Hard Surfacing of the Multi-Processor Jaws
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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 Society2501 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 LaborWashington, D.C. 20210 |
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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. |
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Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
General Guidelines for Build-up and Hard Surfacing
The steel that is used in Cat multi-processors is strong and durable. However, this steel requires special attention during maintenance. Pay very close attention to the preheat and postheat instructions and follow the instructions exactly. Review the following guidelines for buildup and hardsurfacing the work tool. Detailed instructions on maintaining specific areas of the work tool are on the following pages. Contact your Cat dealer for further information.
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Preheat and post-heat instructions must be followed exactly! Failure to do so can compromise warranty coverage. |
Before any thermal process is applied to the steel of the work tool, including welding, tack welding, cutting with a torch, and air-arcing, preheat the area according to the following table.
| Sales Model | Preheat Temp | Interpass (during weld) Temp | Distance heat beyond weld point | Wait time (minutes) |
| MP15 | |
to |
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2 |
| MP20, MP30, and MP40 | |
to |
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2 |
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2 | |||
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3 |
(1) The jaw should be welded at ambient temperatures at or above
(2) Do not allow the temperature of the material to get above
(3) Do not weld on the material if temperature is below
Always keep the burner head at the minimum distance away from the jaw in order to maintain the materials qualities. Refer to table 1. Preheat an area of at least
Preheat must be uniform throughout the thickness of the material and maintained until all welding has been completed. Avoid cyclic heating and large temperature swings.
Localized gas torches or thermal strip blankets may be used for preheating.
The temperature of the weld area must be between
Wrap heat blankets around the welded materials immediately after welding has ended. Do not remove the welding blankets until the temperature has dropped below
Plan to perform build-up and hard surfacing at the end of the day or when there will be adequate time for the welded areas to cool before putting the work tool back into service.
When building up the jaw, closely adhere to the above heating procedures. The proper build-up material for the jaw should conform to the following:
- AWS A5.28-100: ER100S-G
Hard surfacing is present on a new unused jaw. If the jaw has worn, the jaw should first be built up. If hard surfacing the jaw, the weld material should match the following chemical properties:
| 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 | 55-62 |
Some products that meet these properties are:
- LINCOLN Wearshield 420 ESAB
- Wear-Arc 5I ESAB
- OK Tubrodur 15.50
Handling and storage of weld materials
Follow the weld manufacturers instructions for handling and storage closely. Make sure that the electrodes or wire are free of moisture. Moisture can cause hydrogen-cracks and porosity in the weld and possibly the base metal beneath the weld.
Quality and attention to the detail in welding can significantly affect the life of the multi-processor. AVSpare strongly recommends that only qualified and certified welders perform this work. Make sure that the weld consumables and base materials are clean, dry, and free of grease, paint, dirt, or any foreign substance that may harm the weld.
Procedure for Build-up and Hard Surfacing of Certain Jaw Sets
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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool. |
- Clean the work tool.
- Lock the moveable jaw in the open position. Refer to , "Crusher Tooth and Ripper Tooth - Replace" for the proper procedure.
- Remove the cutting edge and teeth from jaw.
- Remove paint from jaw surfaces that need build-up.
- Grind surfaces. The surface should be clean and free of rust.
- Preheat the specific area of repair. Refer to , "General Guidelines for Build-up and Hard Surfacing" for information on preheat.
Show/hide table
Illustration 1 g02155729 Typical example of build-up lower jaw - Build up the original shape. Weld in grain direction. Refer to illustration 1. Refer to , "General Guidelines for Build-up and Hard Surfacing" for the specific welding material.
- Use a straight edge to check the surface. Refer to illustration 1.
- Remove all debris from the weld.
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| Illustration 2 | g02155737 |
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Typical example of weld information on CC jaw | |
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| Illustration 3 | g02155738 |
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Typical example of weld information on CR jaw | |
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| Illustration 4 | g02155739 |
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Typical example of weld information on PP jaw | |
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| Illustration 5 | g02155740 |
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Typical example of weld information on PS jaw | |
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| Illustration 6 | g02155741 |
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Typical example of weld information on S jaw | |
- Apply passes that run the length of the jaw. Refer to the above illustrations for your specific jaw type.
- Weld in the direction of the grain. Refer to the above illustrations.
Show/hide table
Illustration 7 g02155782 Typical example of pass dimensions on CC/CR jaw Show/hide table
Illustration 8 g02155784 Typical example of pass dimensions on PS jaw Show/hide table
Illustration 9 g02155785 Typical example of pass dimensions on S jaw Show/hide table
Illustration 10 g02155786 Typical example of pass dimensions on TS jaw Show/hide table
Illustration 11 g02155787 Typical example of pass dimensions on PP jaw - Start the first pass at the minimum distance (Z) away from the edge. Refer to the above illustrations and table 3.
Show/hide table
Table 3 Sales Model of Jaw Material Thickness Passes Minimum Distance from Edge (Z) Distance Between Passes (Y) Distance Between Passes (T)(1) MP15 CC/CR 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP15 PP 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP15 PS 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP15 S 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP20 CC/CR 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - MP20 PP 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP20 PS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP20 TS - - - - 40 ± 3 mm (1.58 ± 0.12 inch) MP20 S 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP30 CC/CR 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - MP30 PP 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP30 PS 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP30 TS - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP30 S 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP40 CC/CR 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP40 PS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - Show/hide table(1) Cross Hatching - Start the other passes at the required distance (Y) between the passes. Refer to the above illustrations and table 3.
Show/hide table
Illustration 12 g02156226 Typical example of end welds - Taper the ends of the welds into the base material with marks from grinding going with the direction of the grain.
Note: The hard surface should end at the elevation on the jaw.
Note: The hard surface should end at the dimensions shown in illustration 12.
- Allow the weld to air cool slowly in still air to ambient temperature. Blanket the area if required.
- Remove all the debris from the weld.
- Install the cutting edge and teeth in the jaw. Refer to , "Crusher Tooth and Ripper Tooth - Replace" and , "Cutting Edges - Inspect/Replace" for more information.
- 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.
- Unlock the jaw of the work tool. Refer to , "Crusher Tooth and Ripper Tooth - Replace" for the proper procedure.
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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool. |
- Clean the work tool.
- Lock the moveable jaw in an open position. Refer to , "Crusher Tooth and Ripper Tooth - Replace" for the proper procedure.
Show/hide table
Illustration 13 g02156229 Typical example - Remove the cutting edge and teeth (Y) from the jaw.
- Remove paint from the jaw surfaces that need build-up.
- Grind surfaces. The surface should be clean and free of rust.
- Preheat the specific area of repair. Refer to , "General Guidelines for Build-up and Hard Surfacing" for information on preheat.
Show/hide table
Illustration 14 g02156231 Direction of the weld on the jaw - Build up the original shape. Weld in the direction of the grain. Refer to illustration 14. Refer to , "General Guidelines for Build-up and Hard Surfacing" for the specific welding material.
- Use a straightedge to check the surface. Refer to illustration 14.
- Remove all the debris from the weld.
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| Illustration 15 | g02156397 |
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Typical example of weld information on CC jaw | |
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| Illustration 16 | g02156398 |
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Typical example of weld information on PS jaw | |
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| Illustration 17 | g02156400 |
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Typical example of weld information on PP jaw | |
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| Illustration 18 | g02156402 |
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Typical example of weld information on TS jaw | |
- Apply passes that run the length of the jaw. Refer to the above illustrations for your specific sales model.
Show/hide table
Illustration 19 g02156405 Typical example of pass dimensions on CC/CR jaw Show/hide table
Illustration 20 g02156406 Typical example of pass dimensions on PP/PS jaw - Weld in the direction of the grain. Refer to the above illustrations and table 4 for your specific sales model.
Show/hide table
Table 4 Sales Model of Jaw Material Thickness (Y) Passes Minimum Distance from Edge (W) Distance Between Passes (X) Distance Between Passes (Z)(1) MP15 CC/CR 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 40 ± 3 mm (1.58 ± 0.12 inch) MP15 PP 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP15 PS 40 mm (1.58 inch) 3X 10 mm (0.39 inch) 10 ± 3 mm (0.39 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP20 CC/CR 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP20 PP 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP20 PS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP20 TS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP30 CC/CR 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP30 PP 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - MP30 PS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP30 TS 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - MP40 CC/CR 70 mm (2.76 inch) 4X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - - - - - 50 ± 3 mm (1.97 ± 0.12 inch) MP40 PS 60 mm (2.36 inch) 4X 10 mm (0.39 inch) 12 ± 3 mm (0.47 ± 0.12 inch) - 80 mm (3.15 inch) 5X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - 50 mm (1.97 inch) 3X 10 mm (0.39 inch) 15 ± 3 mm (0.59 ± 0.12 inch) - Show/hide table(1) Cross Hatching - Start the first pass at the minimum distance (W) away from the edge. Refer to (W) in the above illustrations and table 4.
- Start the other passes at the required distance (X) between the passes. Refer to (X) in the above illustrations and table 4.
Note: The amount of passes depends on the material thickness. Refer to table 4 for more information.
- Taper the ends of the welds into the base material with marks from grinding going with the direction of the grain.
Show/hide table
Illustration 21 g02156409 Typical example of end welds on PP jaw Show/hide table
Illustration 22 g02156411 Typical example of end welds on PS jaw Show/hide table
Illustration 23 g02156414 Typical example of end welds on CR jaw Show/hide table
Illustration 24 g02156416 Typical example of end welds on TS jaw Note: The hard surface should end at the elevation on the jaw.
Note: The hard surface should end at the dimensions shown on the above illustrations.
- Allow the weld to air cool slowly in still air to ambient temperature. Blanket the area if required.
- Remove all the debris from the weld.
- Install the cutting edge and the teeth. Refer to , "Crusher Tooth and Ripper Tooth - Replace" and , "Cutting Edges - Inspect/Replace" for more information.
- 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.
- Unlock the jaw of the work tool. Refer to , "Crusher Tooth and Ripper Tooth - Replace" for the proper procedure.
