INSULATION GP-WEATHER 3427130 - Caterpillar

1. Straighten the frame. Use a straight edge on the top of the rail to check for straightness.2. On the outside of the top rail, directly above where the rail is to be opened, tack weld on a reinforcement plate of approximately 25 mm (1.0 in) thick and extending approximately 500 mm (19.7 in) each side of the crack in the bottom rail.
Illustration 1. (1) Frame rail. (B) Cutout.3. Remove the outside side plate at location (B) of frame rail (1) approximately 500 mm (19.7 in) each side of the crack in the bottom rail. (This is to provide access to the inside of the frame rail for welding.) See Illustration 1 and Chart 1.4. Remove the inside plate in the same manner as the outside, however the length of the opening can be adjusted to fit the conditions.5. On the inside of the frame rail, at edge of transition casting, remove the backup strip and clean up the edge of the casting.
Illustration 2. (C) Location of chamfer.6. Cut out approximately 380 mm (15.0 in) each direction from the crack in the bottom rail. Add a 15 mm (.6 in) chamfer at locations (C) on the outside edge of the bottom rail. See Illustration 2 and Chart 1.
Illustration 3. (2) Internal reinforcement plate. (3) Bottom rail.7. If when cutting out the plate in the bottom rail, the cut extends beyond the end of the internal reinforcement plate (2), cut the reinforcement plate back approximately 50 mm (2.0 in) (D) beyond the edge of the bottom plate (3). See Illustration 3 and Chart 1.
Illustration 4. (4) New section of 8X0582 Rail. (C) Location of chamfer. (E) Second weld. (F) First weld.8. Cut plate (4) to fit the opening cut in bottom rail (3). Chamfer the outside edges of plate (4) 15 mm (.6 in) at locations (C). See Illustration 4 and Chart 1.9. Weld plate (4) in place from the outside first (F) using E7018 electrode or equivalent. Arc out joint from the inside (E) being sure to cut into weld (F). Weld full at (E) to obtain 100% penetration of the weld at (F). See Illustration 4.
Illustration 5. (2) Internal reinforcement plate. (3) Bottom rail. (5) Inside of frame. (J) Length to replace original plate. (K) Weld 12 mm (.5 in) fillet.10. If the inside reinforcing plate was cut off in Step 7. fabricate a new one using 12 mm (.5 in) thick carbon steel to the dimensions shown in the chart. Weld plate (2) in place at two locations (K). See Illustration 5 and Chart 1.
Illustration 6. (3) Bottom of rail. (6) Backup strip. (N) Length as required. (T) No weld two ends. (U) 16 mm (.6 in) fillet weld to continue beyond end of strap both ends. (W) 16 mm (.6 in) fillet weld.11. The length of the outside plates should be such that a minimum of 10 mm (.4 in) weld gap width is provided for welding. Make backup strips (6) from available material at