HOSE A 5U2353 - Caterpillar

Illustration 1 g00699944
Refer to Table 1 for the dimensions shown in Illustration 1. Fabricate the gusset from the following dimensions: A, B and C. Chamfer the gusset using dimension D and dimension E.
Illustration 2 g00722641
Typical fabricated gusset with chamfers
Table 1
Dimensions that are Required in order to Fabricate Gussets    
Dimension     14G, 14H     16G, 16H    
A    
44.5 mm (1.75 inch)    
63.5 mm (2.50 inch)    
B    
101.6 mm (4.00 inch)    
127 mm (5 inch)    
C    
44.5 mm (1.75 inch)    
47.63 mm (1.875 inch)    
D    
12.7 mm (0.50 inch)    
12.7 mm (0.50 inch)    
E    
12.7 mm (0.50 inch)    
12.7 mm (0.50 inch)    
Refer to the dimensions in Illustration 1, when you fabricate the two gussets. Use ASTM A 36 or SAE 1018 Steel .
You may need to remove some items before you begin repairs. Remove all of the following items: paint, rust, dirt, grease and oil.
Illustration 3 g00699945
Differential Case Assembly Crack Location
Use an air carbon arc torch or a similar tool in order to remove the weld from Area (1) in Illustration 3. Gouge a groove that is a minimum of 6.4 mm (.25 inch) deep, in which to deposit the weld.
On the outside of the case assembly, gouge a groove to a depth that is half the thickness of the side plate. The groove should extend the length of the crack. See Area (2) in Illustration 3.
Clean the groove joint. Prepare the groove joint for welding.
Refer to Illustration 3. Weld repair the groove joints in Areas (1) and (2). Keep the weld in Area (1) flush with the plate. Remove the slag after each weld pass.
Weld the corresponding area on the inside of the differential case assembly .
Illustration 4 g00733531
View of Area ALocation of the gusset
Refer to Illustration 4. Tack weld the fabricated gussets in position.
Weld Area (4) in Illustration 4. Make sure the joint is completely filled with weld. Remove the slag after each pass.
Weld Area (3), completely filling the joint. Remove the slag after each pass.
Repeat Steps 9 and 10 on the inside of the case assembly .
Illustration 5 g00733532
View of Area ABlending Weld.
Weld Area (5) in Illustration 5. Blend the weld from the top of the case assembly side plate to the gusset. Remove the slag after each pass.
Weld Area (6) in Illustration 5. Blend the weld from the gusset to the yoke plate. Remove the slag after each pass.
Repeat the preceding steps for the opposite side of the differential case assembly. Paint the case assembly, if necessary.