A Mainframe Rework Procedure is Now Available on Certain Pipelayer {7051} Caterpillar

Pipelayer

583R (S/N: 2XS1-UP)

587T (S/N: FAT1-UP)

Introduction

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

This special instruction provides the procedure to repair the Pipelayer tower support for the Pipelayer crossbeam structure. This procedure requires the replacement of the side sheet and installation of reinforcement material.

Safety Section

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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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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Reference Section

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

Reference: Reuse And Salvage Guidelines, SEBD0512, "Service Welding Guide"

Reference: Operation and Maintenance Manual, SEBU8031, "587T Pipelayer"

Reference: Disassembly and Assembly, SENR8456, "587T Pipelayer"

Reference: Disassembly and Assembly, RENR8169, "587T Pipelayer"

Reference: Operation and Maintenance Manual, SEBU7109, "583R Pipelayer"

Reference: Disassembly and Assembly, SENR1811, "583R Pipelayer Machine Systems"

Processes for Repair and Welding

Use the following electrodes: low hydrogen E7018 electrode, E70S-3 (dual shield) solid wire, and E71T-1 flux cored wire.

All electrodes must be dry.

Do not weld in areas if there is a strong movement of air or in temperatures of less than 16 deg C (61 deg F).

The following welding processes are acceptable for this procedure:

• Gas metal arc welding (GMAW) - Use 35 ± 5 cfh of shielding gas (75% argon and 25% carbon dioxide).

• Flux cored arc welding (FCAW) - Use 35 ± 5 cfh of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.

• Shielded metal arc welding (SMAW) - Use E7018 electrodes in this DCEP process.

• Air arc gouging (DCEP) - Use 5/16 inch diameter rods for carbon arc.

Rework Preparation

• Tracks need separated to provide access to the inside mainframe area.

• Remove extra hardware as needed for access.

Required Parts

All fabricated plates are 290Mpa yield strength.

ASTM A572 Grade 42 or 50.

EN10025 s355k2g3 or equivalent.

Illustration 1	g06313352
(Plate 1) 10 mm (0.39 inch) thick

Illustration 2	g06313362
(Plate 2) 10 mm (0.39 inch) thick

Illustration 3	g06313659
(Plate 3) 10 mm (0.39 inch) thick

Illustration 4	g06313734
(Plate 4) 16 mm (0.63 inch) thick

Illustration 5	g06313738
(Plate 5) 16 mm (0.63 inch) thick

Illustration 6	g06313742
(Plate 6) 16 mm (0.63 inch) thick

Rework Procedure

Right-hand Tower

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Illustration 7	g06313747
(W1) 12 mm (0.47 inch)

1. Position doubler plate (4) next to the tower plate.

2. Weld (W1) around doubler plate (4) or the thickness of plate (4).

   Note: Grind the weld flush on the face and at the ends to eliminate additional stress concentrations.

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   Illustration 8	g06313772

3. Locate plate (1) and tack into position. Top edge should be in line with tower plate (4).
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   Illustration 9	g06313774
   (D2) 90 mm (3.54 inch) (W2) 8 mm (0.32 inch)

4. Weld (W2) all the way around plate (1). Terminate weld (W2) at dimension (D2).

5. Weld the gap between plate (1) and plate (4).

Left-hand Tower

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Illustration 10	g06313749

1. Position doubler plate (5) and (6) next to the tower plate.
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   Illustration 11	g06313752
   (W1) 12 mm (0.47 inch)

2. Weld (W1) of plate (5) and (6) in the locations shown in Illustration 11.
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   Illustration 12	g06313775

3. Locate plates (2) at the top edge of plate (5). Tack plate (2) into position.

4. Center plate (3) with respect to tower (C).
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   Illustration 13	g06313704
   (D3) 150 mm (5.90 inch) (W2) 8 mm (0.32 inch)

5. Weld (W2) all the way around two plates (2). Terminate weld (W2) at dimension (D3).

6. Weld (W2) all the way around plate (3).

   Note: If access prevents from welding all the way around plate (3), see the weld in Illustration 13.

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   Illustration 14	g06313779

7. Weld the gap between plates (2) and plates (5) and (6). Weld the gap between plate (3) and plate (B).