SFN-20240108D Install rear bolster extension

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TICO Document #: SFN-20240108D (formerly TES 167)

Description of Procedure: Procedure for installation of the rear bolster extension to TOTE Maritime’s San Juan bombcarts.

Units Affected: N/A

Parts Required: Assembly, Rear Bolster Extension (1 required) White Zinc Primer Signal Yellow Paint, RAL 1003, 520621 (QTY 1)

Planned Labor: N/A

Instructions:

  1. Park the vehicle on a flat surface, apply a parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

  2. Remove the ICC bumper from bombcarts. Make sure any uneven surfaces and the residual weld is grinded smooth and flush with tubes on the rear bolster.

  1. Remove the finish to ½” inside and outside of the weld area perimeter on the rear bolster, as shown, using a wire brush attachment on a hand grinder. The weld area spans the entire width of the rear bolster and 10” below the top of the deck.

  1. Prepare 520621 for installation by removing the finish to ½” inside and outside of the weld area perimeter, as shown, using a wire brush attachment on a hand grinder on the side without conspicuity tape.

  2. The weld area’s top edge is 66 1 4 " long and is 18 1 8 " from the edge. The bottom edge is 57 1 2 ” long and is 22 1 2 " from the edge.

  1. Using lifting straps, position 520621 such that all of the tubes are level with one another and the left side is 18 1 8 " from the left edge of the bombcart’s rear bolster.

  2. Apply sufficient tack weld to secure in place. Do not remove the straps.

  1. Using the weld settings shown below, weld the top side of 520621 to the bombcart’s rear bolster by depositing a flare-v groove weld 10” long at each end, as shown below. Weld should be flush with the top of the tubes.

Note: Weld settings are for the FCAW process using Lincoln Electric UltraCore 71A85 wire and 85% Argon/15% CO2 gas mixture or equivalent.

  1. Weld the bottom side of 520561 to the bombcart by depositing a flare-bevel groove weld, as shown below.

Note: Weld settings are for the FCAW process using Lincoln Electric UltraCore 71A85 wire and 85% Argon/15% CO2 gas mixture or equivalent.

  1. Weld the front side of 520561 to the ends of the bolster by depositing a ¼” fillet weld, as shown below.

  2. Repeat weld on the opposite side.

Note: Weld settings are for the FCAW process using Lincoln Electric UltraCore 71A85 wire and 85% Argon/15% CO2 gas mixture or equivalent.

  1. Weld the front side of 520561 to the bombcart by depositing a flare-bevel groove weld at the rear bolster and then a ¼” fillet weld at the main beams, as shown below.

Note: Weld settings are for the FCAW process using Lincoln Electric UltraCore 71A85 wire and 85% Argon/15% CO2 gas mixture or equivalent.

  1. Finish welding the top side of 520621 to the bombcart’s rear bolster by depositing a flare-v groove weld into the remaining section of the groove, as shown below. The weld should be flushed with the top of the tubes.

Note: Weld settings are for FCAW process using Lincoln Electric UltraCore 71A85 wire and 85% Argon/15% CO2 gas mixture or equivalent.

  1. Apply white zinc primer to all bare metal surfaces and welds. Paint primed surfaces Signal Yellow, RAL 1003.

  1. Remove straps from bolster extension.

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.