COVER-TAIL LIGHT 3382940 - Caterpillar

Procedure
Illustration 2 g06192048
Left side of truck bed
(A) Area of work
Illustration 3 g06190538
Partial view of area (A)
( 2) Weld crack
Go to the left side of the truck body. Use a dye penetrant test, or a magnetic particle test in the affected area to determine the extent of weld crack (2).
Prepare the area for welding. For the proper procedure, refer to the above listed special instruction.
Illustration 4 g06190540
Weld crack fully gouged
Gouge and completely remove the weld crack to a depth of 6.0 mm (0.24 inch).
Use a dye penetrant test, or a magnetic particle test to verify that the crack was removed.
Illustration 5 g06190545
Proper profile of the joint before welding
Clean all indication of carbon and copper residue from the arc gouging process from the weld joint. The joint must have the profile of the original joint as shown in Illustration 5.
Illustration 6 g06190548
Proper cross section profile
Apply a two-pass weld to achieve a minimum penetration of 5 mm (0.2 inch) between the cover plate, and the side transition plate. Illustration 6shows the cross section weld profile required to fill the joint. The finished weld must be a 6.0 mm (0.24 inch) weld.
Perform an ultrasonic inspection on the weld to unsure a minimum penetration of 5 mm (0.2 inch) between the plates.
Illustration 7 g06191529
Area of left side repair
Illustration 8 g06191532
View of area (A)
( 1) Plate
(A) 100 5 mm (3.9 0.2 inch)
Illustration 9 g06191891
View (A-A) showing plate alignment
(1) New plate
(B) Tops aligned within 3.0 mm (0.12 inch)
Install one plate (1) that was manufactured earlier to the left side of the truck body. Use the information in Illustration 7, and Illustration8 to position the plate on the truck body. Position plate (1) so the top of the cover plate and the top of plate (1) are aligned within 3.0 mm (0.12 inch) (B).
Illustration 10 g06191941
Tack weld positions
(1) Plate
(C) Minimum length of 20 mm (0.8 inch)
(D) Less the 300 mm (11.8 inch)
Tack weld plate (1) in position. Make each tack weld at least 20 mm (0.8 inch) long. Space the tack welds along the perimeter of the plate less than 300 mm (11.8 inch) apart.
Illustration 11 g06191991
Installation of plate (1)
( 1) Plate
Apply a 6.0 mm (0.24 inch) fillet weld on both ends of plate (1).
Apply a 6.0 mm (0.24 inch) fillet weld on bottom of plate (1).
Apply a 6.0 mm (0.24 inch) weld bead on the top of the plate to complete the weld around the perimeter of the plate.
Illustration 12 g06192015
View (B-B)
( E) Minimum 16 mm (0.6 inch)
Weld the cover plate and plate (1) so the finished weld forms flare bevel groove weld (E) as shown in Illustration 12. Grind smooth all starts and stops. Visually inspect all welds per the weld criteria listed in Table 1.
Repeat the procedure on the right side of the machine.