10/4/25, 9:56 SIS 2.
Procedure to Weld the Tool Holder Block on K-Type Rotor for Certain Cold Planers
2021/01/05
{6637} (M0125691)
SMCS - 6637 i08328359
Cold Planer
PIP
PM310 (S/N: NM91-UP; KWA1-UP; NMA1-UP)
PM312 (S/N: NA91-UP; NJ91-UP; NJX1-UP)
-
202 1054
PM313 (S/N: DK91-UP; JH91-UP; JHZ1-UP)
12: 5 / 0 7 764
5 4/ 1
M0 :07- 0
6
PM620 (S/N: FG41-UP; LB81-UP; JB91-UP; LH91-UP; 8RF1-UP)
PM622 (S/N: EL61-UP; XS61-UP; JFC1-UP; JCF1-UP; TPH1-UP)
1
© 2 2569 03:00
PM820 (S/N: RL31-UP; AN81-UP; HN81-UP; TLZ1-UP)
025 1
PM822 (S/N: JB71-UP; SL81-UP; E8S1-UP; H6S1-UP)
Cat
PM825 (S/N: 6261-UP; 6271-UP; HC81-UP; ESE1-UP)
Introduction erp
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listed above. rI
To weld the crack between the tool holder blocks on "K" type system rotors on the machines
nc.
Do not perform any procedure in this Special Instruction until you have read the information and
you understand the information.
Reference Section
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.
Caterpillar cannot anticipate every possible circumstance of a potential hazard.
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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 Caterpillar.
Ensure that the product will not be damaged or the product will be made unsafe by the
operation, lubrication, maintenance, or the repair procedures.
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.
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.
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.
Personal injury or death can result from improper maintenance
procedures. To avoid injury or death, follow the procedures
exactly as stated below.
Personal injury or death can result from sudden movement.
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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.
Illustration 1 g06276183
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.
Do not operate the machine if any guards or covers are missing
or inadequately secured. Personnel could be seriously injured
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or machine damage may occur.
Personal injury or death can result from fumes, gases, and
ultraviolet rays from the weld arc.
Welding can cause fumes, burn skin, and produce ultraviolet
rays.
Keep your head out of the fumes. Use ventilation, exhaust at the
arc, or both to keep fumes and gases from your breathing area.
Wear eye, ear, and body protection before working.
Protect yourself and others by reading and understanding 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 cause death.
Read and understand the instructions of the manufacturer and
the safety practices of your employer. Do not touch live
electrical parts.
See “American National Standard Z49.1, Safety in Welding and
Cutting” which is published by the American Welding Society.
American Welding Society
8669 NW 36 Street #130
Miami, Florida 33166-6672
1-800-443-9353
See “OSHA Safety and Health Standards, 29 CFR 1910” which is
available from the U.S. Department of Labor.
U.S. Department of Labor
Washington, D.C. 20210
See applicable requirements for your local area.
The below procedures contain instructions for the following repairs:
To change the base blocks on the rotor shell or installation of rotors that are configured with
15.0 mm (0.59 inch) (standard) axial pitch using the 553-2020 Tool Gp for 2.0 m, 2.2 m, and
2.5 m rotor. For 1.0 m, 1.2 m, and 1.3 m rotor use 577-4187 Tool Gp.
Process to repair the weld crack between base blocks.
"K" type rotor block replacement procedure.
"K" type rotor end ring block replacement procedure.
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Procedure to Weld a Spiral Block
Table 1
Required Part
Item Qty Part Number Part Name
1 496-3470 Block
1
1 512-3231 Block
Table 2
Required Tools
Item Qty Part Number Part Name
553-2020 Tool Gp
T1 1
577-4187 Tool Gp
Illustration 2 g06622202
Base blocks on shell
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Illustration 3 g06622216
Illustration 4 g06622236
1. Grind and clean the shell surface from the remaining welds or weld portions. Refer to
Illustration 3 and Illustration 4.
Illustration 5 g06620372
2. Assemble the pins on the blocks close to the removed block. Refer to Illustration 5.
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Illustration 6 g06622603
(1) 512-3231 Block
3. Assemble the pin on new block (1) with the slot facing up, similar to Step 2.
Illustration 7 g06624397
(T1) 553-2020 Tool Gp/ 577-4187 Tool Gp
(A) 172-9966
(B) 548-8898
(C) 548-8896
(D) 548-8897
4. Assemble the tool on rotor as shown in Illustration 7.
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Illustration 8 g06624409
(1) 512-3231 Block
5. Tack weld the new block (1) on the shell on the two corners of the base.
Illustration 9 g06626027
(1) 512-3231 Block
6. Tack weld the new block (1) on the shell on the other two corners of the base.
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Illustration 10 g06624441
Illustration 11 g06624768
Illustration 12 g06624770
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Weld to be performed in vertical position
Illustration 13 g06624873
Illustration 14 g06624874
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Illustration 15 g06624877
Illustration 16 g06624878
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Illustration 17 g06624881
Illustration 18 g06625273
(W1) 10.0 mm (0.40 inch) bevel- groove weld
(W2) 15.0 mm (0.60 inch) bevel-groove weld on both sides
(W3) 15.0 mm (0.60 inch) fillet weld
7. Use "Carbofil" 1 or equivalent filler material complete welding of the block as per the
following geometry and specification.
Material: AWS A5.18 ER70S-6
Gas protection 83% Ar -17% C02
Voltage (V): 26-27,5 V
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Current (A): 220-260 A
Speed: 250-310 mm/ min
Wire speed: 6.3 +/-0,4 m/min
Heat input (KJ/mm): 1.1 KJ/mm
Weld the block to the rotor assembly in two separate passes. Follow the weld sequence
from Illustration 10 to Illustration 17.
First pass - Weld passes as per the weld sequence from Illustration 10 to Illustration 17
should be large enough to fill the gaps only.
Second pass - Repeat the weld passes as per the weld sequence from Illustration 10 to
Illustration 17. The final weld dimensions are referred in Illustration 18.
Welds are allowed to air cool back to ambient temperatures. Do not return to milling until
fully cooled.
Process to Repair Weld Crack Between Base Blocks
Illustration 19 g06625274
1. Grind the weld cracked area. The ground zone needs to continue at a minimum of 3.0 mm
(0.12 inch) at the end of the visual crack.
2. Use acetylene torch to heat the area to be rewelded to a temperature of 150° C (302° F),
and the process will take approximately 1-2 minutes.
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Illustration 20 g06625278
(D1) is 12.0 mm (0.50 inch)
(D2) is 72.0 mm (2.83 inch)
(D3) is 37.946 mm (1.4939 inch)
3. Use "Carbofil" 1 or equivalent filler material and place a weld per dimension shown in
Illustration 20.
Note: Basically a weld with 12.0 mm (0.5 inch) on face.
4. Welds are allowed to air cool back to ambient temperatures. Do not return to milling until
fully cooled
K- Type Rotor Block (Triple) Replacement Procedure
Table 3
Required Part
Item Qty Part Number Part Name
1 6 541-7553 Block
Illustration 21 g06625283
(A) Block
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1. Cut off the existing block (A).
2. Grind away the remaining weld on the ring surface.
3. Place the new block on cleaned surface.
Illustration 22 g06625286
(1) 541-7553 Block
(D1) is 67.0 mm (2.64 inch)
4. Position the block with its external surface at dimension (D1) from the inner side of the ring.
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Illustration 23 g06625297
(1) 541-7553 Block
5. Keep the block parallel to the outer surface of the ring.
Illustration 24 g06625299
(1) 541-7553 Block
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Illustration 25 g06625300
(1) 541-7553 Block
Illustration 26 g06625302
(1) 541-7553 Block
(W1) 10.0 mm (0.40 inch) fillet weld on both sides
(W2) Top 10.0 mm (0.40 inch) flare V-groove weld
(W3) Bottom 20.0 mm (0.80 inch) flare V-groove weld
6. Weld the block (1) to the rotor assembly in two separate passes.
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First pass- Weld passes as per the weld sequence from Illustration 24 and Illustration
25 should be large enough to fill the gaps only.
Second pass- Repeat the weld passes as per the weld sequence from Illustration 24
and Illustration 25. The final weld dimension to be large enough that is referred in
Illustration 26.
7. Welds are allowed to air cool back to ambient temperatures. Do not return to milling until
fully cooled
K- Type Rotor End Ring Block Replacement Procedure
Table 4
Required Part
Item Qty Part Number Part Name
1 - 496-3468 Block
Illustration 27 g06625306
(A) Block
1. Cut off the end ring block (A).
By grinding, remove the remaining weld to a flat plane. Ensure the plane surface to position
the new block to be flat and clean.
2. The new block (1) may be positioned using two 6B-6863 Spring Pins (6mm Dia. x 50 mm
long elastic pins) inserted in the locating holes of the block and the end ring. Ensure that the
bottom flat surface of the block is mating the inclined plane of the end ring.
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Illustration 28 g06625322
(1) 496-3468 Block
(W1) 15.0 mm (0.60 5 inch) fillet weld
(W2) 10 .0 mm (0.40 5 inch) flare bevel groove weld
Illustration 29 g06625325
(1) 496-3468 Block
(W3) 15.0 mm (0.60 5 inch) bevel groove weld on both sides
3. Use "Carbofil" 1 or equivalent filler material in place to weld as per the weld specification
shown in Illustration 28 and Illustration 29.
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Illustration 30 g06625344
Illustration 31 g06625346
Illustration 32 g06625348
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Illustration 33 g06625351
4. Weld the new block (1) to the rotor assembly in two separate passes.
First pass- Weld passes as per the weld sequence from Illustration 30 to Illustration 33
should be large enough to fill the gaps only.
Second pass- Repeat the weld passes as per the weld sequence from Illustration 30 to
Illustration 33. The final weld dimension to be large enough that is referred in Illustration
28 and Illustration 29.
PIP-10547764
2025/04/10
12:49:32-03:00
i08328359
© 2025 Caterpillar Inc.
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