BRAKE G. 4D5430 - Caterpillar

The recommended repair technique depends on the extent of the damage. Reinforcement may be added if the damage is not too extensive. If the tower is badly damaged it is recommended that it be removed completely and a new one installed.Reinforcement of Existing Tower
Use structural type steel with 290 MPa (42,000 psi) minimum yield strength, and with 435 MPa (63,000 psi) minimum tensile strength for all fabricated plates. 1. Fabricate two reinforcement plates (1), one for each side, using the dimensions shown. 2. Fabricate four reinforcement ribs (2), two for each side, using the dimensions shown.3. Park the machine in a straight ahead position.
Do not disconnect or remove hoses or fittings until all pressure in the suspension system has been relieved. Failure to relieve pressure may cause personal injury.
4. Operate the handle on the suspension control valve to release the pressure in the suspension system. Do not release the handle until the hissing noise has stopped.5. Raise the tractor unit up and support it on suitable stands.6. Remove the front wheels.7. Disassemble the tractor unit until the suspension towers are fully accessible. Detailed instructions are not given, but assemblies which must be removed include the access steps, deck plates, transmission guard, accumulator, suspension cylinders, hydraulic module, and air system module. (See the Service Manual).8. To ensure correct reassembly, mark all lines, hoses and fittings before they are disconnected.9. Plug all hydraulic hoses, pipes, fittings and open ports.10. Make sure that all pipes, hoses and wiring harness assemblies passing behind the towers are protected or moved out of the way.11. Thoroughly clean the two suspension towers and inspect them for damage.12. Correct all damage (cracks) by gouging out and rewelding as required. All welds must be 8 mm (.3") fillet welds.13. Put the reinforcement plate and ribs in position on the tower and tack weld the ribs only. Remove the plate. 14. Weld ribs (2) in place as shown with an 8 mm (.3") fillet weld all around.Make sure that outer welds (3) do not cut into the corners of the existing tower flanges. 15. Weld plate (1) in place as shown with an 8 mm (.3") fillet weld all around.Make sure that the weld area does not get too close to the holes in the right hand tower, or to the top of the main frame as shown.16. Remove all weld spatter and paint the area.17. Check all pipes, hoses and wiring harness assemblies to make sure there has been no accidental damage, then strap them in place as before.18. Reassemble all parts that were removed earlier. On start-up make sure all systems are operating correctly before putting the machine to work. Check for air and oil leaks and be sure that the braking system and hydraulic systems (particularly the steering) are operating correctly.Replacement of Towers
If tower damage is extensive, the existing towers can be removed and new ones installed.New towers can be purchased complete if required. Part numbers are: 5U3553 (L.H.) and 5U3554 (R.H.).Alternatively, new towers can