HEAD G-CYL 4W5438 - Caterpillar

Measure and record the position of the Steering Frame Lock Stowage Brackets (B) on each side of the rear frame.
Using a suitable cutting method (grinding, air carbon arc torch, plasma arc, oxy/fuel cutting), remove the hoist cylinder support plates and the steering frame lock stowage brackets from both sides of the rear frame. Refer to Illustration 75 and Illustration 76. If any voids are created during the plate removal, fill the voids with weld and grind flush with the surface of the frame rail. The Hoist Cylinder Support Plates (A) may be discarded. Retain the steering frame lock stowage brackets for reuse.
Thoroughly clean the area around the cracks. remove all dirt, paint, grease, or other contaminants from the area to be repaired. determine the size, orientation, and length of the cracks by Magnetic Particle Testing (MPT), Ultra-Sonic Testing (U/T) or Dye Penetration Testing (DPT). Ensure that the cracks (including branches), are marked and identified appropriately.
Illustration 77 g03652289
(C) Example of 6 mm (0.24 inch) hole
Prevent the crack from propagating by drilling 6 mm (0.24 inch) holes (C) at a distance of up to 10 mm (0.39 inch) from the ends of the cracks. Refer to Illustration 77
Remove and repair the cracks by following the same procedures for Low Severity Cracks detailed earlier in this instruction.Bracing Plate Installation - Item 1 Plate - Right Hand
Illustration 78 g03652294
(A) 8 mm (0.315 inch) fillet welds around the outside edge of the plate and in the 2 "pockets" in the plate (B) Flush Bevel Weld (1) Plate - Right Hand
Position Item (1) Plate - Right Hand as shown in Illustration 78. weld the plate to the frame side rail using 8 mm (0.315 inch) fillet welds around the outside edge of the plate and in the two pockets in the plate (A). Use a Flush Bevel Weld (B) at all the joints between the Item (1) Plate and the existing plate for the dump body prop support bracket. Ensure that all weld transitions are smooth and have no "stop - starts".
Using the dimensions recorded in Step 1 of the Crack Repair procedure, reattach the stowage bracket for the steering frame lock to the Item (1) Plate Right -Hand as close to the original location as is possible. Ensure that any attaching welds for the stowage bracket do not contact the attaching welds between the plate and the frame rail.Note: Attaching the bracket in the same location may not be possible due to the shape