S-Series Posilok®
`Installation, Removal and Maintenance
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 1
`
`

`

`Safety
`General Safety Information
`The safety practices described in 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 in force in your area. Your safety and the safety of
`others results from putting into practice the correct operating procedures.
`
`Read this entire manual prior to conducting the maintenance procedures described
`in this manual.
`
`Signal Words
`”. The symbol is used with the
`Throughout this manual are statements preceded by a special attention symbol: “
`following signal words to attract your attention to information of special priority. Read the paragraphs carefully and
`make sure you understand their significance, especially the possible causes of injury or death.
`
`WARNING: A statement preceded by “WARNING” is information that should be acted upon to prevent serious
`injury or death.
`
`CAUTION: A statement preceded by “CAUTION” is information that should be acted upon to prevent machine
`or equipment damage.
`
`Additional signal words that are not preceded by the attention symbol are:
`
`IMPORTANT: A statement preceded by the word “IMPORTANT” is information that possesses special
`significance.
`
`Tip: A statement preceded by “Tip” is information that is handy to know and may make your job easier.
`
`Personal Safety
`WARNING: When performing the work described in these instructions, always work safely
`and use proper safety equipment to help avoid injury. 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 avoid injury to others, keep bystanders well out of the way.
`
`2
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`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 2
`
`

`

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`Table of Contents
`
`Adapter Installation – S95 only
` Component Preparation
` Install Pin
` Install Adapter
` Retighten Pin
`Adapter Removal – S95 Only
`Adapter Installation – S110, S130 and S145
` Install Pin
` Install Adapter
` Retighten Pin
`Adapter Removal with – S110, S130 and S145
` Retract Pin
`Nose Rebuild – All Sizes
` Nose Fit
` 1. Nose End and Sides Rebuild
` 2. Nose Flats Rebuild
` 3. Rear Corner Rebuild
`Lock Style Wear Cap Installation
` For use on Weld-on Bases
`Lock Style Wear Cap Removal
` For Use on Weld-on Bases
`Non-lock Style Wear Cap Installation
` For Use on Intermediate Adapters
`
`IMPORTANT The recommended installation and removal tool is a socket drive with the
`appropriately-sized hex bit (refer to Table 1).
`
`Do NOT use an air impact tool when installing the locking pins, as this may damage the pins,
`resulting in installation and removal problems.
`An air impact tool may be used with caution during the removal process only.
`
`System Size
`S95
`S110
`S130 & S145
`
`Table 1
`
`Hex Bit
`14mm
`17mm
`19mm
`
`3
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 3
`
`

`

`Adapter Installation with S95
`Component Preparation
`IMPORTANT: For S110, S130 or S145 sizes, go to pages 6 and 7.
`Prior to installing the Posilok tooth system components:
`
`• Thoroughly clean all bearing surfaces on the tooth base, adapter, and pin.
`
`• Visually inspect top and bottom of tooth base for wear, refer to the nose rebuild section for
`acceptance standards.
`
`Install S95 Pin
`
`• For applications where soil fines pack and harden,
`it is recommended that the outer sleeve of the pin
`be covered in grease (see Pin Rebuild section).
`• Place pin into adapter base.
`
`
`
`Tip: Pin can be inserted from either side of base.
`Recommended corner positions should be installed
`from the inside.
`
`•
`If pin is not fully retracted, use hex bit to turn
`head until pin body is flush with the end of the
`pin sleeve. For S95PN pin only, retract by
`turning clockwise.
`
`Sidewinder pin
`S95RPN only
`
`Install S95 Adapter
`
`• Use appropriate lifting devices to position adapter
`onto tooth base until it solidly contacts end of
`base. For wear cap style, pre-assemble so that
`eye on tip can be utilized as shown.
`
`Pre-assembled for
`easy lifting.
`
`Adapter
`base
`
`Posilok®
`base
`
`4
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 4
`
`

`

`Adapter Installation with S95 – Continued
`
`• Using a 14 mm hex bit and a socket drive, turn hex
`socket end of the S95RPN pin counterclockwise to
`extend the pin into the pin hole in the opposite side
`of the adapter. Tighten to the recommended pin torque
`value indicated below.
`Insert the pin cap to prevent the pin hex socket from filling
`with soil fines. Cap should snap into place.
`
`•
`
`
`
`Retighten S95 Pin
`Retighten the pin every 600 to 1200 hours of operating service
`depending on the severity of application.
`Recommended Pin Torque
`(To assure adapter is fully installed).
`Size S95: 120-150 ft-lb (160-200 nm).
`
`Retracted
`
`Extended
`
`Adapter Removal for S95
`Clean debris from adapter pin head slot and remove cap from pin head.
`
`• Retract Pin – Insert 14 mm hex bit into the head of the S95 pin and turn clockwise until the pin body is
`fully retracted. Do not continue to turn after ‘stop’ is felt. The Sidewinder® pin is designed for operation with
`a ratchet wrench and should not normally require use of an air-impact wrench.
`IMPORTANT: The Sidewinder pin is not usually removed from the nose hole during an adapter change-out.
`Remove only when there appears to be damage or the pin is due for maintenance.
`
`• Remove Adapter – Use appropriate lifting devices to support and remove adapter. If soil fines resist adapter
`removal, use a pry bar between the back sides of the adapter and the side shoulders of the nose.
`
`IMPORTANT: Remove worn out adapters directly after
`taking the bucket out of service, before soil fines
`harden in place.
`
`WARNING: When performing the work
`described in these instructions, always work safely
`and use proper safety equipment to help avoid
`injury. 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 avoid injury to
`others, keep bystanders well out of the way.
`
`5
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 5
`
`

`

`Adapter Installation with S110, S130 and S145
`Prior to installing the Posilok® tooth system components:
`
`• Thoroughly clean all bearing surfaces on the tooth base, adapter, and pin.
`
`• Visually inspect top and bottom of tooth base for wear, refer to the nose rebuild section for
`acceptance standards.
`
`Install Pin
`
`• For applications where soil fines pack and harden, it is
`recommended that the outer sleeve of the pin be covered
`in grease (see Pin Rebuild section).
`• Place pin into adapter base.
`
`
`
`IMPORTANT: For S110, S130, and S145 sizes, the end with
`hex socket must be inserted first.
`
`Tip: Pin can be inserted from either side of base.
`Recommended corner positions should be installed
`from the inside.
`
`•
`If pin is not fully retracted, use hex bit to turn
`head until pin body is flush with the end of the pin
`sleeve. Retract pin by turning counterclockwise.
`
`Hex bit size: 17 mm for S110, 19 mm for S130 and S145.
`
`Install Adapter
`
`• Use appropriate lifting devices to position adapter
`onto tooth base until it solidly contacts end of
`base. For wear cap style, pre-assemble so that eye
`on tip can be utilized as shown.
`
`Sidewinder® pin
`S110, S130, & S145 sizes
`
`Pre-assembled for
`easy lifting.
`
`Adapter
`base
`
`Posilok®
`base
`
`6
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 6
`
`

`

`Adapter Installation with S110, S130 and S145 – Continued
`Install Adapter
`
`• Using hex bit and socket drive, turn hex socket end of
`pin clockwise to extend the pin into the pin hole in the
`opposite side of the adapter. Tighten to the specified
`torque value shown below.
`Insert the pin cap to prevent the pin hex socket from filling
`with soil fines. Cap should snap into place.
`
` •
`
`Retracted
`
`Extended
`
`Retighten Pin
`Retighten the pin every 600 to 1200 hours of operating service depending on the severity of application.
`Recommended Pin Torque (To assure adapter is fully installed).
`Size S110: 150-190 ft-lb (200-260 nm) Sizes S130 and S145: 90-290 ft-lb (260-390 nm).
`
`Adapter Removal with S110, S130 and S145
`Clean debris from adapter pin head slot and remove cap from pin head.
`
`• Retract Pin – Insert Allen hex bit into the head of pin and turn counterclockwise until the pin
`body is fully retracted. Do not continue to turn after ‘stop’ is felt. The Sidewinder® pin is designed for
`operation with a ratchet wrench and should not normally require use of an air-impact wrench.
`IMPORTANT: The Sidewinder pin is not usually removed from the nose hole during an adapter change-out.
`Remove only when there appears to be damage.
`
`• Remove Adapter – Use appropriate lifting devices to support and remove adapter. If soil fines resist adapter
`removal, use a pry bar between the back sides of the adapter and the side shoulders of the nose.
`
`IMPORTANT: Remove worn out adapters directly
`after taking the bucket out of service, before soil fines
`harden in place.
`
`WARNING: When performing the work
`described in these instructions, always work safely
`and use proper safety equipment to help avoid
`injury. 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 avoid injury to
`others, keep bystanders well out of the way.
`
`7
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 7
`
`

`

`Nose Rebuild – All Sizes
`Nose Fit: The S-Series Posilok® tooth system is designed to operate with
`movement of the adapter on the nose. However, movement may become
`excessive over long term service because of nose wear. In this event, the
`nose can be rebuilt in the indicated areas with welding and grinding.
`
`IMPORTANT: Perform Step 1 using the nose side template, Step 2 using the
`nose flats template, and step 3 using the 3D nose template.
`
`1. Nose End and Sides Rebuild
`
`• Place the ESCO nose side template on the centerline of nose. Weld
`rebuild nose end surface and grind flat until gage ends align with front
`edge of pin hole.
`
`Note: Refer to ESCO Weld Procedures P6000GEN. Weld stringer beads
`should run parallel to the nose width.
` • Rebuild nose end radii as necessary.
`
`Nose end
`
`Nose radii
`
`Nose
`sides
`
`Nose
`flats
`
`Rear nose
`corners
`
`Nose side
`template
`
`2. Nose Flats Rebuild
` • Place the ESCO nose flats template over the nose as shown.
`Weld buildup nose flats and radii, and grind flat until template
`contacts nose end.
`
`CAUTION: Weld beads must be oriented parallel to the nose end.
`
`Nose flats template
`
`8
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 8
`
`

`

`Nose Rebuild Continued
`3. Rear Corner Rebuild
` • Place the 3D nose template on the nose.
` • Recheck the nose end, sides, and flats to ensure these areas do not need further
`build-up or grinding.
` • Weld build-up rear corners of nose and grind flat until the 3D nose template makes
`contact on the nose end, the bayonets are aligned with the front of the keyslot, and
`the 3D template has little or no movement.
` • Grind the rear nose corner weld smoothly into the rear shoulders.
`
` Nose
`3D Nose
`Nose Flats
`Nose Side
`Template
`Template
`Template
` Size
`WRT-S95-3D
`WRT S95CT
`WRT S95ST
` S95
`WRT-S110-3D
`WRT S110CT
` S110 WRT S110ST
` S130 WRT S130STA WRT S130CTA WRT-S130-3D
` S145 WRT S145ST
`WRT S145CT WRT-S145-3D
`
`1. Slide gauge onto nose
`
`2. Insert bayonets into pin cavity
`
`3. Pull gauge forward
`
`Check
`gaps
`
`Check
`gaps
`
`4. Weldment fit instruction
`
`Primary fit areas
`
`Secondary fit areas
`
`Blend well
`
`WARNING: When performing the work
`described in these instructions, always work safely
`and use proper safety equipment to help avoid
`injury. 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 avoid injury to
`others, keep bystanders well out of the way.
`
`9
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 9
`
`

`

`Lock Style Wear Cap Installation
`For Use on Weld-on Bases
`Wear cap tabs, adapter tab slots, and lock recesses must be thoroughly cleaned.
`Inspect all components for damage. Replace any damaged parts.
`
`• Position Wear cap Lock – First place the lock flat side down against the
`inside of the wear cap, adjacent to the lock opening. Slide it toward the wear
`cap lug. One of the lock shafts will enter the hole in the lug. Push the lock up
`tight against the lug. Then, using a drift placed in one of the lock pockets, tap
`the drift with a hammer to cause the lock to rotate halfway around, until the flat
`side of the lock is facing you and is lined up with the inside face of the wear cap.
`
`IMPORTANT: Lock can rotate either way.
`
`• Wear cap Installation – Place the wear cap on the adapter. The tabs on
`the inside of the wear cap fit into the tab slots in the adapter.
`• Lock Wear cap – Use an ESCO lock removal tool (37V/57V) and hammer to
`rotate the lock to the locked position. If lock resists rotation, this indicates more
`cleaning of the adapter slots is required. When flat is facing out, the lock is in a
`locked position.
`
`
`
`Recommended Tools
`
`Rotate lock
`
`Hammer
`
`Lock removal tool
`37V/57V
`
`Locked
`
`10
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 10
`
`

`

`Lock Style Wear Cap Removal
`For Use on Weld-on Bases
`Clean debris from the gaps around the wear cap lock.
`
`
`
`WARNING: Do not strike corners or edges with hammer.
`• Rotate Lock – Use a drift and a 4-8 lb (2-4 kg) hammer to rotate the
`lock to the unlocked position. Use ESCO lock removal tool for safe
`and effective removal. It may be necessary to partially rotate the lock in
`both directions to break loose soil fines, before fully rotating it.
`
`IMPORTANT: Lock must be rotated completely (180°) to release
`the wear cap.
`
`• Remove Wear cap – Slide wear cap out of adapter slots.
`Use appropriate lifting devices to support and remove wear cap.
`It may be necessary to place a pry bar between the adapter
`and the rear inside face of the wear cap to lift and free it
`from soil fines.
`
`Non-lock Style Wear Cap Installation
`For Use on Intermediate Adapters
`Inspect all components for damage. Replace any damaged parts.
`
`• Slide wear caps onto the adapter top and bottom surfaces, so that the wear
`cap rear central and two forward side tabs insert fully into the respective slots
`of the adapter.
`Install and pin the point.
`
`•
`
`
`
`Non-lock Style Wear cap Removal
`
`• Drive out the point pin and remove the point.
`
`• Slide the worn wear cap off the adapter.
`
`IMPORTANT: If soil packs tightly between the wear
`cap and the adapter, it may be necessary to strike
`the flat sides of the wear cap several times with a
`dead blow hammer, to loosen it for removal.
`
`WARNING: Do not strike corners or edges
`with hammer.
`
`Front view new style
`of wear cap
`
`Back view of wear cap
`
`WARNING: When performing the work
`described in these instructions, always work safely
`and use proper safety equipment to help avoid
`injury. 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 avoid injury to
`others, keep bystanders well out of the way.
`
`11
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 11
`
`

`

`escocorp.com
`
`P6009MIN01L0914
`
`© 2014 ESCO Corporation. All Rights Reserved.
`
`Caterpillar v. ESCO IPR2015-00409
`ESCO Exhibit 2020 Page 12
`
`