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ESCO*

Butt against nose

Pry bar to contact ground

InstalSation Steps
Step 1
Adapter installation using Whisler Plus
components is the same as with
conventional Whisler adapters. Make sure
the entire rea where the adapter fits and
the lip keyslot are free of any dirt or foreign
material. Using an appropriately rated hook
or shackle attached to the adapter lifting
eye and a suitable hoist, lift the adapter
onto the lip. Use a large pry bar to push it
fully on by putting the end into the ground
and the bar against the end of the nose as
shown in the illustration to the right. When
the adapter is fully installed it will allow
easy, hand installation of the Torque Wedge
pin and spool.
LCAUTION: Do not place feet under adapter
and keep hands well away from the adapter
legs during installation.

Step 2
Grasp the Torque Wedge spool using the tee
shaped handle and lower it into the rear par
of the keyslot, until it rests securely on the
nternal adapter ledge.

Step 3
Grasp the large end of the Torque Wedge pin
and lower it into the keyslot, forward of the
Torque Wedge spool. Once it comes to rest,
hand wind it clockwise about one turn to
assure engagement of the threads.

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SCO

Pin should not be more than 6mm/0.25in. above or 50mm / 2.00in. below top adapter

Step 4
Tighten the Torque Wedge pin to approximately 540Nm /
400 ft-lb. torque with a 22mm/0.88in. hex bit. A 3/4 inch
drive air-impact wrench is recommended, but a long
handled ratchet wrench can be used (approximately
1.5M. / 5 ft). For installation on a new or fully rebuilt lip,
the top of the tightened Torque Wedge pin should be not
more than 6mm / 0.25in. above or 50mm / 2.00in. below
the top of the adapter. If it is outside this range, consult
with an ESCO technical representative.

Step 5
When the Torque Wedge pin tightens to a depth of 1
9mm / 0.75in. or more below the top of the adapter, an
available cap can be thumb pressed into the hex recess
to keep it free of impacted fines. Recess must be clean to
assure the cap inserts fully so the top of the cap rests on
the Torque Wedge pin.

Torque Wedge Retightening


When a new adapter is installed, the Torque Wedge pin
should be retightened after one to three days of
operation. Following this, the pin should be retightened
as noted below.
Every 750 to 1000 hours of operation in tough "XHD"
digging conditions.
* Every 1500 to 2000 hours in more modrate digging
conditions.

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SCO

Retightening Procedure
Clean out impacted fines down to the top of the pin.
1

Clean out the hex recess in top of the pin. If a cap is being used, pry it out.
Retighten pin to approximately 540Nm / 400 ft-lb. torque. Make sure the pin is not tightened
against spool web stop (see first page 3). If it is, remove the pin and spool per the removal
instructions (page 6). Install the oversize -2 spool, and then reinstall and tighten the pin.
If the pin is at least 19mm / 0.75in. below the top of adapter, reinstall the used cap if is not
significantly worn, distorted or cracked. If damaged, install a new cap.

A WARNING: W h e n p e r f o r m / n g t h e w o r k d e s c r i b e d i n
these instructions, always work safely and use
p r o p - e r s a f e t y e q u i p m e n t t o h e l p a v o i d i n j u r y.
Always wear hard hat, gloves, safety shoes, eye
protection, hearing protection and fall protection
per regional, national and site requirements (e.g.
OSHA, MSHA) when performing maintenance work.
To a v o i d i n j u r y t o o t h e r s , k e e p b y s t a n d e r s w e l l o u t
o f t h e w a y.

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ESCO*

Removai Steps
Worn Out Adapter Replacement
The amount of allowable adapter wear vares with the severity of the application.
Excess wear can lead to adapter breakage. The adapter boss will be weakened if the
rear part of adapter legs are allowed to completely wear away. Adapters should be
replaced before the back end begins to show an irregular shape. The illustration
insert shows a worn boss at the absolute limit of wear.

ESCO*
Remove the point and wearcap to keep the
adapter from tipping during removai from the
lip.
Clean out mpacted fines from the pin and
spool rea, remove the cap, and unwind the
Torque Wedge pin counterclockwise out of the
assembly. A 3/4 inch drive air-impact wrench
is recommended to spin the pin free from the
Torque Wedge spool. If a ratchet wrench is
used, the required handle length to break the
pin free will be dependent on the tightness of
the assembly. Once it is broken free, winding
the pin up and out of the assembly can be
done easily with a conventional length ratchet
wrench. Use the wrench to keep the pin
threads engaged with the spool while winding
it out, when the pin is out far enough, grasp
the top and pul it out of thread engagement
and out of the assembly.

Worn Boss

Absolute
Wear

Limit

of

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ESCO*

Pry the worn spool forward with a small pry bar and push it down through the keyslot.
To free the adapter for removal, clean out impacted fines from the spaces between
the adapter legs and the lip, and the keyslot rea.
Pry the adapter forward 100-1 50mm / 4-6in., keeping it centered to avoid binding on
the keyway Insert.
Use the preferred method for pulling adapters clear of the lip. An appropriately rated
nylon sling strung between the adapter legs is a good method to remove the adapter.
Prior to installation of a new adapter, all impacted fines and foreign materials must
be cleaned from the adapter lip pad to allow the replacement adapter to be safely
and easily installed.

ESCO*

A WARNING: W h e n p e r f o r m i n g t h e w o r k d e s c r i b e d i n t h e s e i n s t r u c t i o n s , a l w a y s w o r k
s a f e l y a n d u s e p r o p - e r s a f e t y e q u i p m e n t t o h e l p a v o i d i n j u r y. A l w a y s w e a r h a r d h a t ,
gloves, safety shoes, eye protection, heahng protection and fall protection per
regional, national and site requirements (e.g. OSHA, MSHA) when performing
m a i n t e n a n c e w o r k . To a v o i d i n j u r y t o o t h e r s , k e e p b y s t a n d e r s w e l l o u t o f t h e w a y.

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Welding Procedures

P6000GEN01L1111

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E
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of
Co
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Safety

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General/Safety Information
4
Signa! Words
4
Personal Safety
4

ESCO Alloys
4

Acceptance Standard
Uses for ESCO Series 12 Alloys
How to Weld ESCO Series 12 Alloys
Recommended Welding Procedures for ESCO Series 12 Alloys
Dot Hardfacing ESCO Series 12 Alloys
How to Weld ESCO Series 14 Manganese Steel Alloys
Alloy Specifications

ESCO

Safety and
Warnings

others results from putting into practice


your knowledge of the correct operating
procedures.

Generai/Saety
nformation
The safety practices described n this
manual are meant as guidelines for safe
operation under most conditions and are
meant to supplement any safety rules
and/or laws that may be n forc n your
rea. Your safety and the safety of

Signal Words
Throughout this manual are statements
preceded by a special attention symbol:
kThe symbol is used with the following
signal words to attract your attention to
nformation of special priority. Read the
paragraphs carefully and make sure you
10

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understand their significance, especially
the possible causes of injury.
A WARNING: A s t a t e m e n t p r e c e d e d b y
"WARNING" i s
nformation that should be acted upon to
p r e v e n t s e r i o u s i n j u r y.
ACAUTION: A s t a t e m e n t p r e c e d e d b y
"CAUTION" i s
nformation that should be acted pon to
prevent machine damage.

Additional signal words that are not


preceded by the attention symbol are:
IMPORTANT: A s t a t e m e n t p r e c e d e d b y
t h e w o r d "IMPORTANT" i s n f o r m a t i o n
t h a t p o s s e s s e s s p e c i a l s i g n i fi c a n c e .
Tip: A s t a t e m e n t p r e c e d e d b y "Tip" i s
nformation that is handy to know and
m a y m a k e y o u r J o b e a s i e r.

Personal Safety
LWARNING; W h e n p e r f o r m i n g t h e w o r k
described in these instructions, always
work safely and use proper safety
e q u i p m e n t t o h e l p a v o i d i n j u r y. A l l
persons performing maintenance work
should wear OSHA-approved hard hat,
safety glasses, steel-toed shoes, and
gloves.

ESCO loys
ESCO Series 1 2 alloys are used
tqprovide strength and hardness to a
variety of ESCO mining, construction,
industrial and dredging tools. They have
been developed for toughness, with
hardness ranging from 229-550 BHN.
Most ESCO teeth, adapters, rippers,
blades and end bits are made of durable

Series 1 2 alloys. Some are weldable and


some are not.
ESCO Series 14 alloy castings are
manganese steels which work-harden on
impact and thus maintain surface
hardness and wear resistance. ESCO
Series 14 alloys are used in select bucket
applications, such as shovel dipper
doors, lips and fronts, bushings, and
other applications.
By following the welding instructions in
this brochure you should have no
difficulty welding and maintaining ESCO
products. If questions arise that are not
fully answered here, please contact your
ESCO dealer or cali ESCO direct at one of
the locations listed on the back of this
brochure.

Acceptance Standard
The following requirements apply to any
one layer of weld, including root and
final. One layer is generally ntended to
mean a single plae of weld stringer
beads, but suitable nterpretation must
be used if the shape results in a curving
layer.

Linear Discontinuity
No cracks, including crter cracks, are
allowed in welds or heat affected zones.
No other linear discontinuity in these
reas shall exceed 6mm / 0.25in. in
length.

Porosity
Porosity shall not exceed (4) holes in
every 100mm / 4.00in. of length of a
single weld bead. No single void shall
exceed 1,50mm / 0.06n. in diameter.

Slag
No visual slag in any layer is allowed.

WARNING: W h e n
performing the work
described in these
instructions, always work
11

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safely and use proper safety
equipment to help avoid
i n j u r y. A l w a y s w e a r h a r d h a t ,
gloves, safety shoes, eye
protection, hearing
protection and fall
protection per regional,
national and site
requirements (e.g. OSHA ,
MSHA) when performing
m a i n t e n a n c e w o r k . To a v o i d
injury to others, keep
bystanders well out of the
w a y.

12

ESCO'

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Undercutting

12E (low hardness)

Good

Undercutting shall not exceed 1.50mm / 0.06n. for


material over 13mm / 0.50in. in thickness.

12E (high hardness)

Fair

12F (low hardness)

Good

Rollover or weld overlap shall not exceed


1.50mm / 0.06n. beyond the fusin line of the
weld.

12F (high hardness)

Fair

12C

Good

Weld Spatter

12H

Not
Recommended

12K

Not
Recommended
Good

Rollover

\: bead ofweld spatter shall exceed 0.8mm/0.03in.


in diameter. The scatter density of beads of
acceptable size shall not exceed 25 per 230 sq.
cm. / 36 sq. in.

Grinding
Grinding requirements shall be as specified on the
appcable drawing. If grinding must be performed
in only certain directions, these requirements will
also be specified on the drawing.
Overlay pate can be an effective method of
prolonging the life of some ESCO products in
certain applications. However, improper design,
installation, and/or maintenance of the overlay
pate may contribute to premature failure of any
adjacent ESCO product.
Refer to and follow the recommendations of the
specific overlay pate manufacturer for proper
overlay pate design, installation, and
maintenance. Cases may exist where the
recommendations of the overlay pate
manufacturer conflict with ESCO requirements or
procedures. If a conflict exists, follow the ESCO
requirements.
Wylefcl'olti^

12M (high hardness)

Not
Recommended

12S

Not
Recommended
Very Good

12T

Structural parts for


smaller buckets
Bolt-on adapters
and wearparts
Points and wearparts
Structural parts for
larger buckets

How to Weld ESCO Series 12 Alloys

Overlay Pate Attachment

uses for ESCO Seres

12M (low hardness)

Bucket lips and


structural components
Bolt-on or shank-type
adapters
Bucket lips and
structural components
Bolt-on shank-type
adapters
Front end loader
weld-on adapters
Large points and
adapters
Points and wearparts

12

Alloys

f fVcc|t|<( ,'Y])t:|t!

Certain Series 12 alloys are not meant to be


welded. See chart above. Welding can destroy the
heat treatment given these parts, and cause
inferior performance or failure.
As a rule, ESCO points should never be welded,
repaired, or hardfaced. They are manufactured as
hard as possible.
ESCO alloys 12E, 12C, 12M and 1 2T have excellent
weldability. They are used for weld-on adapters, as
well as structural parts such as dragline bucket lips,
cheeks and arches; shovel dipper beams, lips and
fronts; and dredge cutter arms, rings and hubs.
Structural parts in these alloys can be hardfaced,
but this is generally unnecessary because of wear
shrouds that ESCO provides to protect high wear
reas.

i.VtA

A WARNING: W h e n p e r f o r m i n g t h e w o r k d e s c r i b e d
in these instructions, always work safely and use
p r o p e r s a f e t y e q u i p m e n t t o h e l p a v o i d i n j u r y.
Always wear hard hat, gloves, safety shoes, eye
protection, hearing protection and fall protection
per regional, national and site requirements (e.g.
OSHA, MSHA) when performing maintenance work.
To a v o i d i n j u r y t o o t h e r s , k e e p b y s t a n d e r s w e l l o u t
o f t h e w a y.

Any electrode exposed to the air for more than


one hour should be rebaked per the instructions
above.
The alloy type is prominently marked on all ESCO
cast parts: 1 2S, 1 2K, etc. In cases where
extreme wear has obliterated the markings, Series
1 2 alloys can be identified by their magnetism;
Series 14 manganese alloys are nonmagnetic.

* Preheat and nterpass temperatures are in the


table in the back of this booklet.

* When welding, use short stringer beads and


remove slag after each pass.

Recommended Welding Procedures for


Series 12 Alloys

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Follow these procedures for best results when


welding the weldable Series 1 2 alloys together or
to other low alloy castngs, carbn steel castings,
forgings, or pate.

m Dot Hardfacing ESCO Series 12 Alloys


ESCO does not recommend hardfacing ESCO Series
1 2 alloys. However, if hardfacing is performed, dot
hardfacing is recommended over other methods.

Use filler material as specified in the table on the


back page:
* Control the moisture in low hydrogen electrodes
by purchasing electrodes in 4.5kg / 10lb sealed
packages. Larger packages invite moisture
contamination which can result in inferior welds.

Dot welding is faster, uses less material, and costs


less than continuous beads or solid overlays. It also
reduces the chance of cracking and weld failure
that is comrtjon with other methods.

Apply dots about 10-1 2mm / 0.38-0.50in. in


diameter welded in rows about 25-37mm / 1.001.50in. apart.

Bake previously opened packages of electrodes


in a ventilated oven at 260C / 500F for two
hours before using.

Dots serve as good wear indicators. Reweld them


before they are completely worn off.

Remove only one hour's supply at a time. Keep

UseStoody31 or equivalent electrodes for


hardfacing.

the remainder in a ventilated holding oven at


65C/ 150F .

Electrodes taken from cardboard boxes or non-

Always rebuild worn reas to the original


contour with an appropriate base filler material
before hardfacing. If wear is very deep or
excessive, buildup with low alloy steel pate to
original contour, then use the dot hardfacing
method described above.

airtight containers should also be heated to


260C / 500F for two hours in a ventilated
oven. Then they should be placed in a ventilated
holding oven set at 65C / 150F while still
warm. Remove only one hour's supply at a time.
Bevel joints to get 100% weld penetration,
when possible.

A WARNING: W h e n p e r f o r m i n g t h e w o r k d e s c r i b e d
in these instructions, always work safely and use
p r o p e r s a f e t y e q u i p m e n t t o h e l p a v o i d i n j u r y.
Always wear hard hat, gloves, safety shoes, eye
protection, hearing protection and fall protection
per regional, national and site requirements (e.g.
OSHA, MSHA) when performing maintenance
w o r k . To a v o i d i n j u r y t o o t h e r s , k e e p b y s t a n d e r s
w e l l o u t o f t h e w a y.

14

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ESCO*

How to Weld ESCO Series 14


anganese Stee Aioys

Scarf out cracks completely before


welding.

To rebud parts made of Series 14 alloys, follow


these

Skip weld. Make beads lessthan 1 25mm /


5.00in. long.
1

Check with a magnet to be certain the part


is a -anganese alloy. ESCO Series 1 4 manganese
; :_.s are not magnetic.

Weld with short are at low current setting


"cold are". You should be able to touch the part
1 50mm / 6.00in. away.

Use filler materials as specified in the table on


the back page.

Peen each bead mmediately to reduce

Bevel joints with torch, grinder or are air

contraction stress.

equipment to obtain 100% weld penetration.

Avoid wide weaving beads in order to distribute


heat evenly.

Rebuild worn reas to original contour with

Avoid overheating when gouging.

austenitic manganese nickel electrodes to


closely match the base material and al low
work hardening.

Grind or torch cut work-hardened surfaces at


least 0.80mm / 0.03in. deep before welding.

Check with prickpunch to determine if all


hardened surface has been completely removed.

ESCO Alloy Welding Specifications


Series 1 2 Alloys and Pate
perAWS A5.1

E70T-5

E7018
E7018-C1

perAWSA5.1
perAWSA5.1

E71T-1
E71T-1 H4

E8018-C1

perAWSA5.1

E80T5-N2

perAWS A5.20
Wire must be certified by either the
supplier or the manufacturer to deposit
weld metal with less than 5 mi / 100g
diffusible hydrogen

E70T-5

ER70S-6

perAWS A5 1 8

ER80S-N2

perAWSA5.28

E71T1-N2

Series 1 4 Alloys and Pate


SMAW

TCAW

E308-16
E309-16

perAWSA5.4
perAWSA5.4

ER308
Stoody Nicro-Mang

E310-16

perAWSA5.4

McKay Vertiwear

NHHE
l
perAWS A5.9

ER309
E309L

1AW

perAWS A5.9
perAWS A5.9

Stoody NicroManq
Stoody Trackwear
Continued on the next page.

o & 1 *10

Preheat and Interpass Temperatures


A!f>'/

12C Adapters
12C Whisler Plus"
Components
All other Series 12
Alloys
All Series 14
Alloys
Note:

i'/fl f|"fi M 'ln) V^.i^it

150C/300F
120C/250F
120C/250F
Do Not Preheat

;<>.<: y/Oi-l
Alfov/si;
r .-.<:
;<-;>>>h -'i
260C / 500F If welding in cold
If surrounding air temperature is above 5C / 40F,
conditlons, 5C / 40F or less, preheat
post heating after welding is not necessary. If
between 175-205C / 350-400F.
surrounding temperature isHess than 5C / 40F,
Check temperature with a Tempilstik. postheat the entire part uniformly between 4 and
24 hours at 175-205C / 350-400F, then air cool.
120C/250F

Whenever fabrcation involves a combinaron of castings and pate material, those preheat and interpass temperatures applicable to the alloy of

the casting involved shall be observed, regardless of the type or section thickness of the pate material.

vitiiii'""
\r'--i

ASTM A514 or EN
10137
AR Pate
Mild Steel Pate
*Note: For

Less than 25mm /1 .Oin.*


25mm /1 .Oin. - 50mm /
2.0in.
Over50mm/2.0in.
25mm /1 .Oin. or less
Over 25mm /1 .Oin.
50mm / 2.Oin. or less
Over 50mm / 2.0in.

'i !

20C / 70F
65C/150F

260C/500F

120C /250F
20C / 70F
177C/350F
20 C / 70 F
95C /200F

thin sections of 25mm I 1.0in. or less, at ambient temperature of 20C I 70Fand greater, no

pre-heat is required, however burning the moisture off the surfaces is still considered good welding
practice to elimnate the possibility of hydrogen problems.

15

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Whenever fabrcation involves welding plates of diff erent grades to one another, use the higher
pie heat requirement.

16

ESCO Afloy Welding Specitcalions conlinued

O
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ESCO Corporation is the preferred


provider of
teohnically rich metal components and
wear solutions for industrial
applications. ESCO has over 40
locations and affiliates worldwide.
North America
2141 NW 25* Avenue Portland, OR97210 | PH:
800.523.3795 | 503.228.2141

Latin America
Ra Engenheiro Gerhard Ett, 1 215
Distrito Industrial Paulo Camilo Sul
Betim/MG - CEP: 32669-110
Caixa Postal 256 - Betim, Minas Gerais - Brasil
PH: 55.31.3539.1200

Europe, frica, Middle East,


Commonwealth of Independent
States
Ru des Fours Chaux
7080 Frameries,
Belgium PH:
32.65.611.555

Asia Pacific
1 Scotts Road, Number 1 6-08
Singapore 228208 PH:
65.6733.5858

ESCO Afloy Welding Specitcalions conlinued


2011 ESCO Corporation. All Rights Reserved.