Procedure To Repair The Center Tube Assembly On Certain 777 Off-Highway Trucks

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Special Instruction
Procedure to Repair the Center Tube Assembly on Certain 777 Off-Highway Trucks {0679, 7050,
7051}
Media Number -SEHS0324-00 Publication Date -02/11/2015 Date Updated -02/11/2015
i06240533
Procedure to Repair the Center Tube Assembly on Certain 777 Off-

Highway Trucks {0679, 7050, 7051}
SMCS - 0679; 7050; 7051
Off Highway Truck

777F (S/N: JRP1-UP)
777G (S/N: TNM1-UP; T4Y1-UP)
Introduction
Reference: Special Instruction, REHS1841, "General Welding Procedures"
Reference: Operation and Maintenance Manual, SEBU8227, "Capacities (Refill)"
Reference: Operation and Maintenance Manual, SEBU7790, "Capacities (Refill)"
A raised body (bed) may fall unexpectedly and without warning

resulting in personal injury or death.
When it is necessary to work under the truck with the body (bed) raised,
install the body (bed) retaining pins through the pin bores in the frame
and the retaining brackets on the body.
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.
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Advanced Full Text Search - SEHS0324 - Procedure to Repair the Center Tube Assembly on Certain 777 Off-Highway Trucks {0679, 70…
Always wear protective clothing and eye protection when working with
cleaning solvents.
NOTICE
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
NOTICE
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.
Illustration 1 g03870553
This procedure applies to the repair of fatigue cracking issues related to fillet weld toe. Due to the stress
concentrations that exist at weld toes and weld stop/starts, blend grinding and post-weld treatment in this area may
be necessary to prevent cracking.
Note: The truck body must be in the RAISED position and the safety retaining pins installed correctly, prior to
performing this task.
Note: The battery disconnect switch should be turned off and locked out prior to performing this task.
Important Safety Information

The following information is an explanation of various labels that are found in this document.
Warnings
The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.
Notices
A notice informs the technician that component damage can occur as a result of a condition that exists.
Notes
A note contains general information for the technician about the operation that is being performed.
Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines
basic recommended procedures. Some of the procedures require special tools, devices, or work methods.
Before you perform any repairs or before you perform any maintenance, read all safety information.
Understand all safety information before you perform any repairs or before you perform any maintenance.
Safety information is provided in this document and on the machine. If these hazard warnings are not heeded,
bodily injury or death could occur to you or other persons.
The “Safety Alert Symbol” that is followed by a “Signal Word” identifies a hazard. “DANGER”, “WARNING”,
and “CAUTION” are “Signal Words”.
The signal word “WARNING” has the following meanings:
Pay Attention !
Become Alert !
Your Safety Is Involved !
The message that appears under the safety alert symbol explains the hazard.
Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in
the service information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution
when you perform service work. Special knowledge of the systems and of the components is important. Before
you remove or disassemble any component, obtain knowledge of the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety
information in this document and the safety information on the machine are not all inclusive. Determine
that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation,
lubrication, maintenance, and repair procedures will not damage the machine. Determine that the
operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
Basic Precautions
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Always observe the list of basic precautions that follows:
Safety Signs
Safety signs include the items that follow: signs, information plates, and decals. Read all “Safety” signs on the
machine before operating, lubricating, or repairing the machine. Understand all “Safety” signs on the machine
before operating, lubricating, or repairing the machine. Replace any safety signs that are in the conditions that
follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions.
Protective equipment includes the items that follow: hard hat, protective glasses, and protective shoes. In
particular, wear protective glasses when you use a hammer or when you use a sledge hammer. When you weld, use
the appropriate protective equipment that is required by the job conditions. Protective equipment for welding
includes the items that follow: gloves, welding hood, goggles, and apron. Do not wear loose clothing or jewelry
that can catch on parts of the machine.
Mounting and Dismounting
Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a
machine. Before you mount the machine, clean any mud or debris from steps, walkways, or work platforms.
Always face the machine when you use steps, handholds, and walkways. When you cannot use the accesses on the
machine, use ladders, scaffolds, or work platforms to perform safe repair operations.
Specifications for Cables, Chains, and Lifting Devices
Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's weights to
determine the application when you select the following items: cable, chain, and lifting devices. When you lift a
component, the lift angle is critical. Refer to the Illustration that follows to see the effect of the lift angle on the
working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a
lifting operation.
Lift angles for lifting slings.
(A) The load capacity is 100% of the working load limit for the sling.
(B) The load capacity is 86% of the working load limit for the sling.
(C) The load capacity is 70% of the working load limit for the sling.
(D) The load capacity is 50% of the working load limit for the sling.
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and
compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug to
prevent being sprayed by pressurized liquids. When the machine has been stopped, the danger of hot fluids is
greater.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the
skin for extended periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor. If there is
contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with large amounts
of water for at least 15 minutes. Seek medical attention.
Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit
circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion
from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery
outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an acid. If there is contact
with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes
with large amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can
penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
2. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected
or removed. Always make sure that all raised components are blocked correctly. Be alert for possible
pressure when you disconnect any device from a system that utilizes pressure.
3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged
and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can
cause fires. Loose hydraulic lines, loose tubes, and loose hoses can cause fires. Do not bend or strike high-
pressure lines. Do not install lines which have been bent or damaged. Check lines, tubes, and hoses
carefully. Do not use your bare hand to check for leaks. If fluids are injected into your skin, you must get
treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
4. Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a
protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning
purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in mind that the nozzle
pressures are high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all of the
recommended practices that are provided by the manufacturer of the pressure washer.
Welding Specifications and Qualifications
Protect yourself and others; read and understand this warning. Fumes
and gases can be dangerous to your health. Ultraviolet rays from the
weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instruction and your

employer's safety practices. Keep your head out of the fumes. Use
ventilation, exhaust at the arc, or both, to keep fumes and gases from
your breathing zone and the general area. Wear correct eye, ear and
body protection. Do not touch live electric parts.
Refer to the American National Standard Z49.1, "Safety in Welding and

Cutting" published by the American Welding Society, 2501 N.W. 7th
Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29
CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.
Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing
protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for
breathing protection.
Qualifications
Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for
the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is
being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to
Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have
used the process at some time within the last 6 months. The welders must complete the process of certification if
the welders have not used the welding processes for 6 months.
Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with
electronic controls, use the steps that follow:
1. Turn off the engine. Put the key start switch in the OFF position.
2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery
disconnect switch, disconnect the negative battery cable at the battery.
3. Attach the clamp for the ground cable as close as possible to the area that is being welded. This process will
reduce the likelihood of damage from the welding current to the following components: bearings, hydraulic
components, and electrical components. DO NOT weld plates to the frame for grounding/clamping
purposes. Use existing blocks, brackets, bosses, and so on, to attach the clamp.
Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for
electronic components as a ground point for the welder.
4. Protect the wiring harnesses and machine surfaces from sparks and welding spatter.
Area Preparation
The area to be welded shall be clean, dry, and free of the following contaminants:
Oil
Grease
Paint
Dirt
Rust
Any fluids or moisture
All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C
(60° F).
Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum
15.6° C (60° F) requirement.
Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.
Welding Electrodes and Parameters
Flux Cored Welding Electrode for the FCAW Process
Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the
manufacturer's shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies
that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld
that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:
Table 1
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20
E71T-1 H8"
Tensile Strength 480 MPa (70000 psi)
Yield Strength 400 MPa (58000 psi)

Elongation 22%
Impact Toughness 27 J @ -18 °C (20 ft lb @ -0 °F)
The tables that follow show the recommended parameter ranges for out of position welding in the field for two
different flux cored welding electrode diameters.
Table 2
Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate Voltage Amperage

7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute 24 to 28 190 to 240
Table 3
Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate Voltage Amperage

5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute 23 to 27 180 to 220
Note: The settings listed above are recommendations-based on experience from welding in the horizontal, vertical-
up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position
and various formulations by different electrode manufacturers. The use of higher parameters than specified for
welding in the flat position is acceptable.
Use a polarity setting of DC reverse polarity. Remove the slag after each welding pass. The fast freezing
characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld.
Control the size of the weld to reduce the possibility of evolving gas that is trapped in the weld. The maximum size
weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.
Low Hydrogen Electrodes for the SMAW Process
As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet
the following requirements.
Table 4
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1
E7018H4R"
Tensile Strength 480 MPa (70000 psi)

Yield Strength 400 MPa (58000 psi)
Elongation 22%
Impact Toughness 27 J @ -29 °C (20 ft lb @ -20 °F)
Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F) when not in use. If low hydrogen
electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the
manufacturer's specifications.
The table that follows shows the settings for the welding current based on electrode diameter.
Table 5
Welding Current for Low Hydrogen Electrodes
Diameter Amperage Rating
3.2 mm (1/8 inch) 105-155
4.0 mm (5/32 inch) 130-200
4.8 mm (3/16 inch) 200-275
Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width
of the weld should not exceed two times the electrode diameter.
Weld Inspection and Acceptance Criteria
Table 6
ISO 6520 Defect
Defect Name Reference Remarks Defect Limit
Number
Cracks -
1011, 1012, 1013,
Longitudinal,
1014, 1023, 1024,
Transverse,
1031, 1033, 1034,
Radiating, -- Not Permitted
1045, 1046, 1047,
Crater,
1051, 1053, 1054,
Disconnected,
1061, 1063, 1064
Branching
Crack -
1021 Hard Surfacing Welds Only Permitted
Transverse
Crack -
1021 Joining Welds Not Permitted
Transverse
Maximum Diameter for a Single Pore 1 mm (0.040 inch)
Maximum Pores in Any 300 mm

6
2011, 2012, 2014, (11.81 inch) Length of Weld
Porosity
2017
Maximum Number of Pores in Any 50 mm
(2.0 inch) of Weld Length for Welds Less 1
Than 300 mm (11.81 inch) in Length
Clustered 2013 Maximum Length of Cluster in Any Weld 3 mm (0.120 inch)

Porosity
Maximum Height or Width 3 mm (0.120 inch)

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

Maximum Dimension of Any Single
3 mm (0.120 inch)
Cavity
Elongated
2016 10% of Weld Length Not
Cavities Maximum Total Length of Affected Area in
to Exceed 25 mm
Any Weld
(1.00 inch)
Shrinkage
2021, 2024, 2025 Maximum Diameter or Length 1 mm (0.040 inch)
Cavities

Slag or Flux 3011, 3012, 3014, Maximum Length for Any Single
25 mm (1.00 inch)
Inclusions 3021, 3022, 3024 Discontinuity
Oxide Maximum Length for Any Single

3031, 3032, 3033 25 mm (1.00 inch)
Inclusions Discontinuity

Puckering
(Oxide
3034 -- Not Permitted
Inclusion -
Aluminum)
Metallic
3041, 3042, 3043 -- Not Permitted
Inclusion
Visual (Breaking the Surface) Not Permitted
Subsurface Maximum Height or Width 1 mm (0.040 inch)

Lack of Fusion 4011, 4012, 4013 Subsurface Maximum Length for Any
25 mm (1.00 inch)
Single Discontinuity
10% of Nominal
Maximum Reduced Penetration Penetration Not to Exceed
Lack of 1 mm (0.040 inch)
402, 4021
Penetration
Maximum Allowed Total Length of
10% of Weld Length
Reduced Penetration
Undercut 5011, 5012, 5013, Maximum Depth Measured From Plate 0.5 mm (0.020 inch)
5014, 5015 Surface - Any Length
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Any Length --
Weld Face Width 5 mm (0.20 inch) or Less 1 mm (0.040 inch)

Weld Face Width Over 5 mm (0.20 inch)
Excess Weld 1.5 mm (0.060 inch)
But Less Than 10 mm (0.40 inch)
Metal - Groove
Weld 502 Weld Face Width Over 10 mm (0.40 inch)
2 mm (0.080 inch)
Reinforcement But Less Than 20 mm (0.80 inch)
(Convexity)
Weld Face Width Over 20 mm (0.80 inch)
3 mm (0.120 inch)
But Less Than 30 mm (1.20 inch)
Weld Face Width 30 mm (1.20 inch) and
4 mm (0.160 inch)
Over
Convexity Affects Weld Toe Angle,

90 Degrees
Reducing Fatigue Life
Excess Weld
Metal - Fillet Weld Toe Angles of 135 Degrees and More
503 --
Weld Are Better
Convexity
Defect Limits Expressed as Minimum Toe
--
Angles Allowed
2 mm (0.080 inch) (Any

Without Drawing Limitation
Length)
Excess With "Melt - Through" and "Flush" Weld 1 mm (0.040 inch) (Any
5041, 5042, 5043
Penetration Symbols Length)
With "Melt - Through" and "Grind Flush" Not Permitted (After
Symbols Grinding)
Incorrect Weld When 1E2995 Applies (Expressed as a Toe 3 mm (0.120 inch)
505
Toe Radius Rather Than a Toe Angle) Minimum Radius
Overlap 5061, 5062 Expressed as Minimum Toe Angle 90 Degrees

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

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

Sizes May be Oversized (Within Defect

Limitations or Beyond) Without Correction
Provided the Excess Does not Interfere
with Satisfactory End Use of the
Component (i.e., Distortion, Fit-Up
Interference, etc.)
Fillet Weld -
Linear Length Weld Size ≤ 6.5 mm (0.256 inch) ± 6.5 mm (0.256 inch)
when specified
--
at less than the
length of the Weld Size ≥ 6.5 mm (0.256 inch) ± 12.5 mm (0.492 inch)
joint
Nominal Size (0.7 x Leg Size) Not
Inclusive of Penetration Beyond the Weld Not Permitted
Root
Fillet Weld 2 mm (0.080 inch) MAX -
Throat Size - 5213 and Not to Exceed 20% of
Undersize Specified Throat, Not
Weld Crater Only - Maximum Undersize
Inclusive of Penetration
Beyond the Weld Root (0.7
x Leg Size)
Careful Consideration Needs to be Given

Incompletely Not Permitted
When Plate Mismatch is Apparent
Filled Groove 511
Weld Weld Depth Must be Maintained as a
--
Minimum
Root Concavity Maximum Depth measured From Plate
on Open Root 515, 5013 Surface or Tube Inner Surface - Any 0.5 mm (0.020 inch)
Groove Welds Length
Measured in Terms of Excess Weld Metal

(Fillet Weld Convexity) or Overlap on
--
Groove Welds, Lack of Fusion, or
Insufficient Throat
Excess Weld Metal on Fillet Welds, Defect

Limits Expressed as Minimum Toe Angles 90 Degrees
Poor Restart Allowed
5171, 5172
(Tie - In)
Overlap on Groove Welds, Defect Limits
Expressed as Minimum Toe Angles 90 Degrees
Allowed
Lack of Fusion - Visual Maximum Length
3 mm (0.120 inch)
Per Restart
Insufficient Weld Throat Not Permitted

Stray Arc
601 -- Not Permitted
Strike
Slag Residue 615 SMAW, SAW, FCAW, GMAW Not Permitted
GTAW Silicon Residue Permitted

Unless Removal Specified
by Drawing Note
Total Maximum Combined Length of All

Imperfections in a Weld, Expressed as a 15%
Combined Percent of Total Weld Length
--
Discontinuities (No Single Type of Imperfection Can
Exceed the Limits for That Single Type of --
Imperfection)
General Weld Repair

1. Remove any components that prevent access to the cracked weld.
2. Refer to "Area Preparation" Section in this Special Instruction.
3. Use dye penetrant (PT) or magnetic particle (MT) r to identify the extent and/or length of the necessary
repair.
4. Protect machined surfaces from sparks and weld debris.
5. Ensure that the base material is at a minimum temperature of 15.6° C (60° F) before welding. Ensure that a
minimum temperature of 15.6° C (60° F) is maintained throughout the entire welding procedure.
6. The crack (and sound metal 50 mm (2.00 inch) beyond each end of the crack) shall be removed by gouging
and/or grinding. Caution should be used to avoid excessive removal of the surrounding base material. Areas
that are gouged by air carbon arc torch shall be later ground and cleaned prior to welding to remove all
carbon absorption or contamination. Gouged areas requiring rewelding shall have a root radius of not less
than 5 mm (0.20 inch) and a Single V - 60 degree included angle joint preparation to allow the welder
reasonable access to reinstate the weld.
7. Use PT or MT to inspect the gouged and ground area to ensure that the crack has been removed before
welding commences.
8. Repair the prepared groove utilizing the recommendations provided in the "Welding Electrodes and
Parameters" Section in this Special Instruction.
9. Clean the weld area. Inspect the area that was welded. All weld quality shall conform to the criteria specified
in the "Weld Inspection and Acceptance Criteria" section in this Special Instruction.
Component Removal
Note: Ensure that contamination controls for the hydraulic system are implemented.
A raised body (bed) may fall unexpectedly and without warning

resulting in personal injury or death.
When it is necessary to work under the truck with the body (bed) raised,
install the body (bed) retaining pins through the pin bores in the frame
and the retaining brackets on the body.
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
Do not allow any dirt or foreign material to get into the hydraulic
system during assembly, connection of lines, when components are
filled with fluid, or during any maintenance operation.
NOTICE
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.
Typical top view of the center tube assembly
(A) Hydraulic oil distribution manifold
(B) Clip assembly
Note: Step 1 through Step 6 below are for a 777G Truck. Component removal for 777F Truck will be
similar.
1. Remove and retain the two bolts that retain hydraulic oil distribution manifold (A) to the top of the center
tube assembly.
2. Remove and retain the nut securing the transmission oil hose clips to the upper right-hand side of the center
tube assembly and remove and retain clip assembly (B), so that the hoses can be moved.
Note: This area may utilize a steel tube on certain earlier serial number trucks.
Locate the transmission and torque convertor oil filter assemblies (inboard from the backside of the fuel tank)
(C) Clip
(D) Filter head assemblies
(E) Filter base mounting plate
3. .Remove and retain clip (C) securing the fuel hose to the front of filter base mounting plate (E).
4. Disconnect the wiring harness and connectors from filter base mounting plate (E) and the sensors.
5. Disconnect both filter head assemblies (D) from filter base mounting plate (E) and move the filter
assemblies away from filter mounting base plate (E).
Typical bottom view of the center tube assembly
6. Remove filter mounting base plate (E) from the mounting locations on the center tube assembly. Illustration
6 is a view of the center tube assembly with filter head assemblies (D) moved and filter mounting base plate
(E) removed.
Note: No hydraulic hoses require disconnection.
Inspection of the Center Tube Assembly

The first course of action is to identify if a crack exists, and if so what is the extent of the crack. The next
objective is to determine if the crack depth has propagated through the thickness of the center tube
assembly. The crack depth will determine the extent of the repair.
1. Visually inspect the weld around the outside of the D-ring plates on the center tube assembly.
2. Use magnetic particle (MT) or dye penetrant (PT) to identify the extent and/or length of the necessary repair.
3. Determine which repair procedure to execute.
Prepare the Center Tube Assembly for Repair
Typical view of wire brush
View of the back side of the center tube assembly
View of the top side of the center tube assembly
View of the front side of the center tube assembly
View of the bottom side of the center tube assembly
1. Using a wire brush or similar tool, remove the paint from both welds around the complete circumference of
the center tube assembly in the locations shown in Illustration 9, Illustration 10, Illustration 11, and
Illustration 12.
2. Illustration 13 shows the paint removed and the weld exposed around the ring on the center tube assembly.
If no crack is present, perform the steps in the "Post Weld Treatment - TIG Dressing" Section of this
Special Instruction.
If partial through thickness crack is present, perform the steps in the "Partial Through Thickness Crack
Repair" Section of this Special Instruction.
If through thickness crack is present, perform the steps in the "Through Thickness Crack Repair"
Section of this Special Instruction.
Partial Through Thickness Crack Repair

All cracks should be removed by gouging and/or grinding, and then repaired using the electrodes and parameters
defined in the "Welding Specifications and Qualifications" Section.
The center tube assembly is approximately 16 mm (0.63 inch) thick, therefore excavation by arc air should be used
with caution.
1. Illustration 14 through Illustration 16 demonstrate the sequence of steps necessary to obtain the desired joint
configuration prior to welding.
Note: The depth of excavation and grinding will depend on the depth of the crack.
View of excavated crack
(A) Gouged profile
(B) Section thickness
2. Excavate the crack by arc air gouging.
Cross section view of anticipated grinding
(C) 70 degree included angle
3. Finish grind to achieve a 70 degree included angle (C).
Cross sectional view of prepared joint prior to welding (slight radius at root)
(C) 70 degree angle
(D) 35 degree angle
4. Prepare the joint for welding.
5. After the crack removal has been verified, reinstate by welding and sanding the excess weld material flush to
the profile of the surface of the surrounding tube.
6. Inspect all welds visually to ensure that all the weld quality meets or exceeds the requirements shown in the
"Weld Inspection and Acceptance Criteria" section.
Through Thickness Crack Repair

Fabricate Hydraulic Tank Mount Fixture
Note: Only fabricate the tank mount fixture if through thickness crack exists on the center tube assembly.
Base plate
(A) 19 mm (0.75 inch)
(B) 2X 964.8 mm (38 inch)
(C) 4X 22 mm (0.90 inch) diameter
(D) 120 mm (4.70 inch)
(E) 2X 18.725 mm (0.74 inch)
(F) 1031 mm (40.60 inch)
(G) 2X 82.55 mm (3.25 inch)
(H) 2X 33 mm (1.30 inch)
Vertical plate
(J) 50 mm (2.00 inch)
(K) 260 mm (10.24 inch)
(L) 9.5 mm (0.40 inch)
Gusset
(M) 110 mm (4.30 inch)
(N) 230 mm (9.05 inch)
(P) 9.5 mm (0.340 inch)
Semi-completed right-hand tank mount fixture
(R) 135 mm (5.30 inch)
(S) 155.25 mm (6.10 inch)
Rod
(T) 250 mm (9.84 inch)
(U) 25 mm (1.00 inch)
1. Use Illustration 17 through Illustration 21 to fabricate and construct a locating fixture to capture the location
of the front hydraulic tank mount in relation to the rear hydraulic tank mount, the rear hydraulic tank mount
will remain on the truck.
Note: Material for fixtures can be common structural steel such as ASTM A36.
Fabricate Fuel Tank Mount Fixture
Note: Only fabricate the tank mount fixture if through thickness crack exists on the center tube assembly.
Base plate
(A) 19 mm (0.75 inch)
(B) 2X 1285 mm (50.59 inch)
(C) 4X 22 mm (0.90 inch) diameter
(D) 156 mm (6.14 inch)
(E) 2X 18 mm (0.71 inch)
(F) 1351 mm (53.19 inch)
(G) 2X 120.65 mm (4.75 inch)
(H) 2X 33 mm (1.30 inch)
Vertical plate
(J) 50 mm (2.00 inch)
(K) 100 mm (3.94 inch)
(L) 9.5 mm (0.40 inch)
Gusset
(M) 70 mm (2.76 inch)
(N) 145 mm (5.71 inch)
(P) 9.5 mm (0.340 inch)
Semi-completed right-hand tank mount fixture
(R) 400 mm (15.75 inch)
(S) 421 mm (16.57 inch)
Rod
(T) 250 mm (9.84 inch)
(U) 25 mm (1.00 inch)
1. Use Illustration 22 through Illustration 26 to fabricate and construct a locating fixture to capture the location
of the front fuel tank mount in relation to the rear fuel tank mount, the rear fuel tank mount will remain on
the truck.
Note: Material for fixtures can be common structural steel such as ASTM A36.
Procedure to Remove the Outside Window Plate (Left-Hand Side)
1. Attach tank mount fixture to the tank mounts using the tank mounting hardware as shown in Illustration 27.
View of the tank mount fixture location (LH side)
2. Position the rod shown in Illustration 28 on top of the rail section and against the fixture to capture the
height of the front tank mount. Tack weld rod to the fixture.
The tank mount fixture will be used to relocate the front tank mount for the left-hand side after repairs have
been completed. Refer to Illustration 29 for an example of the fabricated fixture on the frame.
Note: If a single fixture is used for multiple repairs, the rod must be removed, and reattached for each repair
to ensure that the tank mount location is in the original position prior to removing the outside window plate.
Refer to Illustration 28
3. Remove the tank mount fixture.
View of the left-hand side of the frame
(B) Bracket assembly (tank mount)
(C) Outside window plate
4. Attach a suitable lifting device to outside window plate (C). The approximate weight of outside window
plate (C) and bracket assembly (B) is 50 kg (110 lb).
Note: The front bracket assembly (tank mount) (B) has been TIG dressed at the fillet weld toe to prevent
fatigue cracking. To retain the factory TIG dressing, leave bracket assembly (tank mount) (B) attached to
outside window plate (C).
View of the left-hand side of the frame
(B) Bracket assembly (tank mount)
(C) Outside window plate
(AA) 50 mm (2.00 inch)
5. Gouge/excavate the welds securing outside window plate (C) as shown in Illustration 31. Extend excavation
50 mm (2.00 inch) beyond intersection of vertical welds.
Note: Be cautious when removing outside window plate (C). Retain as much of the window plate as
possible as the window plate will need to be reused after the repair is complete.
Weld joint details
(D) Weld joint detail
(E) Weld joint detail
6. To assist with the removal of outside window plate (C), refer to the following Illustrations to understand the
weld joints securing outside window plate (C) in place.
View of weld joint detail (D)
( F) 12 mm (0.50 inch)
(G) 32 mm (1.25 inch)
7. The top and bottom horizontal weld joints (D) are composed of a steel rail section that is 32 mm (1.25 inch)
thick (top/bottom) and a vertical plate that is 12 mm (0.50 inch) thick. Refer to Illustration 33.
View of weld joint detail (E)
( H) 12 mm (0.50 inch)
(J) 25 mm (1.00 inch)
8. There is an internal 25 mm (1.00 inch) thick gusset/plate that is used for both backing and structural
purposes. Refer to Illustration 34.
View of the left-hand side of the frame with the outside window plate removed
Typical view of a through thickness crack on the inside of the center tube assembly
9. After outside window plate (C) has been removed, the extent of the cracking should be visible inside the
center tube assembly.
Procedure to Remove the Outside Window Plate (Right-Hand Side)
View of the fuel tank mount fixture
(A) Fuel tank mount fixture
(B) Rear fuel tank mount
(C) Front fuel tank mount
(D) Rod
1. Attach fabricated fuel tank mount fixture (A) to rear fuel tank mount (B) (with mounting hardware) so that
the fixture lies across front fuel tank mount (C).
2. Position rod (D) on top of the rail section and against fuel tank mount fixture (A), to capture the height of
front fuel tank mount (C). Tack weld rod to the fixture.
Note: If a single fixture is used for multiple repairs, the rod must be removed, and reattached for each repair
in order to ensure that the tank mount location is in the original position prior to removing the outside
window plate refer to Illustration 37.
3. Remove fuel tank mount fixture.
4. Remove front fuel tank mount (C), use caution not to leave gouging or grinding marks in the window plate
base metal.
View of the right-hand side outside window plate
5. Attach a suitable lifting device to outside window plate (E), the approximate weight of window plate (E) is
43 kg (95 lb).
Note: The front bracket assembly (tank mount) (C) has been TIG dressed at the fillet weld toe to prevent
fatigue cracking.
View of the right-hand side
(E) Window plate
(F) Weld joint detail
(G) Weld joint detail
(AA) 50 mm (2.00 inch)
6. To assist with the removal of outside window plate (E), refer to Illustration 33 and Illustration 34 to
understand the weld joints securing outside window plate (E) in place.
7. Gouge/excavate the welds securing outside window plate (E) as shown in Illustration 40. Extend excavation
50 mm (2.00 inch) beyond intersection of vertical welds.
Note: Be cautious when removing outside window plate (E). Retain as much of the window plate as
possible as the window plate will need to be reused after the repair is complete.
8. After outside window plate (E) has been removed, the extent of the cracking should be visible inside the
center tube assembly.
Crack Repair Procedure (Through Thickness)

All cracks should be removed by gouging and/or grinding, and then repaired using the electrodes and parameters
defined in the "Welding Specifications and Qualifications" section.
NOTICE
The center tube assembly is approximately 14 mm (0.55 inch)to 16 mm
(0.63 inch) thick, therefore excavation by arc air should be used with
caution.
(A) 3 mm (0.12 inch) Cutoff wheel
(C) Root opening 3 mm (0.12 inch)
(D) 2 mm (0.08 inch)
1. Excavate the crack. Do not remove the crack by arc air all the way through the thickness, but only to a depth
of approximately 12 mm (0.50 inch). The last 2 mm (0.08 inch) to 4 mm (0.16 inch) of the depth of the
crack should be removed using a grinder with a cutoff wheel.
Finish grind to achieve a 70 degree included angle
(C) 3 mm (0.12 inch) root opening
(D) 2 mm (0.08 inch) root face
(E) 70 degree included angle
Finished profile
(C) 3 mm (0.12 inch)root opening
(D) 2 mm (0.08 inch) root face
(E) 70 degree included angle
(F) 35 degree angle
2. Prepare the groove to as shown in Illustration 43 and Illustration .
3. Weld root pass using the SMAW guidelines in the "Welding Specifications and Qualifications" section.
Note: GTAW (TIG) can also be utilized for root pass welding if skill and equipment are available.
Fill passes can be completed using either SMAW or FCAW and guidelines in the "Welding Specifications
and Qualifications" section.
4. Grind /sand weld reinforcement flush to original center tube support outer diameter to reinstate the center
tube support to original condition.
(H) Ring plate
(J) 16 mm (0.63 inch) thick center tube
5. Restore to original 12 mm (0.47 inch) fillet weld
6. Back gouge the crack to sound weld metal from inside the center tube assembly.
View of the inside the center tube assembly after welding
7. Weld inside the center tube assembly using either SMAW or FCAW and guidelines in the "Welding
Specifications and Qualifications" Section.
View of weld after blending/sanding and tested using dye penetrant
8. Blend grind/sand the weld surface to profile.
9. Inspect all welds visually to ensure that all the weld quality meets or exceeds the requirements shown in the
"Weld Inspection and Acceptance Criteria" Section.
Procedure to Install the Outside Window Plate (Left-Hand and Right-Hand Side)
1. Grind/sand the edges of the outside window plate that was previously removed to clean/bright base material.
2. Use the temporary fixture to relocate the bracket assembly (tank mount) on the window plate in relationship
to the rear bracket assembly (tank mount).
(A) Weld joint detail
(B) Weld joint detail
View of weld joint detail (A)
( C) 14 mm (0.55 inch)
(D) 12 mm (0.50 inch)
(E) 32 mm (1.25 inch)
Note: To provide better access for weld joint detail (D), grind/sand a slight 10 degree to 15 degree bevel on
the 12 mm (0.50 inch) window plate.
View of weld joint detail (B)
( F) 45 degree bevel
(G) 12 mm (0.50 inch)
(H) 6 mm (0.24 inch) minimum
(J) 25 mm (1.00 inch)
(K) Internal gusset
(L) Outside window plate
3. Observe the resulting fit up of weld joints (A) and weld joints (B), then remove and prepare the edges of
outside window plate (L) to obtain the weld joints shown in Illustration 49 and Illustration 50.
4. Once proper fit up is achieved, secure outside window plate (L) into position. Weld 6 mm (0.24 inch) (
50 mm (2.00 inch) length) fillet welds in 12 places as shown in Illustration 51.
5. Grind/taper the ends of all 6 mm (0.24 inch) fillet welds. Finish the root pass on all four sides of the window
plate by welding a 6 mm (0.24 inch) fillet weld between all the previously deposited 6 mm (0.24 inch) fillet
welds.
6. Complete the welding of the vertical weld joints as shown in Illustration 52.
7. Complete the welding of the horizontal weld joints as shown in Illustration 53.
8. Inspect all welds visually to ensure that all weld quality meets or exceeds the requirements shown in the
"Welding Specifications and Qualifications" Section.
Note: Ultrasonic testing of the complete joint groove weld is recommended.
9. Sand all weld starts and stops and ensure that corners are slightly rounded.
Install the Front Fuel Tank Mount
View of the fuel tank mount fixture
(A) Fuel tank mount fixture
(B) Rear fuel tank mount
(C) Front fuel tank mount
(D) Rod
1. Use temporary fixture (A) to relocate front fuel tank mount (C) on the window plate in relationship to rear
fuel tank mount (B) and secure front fuel tank mount (C) into position with tack welds.
View of the right-hand side front fuel tank mount
2. Secure front fuel tank mount into position using the weld dimensions shown in Illustration 55.
3. For this connection it is required that the fillet weld toe touching the window plate is TIG dressed. Refer to
Illustration 56.
For detailed information regarding TIG dressing refer to the "Post Weld Treatment - TIG Dressing" Section.
Post Weld Treatment - TIG Dressing

The fatigue performance of fabricated structures involving fillet welded attachments to highly stressed members is,
among other things, controlled by the profile or geometry of the weld toe. Fatigue performance improvements can
be achieved through alteration of the original, as-welded toe profile by several post weld treatment options. This
procedure describes a method whereby an electric arc is used to reduce and/or remove unfavorable profiles/stress
risers thus creating a smooth, seamless transition from one component to the next component.
Note: Training: Anyone performing this procedure is advised to view the training video “Post Weld
Treatment: TIG Dressing Fundamentals”, course number 41737, in the Dealer Learning Management
System.
Equipment Requirements
Table 7
Required Equipment
Tool Description
The power supply must be able to produce 200 amps (min. 60% duty cycle) with
GTAW (TIG) Power supply
a hand control or a foot control.
and a torch.
Polarity - DC negative
Shielding Gas 100% Argon and flow meter
Lanthanated or
Ceriated or
Thoriated Tungsten
Electrode 2.4 mm (0.09 inch diameter)
If needed:
ER70S-2 filler metal
1.5 mm (0.06 inch diameter)
Grinder Pneumatic or electric with carbon steel wire wheel attachment
Grinding Wheel Aluminum Oxide
Radius gauges
Method
1. The first steps to ensure that proper TIG dressing are cleanliness and tungsten electrode preparation.
The fillet weld and surrounding base metal must have all contaminants thoroughly removed. It is imperative
that all paint, rust, dirt, oil scale, and silicate islands are non-existent, remove by using a grinder with a
carbon steel wire attachment.
2.4 mm (0.09 inch) Tungsten Electrode Preparation
(A) Grinding Marks
(B) 2 X 3 diameter
(C) 1/4 diameter
2. Prepare a 2.4 mm (0.09 inch) tungsten electrode. Refer to the dimensions that are shown in Illustration 57.
The grinding marks should run parallel to each other.
3. Adjust the shielding gas flow rate to 15 - 25 CFH. Adjust the current control to approximately 200 amps. If a
ramp down control is present on the power source, utilize the ramp down control to ensure that proper crater
fill control is achieved.
4. Several different techniques exist for TIG dressing due to the variation of the contour of the fillet weld toe.
The contour of the fillet weld toe must be reshaped. Use a stringer or weave manipulation of the torch to
achieve a smooth radius of the weld. A minimum radius of 5.0 mm (0.20 inch) must exist between the base
material and the weld metal.
Stringer Technique
(D) 0 degree work angle
Note: Use a 10 degree to 15 degree push angle for the stringer technique.
5. Illustration 58 represents the stringer technique of welding. The center of the arc needs to be 0.0 - 2.0 mm
(0.0 - 0.08 inch) from the weld toe into the base material.
Weave Technique
(E) 0 degree to 45 degree work angle
Note: Use a 10 degree to 15 degree push angle for the weave technique.
6. Illustration 59 represents the weave technique of welding.
7. Illustration 60 represents an acid etched, cross section view of a TIG dressed weld toe.
8. Illustration 61 and Illustration 62 demonstrate the expected results.
9. Once TIG dressing is completed, the area needs to be cleaned and painted to prevent pitting due to
corrosion.
Note: Poorly shaped fillet welds with 90 degree to 100 degree transition angles to the base material will
require several overlapping TIG dressing runs to smooth out the weld toe transition region.
Note: TIG dressing can be conducted in the vertical position as long as the TIG dressing is performed in a
downhill progression.
Note: If undercut or other circumstances require the addition of filler metal. Adding filler metal can be
accomplished by hand feeding ER70S-2 1.6 mm (0.06 inch) into the weld pool. You then repeat the TIG
dressing to achieve the desired toe radius and the desired profile.
10. Inspect using a radius gage to ensure a 5 mm (0.20 inch) minimum radius.
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Procedure To Repair The Center Tube Assembly On Certain 777 Off-Highway Trucks

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Procedure to Repair the Center Tube Assembly on Certain 777 Off-

Off Highway Truck

Reference: Operation and Maintenance Manual, SEBU8227, "Capacities (Refill)"

Reference: Operation and Maintenance Manual, SEBU7790, "Capacities (Refill)"

A raised body (bed) may fall unexpectedly and without warning

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Important Safety Information

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:

Mounting and Dismounting

Specifications for Cables, Chains, and Lifting Devices

Hot Fluids and Parts

Welding Specifications and Qualifications

Read and understand the manufacturer's instruction and your

Refer to the American National Standard Z49.1, "Safety in Welding and

Proper Welding Procedure on Machines and Engines with Electronic Controls

Any fluids or moisture

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Tensile Strength 480 MPa (70000 psi)

Yield Strength 400 MPa (58000 psi)

Impact Toughness 27 J @ -18 °C (20 ft lb @ -0 °F)

Wire Feed Rate Voltage Amperage

Wire Feed Rate Voltage Amperage

Low Hydrogen Electrodes for the SMAW Process

Tensile Strength 480 MPa (70000 psi)

Yield Strength 400 MPa (58000 psi)

Impact Toughness 27 J @ -29 °C (20 ft lb @ -20 °F)

3.2 mm (1/8 inch) 105-155

4.0 mm (5/32 inch) 130-200

4.8 mm (3/16 inch) 200-275

Weld Inspection and Acceptance Criteria

Maximum Pores in Any 300 mm

Clustered 2013 Maximum Length of Cluster in Any Weld 3 mm (0.120 inch)

Maximum Height or Width 3 mm (0.120 inch)

Maximum Length in Any Weld 10% of Weld Length

Maximum Height or Width 1 mm (0.040 inch)

Maximum Height or Width 1 mm (0.040 inch)

Oxide Maximum Length for Any Single

Maximum Length in Any Weld 10% of Weld Length

Visual (Breaking the Surface) Not Permitted

Subsurface Maximum Height or Width 1 mm (0.040 inch)

Maximum Length in Any Weld 10% of Weld Length

Weld Face Width 5 mm (0.20 inch) or Less 1 mm (0.040 inch)

Convexity Affects Weld Toe Angle,

2 mm (0.080 inch) (Any

Overlap 5061, 5062 Expressed as Minimum Toe Angle 90 Degrees

Fillet Weld Leg -- Applies to Either Weld Leg Measured

Conformance to Design - Fillet Weld Leg --

Sizes May be Oversized (Within Defect

Careful Consideration Needs to be Given

Measured in Terms of Excess Weld Metal

Excess Weld Metal on Fillet Welds, Defect

Insufficient Weld Throat Not Permitted

Slag Residue 615 SMAW, SAW, FCAW, GMAW Not Permitted