TUBE AS 1546569 - Caterpillar

Illustration 1 g01230650
Crack In The Hood Group (J) Typical crack in the corner of the hood assemblyRepair Procedure
Fabricate four gussets from a steel plate that is 6 mm (0.24 inch) thick. Each of the fabricated gussets has different dimensions. Refer to Illustration 2 for the details of the gussets. Refer to Table 1 for the dimensions of the gussets.
Illustration 2 g01230560
Fabricated Gusset (E) 20 mm (0.8 inch) by 45° (F) 3 mm (0.1 inch) (G) 50 mm (2.0 inch) Radius (H) 20 mm (0.8 inch) Radius
Table 1
Dimensions For The Gussets    
Corner    A    B    C    D    
1    
112 mm (4.4 inch)    
92 mm (3.6 inch)    
44 mm (1.7 inch)    
24 mm (0.9 inch)    
2    
102 mm (4.0 inch)    
92 mm (3.6 inch)    
34 mm (1.3 inch)    
24 mm (0.9 inch)    
3    
102 mm (4.0 inch)    
87 mm (3.4 inch)    
34 mm (1.3 inch)    
19 mm (0.7 inch)    
4    
112 mm (4.4 inch)    
87 mm (3.4 inch)    
44 mm (1.7 inch)    
19 mm (0.7 inch)    
Disassemble the engine hood. Refer to the Disassembly and Assembly Service Manual for the correct procedure regarding removal of the engine enclosure group. The weight of the enclosure is 77 kg (170 lb).
Illustration 3 g01230658
Interior View Of The Hood Assembly (K) Crack
Repair the cracks on the interior of the hood assembly. Grind the crack to a vee groove. Weld the crack and grind the weld smooth.
Remove the paint and prepare the surfaces at the four corners for welding the gussets.
Illustration 4 g01230666
Hood Assembly (1) Corner 1 (2) Corner 2 (3) Corner 3 (4) Corner 4
Position the four gussets. Refer to Illustration 4.
Illustration 5 g01230672
Fabricated Gusset In The Hood Assembly (L) Start of the weld (M) End of the weld
Weld the gusset in corner 1 from point (L) to point (M) in the direction that is shown in Illustration 5.Note: An additional 1.5 mm (0.06 inch) thick spacer is required for corner 2 and corner 4. The additional spacer compensates for the thickness differences.
Repeat Step 5 at the remaining three corners.
Illustration 6 g01230847
Chamfer the crack on the outside of the sheet metal. Refer to Illustration 6.
Weld the crack. Use a backup strip behind the crack, if necessary.
Illustration 7 g01230849
Grind the weld flush with the sheet metal. Refer to Illustration 7.
Illustration 8 g01230887
Detail P From Illustration 9 (G) 50 mm (2.0 inch) Radius (H) 20 mm (0.8 inch) Radius (N) 5 mm (0.2 inch)
Mill a radius in the four corners of the hood assembly. The milled area should duplicate the shape of the gusset. Refer to Illustration 8.
Polish the areas that were welded. If necessary, use a compound in order to obtain a smooth surface finish.
Illustration 9 g01230989
Finished Hood Assembly
Paint the welded areas in order to prevent corrosion.
Reassemble the engine enclosure group. Refer to the Disassembly and Assembly Service Manual for the correct procedure regarding reassembly of the engine enclosure group.