Procedure for Installing Counterweight Rod Holders on Certain PL72 PL83 and PL87 Pipelayers {7056} Caterpillar

Procedure for Installing Counterweight Rod Holders on Certain PL72 PL83 and PL87 Pipelayers {7056} [M0124064]

FRAME AND BODY

COUNTERWEIGHT GP

Procedure for Installing Counterweight Rod Holders on Certain PL72 PL83 and PL87 Pipelayers {7056}

1.1. Introduction

2.1. Reference Section

3.1. Safety Section

4.1. Welding Specifications and Qualifications

5.2. Qualifications

6.2. Area Preparation

7.2. Welding Electrodes and Parameters

8.3. Flux Cored Welding Electrode for the FCAW Process

9.3. Low Hydrogen Electrodes for the SMAW Process

10.2. Weld Inspection and Acceptance Criteria

11.1. Required Parts

12.1. Machine Preparation

13.2. Maintenance with the Engine Running

14.2. Maintenance without the Engine Running

15.2. Maintenance with Electrical System Disabled

16.1. Procedure

17.2. Welding Plates

18.2. Rod Holder Installation

Pipelayer
PL72 (S/N: P721-438; P731-414)
PL83 (S/N: CB21-399; DLW1)
PL87 (S/N: TEC1-UP; ZAC1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Specifications, SENR3130, "Torque Specifications"

Reference: Special Instruction , REHS1841 , "General Welding Procedures"

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury or death can result from sudden movement.
Prevent possible injury by performing the following procedures before work begins:
Move the product or equipment to a smooth, level surface.
When applicable, lower equipment/work tools to the ground.
Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key.
Release system pressure from pressurized systems.
If applicable, block the wheels/tracks.
Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.

Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations.

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Illustration 1	g06276183

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Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information.

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Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.

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Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do the job.
Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Welding Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill.
Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts.

Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Reference: Refer to Special Instruction , REHS1841 , "General Welding Procedures" for more information.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

Oil
Grease
Paint
Dirt
Rust
Any fluids or moisture

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the welding spatter.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1M-JH4 per AWS A5.20 welding electrode. Use shielding gases that are 75% argon and 25% carbon dioxide. The H4 implies that the electrode is designed to provide less than 4 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

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Table 1
Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1M-JH4"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -40 °C (20 ft lb @ -40 °F)

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters.

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Table 2
Welding Current for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate	Voltage	Amperage
7620 mm (300 inch) Per Minute to 10,160 mm (400 inch) Per Minute	24 to 28	190 to 240

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Table 3
Welding Current for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate	Voltage	Amperage
5080 mm (200 inch) Per Minute to 6350 mm (250 inch) Per Minute	23 to 27	180 to 220

Note: The settings listed above are recommendations-based on experience from welding in the horizontal, vertical-up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. Higher parameters are acceptable to use for welding in the flat position.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

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Table 4
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "E8018-C3 H4 per AWS A5.5"
Tensile Strength	550 MPa (80000 psi)
Yield Strength	470 MPa (68000 psi)
Elongation	24%
Impact Toughness	27 J @ -40 °C (20 ft lb @ -40 °F)

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Table 5
Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "E7018-1 H4 per AWS A5.1"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -45 °C (20 ft lb @ -50 °F)

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturers specifications.

The table that follows shows the settings for the welding current based on electrode diameter.

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Table 6
Welding Current for Low Hydrogen Electrodes
Diameter	Amperage Rating
3.2 mm (1/8 inch)	105-155
4.0 mm (5/32 inch)	130-200
4.8 mm (3/16 inch)	200-275

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Weld Inspection and Acceptance Criteria

Abrasion resistant steel plates, which are part of the body structure, are susceptible to hydrogen induced cracking or delayed cracking. This type of cracking normally occurs within 72 hours of welding. As a result, allow the welding areas to cool for 72 hours prior to performing a final inspection. All welds are to be inspected using ultrasonic testing per AWS D1.1 acceptance criteria for cyclically loaded non-tubular connections in tension. Any locations where ultrasonic testing is not possible are to be visually inspected using a method such as dye penetrant or magnetic particle testing.

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Table 7
Defect Name	ISO 6520 Defect Reference Number	Remarks	Defect Limit
Cracks - Longitudinal, Transverse, Radiating, Crater, Disconnected, Branching	1011, 1012, 1013, 1014, 1023, 1024, 1031, 1033, 1034, 1045, 1046, 1047, 1051, 1053, 1054, 1061, 1063, 1064	--	Not Permitted
Crack - Transverse	1021	Hard Surfacing Welds Only	Permitted
Crack - Transverse	1021	Joining Welds	Not Permitted
Porosity	2011, 2012, 2014, 2017	Maximum Diameter for a Single Pore	1 mm (0.040 inch)
		Maximum Pores in Any 300 mm (11.81 inch) Length of Weld	6
		Maximum Number of Pores in Any 50 mm (2.0 inch) of Weld Length for Welds Less Than 300 mm (11.81 inch) in Length	1
Clustered Porosity	2013	Maximum Length of Cluster in Any Weld	3 mm (0.120 inch)
Elongated Cavities	2015	Maximum Height or Width	3 mm (0.120 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Wormholes	2016	Maximum Dimension of Any Single Cavity	3 mm (0.120 inch)
Wormholes	2016	Maximum Total Length of Affected Area in Any Weld	10% of Weld Length Not to Exceed 25 mm (1.00 inch)
Shrinkage Cavities	2021, 2024, 2025	Maximum Diameter or Length	1 mm (0.040 inch)
Slag or Flux Inclusions	3011, 3012, 3014, 3021, 3022, 3024	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Oxide Inclusions	3031, 3032, 3033	Maximum Height or Width	1 mm (0.040 inch)
		Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Puckering (Oxide Inclusion - Aluminum)	3034	--	Not Permitted
Metallic Inclusion	3041, 3042, 3043	--	Not Permitted
Lack of Fusion	4011, 4012, 4013	Visual (Breaking the Surface)	Not Permitted
		Subsurface Maximum Height or Width	1 mm (0.040 inch)
		Subsurface Maximum Length for Any Single Discontinuity	25 mm (1.00 inch)
		Maximum Length in Any Weld	10% of Weld Length
Lack of Penetration	402, 4021	Maximum Reduced Penetration	10% of Nominal Penetration Not to Exceed 1 mm (0.040 inch)
Lack of Penetration	402, 4021	Maximum Allowed Total Length of Reduced Penetration	10% of Weld Length
Undercut	5011, 5012, 5013, 5014, 5015	Maximum Depth Measured From Plate Surface - Any Length	0.25 mm (0.01 inch)
Excess Weld Metal - Groove Weld Reinforcement (Convexity)	502	Any Length	--
		Weld Face Width 5 mm (0.20 inch) or Less	1 mm (0.040 inch)
		Weld Face Width Over 5 mm (0.20 inch) But Less Than 10 mm (0.40 inch)	1.5 mm (0.060 inch)
		Weld Face Width Over 10 mm (0.40 inch) But Less Than 20 mm (0.80 inch)	2 mm (0.080 inch)
		Weld Face Width Over 20 mm (0.80 inch) But Less Than 30 mm (1.20 inch)	3 mm (0.120 inch)
		Weld Face Width 30 mm (1.20 inch) and Over	4 mm (0.160 inch)
Excess Weld Metal - Fillet Weld Convexity		Weld Face Width Less Than 8 mm (0.3125 inch)	Maximum convex height 1.6 mm (0.0625 inch)
		Weld Face Width Greater Than 8 mm (0.3125 inch) but less than 25.4 mm (1 inch)	Maximum convex height 3.2 mm (0.125 inch)
		Weld Face Width Greater Than 25.4 mm (1 inch)	Maximum convex height 4.8 mm (0.1875 inch)
Excess Penetration	5041, 5042, 5043	Without Drawing Limitation	2 mm (0.080 inch) (Any Length)
		With "Melt - Through" and "Flush" Weld Symbols	1 mm (0.040 inch) (Any Length)
		With "Melt - Through" and "Grind Flush" Symbols	Not Permitted (After Grinding)
Incorrect Weld Toe	505	When 1E2995 Applies (Expressed as a Toe Radius Rather Than a Toe Angle)	3 mm (0.120 inch) Minimum Radius
Overlap	5061, 5062	Expressed as Minimum Toe Angle	90 Degrees
Fillet Weld Leg Size - Undersize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Undersize	1 mm (0.040 inch)
		Maximum Length of Undersize Weld	10% of Total Weld Length if at Least 10% of Total Weld Length is at Least 1 mm (0.040 inch) Over Nominal Size, Otherwise, No Undersize Length is Permitted
Fillet Weld Leg Size - Oversize	--	Applies to Either Weld Leg Measured Independent of the Other	--
		Maximum Oversize	+25% (max 3 mm (0.120 inch))
		Conformance to Design - Fillet Weld Leg Sizes May be Oversized (Within Defect Limitations or Beyond). Without Correction Provided the Excess Does not Interfere with Satisfactory End Use of the Component (Distortion, Fit-Up Interference).	--
Fillet Weld - Linear Length when specified at less than the length of the joint	--	Weld Size ≤ 6.5 mm (0.256 inch)	± 6.5 mm (0.256 inch)
	--	Weld Size ≥ 6.5 mm (0.256 inch)	± 12.5 mm (0.492 inch)
Fillet Weld Throat Size - Undersize	5213	Nominal Size (0.7 x Leg Size) Not Inclusive of Penetration Beyond the Weld Root	Not Permitted
Fillet Weld Throat Size - Undersize	5213	Weld Crater Only - Maximum Undersize	Not Permitted
Incompletely Filled Groove Weld	511	Careful Consideration Needs to be Given When Plate Mismatch is Apparent	Not Permitted
Incompletely Filled Groove Weld	511	Weld Depth Must be Maintained as a Minimum	--
Root Concavity on Open Root Groove Welds	515, 5013	Maximum Depth measured From Plate Surface or Tube Inner Surface - Any Length	0.5 mm (0.020 inch)
Stray Arc Strike	601	--	Not Permitted
Slag Residue	615	SMAW, SAW, FCAW, GMAW	Not Permitted
Slag Residue	615	GTAW	Silicon Residue Permitted Unless Removal Specified by Drawing Note
Combined Discontinuities	--	Total Maximum Combined Length of All Imperfections in a Weld, Expressed as a Percent of Total Weld Length	15%
Combined Discontinuities	--	(No Single Type of Imperfection Can Exceed the Limits for That Single Type of Imperfection)	--

Required Parts

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Table 8
Item	Qty	Part Number	Part Name
1	4	8X-5963	Block
2	8	5P-1076	Hard Washer
3	8	8T-4139	Bolt
4	2	575-2169	Bracket

Machine Preparation

Move the machine to a dry, level, solid surface that is free of any debris.
Note: The surface must be solid enough to support the weight of the machine and any tooling that is used to support the machine.
Put the machine in park. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
Lower all the machine implements to the ground. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
Ensure that the pressure is released from any closed system that will be opened during the maintenance procedure. Refer to Operation and Maintenance Manual, "System Pressure Release" for more information.

This machine is equipped with lockout controls to suit the following types of machine maintenance.

Maintenance with the Engine Running

For maintenance that requires the engine to be running, perform the following:

Run the engine at an idle.
Deactivate the implements by using the hydraulic lockout switch. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.

Maintenance without the Engine Running

For maintenance that does not require the engine to be running, perform the following:

Move the engine start switch to the OFF position. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.

Maintenance with Electrical System Disabled

For maintenance that requires the electrical system to be disabled, perform the following:

Move the engine start switch to the OFF position. Refer to Operation and Maintenance Manual, "Operator Controls" for more information.
Move the battery disconnect switch to the OFF position. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" for the proper procedure.

Procedure

Welding Plates

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Illustration 2	g06609387
PL87 (1) 8X-5963 Block (D1) 2 x 2027 ± 2.5 mm (80 ± 0.10 inch) (D2) 2 x 190 ± 1.5 mm (7.50 ± 0.06 inch) (D3) 4 x 130 ± 1.5 mm (5.12 ± 0.06 inch) (W1) 10 mm (0.40 inch)

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Illustration 3	g06609477
PL83 (1) 8X-5963 Block (D1) 2 x 2027 ± 2.5 mm (80 ± 0.10 inch) (D2) 2 x 190 ± 1.5 mm (7.50 ± 0.06 inch) (D3) 4 x 130 ± 1.5 mm (5.12 ± 0.06 inch) (W1) 10 mm (0.40 inch)

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Illustration 4	g06609497
PL72 (1) 8X-5963 Block (D1) 2 x 1708 ± 2.5 mm (67.24 ± 0.10 inch) (D2) 2 x 190 ± 1.5 mm (7.48 ± 0.06 inch) (D3) 4 x 90 ± 1.5 mm (3.54 ± 0.06 inch) (W1) 10 mm (0.40 inch)