) Center tube
(44) Tail casting
Frame Inspection Checklist

Table 1
773E Frame Inspection Checklist
Date: S/N: SMU: Inspector:
Zone Comment - Length -

Left-Hand Side Front Of Suspension Mount OK Cracked
1 Location
1 Front Pedestal
2 Cab Mounts
3 Fore/Aft Beam
4 Upper Suspension Mount (outside and inside)
5 Weld Along Suspension Mount
6 Steering Box
19 of 22 9/6/2017, 12:24 PM
7 Engine Mount

Left-Hand Side Behind Suspension Mount OK Cracked
2 Location
8 Upper Suspension Mount (outside and Inside)
9 Cab Mounts
10 Rear Pedestal
Front Fuel Tank Mount (outside) / Engine Mount

11
(inside)
12 Center Tube
13 Steering Box
14 Filter Bracket (outside ) / Engine Mount (inside)

Left-Hand Side Behind Fuel Tank OK Cracked
3 Location
15 Rear Fuel Tank Mount
16 Window Plate Welds (outside and inside)
17 Drop Tube Welds
Hoist Cylinder Trunnion Welds / Inside Drop Tube /

18
Lower Fuel Tank Mount
19 Center Tube / A-Frame King Pin

Rear Tail Casting OK Cracked
4 Location
Left-Hand Body Pivot Boers / Suspension Cylinder

20
Mounts
21 Tail Casting Center Tube
22 Sway Arm Radius and Bore
Right-Hand Body Pivot Bores / Suspension Cylinder

23
Mounts
20 of 22 9/6/2017, 12:24 PM

Right-Hand Side Behind Hydraulic Tank OK Cracked
5 Location
24 Window Plate Welds (outside and inside)
25 Hydraulic Tank Rear Mount
26 Drop Tube Welds
27 Hoist Cylinder Trunnion Welds / Inside Drop Tube
28 Center Tube / A-Frame King Pin

Right-Hand Side Behind Suspension Mount OK Cracked
6 Location
29 Hydraulic Tank Front Mount
30 Air Dryer Mount
31 Rear Pedestal
Suspension Mount (outside) / Engine Mount

33
(inside)
34 Steering Box

Right-Hand Side Front of Suspension Mount OK Cracked
7 Location
36 Rear fore/aft beam welds
37 Front fore/aft beam welds
38 Front Pedestal
Window Plate Welds (inside) / Engine Mounts

39
(outside)
40 Window Plate Welds at Suspension Mount
41 Welds at Steering Box

Top View OK Cracked
8 Location
21 of 22 9/6/2017, 12:24 PM
42 Main Beam
43 Center Tube
44 Tail Casting
Fill in all areas of the checklist and circle cracked areas on the diagrams in Illustration 17.
Copyright 1993 - 2017 Caterpillar Inc. Wed Sep 06 2017 12:24:28 GMT+0700 (SE Asia Standard Time)
All Rights Reserved.
j210es
Private Network For SIS Licensees.
22 of 22 9/6/2017, 12:24 PM

Procedure To Inspect The Frame of 773E Off

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Procedure To Inspect The Frame of 773E Off

Încărcat de

Drepturi de autor:

Formate disponibile

Advanced Full Text Search - M0074926 - Procedure to Inspect the Frame... https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Procedure to Inspect the Frame of 773E Off-Highway Trucks {0374,

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme

The signal word WARNING has the following meanings:

Your Safety Is Involved !

Improper operation, lubrication, maintenance or repair of this product

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

Always observe the list of basic precautions that follows:

or jewelry that can catch on parts of the machine.

Hot Fluids and Parts

Mounting and Dismounting

Proper Cleaning for Inspection

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Frame Inspection Procedure

Maintenance and Repair

2. Clean the frame prior to inspection.

2. Evaluating tendencies enables site-specific identification and ranking of crack severity/importance.

Frame Component Identification

Fillet Weld Toe Crack Examples

Fillet Weld Through Throat Crack Examples

Frame Inspection Checklist

Date: S/N: SMU: Inspector:

Zone Comment - Length -

4 Upper Suspension Mount (outside and inside)

5 Weld Along Suspension Mount

Zone Comment - Length -

8 Upper Suspension Mount (outside and Inside)

Front Fuel Tank Mount (outside) / Engine Mount

14 Filter Bracket (outside ) / Engine Mount (inside)

Zone Comment - Length -

15 Rear Fuel Tank Mount

16 Window Plate Welds (outside and inside)

17 Drop Tube Welds

Hoist Cylinder Trunnion Welds / Inside Drop Tube /

19 Center Tube / A-Frame King Pin

Zone Comment - Length -

Left-Hand Body Pivot Boers / Suspension Cylinder

21 Tail Casting Center Tube

22 Sway Arm Radius and Bore

Right-Hand Body Pivot Bores / Suspension Cylinder

Zone Comment - Length -

24 Window Plate Welds (outside and inside)

25 Hydraulic Tank Rear Mount

26 Drop Tube Welds

27 Hoist Cylinder Trunnion Welds / Inside Drop Tube

28 Center Tube / A-Frame King Pin

Zone Comment - Length -

29 Hydraulic Tank Front Mount

30 Air Dryer Mount

32 Upper Suspension Mount (outside and inside)

Suspension Mount (outside) / Engine Mount

Zone Comment - Length -

35 Upper Suspension Mount (outside and inside)

36 Rear fore/aft beam welds

37 Front fore/aft beam welds

Window Plate Welds (inside) / Engine Mounts

40 Window Plate Welds at Suspension Mount

41 Welds at Steering Box