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. |
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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 Verachtert 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 Verachtert 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. |
Preheat
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) |
| VT-30 | 100° C (210° F) |
75° C (165° F) to 175° C (345° F) |
160 mm (6.30 inch) |
2 |
| VT-40, VT-50, and VT-60 | 125° C (255° F) |
100° C (210° F) to 175° C (345° F) |
200 mm (7.87 inch) |
2 |
200 mm (7.87 inch) |
2 | |||
240 mm (9.45 inch) |
3 |
(1) The jaw should be welded at ambient temperatures at or above 15° C (60° F).
(2) Do not allow the temperature of the material to get above 200° C (390° F).
(3) Do not weld on the material if temperature is below 100° C (210° F) for VT-30 or if temperature is below 125° C (255° F) for the VT-40, VT-50, and VT-60.
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 200 mm (8 inch) around the point that will be welded. After heating the area, wait for the proper amount of time before measuring the temperature. Refer to table 1. Do not measure the temperature directly after removing the heat source. Measure preheat temperature at a distance of 75 mm (3 inch) away from the point that will be welded at the opposite side of the heated side. If using an infrared temperature meter, keep the meter 300 mm (12 inch) to 500 mm (19.5 inch) away from the jaw, in order to prevent inaccurate measurements. If using temperature-indicating sticks, use the correct stick for the range of temperatures 100° C (210° F) to 125° C (255° F).
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.
Interpass
The temperature of the weld area must be between 75° C (165° F) to 175° C (345° F) before another weld pass may be made. If the temperature has dropped below the minimum temperature, the weld area should be heated again to the minimum temperature. If the temperature is above the maximum interpass temperature, the weld area must be allowed to cool slowly until the weld area is below the maximum temperature. Do not allow material to be heated above 200° C (390° F). Do not accelerate the cooling process. Accelerating the cooling process will result in increased brittleness of the material.
Wrap heat blankets around the welded materials immediately after welding has ended. Do not remove the welding blankets until the temperature has dropped below 80° C (175° F). This temperature drop will typically take approximately 4 hours or more.
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.
Build-up Material
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 surface Material
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.
Weld Quality
Quality and attention to the detail in welding can significantly affect the life of the multi-processor. Verachtert 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. |
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Build-up of the Lower Jaw
- 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.
- 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.
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| Illustration 1 | g02155729 |
Typical example of build-up lower jaw | |
- Use a straight edge to check the surface. Refer to illustration 1.
- Remove all debris from the weld.
Hard Surfacing the Lower Jaw
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| Illustration 2 | g02155737 |
Typical example of weld information on VTC jaw | |
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| Illustration 3 | g02155738 |
Typical example of weld information on VTB jaw | |
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| Illustration 4 | g02155739 |
Typical example of weld information on VTK jaw | |
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| Illustration 5 | g02155740 |
Typical example of weld information on VTP jaw | |
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| Illustration 6 | g02155741 |
Typical example of weld information on VTS 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.
- Start the first pass at the minimum distance (Z) away from the edge. Refer to the above illustrations and table 3.
Show/hide tableTable 3 Sales Model of Jaw Material Thickness Passes Minimum Distance from Edge (Z) Distance Between Passes (Y) Distance Between Passes (T) (1) VT-30 VTC/VTB
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)- VT-30 VTK
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)- VT-30 VTP
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)VT-30 VTS
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)VT-40 VTC/VTB
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)- VT-40 VTK
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)- VT-40 VTP
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)VT-40 VTZ - - - -
40 ± 3 mm (1.58 ± 0.12 inch)VT-40 VTS
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)VT-50 VTC/VTB
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)- VT-50 VTK
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)- VT-50 VTP
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)VT-50 VTZ - - - -
50 ± 3 mm (1.97 ± 0.12 inch)VT-50 VTS
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)VT-60 VTC/VTB
60 mm (2.36 inch)4X
10 mm (0.39 inch)
12 ± 3 mm (0.47 ± 0.12 inch)- VT-60 VTP
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
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| Illustration 7 | g02155782 |
Typical example of pass dimensions on VTC/VTB jaw | |
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| Illustration 8 | g02155784 |
Typical example of pass dimensions on VTP jaw | |
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| Illustration 9 | g02155785 |
Typical example of pass dimensions on VTS jaw | |
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| Illustration 10 | g02155786 |
Typical example of pass dimensions on VTZ jaw | |
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| Illustration 11 | g02155787 |
Typical example of pass dimensions on VTK jaw | |
- Start the other passes at the required distance (Y) between the passes. Refer to the above illustrations and table 3.
- 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.
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| Illustration 12 | g02156226 |
Typical example of end welds | |
- 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. |
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Build-up of the Upper Jaw
- Clean the work tool.
- Lock the moveable jaw in an open position. Refer to, "Crusher Tooth and Ripper Tooth - Replace" for the proper procedure.
- Remove the cutting edge and teeth (Y) from the jaw.
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| Illustration 13 | g02156229 |
Typical example | |
- 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.
- 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.
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| Illustration 14 | g02156231 |
Direction of the weld on the jaw | |
- Use a straightedge to check the surface. Refer to illustration 14.
- Remove all the debris from the weld.
Hard Surfacing the Upper Jaw
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| Illustration 15 | g02156397 |
Typical example of weld information on VTC jaw | |
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| Illustration 16 | g02156398 |
Typical example of weld information on VTP jaw | |
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| Illustration 17 | g02156400 |
Typical example of weld information on VTK jaw | |
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| Illustration 18 | g02156402 |
Typical example of weld information on VTZ jaw | |
- Apply passes that run the length of the jaw. Refer to the above illustrations for your specific sales model.
- Weld in the direction of the grain. Refer to the above illustrations and table 4 for your specific sales model.
Show/hide tableTable 4 Sales Model of Jaw Material Thickness (Y) Passes Minimum Distance from Edge (W) Distance Between Passes (X) Distance Between Passes (Z) (1) VT-30 VTC/VTB
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)VT-30 VTK
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)- VT-30 VTP
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)- VT-40 VTC/VTB
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)VT-40 VTK
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)- VT-40 VTP
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)- VT-40 VTZ
50 mm (1.97 inch)3X
10 mm (0.39 inch)
15 ± 3 mm (0.59 ± 0.12 inch)- VT-50 VTC/VTB
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)VT-50 VTK
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)- VT-50 VTP
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)- VT-50 VTZ
50 mm (1.97 inch)3X
10 mm (0.39 inch)
15 ± 3 mm (0.59 ± 0.12 inch)- VT-60 VTC/VTB
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)VT-60 VTP
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
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| Illustration 19 | g02156405 |
Typical example of pass dimensions on VTC/VTB jaw | |
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| Illustration 20 | g02156406 |
Typical example of pass dimensions on VTK/VTP jaw | |
- 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.
- Allow the weld to air cool slowly in still air to ambient temperature. Blanket the area if required.
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| Illustration 21 | g02156409 |
Typical example of end welds on VTK jaw | |
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| Illustration 22 | g02156411 |
Typical example of end welds on VTP jaw | |
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| Illustration 23 | g02156414 |
Typical example of end welds on VTB jaw | |
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| Illustration 24 | g02156416 |
Typical example of end welds on VTZ 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.
- 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.