SFN-20240109E Reinforce innermost joints

TICO Document #: SFN-20240109E (formerly TES 153)

Complication: The cab protection bar may develop cracks at the innermost welded joints between the horizontal top tube and vertical support tubes.

Description of Procedure: Extra reinforcement is needed in the innermost joints between the vertical support tube and the horizontal top tube to strengthen those joints in these types of applications.

Units Affected: Units in railroad application.

Parts Required: Required Gusset, top tube reinforcement, painted cab bar 121213 (QTY 2) or

Required Gusset, top tube reinforcement, galvanized cab bar 12121 (QTY 2)

Planned Labor: 1 hour

Instructions:

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

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2. Remove battery box cover and disconnect the battery cables. Remove batteries or insulate terminal ends with a non-conductive wrap to prevent inadvertent contact between battery terminals and cables.

3. Use a welding blanket to cover the rear of the cab, grating underneath the cab protection bar, tractor protection valve, fuel components, and exhaust components to prevent the weld by-product from damaging these components during the repair process.

4. Locate a vertical post to the immediate right of the cab door.

5. Position 121213, or 121214, gusset 1” in from the outside face of top horizontal tube and flush to the inside surface, facing door, of the vertical support.

6. Mark the location of the gusset with a scribing line all the way around.

7. Remove the finish to 1/2” away from the scribed line. Do not remove the finish inside the scribed line.

8. Repeat for the vertical post to the left of the cab door.

9. On right-hand side of the cab bar, remove the plug at the top of the horizontal tube directly above vertical member.

10. Pull the cab bar lighting harness up towards the top of the horizontal top tube and secure in place to prevent damage from welding heat during the repair process.

11. Repeat for left-hand side of the cab bar.

12. Position 121213, or 121214, gusset 1” in from the outside face of the horizontal top tube and flush to the vertical support tube.

13. Apply sufficient tack weld to secure it in place.

14. Deposit 1/4 filet weld all the way around the edge of the gusset. See table for weld settings.

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

15. Paint gusset with rust inhibitive paint and primer.

16. Remove weld blankets.

17. Reinsert plugs previously removed from horizontal top tube and silicone in place.

18. Reconnect battery terminals.

11. Remove the “Lock Out, Tag Out” plaque.

12. Return vehicle to service.