MP15, MP20, MP30 and MP40 Multi-Processors Wear Tip - Inspect/Replace Caterpillar


Wear Tip - Inspect/Replace
`
1.1. Inspect the Wear Tip
2.1. Replace the Wear Tip
3.1. Procedure for the Buildup and Hard Surfacing of the Wear Tip
4.2. Buildup of the Wear Tip
5.2. Hard Surfacing of the Wear Tip


Inspect the Wear Tip

  1. Clean the work tool.



    Illustration 1g02150645

  1. Place the work tool in a horizontal position. Open the jaw of the work tool.

  1. Lock the jaw in an open position. The following procedure describes maintaining the jaw in the open position.



      Illustration 2g01943988

      MP15, MP20, MP30 and MP40

      Clamp GP for the hydraulic cylinder

    1. In order to hold the movable jaw in the open position, install clamp gp (1) onto cover (2) . The clamp gp (1) must be installed behind guide block (3) for the cover. Refer to Table 1 for the part numbers of the clamp gp.

      Table 1
      Clamp GP  (1)    
      Sales Model     Part Number    
      MP15     200-2959    
      MP20     200-2960    
      MP30     200-2885    
      MP40     200-2961    
      ( 1 ) Part of the maintenance kit



    Illustration 3g02150646

  1. Inspect wear tip (4) for excessive wear or damage. Check wear tip (4) for cracks.

Replace the Wear Tip

  1. Clean the work tool.



    Illustration 4g02150645

  1. Place the work tool in a horizontal position. Open the jaw of the work tool.

  1. Lock the jaw in an open position. Refer to , "Inspect the Wear Tip" for more information.



    Illustration 5g02150648

  1. In order to prevent damage to cutting edge (5) and the guiding blade, remove cutting edge (5) and the guiding blade from the upper jaw.

  1. Grind existing wear tip (4) in order to remove wear tip (4) . The existing wear tip (4) can only be removed by grinding off the wear tip.

  1. After you remove the old wear tip, grind the surface of the upper jaw. The surface should be clean and free of rust.



    Illustration 6g02463160

    (D) 40 degrees

    (E) 20 mm (0.79 inch) for the MP15 and MP20

    (E) 26 mm (1.02 inch) for the MP30 and MP40

  1. Grind a bevel to width (E) with an angle (D) on the nose of the upper jaw. The bevel will create a space for welding the wear tip onto the upper jaw.



    Illustration 7g02150653

    (6) Template (part of maintenance kit)

    (7) Reference surface

  1. Place template (6) against reference surface (7) in order to determine the location of the new wear tip. Place the new wear tip onto the upper jaw of the work tool.

  1. Tack weld the new wear tip to the upper jaw of the work tool. Check for proper positioning.

  1. Preheat the surface of the nose of the upper jaw to 150 °C (302 °F) to 200 °C (392 °F).

    Table 2
    Sales Model     Wear Tip     Welding Height (X)     Welding Height (Y)     Welding Height (Z)     Welding Height (W)     Distance (S)     Distance (T)    
    MP15     294-0198    
    6 mm (0.236 inch)    

    14 mm (0.551 inch)    

    15 mm (0.591 inch)    

    15 mm (0.591 inch)    

    10 mm (0.394 inch)    

    12 mm (0.472 inch)    
    MP20     294-0714    
    6 mm (0.236 inch)    

    14 mm (0.551 inch)    

    15 mm (0.591 inch)    

    15 mm (0.591 inch)    

    10 mm (0.394 inch)    

    15 mm (0.591 inch)    
    MP30     294-0715    
    6 mm (0.236 inch)    

    14 mm (0.551 inch)    

    18 mm (0.709 inch)    

    8 mm (0.315 inch)    

    10 mm (0.394 inch)    

    15 ± 3 mm (0.591 ± 0.118 inch)    
    MP40     266-8899    
    6 mm (0.236 inch)    

    15 mm (0.591 inch)    

    20 mm (0.787 inch)    

    17 mm (0.669 inch)    

    10 mm (0.3937 inch)    

    15 ± 3 mm (0.591 ± 0.118 inch)    



    Illustration 8g02150664

    (A) Hard surfacing

  1. In order to weld the wear tip, use welding material AWS A5.28: ER100S-I. Weld the wear tip onto the upper jaw. Refer to Illustration 8. Refer to Table 2 for the height of each weld for each work tool. The procedure for the hard surfacing needs the following items:

    • Lincoln Wear Shield ME welding rod

    • ESAB Wear Arc-5 welding rod

    • Welding materialDIN8555 MF6-55GP

    • Welding material with chemical composition mentioned in Table 3.

    Table 3
    C
    (%)    
    Mn
    (%)    
    Si
    (%)    
    Cr
    (%)    
    Mo
    (%)    
    Hardness
    Hrc    
    0,5-0,8     0,6-1,0     0,6-1,0     4,5-6,5     0,8-1,2     56-61    

  1. Grind the surface flat with the shape of the upper jaw.

  1. Once the jaw has cooled, install cutting edge (5) .

Procedure for the Buildup and Hard Surfacing of the Wear Tip

------ WARNING! ------

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; 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 cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210
----------------------

------ WARNING! ------

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.

----------------------

Buildup of the Wear Tip

  1. Clean the work tool.



    Illustration 9g02150645

  1. Place the work tool in a horizontal position. Open the jaw of the work tool.

  1. Lock the jaw in an open position. Refer to , "Inspect the Wear Tip" for more information.

  1. Inspect wear tip (B) for excessive wear or excessive damage.

  1. Check wear tip (B) for cracks.

    Note: Replace wear tip (B) if excessive damage, wear, or cracks are noticed. Refer to , "Wear Tip Inspect/Replace".

  1. Remove the paint from the surface of the upper jaw (C) , that requires built up.

  1. Grind surfaces.

  1. Use the welding material AWS A5.28: ER100S-I to repair the area.

  1. Preheat the specific area to a minimum of 150 °C (302 °F) and no higher than 200 °C (392 °F).



    Illustration 10g01142044

    The side of the work tool with the cutting edge

  1. Build up original shape. Weld in the direction of the arrow. Refer to illustration 10. Use a straightedge (A) to check the surface. Refer to illustration 10.

    Note: The wear tip (B) must be flush with cutting edges (D) .

  1. Cool the weld slowly to room temperature. Wrap the weld in an insulating blanket to allow the weld to cool over several hours.

    Note: Building up the wear tips should be performed at the end of the day. Build up the wear tips at a time when the weld will have plenty of time to cool. The weld should have plenty of time to cool before the work tool is placed back into operation.




    Illustration 11g01142055

    The side of the work tool with the wear plate

  1. Repeat step 6 through 10 for the wear plate (G) side. Weld in the direction of the arrow. Refer to illustration 11.

    Note: The wear tip (B) must be flush with the wear plate (G) .

  1. Cool the weld slowly to room temperature. Wrap the weld in an insulating blanket to allow the weld to cool over several hours.

    Note: Building up the wear tips should be performed at the end of the day. Build up the wear tips at a time when the weld will have plenty of time to cool. The weld should have plenty of time to cool before the work tool is placed back into operation.

Hard Surfacing of the Wear Tip

  1. Clean the work tool.



    Illustration 12g02150645

  1. Place the work tool in a horizontal position. Open the jaw of the work tool.

  1. Lock the jaw in an open position. Refer to , "Inspect the Wear Tip" for more information.



    Illustration 13g01450335

    Template

  1. Remove all the debris from the welds. Grind surface (5) .

  1. The procedure for the hard surfacing needs the following items:

    • Lincoln Wear Shield ME welding rod

    • ESAB Wear Arc-5 welding rod

    • Welding materialDIN8555 MF6-55GP

    • Welding material with chemical composition mentioned in Table 4.

    Table 4
    C
    (%)    
    Mn
    (%)    
    Si
    (%)    
    Cr
    (%)    
    Mo
    (%)    
    Hardness
    Hrc    
    0,5-0,8     0,6-1,0     0,6-1,0     4,5-6,5     0,8-1,2     56-61    

  1. Preheat the specific service area to 150 °C (302 °F) to 200 °C (392 °F).

  1. Weld in the direction of the arrow. Refer to illustration 13.

  1. Cool the weld slowly to room temperature. Wrap the weld in an insulating blanket to allow the weld to cool over several hours.

    Note: Building up the wear tips should be performed at the end of the day. Build up the wear tips at a time when the weld will have plenty of time to cool. The weld should have plenty of time to cool before the work tool is placed back into operation.

  1. Remove all the debris from the welds.

  1. Use template (Z) to check the surface (5) of the upper jaw (C) . Refer to illustration 13.

  1. Place template (Z) along reference surface (8) until template (Z) is even with surface (6) of the nose of the upper jaw (C) . If necessary, grind the nose of the upper jaw (C) until the nose of the upper jaw (C) matches the template.

  1. Unlock the upper jaw (C) . Refer to , "Inspect the Wear Tip". Carefully close the upper jaw.



    Illustration 14g02150893

    checking the fit

  1. Check the fit (H) of the wear tip (B) into the shear housing (K) . Grind the surface, if necessary. Lock the upper jaw (C) in the open position. Refer to , "Inspect the Wear Tip".

  1. Paint the welded area with primer. Allow the primer to dry. Paint the welded area with a final coat of paint. Allow the paint to dry. Remove the lock on the upper jaw (C) . Refer to , "Inspect the Wear Tip".

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