STICK A-SHOVEL 4V9027 - Caterpillar

Introduction
The Special Instruction outlines the procedure for reworking the underside of the body when a channel on the base plate of the body is directly above the manifold for the brake cooling lines.This procedure may be used on machines equipped with an original factory fitted body or when a replacement body is installed from another machine. New bodies are built with the improved clearance.
Do not perform the procedures that are outlined in this Special Instruction until you understand the information that is contained in this document.
Rework Procedure
Illustration 1 g03342705
The channel to be relocated (1) The rework information detailed in this Special Instruction, moves the existing channel (1) that is above the brake cooling manifold (2) to a new position closer to the rear end of the body. If the existing channel is damaged, information is supplied for fabricating a new channel. Before performing the procedure, check that the channel is above the manifold.Note: Check the channel to be sure that the channel is in serviceable condition. If the channel needs replaced, fabricate a new channel before removing the existing channel. Refer to the Section ""Fabrication of New Channel"" at the end of this Special Instruction.
Table 1
Required Tools    
Tool    Part No.    Description    Qty.    
A     389-5758     Support Angle     2    
Park machine on a solid level surface.
Illustration 2 g03332027
Raise the body fully. Install two tooling (A) to ensure safety while working. Shut off the engine. Install a suitable working platform. The weight of the 389-5758 Support Angle is approximately 66 kg (146).
Illustration 3 g03332248
Using suitable grinding tools remove the welds (3) holding the channel (1) in place.
Inspect existing channel (1) for damage. If the channel shows damaged that was not seen before or shows damage caused by removal, then fabricate a new channel.
Inspect the area of the body where channel (1) was originally positioned. Remove all remaining weld material and smooth off all the surfaces. Check for cracks. If a crack is found, gouge the crack out ensuring to remove both ends of the crack. Fill in the gouged areas with weld material then smooth off the surface with a suitable grinder. Use dye penetrate to confirm the crack has been removed.
Illustration 4 g03332879
Measure the location for the new position of channel (1). Use channel (3) which is at the rear of the body as a reference. Remove paint and clean the surface of the body to bare metal in the location for the repositioned channel. Mark the new position of the channel, the dimensions are shown in table 2
Table 2
Dimensions for New Position of Channel    
G    
720 mm (28.3 inch)    
H    
8 mm (0.3 inch) fillet weld,
1.5 mm (0.06 inch) root penetration    
Position Channel (1) into the new location. Weld the channel into position. Refer to illustration 4 and table 2. Also, refer to Special Instruction, REHS1841, "General Welding Procedures"
Use a suitable grinder to remove any weld spatter and dress the welds. Paint all surfaces with primer and