CROSS 2072484 - Caterpillar

Cover Machining
Illustration 12 g02357040
Move the end mill until the end mill touches the damaged surface.
Move a 50 mm (2.0 inch) end mill into the cover until the end mill touches the damaged surface.
Machine the face until a clean-up is obtained, and deburr the inside diameter. Do not machine the face deeper than 119.00 mm (4.685 inch) from the cover face.
Illustration 13 g02357096
Thrust face after machining.
Remove the transmission cover from the table of the boring mill.
Use a die grinder to blend the machined area with the webs on the transmission cover. Make sure that there are no sharp corners that could act as stress concentrators.
Illustration 14 g02357159
Casting webs must be blended with the machined area.Spacer Machining
Machine a spacer, from SAE1020 steel, to be used in the Method Two procedure.
Illustration 15 g02357258
Use a depth micrometer to measure from the cover face down to the previously machined thrust face. Record this measurement.
Subtract 114.00 mm (4.488 inch) from the measured depth. The difference will be the thickness of the spacer. Dimensions for the spacer are shown in Illustration 17. The two faces of the spacer should be parallel within 0.03 mm (0.001 inch).
Use a lathe to machine the spacer to the dimensions in Table 4.
Illustration 16 g02357336
Partially machined spacer.
Illustration 17 g02357356
Spacer dimensions (see Table 4 for dimensions.) Make spacer from SAE1020 steel.
Table 4
Machining Dimensions for Spacer    
Item     Dimension    
E    
57.98 + 0.03 - 0.00 mm (2.283 + .001 - .000 inch) diameter    
F    
94 mm (3.7 inch) diameter    
G     Thickness (see Step 2)    
H     Corner break (three places)    
J     30°    
K    
1.5 0.50 mm (0.059 0.020 inch)    Weld Spacer
Illustration 18 g02357441
Alignment plug placed in the bore with spacer in place.
Place the alignment plug in the bore. this procedure will correctly locate the spacer for welding.
Place the spacer over the alignment plug with the chamfered side up. See "Spacer Machining" for the correct method of making the spacer.
Illustration 19 g02357496
Pre-heating the spacer and cover.
Use a torch to raise the temperature of both the spacer and the webs of the cover to approximately 93°C (200°F).
Use a TIG welder to tack weld the spacer at each web. Care must be used to keep the spacer flat against the machined thrust face and the tack welds below the surface of the spacer.
Illustration 20 g02357517
Welding the spacer to the webs of the cover.
Illustration 21 g02358057