TRACTOR PARTS:

Rollers and Rails are seldom done unless by a shop set up with automatic systems.

 

 

Idlers:

 

            Materials          Semi-automatic Automatic

            Build-up           2892-SPL        2873SA

            Overlay            2893-SPL        2877SA

 

1)         Mount on rotating device.

 

2)         All cracked and spalled metal should be removed.

 

3)         Solid rims - heat until warm to the touch. 

            Spoked rims - heat at mid point of spokes to 300º/400ºF(149º/204ºC)).

 

4)         Build up to within 1/4" (6.0 mm) of desired size.  Overlay to desired dimension.

 

5)         The automatic process is recommended where equipment is available.  Transverse or circumferential weld beads can be applied with the semi-automatic process.

 

a)         Sub arc process - 1/16" or 3/32" (1.6 or 2.4 mm) diameter wire.

b)         Gas shielded wire - .045” or 1/16“ (1.2 or 1.6 mm) diameter wire.

 

 

Drive Sprockets:

 

            Materials          Semi-automatic

            Build-up           2892-SPL

            Overlay            2893-SPL

 

1)         Mount on rotating device or shaft to turn the sprocket to weld downhand.

 

2)         Cracked teeth and spalled metal should be removed.

 

3)         Build up worn teeth with .045” or 1/16" (1.2 or 1.6 mm), Postalloy 2892-SPL(30 - 35 Rc), to within 1/4" (6.0 mm) of desired size.  First outline the area with a stringer bead, then fill in the area with 1/2" to 3/4" (12 to 18 mm) weave beads.

 

4)         Cap using the same procedure but with higher hardness Postalloy 2893-SPL(40 - 45 Rc).

 

a)         A template should be used to obtain the proper shape.  Finish by grinding off high spots

BLADES:         (Also Scraper and Grader Blades)

 

            Materials          Semi-automatic

            Overlay            2829-SPL, 2832-SPL, 2836-SPL, 2839-SPL or 299-SPL

 

1)         Repair all cracks and remove all broken or spalled metal.

 

2)         Secure blades in suitable prebending jig, or bolt to mold board to prevent misalignment due to warpage.

 

3)         Using .045” or 1/16" (1.2 or 1.6 mm) diameter wire, apply stringer beads to wear surfaces, 1-1/2" to 2" long (40 to 50 mm).  Each bead should crack transversely every 1/2" to 1" (12 to 25 mm), as deposited.

 

a)         Outline the area by welding the bottom edge first, and the upper limit second.  Then fill in the outlined area with stringer beads.

 

b)         Skip weld to prevent warpage and overheating.

 

END BITS:

 

            Materials          Semi-automatic

            Overlay            2829-SPL, 2832-SPL, 2836-SPL, 2839-SPL or 299-SPL

 

 

1)         Place flat with worn face up.  On badly worn end bits, weld on a new corner.

 

2)         Apply 1-1/2" to 3" (40 to 75 mm) long stringer beads:

 

a)         Apply weld beads along bottom and outside edge, and diagonally on the outside corner.

 

b          Finish by applying stringer beads down at a 45º angle to the bottom edge, using the crisscross pattern.

 

3)         Protect mounting holes with stringer beads.

 

 

TEETH:            (Ripper, Rock, Shovel)

 

New Teeth:

 

            Materials          Semi-automatic

            Overlay            2832-SPL, 2836-SPL, 2839-SPL or 299-SPL

 

1)         At the cutting edge, frame a 2" to 3" (50 to 75 mm) section up from the edge and fill in the area with stringer beads.

 

2)         The sides and top(but not the bottom) of the teeth should be surfaced with a pattern fitting the material being worked:

 

a)         Rock - weld beads should run with the flow of material, spaced 1/2" to 1" apart (12 to 25 mm).

 

b)         Wet material, such as clay, dirt or sand - weld with beads against the flow of material, spaced 1/2" to 1" apart (12 to 25 mm).

 

c)         Mixtures of rock and dirt, or wet rock and fines - use a waffle pattern with beads 1/2" to 1" apart (12 to 25 mm).  An alternate pattern is 1" to 3" (25 to 75 mm) short stringer beads spaced 1" to 1-1/2" apart (25 to 40 mm).

 

 

Worn Teeth:

 

1)         Using repointer bars or plate cut to size, weld to worn teeth.

 

a)         Carbon steel parts(check if magnetic) - use Postalloy 3044-FCG.

 

b)         Manganese steel(non-magnetic) - use Postalloy 2850-FCO, 285-FCO, 285-SPL or 2865-FCO.

 

2)         Build up to within 1/8 (3.2 mm) of desired size using the same wire used for joining.

 

3)         Finish the hardfacing as a new part.

 

 

 

Supporting Parts for Teeth

 

1)         Weld a waffle or criss-cross pattern on the wearing surface of the supporting parts for teeth.

 

 

BUCKETS: (Shovel, Dragline, Backhoe, Clam)

 

New:

 

            Materials          Semi-automatic

            Overlay            2832-SPL

 

1)         If possible, position so that welding can be done in the downhand position.

 

2)         Use Postalloy 2865-FCO to repair all cracks on non-magnetic manganese.  Use Postalloy 3044-FCG on carbon or low alloy steel.

 

3)         Use the same pattern as outlined for teeth on the wearing surface of the buckets.

 

            a)         Skip-weld to avoid overheating.

 

4)         If positioning for downhand welding is not practical, weld using .045” (1.2 mm) diameter wire.  Weld 1" to 3" (25 to 75 mm) stringer beads at a 45º angle, 1" to 1-1/2" apart (25 to 40 mm).

 

5)         Completely fill in the lip area, 2" to 4" wide (50 to 100 mm).

 

            Worn:

 

1)         Weld low alloy steel wear plate to worn areas using Postalloy 3044-FCG, or when welding manganese steel wear plate, use 2865-FCO, 2866-FCO.  Hardface the plates before welding to buckets.

 

 

SHAFTS:

 

1)         Mount on rotating device using a welding head with step over capability.

 

2)         Rebuild with SAW or GMAW process using wire

            .045” to 1/16" (1.2 to 1.6 mm) diameter for 1" to 4" (25 to 100 mm) diameter shafts.

            1/16 to 3/32 (1.6 to 2.4 mm) diameter for 4" to 8" (10 to 20 cm) diameter shafts.

            3/32 to 1/8 (2.4 to 3.2 mm) diameter for shafts above 8" (20 cm) diameter.

 

3)         Use a build up wire with 30 to 35 Rc hardness.

            Postalloy 2892-SPL(GMAW)

            Postalloy 2873SA(SAW)

 

 

AUGERS AND SCREWS:

 

            Materials          Semi-automatic

            Overlay            2832-SPL

 

1)         Hardface the driving surface of the auger or screw.

 

2)         Hardface the cutting edge of augers and reaming edge of pilot bit.

 

3)         Position auger or screw by leaning at the angle of the flight so welding is down hand or at a slight angle.

 

4)         Weld stringer beads using .045” (1.2 mm) diameter wire on the leading edge, and 1" to 2" (25 to 50 mm) inside the edge.

 

5)         Fill in the area using 1/2" to 3/4" (12 to 18 mm) wide weave beads, or stringer beads if automatic.

 

 

PADDLES:      (Mixer, Paving)

 

            Materials          Semi-automatic

            Overlay            2832-SPL, 2836-SPL, 2839-SPL or 299-SPL

 

1)         Groove side and bottom edges if part is over 1/2" thick (12 mm).

 

2)         Weld the leading or worn face using stringer beads to outline the wear area and around exposed bolt holes.

 

3)         Fill in the framed area with 1/2" to 3/4" (12 to 18 mm) wide weave beads.

 

4)         Using .045” to 1/16" (1.2 to 1.6 mm) diameter wire, fill in grooved edges with slight weave beads.  No more than two layers.

 

 

TAMPERS:

 

New:

 

1)         Using 045" to 1/16" (1.2 to 1.6 mm) diameter Postalloy 2832-SPL, weld a stringer bead around the perimeter of each tamp.

 

2)         Weld a stringer pattern of a "Z" or an "X" on the face of the tamper.

 

3)         Weld a second layer on the edge with a 1/2" (12 mm) weave bead.

 

4)         Re-weld the circumference when worn 1/4" to 3/8" (6 to 9 mm).

 

Worn:

 

1)         Heavily worn tampers may be economically returned to size by driving short, cut lengths of pipe to worn tamp.  If pipe is unavailable use cut lengths of angle iron or 1/4" (6.0 mm) plate.  Weld to tamps using .045” to 1/16" (1.2 to 1.6 mm), Postalloy 2865-FCO or 2866-FCO.  Tack in place and join on outside but seal weld bottom on inside of cavity formed. Weld vertical joints to seal the formed cup.

 

2)         Finish overlay with Postalloy 2820-SPL.  Weld in one continuous operation to fill the cup with a cast weld technique.

 

 

Join manganese to manganese with 2850-FCO

 

Join manganese to carbon or low alloy steels with 285-FCO, 285-SPL, or 2865-FCO, 2866-FCO.

 

Join stainless to itself or to other base metals with 30-SPL, 30-FCG, or 2866-FCO.

 

Join carbon and low alloy steels with 306-FCO or 3044-FCG

 

Join high carbon steels and tool steels with 30-FCG or 30-SPL.