Repair Procedure for the Front Tooth Seat on Certain MP324 D and MP324 CC Jaw Sets {6349} Caterpillar

Introduction

A service repair part has been released to rework the front tooth seat when worn on D and CC jaw sets. The worn front tooth seat can be replaced by service repair part 495-1994 Adapter Plate for D jaw sets and 395-0310 Adapter Plate for CC jaw sets.

This publication describes the rework of the front tooth seat on the demolition (D) and combination (CC) jaw sets.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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. AVSpare cannot anticipate every possible circumstance of a potential hazard.

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 AVSpare. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Operation of the machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the warnings are understood.

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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.

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Personal injury or death can occur from not following the proper procedure or the recommended tooling. To prevent the possibility of injury or death, follow the established procedure using the recommended tooling.

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 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.

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 according to Title "Preparing the Material for Welding". Refer to the Illustrations in this Special Instruction for welding symbols and specifications.

All electrodes must be completely 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 (61 °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 3.0 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

For more information, refer to Reuse And Salvage Guidelines, SEBD0512, "AVSpare Service Welding Guide".

Preparing the Material for Welding

All grease, water, paint, rust, dirt, and scale 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 to avoid damage to the electronic controls and to the bearings. The following steps should be followed 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.

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

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. Ensure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure to reduce the possibility of damage to the following components:

   • Bearing of the drive train

   • Hydraulic components

   • Electrical components

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

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

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

Reference Section

Reference: Operation and Maintenance Manual, SEBU9120

Reference: Parts Manual, SEBP6506

Reference: Service Manual, KENR5226

Reference: Special Instruction, REHS1841, "General Welding Procedures"

Reference: Reuse And Salvage Guidelines, SEBD0512, "AVSpare Service Welding Guide"

Rework Procedure for Front Tooth Seat on Demolition (D) Jaw Sets

Required Parts

General Information

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

Illustration 1	g06037693
(1) 495-1994 Adapter Plate

Illustration 2	g06020061
Jaw Set MP324 D type Front Tooth Seat (1) 495-1994 Adapter Plate (2) 280-4092 Wear Block As

Illustration 3	g06020072
Jaw Set MP324 D type (A) Jaw upper (B) Jaw lower (C) Front tooth (D) Crusher tooth (E) Wear plate (F) Cutting edge

Procedure to Remove Front Tooth Seat on Demolition (D) Jaw Set

1. Remove jaw set from the multi-processor. Refer to Operation and Maintenance Manual, SEBU9120, "Operation", Changing the Jaw Sets for proper procedure.

2. Place the jaw set on a surface that is firm and level. Ensure that the work area is safe for cutting and welding.

3. Secure the jaw set against moving.

4. Remove front tooth (C), crusher tooth (D), and wear plates (E) from the jaws.

5. Disassemble jaw set. Refer to Service Manual, KENR5226, "Jaw - Disassemble - Demolition Jaw" for proper procedure.

6. Secure upper jaw (A) and lower jaw (B) against moving.
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   Illustration 4	g06022849
   (A) Upper jaw (G) Front tooth seat (H) Reference cut line

7. Draw a reference cut line (H) on jaw (A).

8. Preheat jaw (A) through reference cut line (H) as shown in Illustration 4 to 125° to 250 °C (257 ° to 482 °F).

9. Flame cut through reference cut line (H) as shown in Illustration 4.

10. Remove the former front tooth seat (G). Discard the part.
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    Illustration 5	g06022851
    (A) Upper jaw

11. Grind weld surfaces of jaw (A). The weld surfaces should be clean and free of rust.

12. Follow same procedure for removing front tooth seat from lower jaw (B).

Procedure to Install Front Adapter Plate on Demolition (D) Jaw Set

1. Remove paint from the new front adapter plate.
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   Illustration 6	g06022871
   (J) Surfaces must be positioned flush (K) Dimension is 50 ± 5 mm (2.0 ± 0.2 inch)

2. Use a suitable lifting device to position new adapter plate (1). Center front adapter plate (1) on jaw (A).

   Note: Weight of new front adapter plate (1) is 28.2 kg (62.2 lb).

3. Position wear block assembly (2) on jaw (A).

4. Preheat jaw (A) at location shown in Illustration 6 to 125° to 250 °C (257 ° to 482 °F).

5. Preheat front adapter plate (1) and wear block assembly (2) to 125° to 250 °C (257 ° to 482 °F).

   Note: Preheating the metal will prevent cracking of the base metal. Preheating will also reduce the changes of hydrogen embrittlement.

6. Flush rear surfaces of new front adapter plate (1) with jaw (A) as shown in Illustration 6.

7. Tack weld front adapter plate (1) onto jaw (A).

   Welding process: Gas Metal Arc Welding (GMAW)

   Welding material: AWS A5.28 ER 100S-1

8. Tack weld wear block assembly (2) onto jaw (A).

   Welding process: Gas Metal Arc Welding (GMAW)

   Welding material: AWS A5.28 ER 100S-1

9. Follow procedure from Step1 to Step 8 for installing new front adapter plate on lower jaw (B).
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   Illustration 7	g06022896
   (W1) 25.0 mm (0.98 inch) bevel weld (W2) 8.0 mm (0.31 inch) all around fillet weld with 1.5 mm (0.06 inch) root penetration (W3) 37.0 mm (1.46 inch) J-Groove weld on both sides

10. Weld front adapter plate (1) onto jaw (A) as per dimensions shown in Illustration 7.

    Interpass temperature: 125° to 250 °C (257 ° to 482 °F)

    Welding process: Gas Metal Arc Welding (GMAW)

    Welding material: AWS A5.28 ER 100S-1

    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 jaw and front adapter plate.

11. Weld wear block assembly (2) onto jaw (A) as per dimensions shown in Illustration 7.

    Interpass temperature: 125° to 250 °C (257 ° to 482 °F)

    Welding process: Gas Metal Arc Welding (GMAW)

    Welding material: AWS A5.28 ER 100S-1

12. Follow the same procedure to weld new front adapter plate (1) and wear block assembly (2) onto jaw (B).

13. Allow welds to cool slowly to ambient temperature. Do not use forced air.

14. Remove all debris from the welds.

15. Assemble the jaw set. Refer to Service Manual, KENR5226, "Jaw - Assemble - Demolition Jaw" for proper procedure.

16. Install front tooth (C), crusher tooth (D), and wear plates (E) to jaws. Refer to Operation and Maintenance Manual, SEBU9120, "Maintenance", Changing the Jaw Sets for proper procedure.

Finish

1. Paint the welded area with primer.

2. Allow the primer to completely dry.

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

4. Allow the paint to completely dry.

5. Install the jaw set onto the multi-processor. Refer to Operation and Maintenance Manual, SEBU9120, "Operation", Changing the Jaw Sets for the proper procedure.

Rework Procedure for Front Tooth Seat on Concrete Crusher (CC) Jaw Sets

Required Parts

General Information

Illustration 8	g06037694
(1) 395-0310 Adapter Plate

Illustration 9	g06029698
Jaw Set MP324 CC type front tooth seat (1) 395-0310 Adapter Plate (2) 280-4092 Wear Block As

Illustration 10	g06029700
Jaw Set MP324 CC type (A) Upper jaw (B) Lower jaw (C) Front tooth (D) Cutting edge

Procedure to Remove Front Tooth Seat on Concrete Crusher (CC) Jaw Set

1. Remove jaw set from the multi-processor. Refer to Operation and Maintenance Manual, SEBU9120, "Operation", Changing the Jaw Sets for proper procedure.

2. Place the jaw set on a surface that is firm and level. Ensure that the work area is safe for cutting and welding.

3. Secure the jaw set against moving.
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   Illustration 11	g06030717
   Jaw with front tooth removed

4. Remove front tooth (C) from upper jaw (A).

5. Disassemble jaw set. Refer to Service Manual, KENR5226, "Jaw - Disassemble - Concrete Crusher Jaw" for proper procedure.

6. Secure upper jaw (A) against moving.
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   Illustration 12	g06030730
   (A) Upper jaw (E) Reference cut line (F) Dimension is 186.31 mm (7.335 inch) (G) Diameter is 24.00 mm (0.945 inch) at two locations (H) Angle is 103 degrees (J) Front tooth seat (K) Wear block assembly (L) Cut line tangent with radius at this location (M) Dimension is 37.15 mm (1.463 inch)

7. Draw a reference cut line (E) on jaw (A) as per dimensions shown in Illustration 12.

8. Preheat jaw (A) through reference cut line (E) as shown in Illustration 12 to 125° to 250 °C (257 ° to 482 °F).

9. Flame cut through reference cut line (E) as shown in Illustration 12.

10. Remove the former front tooth seat (J). Discard the part.

11. Remove the former wear block assembly (K) on both side of upper jaw (A). Discard the part.
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    Illustration 13	g06030734
    (A) Upper jaw

12. Grind weld surfaces of jaw (A). The weld surfaces should be clean and free of rust.

Procedure to Install Front Adapter Plate on Concrete Crusher (CC) Jaw Set

1. Remove paint from the new front adapter plate.
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   Illustration 14	g06030767
   (A) Upper jaw (1) 395-0310 Adapter Plate (New) (N) Surfaces must be positioned parallel (P) Dimension is 10.00 mm (0.394 inch)

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   Illustration 15	g06030778
   (1) 395-0310 Adapter Plate (New) (A) Upper jaw

2. Use a suitable lifting device to position new adapter plate (1). Center front adapter plate (1) on jaw (A).

   Note: Weight of new front adapter plate (1) is 33.5 kg (73.8 lb).

3. Preheat jaw (A) at location shown in Illustration 14 and Illustration 15 to 125° to 250 °C (257 ° to 482 °F).

4. Preheat new adapter plate (1) at location shown in Illustration 14 and Illustration 15 to 125° to 250 °C (257 ° to 482 °F).

   Note: Preheating the metal will prevent cracking of the base metal. Preheating will also reduce the changes of hydrogen embrittlement.

5. Flush rear surfaces of new adapter plate (1) with jaw (A) as shown in Illustration 14.

6. Tack weld new adapter plate (1) onto jaw (A).

   Welding process: Gas Metal Arc Welding (GMAW)

   Welding material: AWS A5.28 ER 100S-1

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   Illustration 16	g06030798
   (1) 395-0310 Adapter Plate (New) (A) Upper jaw (W1) 14.0 mm (0.55 inch) bevel weld and 10 mm (0.39 inch) fillet weld (W2) 35.0 mm (1.38 inch) J-Groove weld on both sides (W3) 24.0 mm (0.94 inch) bevel weld

7. Weld new adapter plate (1) onto jaw (A) as per dimensions shown in Illustration 16.

   Interpass temperature: 125° to 250 °C (257 ° to 482 °F)

   Welding process: Gas Metal Arc Welding (GMAW)

   Welding material: AWS A5.28 ER 100S-1

   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 jaw and front adapter plate.

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   Illustration 17	g06030812
   (1) 395-0310 Adapter Plate (New) (2) 280-4092 Wear Block As (New) (A) Upper jaw (R) Dimension is 605.40 mm (23.835 inch) (S) Dimension is 520.00 mm (20.472 inch) (T) Dimension is 605.40 mm (23.835 inch) (U) Dimension is 554.00 mm (21.811 inch)

8. Position new wear block assembly (2) onto the upper jaw (A). Two on each side of upper jaw (A).

9. Preheat jaw (A) at location shown in Illustration 14 to 125° to 250 °C (257 ° to 482 °F).

10. Preheat wear block assembly (2) to 125° to 250 °C (257 ° to 482 °F)

11. Tack weld wear block assembly (2) onto jaw (A).

    Welding process: Gas Metal Arc Welding (GMAW)

    Welding material: AWS A5.28 ER 100S-1

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    Illustration 18	g06030829
    (W4) 8.0 mm (0.31 inch) fillet weld with 1.5 mm (0.06 inch) root penetration (2) 280-4092 Wear Block As (New) (A) Upper jaw

12. Weld wear block assembly (2) onto jaw (A) as per dimensions shown in Illustration 18.

    Interpass temperature: 125° to 250 °C (257 ° to 482 °F)

    Welding process: Gas Metal Arc Welding (GMAW)

    Welding material: AWS A5.28 ER 100S-1

13. Allow welds to cool slowly to ambient temperature. Do not use forced air.

14. Remove all debris from the welds.

15. Assemble the jaw set. Refer to Service Manual, KENR5226, "Jaw - Assemble - Concrete Crusher Jaw" for proper procedure.
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    Illustration 19	g06030834
    (2) 280-4092 Wear Block As (New) (C) Front tooth (A) Upper jaw

16. Install front tooth (C) onto upper jaw (A). Refer to Operation and Maintenance Manual, SEBU9120, "Maintenance", Changing the Jaw Sets for proper procedure.

Finish

1. Paint the welded area with primer.

2. Allow the primer to completely dry.

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

4. Allow the paint to completely dry.

5. Install the jaw set onto the multi-processor. Refer to Operation and Maintenance Manual, SEBU9120, "Operation", Changing the Jaw Sets for the proper procedure.