Replacement Procedure for the Service Repair Parts on the Multi-Processor Crusher Jaws{6349} Caterpillar

Introduction

This publication describes the replacement of the tooth holders on the crusher jaw sets. These jaw sets contain both the upper jaw and the lower jaw. The tooth holders must be replaced when the tooth holders are worn. The original shape cannot be built up.

Note: Do not perform any procedure that is outlined in this publication. Do not order any parts until you understand the information that is contained in this publication.

Reference

Cat Brand

ReferenceOperations and Maintenance Manual, SEBU7750

ReferenceParts Manual, SEBP5452

ReferenceService Manual, RENR4470

Verachtert Brand

ReferenceOperations and Maintenance Manual, SEBU7751

ReferenceParts Manual, SEBP5453

ReferenceService Manual, RENR4471

Necessary Parts

Illustration 1	g02176467
Tooth holder lower CC/CR/VTB/VTC jaw

Illustration 2	g02176469
Tooth holder upper CC/CR/VTB/VTC jaw

General Information

Note: On some illustrations, parts and subassemblies are left out for clarity.

Component Identification

Illustration 3	g02182596
Jaw Set CR/VTB (typical example) (A) Jaw Upper (B) Jaw Lower (C) Tooth Holder Upper (D) Tooth Holder Lower

Illustration 4	g02182597
Jaw Set CC/VTC (typical example) (A) Jaw Upper (B) Jaw Lower (C) Tooth Holder Upper (D) Tooth Holder Lower

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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.

Welding Requirements

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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 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

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding. Refer to the illustrations in this Special Instruction for welding symbols and specifications.

Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the plates to the stick of the machine. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-5 with positive polarity. The welding wire must be protected with CO2 gas.

All electrodes must be dried. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics may vary greatly depending on the following conditions:

• Electrode diameter

• Shielding gas

• Welding current

• Plate thickness

The following items also affect the welds:

• Geometry of welded joints

• Surface conditions

• Composition of the base metal and of the electrode

A root pass should be applied before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

For more welding information, consult the AVSpare Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

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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.

All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove paint, rust, dirt and scale with a wire brush or by buffing, or grinding. Shot blasting all work areas will also remove foreign material.

Remove any oil or grease with a AVSpare approved solvent.

Welding on Machines with Electronic Controls

Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat-related damage. The following steps should be followed in order to weld on a machine or an engine with electronic controls.

Note:

If you are welding on a work tool, AVSpare recommends removing the work tool from the host machine before welding.

1. Turn off the engine. Place the engine start switch in the OFF position.

2. If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

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NOTICE
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:
   • Bearings of the drive train

   • Hydraulic components

   • Electrical components

   • Other components of the machine

4. Protect any wiring harnesses from the debris which is created from welding. Protect any wiring harnesses from the debris which is created from welding.

5. Use standard welding procedures in order to weld the materials together.

Removal Tooth Holder Lower Jaw

1. Remove the work tool from the host machine. Refer to Operation and Maintenance Manual, "Work Tool Installation and Removal" for the proper procedure. Place the work tool on a surface that is firm and level. make sure that the work area is safe for cutting and welding.

2. Open the jaw of the work tool.

3. Lock the jaw in an open position. Refer to Operation and Maintenance Manual, "Crusher Tooth and Ripper Tooth-Replace" for the proper procedure.

4. Remove the teeth from the lower jaw.

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Illustration 5	g02177067
Securing the lower jaw

5. Tack weld a strip of metal (T) onto the bottom of the plates of the lower jaw. This strip of metal will keep the original shape of the lower jaw when the tooth holder has been removed. Refer to Illustration 5 for more information.

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Illustration 6	g02177070
Lower Jaw CR/VTB (typical example)

6. Preheat the lower jaw at the transition of the tooth holder and the lower jaw at Position shown in Illustration 6 to 150° C (302° F) to 200° C (392° F).

7. Gouge out the welds at the transition of the tooth holder and the lower jaw at Position shown in Illustration 6.

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Illustration 7	g02177080
Lower jaw CC/CR (typical example)

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Illustration 8	g02178818
Lower jaw CC/CR (typical example)

8. Machine the corners of the lower jaw. Refer to Table 2 and Illustration 7
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   Table 2

   Model	H (°)	K (mm)
   MP15 CC/VTC	40	17.5 ± 1 mm (0.7 ± 0.04 inch)
   MP15 CR/VTB	40	15 ± 1 mm (0.6 ± 0.04 inch)
   MP20 CC/VTC	40	22.5 ± 1 mm (0.9 ± 0.04 inch)
   MP20 CR/VTB	40	22.5 ± 1 mm (0.9 ± 0.04 inch)
   MP30 CC/VTC	40	22.5 ± 1 mm (0.9 ± 0.04 inch)
   MP30 CR/VTB	40	22.5 ± 1 mm (0.9 ± 0.04 inch)
   MP40 CC/VTC	40	28 ± 1 mm (1.1 ± 0.04 inch)
   MP40 CR/VTB	40	28 ± 1 mm (1.1 ± 0.04 inch)

9. Grind surfaces. The surface should be clean and free of rust.

Installation Tooth Holder Lower Jaw

1. Remove paint from the new tooth holder.

2. Use a suitable lifting device to position the new tooth holder. Center the new tooth holder on the lower jaw. Refer to Table 3 for the weight of the service repair parts.
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   Table 3

   Service Repair Parts
   Pt. No.	Weight
   347-2495	39.9 kg (88 lb)
   347-0729	48.2 kg (106 lb)
   347-2503	62.1 kg (137 lb)
   347-2511	119.6 kg (264 lb)

3. Before and during the welding the tooth holder into position, preheat the welding surfaces to 150° C (302° F) to 200° C (392° F)

Positioning of the Tooth Holder

Illustration 9	g02177296

Illustration 10	g02177298

1. Position the tooth holder in line with the lower jaw. Refer to Illustrations 9 and to 10 Table 4 for dimensions.

   Note: Build up the tooth holder contact surface of the lower jaw, if the dimension P is not practicable after the worn tooth holder is removed.

2. Tack weld the tooth holder onto the lower jaw.

   Note: Use the following welding materials in order to weld the tooth holder onto the lower jaw: AWS A5.28 ER100S-1.

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   Table 4

   Model	P	S
   MP15	811 mm (32 inch)	23.5 mm (1.0 inch)
   MP20	935.5 mm (37 inch)	18.5 mm (0.75inch)
   MP30	1061 mm (42 inch)	18.5 mm (0.75inch)
   MP40	1296 mm (51 inch)	28.5 mm (1.0 inch)

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Illustration 11	g02177865
Lower jaw detail (typical example)

3. Weld the tooth holder onto the lower jaw. Refer to Illustration 11 for welding dimensions.

   Note: Weld in a pass sequence that builds up the deposit equally on each side of the joint. This procedure will keep the original shape of the lower jaw.

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   Table 5

   Model	T (mm)	X (mm)	Z (mm)
   MP15	20 mm (0.78 inch)	20 mm (0.78 inch)	20 mm (0.78 inch)
   MP20	22 mm (0.87 inch)	26 mm (1.0 inch)	26 mm (1.0 inch)
   MP30	22 mm (0.87 inch)	26 mm (1.0 inch)	26 mm (1.0 inch)
   MP40	28 mm (1.1 inch)	30 mm (1.2 inch)	30 mm (1.2 inch)

4. Apply hard surfacing to the lower jaw. Refer to Operation and Maintenance Manual,, "Jaw Repair" for the proper procedure.

5. Allow the welds to air cool slowly in still air to ambient temperature. Blanket the area if required.

6. Remove the strip of metal (T) .

Removal Tooth Holder Upper Jaw

1. Remove the work tool from the host machine. Refer to Operation and Maintenance Manual,, "Work Tool Installation and Removal" for the proper procedure. Place the work tool on a surface that is firm and level. make sure that the work area is safe for cutting and welding.

2. Open the jaw of the work tool.

3. Lock the jaw in an open position. Refer to Operation and Maintenance Manual,, "Crusher Tooth and Ripper Tooth-Replace" for more information.

4. Remove the teeth from the upper jaw.

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Illustration 12	g02177931
Upper jaw detail (typical example)

5. Preheat the upper jaw at the transition of the tooth holder and the lower jaw at position GG to 150° C (302° F). Refer to Illustration 12.

6. Gouge out the welds at the transition of the tooth holder and the upper jaw at position GG show in Illustration 12.

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Illustration 13	g02178051
Upper Jaw CC/CR (typical example)

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Illustration 14	g02260636

7. Machine the corners of the upper jaw. Refer to Table 6 and to Illustrations 13 and 14.
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   Table 6

   Model	HH (°)	KK (mm)
   MP15 CC/VTC	40	15 ± 1 mm (0.6 ± 0.04 inch)
   MP15 CR/VTB	40	20 ± 1 mm (0.8 ± 0.04inch)
   MP20 CC/VTC	40	20 ± 1 mm (0.8 ± 0.04inch)
   MP20 CR/VTB	40	20 ± 1 mm (0.8 ± 0.04inch)
   MP30 CC/VTC	40	20 ± 1 mm (0.8 ± 0.04inch)
   MP30 CR/VTB	40	22.5 ± 1 mm (0.9 ± 0.04 inch)
   MP40 CC/VTC	40	33 ± 1 mm (1.3 ± 0.04 inch)
   MP40 CR/VTB	40	30 ± 1 mm (1.2 ± 0.04 inch)

8. Grind surfaces. The surface should be clean and free of rust.

Installation Tooth Holder Upper Jaw

1. Remove paint from the new tooth holder.

2. Use a suitable lifting device to position the new tooth holder. Center the new tooth holder on the upper jaw. Refer to Table 7 for the weight of the service repair parts.
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   Table 7

   Service Repair Parts
   Part No.	Weight
   347-2494	18.6 kg (41 lb)
   347-0728	25.1 kg (55 lb)
   347-2502	27.3 kg (60 lb)
   347-2510	52.1 kg (114 lb)

3. Before and during welding the tooth holder into position, preheat the welding surfaces to 150° C (302° F) to 200° C (392° F).

Positioning of the Tooth Holder

Illustration 15	g02178095
Upper Jaw (typical example)

1. Position the tooth holder in line with the upper jaw. Refer to Illustration 15 and Table 8

2. Tack weld the tooth holder onto the upper jaw.

   Note: Use the following welding materials in order to weld the tooth holder onto the upper jaw:AWS A5.28 ER100S-1.

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   Table 8

   Model	PP (mm)
   MP15	870 ± 2 mm (34.3 ± 0.08 inch)
   MP20	1010 ± 2 mm (39.8 ± 0.08inch)
   MP30	1135 ± 2 mm (44.7 ± 0.08 inch)
   MP40	1380 ± 2 mm (54.3 ± 0.08 inch)

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Illustration 16	g02178119
Upper Jaw detail (typical example)

3. Weld the tooth holder onto the upper jaw. Refer to Illustration 16 and to Table 9 for welding dimensions.

   Note: Weld in a pass sequence that builds up the deposit equally on each side of the joint. This procedure will keep the original shape of the upper jaw.

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   Table 9

   Model	T	X	Y	Z	ZZ
   MP15	20 mm (0.8 inch)	15 mm (0.6inch)	15 mm (0.6inch)	20 mm (0.8 inch)	15 mm (0.6inch)
   MP20	25 mm (1.0 inch)	20 mm (0.8 inch)	20 mm (0.8 inch)	20 mm (0.8 inch)	15 mm (0.6inch)
   MP30	25 mm (1.0 inch)	20 mm (0.8 inch)	20 mm (0.8 inch)	20 mm (0.8 inch)	15 mm (0.6inch)
   MP40	25 mm (1.0 inch)	30 mm (1.2 inch)	25 mm (1.0 inch)	30 mm (1.2 inch)	NA

4. Apply hard surfacing to the upper jaw. Refer to Operation and Maintenance Manual,, "Jaw Repair" for the proper procedure.

5. Allow the welds to air cool slowly in still air to ambient temperature. Blanket the area if required.

Finish

1. Remove all the debris from the welds.

2. Install the tooth. Refer to Operation and Maintenance Manual,, "Crusher Tooth and Ripper Tooth -- Replace" for the proper procedure.

3. Paint the welded area with primer.

4. Allow the primer to dry completely.

5. Paint the welded area with a final coat of paint.

6. Unlock the jaw of the work tool. Refer to Operation and Maintenance Manual,, "Crusher Tooth and Ripper Tooth -- Replace" for the proper procedure.

7. Install the work tool onto the host machine. Refer to Operation and Maintenance Manual,, "Work Tool Installation and Removal" for the proper procedure.