Wear Protection Page 2Q

Transcription

1 Wear Protection Section Contents Page Weld-On Half-Arrow Edges Weld-On Heel Shrouds Chocky Bars Wear Buttons Roll Bars Wear Block Bolt Protector White Iron Wear Block Mechanically Attached Wear Plate System (MAWPS) MAWPS Remove and Install Instructions Wear Bars Q

2 WELD-ON HALF-ARROW EDGES / WELD-ON HEEL SHROUDS WELD-ON HALF-ARROW EDGES Weld-on half-arrow edges protect the bucket structure by adding more wear material to the base edge, and they will fit other brand buckets. H T The weld-on half-arrow edges can be used to customize loader buckets. For example, they could be used as sidecutters on bucket side bars to improve penetration, or welded between bucket teeth to reduce scalloping. Before welding half-arrow sections between bucket teeth, be sure to check for tip and pin hole clearance. This is a concern primarily when using bottom strap adapters. Options W T H B Overall Length Part No. in. mm in. mm in. mm in. mm feet mm J J Y B W WELD-ON HEEL SHROUDS Weld-on heel shrouds protect the lower outside corner of all types of Caterpillar and other brand buckets. Protection is given to the bottom and the side of the bucket with extra wear material concentrated in the corner where it s needed most. Straight and curved heel shrouds are available in two different sizes to best match bucket contour and size, and abrasiveness of the application. The inside corner is relieved to eliminate interference with the bucket structure. Shrouds need not be placed tightly together. They can be spaced apart and still provide full protection due to shadowing. Weld-on heel shrouds are especially applicable for LHEX and underground LHD buckets. For high wear applications Caterpillar s Mechanically Attached Wear Plate System (MAWPS) should be considered due to their quick change design. However, for moderate wear applications and sites especially concerned about mechanically fastened parts these weld-on heel shrouds are an excellent option to consider. B Weight A B C D E F G H R lb in in in in in in in in in Part No. Type (kg) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) straight (31.0) (250) (200) (270) (50) (45) (30) (200) curved (28.6) (250) (200) (193) (270) (50) (45) (30) (200) (800) straight (13.8) (175) (150) (205) (40) (35) (25) (150) curved (13.4) (175) (150) (136) (205) (40) (35) (25) (150) (600) straight (4.88) (120) (108) (150) (28) (20) (20) (113) curved (4.5) (120) (108) (90.6) (150) (28) (20) (20) (113) (400) R A C A 1-2 2Q2011

3 CHOCKY BARS / WEAR BUTTONS CHOCKY BARS Cat-branded wear protection parts have been designed to protect more expensive components, such as machines and buckets, resulting in less downtime and greater productivity. These combine optimal material characteristics with a uniquely engineered design that provides an effective solution for a wide range of applications. The wear protection parts consist of the following components: Chrome White Iron (CWI): Heat-treated ASTM Class 2, Type B, with a material hardness of Rockwell C 63. Mild Steel Backing Plate: Designed to provide impact absorption resulting in longer product life. The CWI and backing plate are bonded together using a copper brazing process. The result of this process is a highly wear resistant product yielding optimal bonding strength. Part Number Part Name Description Length (mm) Width (mm) Thickness (mm) Block As. Wear 1.5" Chocky Block As. Wear 2.0" Chocky Block As. Wear 2.5" Chocky Block As. Wear 4.0" Chocky WEAR BUTTONS Cat wear buttons are used in applications that lend themselves to optimizing their round profile or where their designs are required to cover a specific surface area. The buttons utilize a tri-bar design, which traps fine media between the three raised bars. The trapped media will provide material-on-material wear prolonging the life of the product. Part Number Part Name Description Diameter (mm) Thickness (mm) Block As. Wear 2.5" Button Block As. Wear 3.5" Button Block As. Wear 4.5" Button Block As. Wear 6.0" Button Q

4 ROLL BARS / WEAR BLOCK ROLL BARS Cat roll bars are designed to protect the leading edge of earthmoving machinery such as dozers, loaders, mining shovels, etc. Their round profile is designed to provide maximum wear protection while minimizing drag as the edge proceeds through the media. Some of the benefits of this design, compared to other wear protection products, are impact deflection, improved media penetration, and overall weight reduction. Part Number Part Name Description Length (mm) Width (mm) Diameter (mm) Block As. Wear 1.25" Roll Bar Block As. Wear 2.0" Roll Bar Block As. Wear 3.0" Roll Bar WEAR BLOCK Cat wear blocks are used in areas where a single piece needs to cover a large or specific surface area. The wear block has a thicker profile, which allows for extended wear life in extreme applications. The zig zag inset design allows for materialon-material wear and prevents the detrimental channel wear common in grooves that are parallel to the direction of media flow. Part Number Part Name Description Length (mm) Width (mm) Thickness (mm) Block As. Wear 6" 8" Tile For further information including welding instructions, please reference the IRM PELJ0896 (July 2008) which can be found in the Electronic Sales Library. BOLT PROTECTOR Bolt protectors have been designed to protect hardware (bolts and nuts, pins, etc.) on items such as cutting edges, vertically pinned tips such as V780, top plates, edge segments, sidebar protectors, etc. This product allows material to pack between the bolt protector and the hardware, thus preventing wear on the hardware and provides easier removal at the time of GET replacement. These products are part of the wear protection family and have the following description: Chrome White Iron (CWI): Heat-treated ASTM Class 2, Type B, with a material hardness of Rockwell C 63. Mild Steel Backing Plate: Designed to provide impact absorption resulting in longer product life. Single bolt protector with a 4.5" outer diameter and 3.126" diameter opening for bolt protection. The CWI and backing plate are bonded together using a copper brazing process. The result of this process is a highly wear resistant product yielding optimal bonding strength. Part Number Part Name Description Outer Diameter (mm) Inner Diameter (hole) (mm) Thickness (mm) Block As. Wear Single Bolt Protector Q2011

5 WHITE IRON WEAR BLOCK WHITE IRON WEAR BLOCK The high chrome alloy white iron is brazed to a mild steel backing plate which can be plug-welded with an E7018 3/32" (or similar) stick electrode to a bucket, dozer moldboard, or anywhere quick installation, low cost, abrasion protection is desired. As with any welding, traditional preheating practices apply, depending upon the location. In addition to quick installation, another advantage of the design is that the plug welds and steel base are protected from wear. This product is designed to add long wear life in highly abrasive applications. It has a hardness rating of Rc and offers lower cost protection than hardfacing. In addition to its ease of application, it is environmentally neutral, unlike some other wear protection products " x 4.6" x.54" (117 mm x 117 mm x 14 mm) " x 8" x 1" (102 mm x 205 mm x 25 mm) " x 2" x.54" (117 mm x 51 mm x 14 mm) Part Numbers: Sizes: (inches) 4 x 8 x x 4.6 x x 2 x.54 (mm) 102 x 205 x x 117 x x 51 x 14 Weights: (lbs) (kg) Features: Applications: quick installation versatility low cost environmentally neutral hardness Rc protected welds and steel base Anywhere extra protection is needed for abrasive wear. May not be suitable for higher impact job sites. 2Q

6 MECHANICALLY ATTACHED WEAR PLATE SYSTEM MECHANICALLY ATTACHED WEAR PLATE SYSTEM (MAWPS) The Mechanically Attached Wear Plate System provides a hammerless means of installation and removal. They are capable of protecting wear areas previously unprotected or protected by weld-on or bolt-on wear plates in a large variety of applications on Cat and competitive machines. The Skeletal MAWPS uses the same Series 20 base and retainer as the regular MAWPS, but has a modified skeletal plate that fits on the base. The Skeletal MAWPS wear plate is skeletal in form so it traps material in the plate and between the plates. Features and Benefits Mechanical, hammerless installation. The Mechanically Attached Wear Plate System consists of a thru-hardened DH-2 steel wear plate which slides onto a weld-on base plate and is held in place with a patented compression retainer. The Skeletal MAWPS wear plate is skeletal in form so it traps material in the plate and between the plates. With both MAWPS systems, worn wear plates can be quickly replaced using a common prybar or a MAWPS removal tool, , without hammering or welding. This makes removal and installation quick and easy. Worn wear plates can be quickly replaced using a common prybar without hammering or welding, making removal and installation quick and easy. Reduced downtime and maintenance. Because the wear plates can be changed quickly, usually in two minutes or less, downtime and maintenance time are reduced compared to weld-on or bolt-on wear plates. Extended wearing. The patented compression retainer is positioned low in the base plate allowing a greater percentage of the wear plate to be worn away before replacement. Competitive wear plates house the retainer higher in the wear plate thereby reducing the amount of available wear material. The Cat wear plate s more efficient use of total material lengthens replacement intervals and allows for less additional bucket weight for comparable protection. Flexible application. The weld-on base plate can be welded on virtually any flat or moderately curved surface. The system should be placed horizontally to the load path of material flow. The Mechanically Attached Wear Plate System can easily be used to customize a wide variety of wearing surfaces. MAWPS SKELETAL MAWPS Description Wear plates are made from Caterpillar DH-2 steel and are thru hardened to obtain optimum strength and wear life. The base plate is made from slightly softer but tough weldable steel to withstand high load forces. The base plate is not subject to wear under normal conditions since it is entirely covered by the wear plate. The patented compression retainer is investment cast from spring steel material and acts as a spacer when located in the holding position. As a system, the Mechanically Attached Wear Plate System should be placed horizontally to the load path of material flow. They only require approximately 2 inches (50 mm) of space from adjacent objects on one end to facilitate replacement. Application The Mechanically Attached Wear Plate System can be installed on virtually any flat surface or on moderately curved surfaces providing the radius is not extremely small. Radius capability is specified in the parts consist chart. Bucket bottoms and sides, dozer push arms, Hydraulic Excavator bucket ski runners and sides, truck body duck tails, Tiger dozer blades, crusher hoppers are all candidates for wear plate protection. Long life, ability to customize protection and ease of use promise to make this unique wear system a popular alternative to bolt-on or weld-on wear plates. The Skeletal Mechanically Attached Wear Plate System can be installed on virtually any flat or moderately curved surfaces of the truck bed. They come in two sizes, standard and heavy duty. Long life, ability to customize protection and ease of use promise to make this unique wear system a popular alternative to weld-on wear protection Q2011

7 Wear Indicator The wear plate has recessed holes (blind holes) cast into each corner to serve as a wear indicator making inspections quick and easy. When the holes become exposed in one or more corners, it is time to change the wear plate. If the wear plate is allowed to wear beyond the wear indicator, damage to base plate may occur. Wear Protection MECHANICALLY ATTACHED WEAR PLATE SYSTEM Parts Consist Mechanically Attached Wear Plate System Suggested Base Plate Wear Plate Compression Radius Retainer Series Models (thk) (dimension) Retainer Capability* Plug 20 Series 844, 966, 980, 988, in (200 mm) B, other similar 0.70 in thick 8.85 in x 7.87 in x 1.38 in minimum sizes (18 mm) (225 mm x 200 mm x 35 mm) 5.35 lb (2.43 kg) lb (6.42 kg) Heavy Duty same same same in x 7.87 in x 1.97 in (225 mm x 200 mm x 50 mm) 23.9 lb (10.85 kg) Heavy Duty ARM same same same Series 854, 990, 992, 375, in (400 mm) , other similar 0.86 in thick 10.8 in x 7.87 in x 1.77 in minimum sizes (22 mm) (275 mm x 200 mm x 45 mm) 8.2 lb (3.72 kg) 21.3 lb (9.67 kg) Standard ARM same same same Heavy Duty same same same (10.8 in x 7.87 in x 2.36 in) 275 mm x 200 mm x 60 mm 32.6 lb (14.8 kg) Heavy Duty ARM same same same Series 5110, 5130, in (800 mm) other similar 1.14 in thick 10.8 in x 7.87 in x 2.36 in minimum sizes (29 mm) (275 mm x 200 mm x 60 mm) lb (4.61 kg) lb (13.28 kg) Heavy Duty same same same in x 7.87 in x 2.95 in (275 mm x 200 mm x 75 mm) 41.2 lb (18.7 kg) 50 Series 994, 5230, in (1200 mm) other similar 1.14 in thick in x 9.8 in x 2.95 in minimum sizes (29 mm) (300 mm x 250 mm x 75 mm) 13.4 lb (6.08 kg) lb (25.08 kg) Heavy Duty same same same in x 9.8 in x 3.93 in (300 mm x 250 mm x 100 mm) lb (37.75 kg) Skeletal Mechanically Attached Wear Plate System Suggested Base Plate Wear Plate Compression Radius Retainer Series Models (thk) (dimension) Retainer Capability* Plug Standard Off Highway in (200 mm) Trucks 0.70 in thick 8 in x 12.2 in x 1.38 in (18 mm) (202 mm x 310 mm x 35 mm) 5.35 lb (2.43 kg) 12.9 lb (5.9 kg) Heavy Duty Off Highway in (200 mm) Trucks 0.70 in thick 8.15 in x 12.2 in x 1.77 in (18 mm) (207 mm x 310 mm x 45 mm) 5.35 lb (2.43 kg) 18.3 lb (8.4 kg) * Not recommended for convex radii smaller than those specified in this chart. 2Q

8 MECHANICALLY ATTACHED WEAR PLATE SYSTEM MAWPS Kits: For customers that are in the process of installing large volumes of MAWPS products in off highway truck beds, kits have been set up to assist on the initial purchase. Each kit contains 5 pieces of the following: base plate, cover (skeletal or solid), retainer and plug. Table 1 lists the current kit part numbers followed by the replacement kit part number which now includes the retainer plug. Table 1 Current New Standard vs. Part No. Part No. Description Series Heavy Duty Kit MAWPS 20 Standard Kit MAWPS 20 Heavy Duty Kit MAWPS Skeletal Standard Kit MAWPS Skeletal Heavy Duty Kit MAWPS 30 Standard Kit MAWPS 30 Heavy Duty Kit MAWPS 40 Standard Kit MAWPS 40 Heavy Duty Kit MAWPS 50 Standard Kit MAWPS 50 Heavy Duty Table 2 lists the individual kit piece part numbers as they appear in the kits. Table 2 Standard Wear Wear Current vs. Base Plate Plate Retainer Part No. Series No. Heavy Duty Plate (Solid) (Skeletal) Retainer Plug Standard N/A Heavy Duty N/A Standard N/A Heavy Duty N/A Standard N/A Heavy Duty N/A Standard N/A Heavy Duty N/A Standard N/A Heavy Duty N/A Q2011

9 Replacement Kits: Caterpillar now also offers kits for easier conversion on all versions of Mechanically Attached Wear Plate, all with a discounted price for both standard and heavy-duty versions. 5 base plates, 5 covers and 5 retainers form each kit. Wear Protection MECHANICALLY ATTACHED WEAR PLATE SYSTEM Solid Skeletal Standard Heavy Duty Standard Heavy Duty Series Series N/A N/A Series N/A N/A Series N/A N/A N/A = Not Applicable Promotion Material CD ROM Training/Sales Presentation: A CD ROM titled Caterpillar Mechanically Attached Wear Plate System (PEXT7000) is available through literature distribution. This can be used by dealer machine and parts sales people for training or customer sales presentations. The CD Rom is interactive covering an Intro - duc tion, Features and Benefits, Size Comparison, How To Remove and Install and Questions and Answers. The CD plays for approximately 20 minutes and is complete with video, narration and virtual reality features. Remove and install instructions can be printed and used as a field reference. Demonstration Kit: A scale model demonstration kit (PEKP8025) is also available through literature distribution. The kit contains a full scale 20 series wear plate, base plate and compression retainer and is enclosed in a carrying case. The demonstration kit can be used in conjunction with the CD Rom when making customer presentations. Video: A six-minute video on Skeletal MAWPS PEVN4817 Datasheet: PEHJ0063 Warranty As with all Ground Engaging Tools from Caterpillar, the Mechanically Attached Wear Plate System components are warranted against breakage for the normal wear life of the product. Caterpillar will not provide warranty coverage under the breakage terms of the warranty statement if the wear plates are worn beyond the wear indicators on the wear plate. 2Q

10 MECHANICALLY ATTACHED WEAR PLATE SYSTEM Mechanically Attached Wear Plate Competitive Review Standard Size Comparison Total Weight Wear Material of Assembly % Wear Material of % Throw Away Part inch mm lbs kg Total Assembly Weight Wear Plate Cat Series % 35% Competition % 50% Cat Series % 32% Competition % 47% Cat Series % 22% Competition % 47% Cat Series % 21% Competition % 31% Heavy Duty Comparison Total Weight Wear Material of Assembly % Wear Material of % Throw Away Part inch mm lbs kg Total Assembly Weight Wear Plate Cat Series % 20% Competition % 24% Cat Series % 18% Competition % 23% Cat Series % 14% Competition % 23% Cat Series % 10% Competition % 18% Q2011

11 Remove and Install Instructions 1) Locate wear area to be protected and clean free of dirt/paint/debris. Be sure to leave 2 inches (50 mm) minimum clearance from adjacent objects to allow for wear plate removal and installation. 2) Position the base plate in the desired location and weld the base plate in position welding at locations A & B as shown in the following illustration. Location C is used only for the 50 series base plate. Make one pass at a time in each location to avoid excess heat build-up. The base plate will require several passes at each location to ensure proper strength is achieved. Use the chart to determine fillet weld size and number of passes for each series base plate. Wear Protection MECHANICALLY ATTACHED WEAR PLATE SYSTEM Series Fillet Base Plate Weld Size 20 Series 0.6 in (15 mm) 30 Series 0.6 in (15 mm) 40 Series 0.7 in (18 mm) 50 Series 0.8 in (20 mm) 3) Position the wear plate over the base plate and slide the wear plate onto the base. 4) Install one end of the compression retainer under the resting point. 5) Insert installation tool or a small pry bar with an 8 mm (0.31") width point between the base and wear plate and pry the compression retainer into place. After the retainer compresses and goes over center, it will pop into place and expand. 6) Remove the installation tool and check the compression retainer to assure it is in position. Removal 1) Clean the compression retainer opening in the wear plate free of packed material. A pneumatic chipper is the most effective method to clean the packed material. Not all packed material needs to be cleaned away to remove the retainer. 2) Insert the installation tool or a small pry bar in the slotted area of the compression retainer and pry up. The compression retainer will pop up out of the locking position. 3) Remove the retainer and slide the wear plate off the base plate. NOTE: Compression retainers can be reused if they meet the following criteria: no less than 87 mm (3.43") length no less than 97 mm (3.82") length. 2. Retainer is no more than 2 mm (0.080") out of flat. 3. There is no deformation of the retainer material. 2Q

12 WEAR BARS WEAR BARS Wear bars provide additional blade protection in highly abrasive applications where short liner life has been encountered. Wear bars are designed to be welded on top of a wear surface. Wear bars come in different lengths to allow a customer to tailor the placement of the wear protection while minimizing the amount of throw-away iron. Part numbers for the various lengths are shown below: Wear bars are made from DH-2 steel alloy, through-hardened for greater wear resistance and strength. Core hardness of the bars will be between Rc ( BR). If the bars are to be flame cut, the burn zone must be preheated to F ( C). It is also recommended to preheat the bars to the F ( C) temperature when welding. The bars are to be positioned so the bevel is next to the surface shown at right. Length Width Thickness Part Number in mm in mm in mm S-4738* G-3897* G-3488* G-4642* G-5764* R-0316* W-7943* W-7937* K-7099* R-5317* K-9916* V-3915* V-7415* V-7418* * Straight Base Edge without holes, can be used as wear bar. WELD HERE BAR SURFACE Q2011 PECJ