2000/08/21 Caterpillar

Motor Grader:

14G (PIN: 96U1-UP)

14H (PIN: 7WJ1-UP)

16G (PIN: 93U1-UP)

16H (PIN: 3JR1-UP; 6ZJ1-UP)

Service Magazine, SEPD0531, 03 July 2000, "Correction to Service Magazine, "Add Gussets To Strengthen Differential Case Assembly Side Plates If Weld Cracks Are Found In Seams"". Some of the information in this article is incorrect. Disregard this article. See the following article.

Use the following procedure in order to repair any cracks that may form in the differential case assembly side plates.

Note: E7018 welding rod should be used to make the following repairs and the temperature of the case assembly should be at least 15°C (60°F). Use the direct current electrode positive (DCEP) polarity setting and remove slag after every pass.

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)

1. Refer to the dimensions in Illustration 1, when you fabricate the two gussets. Use ASTM A 36 or SAE 1018 Steel .

2. 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

3. 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.

4. 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.

5. Clean the groove joint. Prepare the groove joint for welding.

6. 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.

7. Weld the corresponding area on the inside of the differential case assembly .

Illustration 4	g00733531
View of Area A Location of the gusset

8. Refer to Illustration 4. Tack weld the fabricated gussets in position.

9. Weld Area (4) in Illustration 4. Make sure the joint is completely filled with weld. Remove the slag after each pass.

10. Weld Area (3), completely filling the joint. Remove the slag after each pass.

11. Repeat Steps 9 and 10 on the inside of the case assembly .

Illustration 5	g00733532
View of Area A Blending Weld.

12. 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.

13. Weld Area (6) in Illustration 5. Blend the weld from the gusset to the yoke plate. Remove the slag after each pass.

14. Repeat the preceding steps for the opposite side of the differential case assembly. Paint the case assembly, if necessary.