ESCO Dredge Maintenance

Helilok Rock and Sand/Clay

®

Dredge Cutterheads
Table of Contents
Safety
General Safety Information 4
Signal Words 4
Personal Safety 4
Introduction
Adapter Replacement is Fast and Easy 5
Easy-to-Replace Helilok /Vertalok Points Provide Unmatched Strength
® ®
5
Modification Disclaimer 5
Technical Support 5
Replacement Part Ordering 5
Rock Cutterheads – Component Identification 6
Sand/Clay Cutterheads – Component Identification 7
Welding Instructions
Welding Procedures for ESCO 12 Alloys 8
Weld-Rebuilding Structural Components 8
Cutterhead Hardfacing 8
Changing Points with Sandwich Pins 9
Changing Helilok/Spherilok Adapters 11
Improving Fatigue Resistance with Spherilok Adapters 13
Temper Beads 14
Replacing Epoxy 15
Replacing Sand/Clay Winged Adapters 16
Replacing Single Leg Adapters, Weld-On Noses 18
Helilok Nose Weld Rebuild Instructions 19
Rebuilding Worn Sockets 21
Rebuilding Heavily Damaged Sockets 21
Sweep Board 23

3
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
Throughout this manual are statements preceded by a special attention symbol: “ ”. The symbol is
used with the 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.

4
Introduction
This manual provides a detailed step-by-step
maintenance guide for the ESCO Helilok Rock and
®
Sand/Clay Dredge Cutterhead. Please read this
manual carefully before beginning the maintenance
process. Be sure to follow all recommended safety
and maintenance instructions.
The ESCO Dredge Cutterheads feature
unique adapter and point designs to provide
superior dredging productivity, while significantly
reducing the downtime required for point and
adapter replacement.
Adapter Replacement is Fast
and Easy
Rock cutterhead adapters are tightly supported in
sockets which are integrally cast with the cutter arm.
This style of adapter and socket require much less
welding than conventional dredge adapters. Thrust
loading is carried by the forward portion of the
socket and side loading is carried by epoxy which
surrounds the adapter shank.
ESCO’s adapter design permits precise positioning of
replacement adapters with the aid of special designed
sweep boards and setup points. Adapter replacement
on an ESCO cutterhead can be completed faster and
more accurately than conventional adapters.
5
Easy-to-Replace Helilok /Vertalok® ®
Points Provide Unmatched Strength
ESCO Helilok/Vertalok points fit onto the adapters
with a slight twisting motion, and are secured by a
sandwich pin that fits between the point ear and the
adapter nose.
The adapter nose of the Helilok/Vertalok system
is stronger and longer-lasting than comparable
conventional dredge point/nose systems that employ
central locking pins.
Modification Disclaimer
ESCO parts are designed to be installed in
accordance with instructions and/or drawings in
this manual. Any alternate materials, or any other
additions or modifications to the product become the
sole responsibility of the customer who assumes all
costs and liabilities connected thereto.
CAUTION: Failure to follow the instructions as
provided could result in damage to structural
cutterhead components.
Technical Support
If you experience any difficulty with the
maintenance instructions for the ESCO
Spherilok Dredge Cutterhead, please call
your ESCO sales representative.
Replacement Part Ordering
To order replacement parts call your ESCO
sales representative.
Rock Cutterheads
Component Identification
Hub
Cutter arms

Helilok / ®

Vertalok points
®

Spherilok®

socket
and adapter
(with epoxy)
Ring

High impact epoxy

Sandwich pin

Adapter socket
Spherilok adapter

Helilok/Vertalok
chisel point

Helilok/Vertalok
pick point
6
Sand/Clay Cutterheads
Component Identification
Hub
Helilok /Vertalok points
® ®

Cutter arms

Ring
Helilok ring adapter

Sandwich pin

Helilok winged adapter

Helilok/Vertalok
pick point

Helilok/Vertalok
flared point

Helilok/Vertalok
chisel point

7
Welding Instructions
Welding Procedures for
ESCO Series 12 Alloys
The ESCO Welding Procedures in publication
P6000GEN detail the recommended welding
procedures for best results when welding the
Series 12 alloys together or to other low alloy
castings, carbon steel castings, forgings or plate.
Before preforming any welding, cutting, or air-
arcing, thoroughly preheat with a torch or electric
device to the applicable temperatures found in
the ESCO Welding Procedures or in this manual.
It is recommended to use a Tempilstik or infrared
temperature gun to monitor preheat temperatures
and interpass temperatures.
Please refer to ESCO Welding Procedures
P6000GEN for the best method for applying
dot hardfacing.
If you use stringer beads instead of dot butter as
described in step 3, using mild steel or stainless
308, 309, or 310 rod is sufficient. Stringer beads
should be no longer than 50mm/2.0in. long and
parallel to the direction of adjacent structural welds.
Stringer beads on arms should be no closer than
100mm/4.0in. from the outside of the surface of the
hub cylinder.
CAUTION: Hardfacing ESCO Series 12
Alloy can lead to cracking and failure of
cutterhead components.

Weld-Rebuilding
Structural Components
Although ESCO cutterheads are designed to
minimize wear on structural components, opera-
ting in extremely abrasive materials may result in
Parrallel
accelerated wear of cutterhead components.
The leading edge of a cutterhead arm should
be rebuilt if 40mm/1.50in. has worn away. Rings
should be rebuilt if 15% of the original cross
section is worn away.
Use of low hydrogen E7018 or E8018 electrodes
are recommended for the first few passes when
rebuilding to the original contour. For greater life,
finish the last two to three passes with E9018
electrodes or equivalent wire.
All welds should run parallel to the leading edge
of the arm. Weld material placed transverse
could lead to cracks. Refer to P6000GEN ESCO
Welding Procedures for preheat, max interpass,
and post-weld heat treat if applicable. WARNING: When performing the work
Cutterhead Hardfacing described in these instructions, always work
safely and use proper safety equipment to
ESCO does not recommend hardfacing Series
help avoid injury. Always wear hard hat,
12 alloys. However, if hardfacing is performed, dot
gloves, safety shoes, eye protection, hearing
hardfacing should be used over other methods.
protection and fall protection per regional,
Dot welding is faster, uses less material, and costs
national and site requirements (e.g. OSHA,
less than continuous beads or solid overlays. It also
reduces the chance of cracking and weld failure that MSHA) when performing maintenance work.
is common with other methods. To avoid injury to others, keep bystanders
well out of the way.

8
Changing Points with
Sandwich Pins
IMPORTANT: ESCO recommends the
immediate removal of all points when the
cutterhead is removed from the shaft. Fines,
water, corrosion, and temperature changes
can cement the point to the adapter making
point removal difficult.
Note: The sandwich pin does not require use of
a dedicated removal tool for disassembly. How-
ever, an ESCO removal tool is recommended for
maximum ease and safety. The ESCO removal
tool has both a short drift extension and a long
drift extension. The short extension is useful to
start removal of the pin, the long extension helps
to drive it all the way out.

Step 1 – Drive Out Pin

Use a 1-4kg / 2-8lb hammer and removal tool to
drive out the sandwich pin. It is best to remove teeth
with a two person team, one to use the hammer and
one to hold the removal tool and to catch the pin.
To catch the pin it helps to use a small bucket or
receptacle with a handle as shown.

Step 2 – Remove Point

Remove the Helilok /Vertalok point with a slight
® ®

counterclockwise twist. It may be necessary to strike

the side of the point box section with a dead-blow
hammer to free it from the fines.
WARNING: DO NOT hit edges or corners.
Only strike a flat surface. Failure to follow
these instructions could result in serious
injury or death.
Step 3 – Clean Surfaces
Wipe the fines off the nose surfaces before installing
a new point.

Step 4 – Install Point

Install the replacement point onto the adapter nose,
rotated about 20° counterclockwise from its final
assembled position; then push the point in place
with a clockwise twist.

9
Step 5 – Insert Pin 1
Insert the pin by hand into the ear-nose key slot.
It will insert 10-15mm / 0.38-0.59in. and stand
straight up. If the pin will not insert by hand make
sure the nose is clean and the point is fully seated
on the nose.

Step 6 – Drive Pin

Drive the sandwich pin in until it seats securely in the
keyslot of the point. Sandwich pins may be reused
until there is significant tearing of the elastomer.
Occasionally, on well used pins or bent pins, the
steel insert will slip out from under the head of the
pin. In this case drive the insert back down under the
head of the pin and drive the pin into position.
Alternatively, a pin installation tool may be used.
Insert the pin by hand into the ear/nose keyslot as
seen in Step 5. Place an ESCO Pin Installation Tool 2
over the end of the sandwich pin. Drive the pin in
until the tool starts to contact the keyslot. Remove
the tool and finish driving in the pin until it is fully
seated in the keyslot.

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 protec-
tion 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.
10
Changing Helilok/
Spherilok Adapters
®
Adapters are replaced due to damages in various
areas, e.g., worn beyond repair, cracked or broken.
If there are cracks in the adapter weld, it must be
determined if the cracks follow the weld on the
surface or if the cracks go into the adapter. If the
crack follows the weld on the adapter, arc out the
crack, grind and clean and, weld per procedures
found in ESCO Welding Procedures publication
P6000GEN. If the crack goes into the adapter
base metal, the adapter should be replaced.
Step 1 – Preheat Area
Mark the arm to show location of adapter. Before
cutting the welds preheat the cutter arm adjacent to
the adapter to be removed to 95°C/200°F. During
adapter removal be sure to minimize damage to arm
surfaces to reduce repair time.
Step 2 – Remove Weld
When the socket is heated from arcing out the weld,
there is a possibility the adapter may be forcefully
ejected out of the socket. It is advisable to arc out
a small length of weld first and/or to drill through
the epoxy fill hole until reaching shank metal (and
refilling after the repairs are complete and the area
has cooled) to act as a vent hole prior to removing
the remainder of adapter weld. Keeping the socket
area as cool as possible through alternating arcing
and cooling will also reduce potential pressure build
up. When the weld is arced away, DO NOT allow
personnel to be in front of the adapter!
WARNING: Failure to keep personnel away
from front of adapter during the arcing process
could result in serious injury or death.
Air arc the weld away. As the arc burns the root
weld, the ball shape of the adapter should become
apparent. Use the shape of the adapter ball socket
to guide the arc in weld removal. A cutting torch may
also be used to cut away weld.
11
Minimize damage to the front face of the socket.
This reduces the total time to replace an adapter
by reducing the weld build up and grinding of the
front face of the socket. Regardless of method
used, monitor the temperature of the socket. It may
be necessary to work on multiple adapters to allow
sockets to cool.
CAUTION: Temperatures over 260°C/500°F
degrade the steel and the epoxy and could lead
to assembly failure.
Step 3 – Remove Old Adapter
Force out the old adapter with a pry bar. It helps to
strike the adapter a few times with a 4-6kg / 8-12lb
hammer to loosen it. Only strike flat surfaces and
be sure to wear proper safety equipment. If blocks
are welded to the adapter for purposes of prying
make sure that the adapter and block have an
electrical ground, the adapter is in epoxy.
Broken
adapter shown
with bar
Ground
adapter when
welding
Broken
adapter shown
with tee
WARNING: Failure to follow this recom-
mended procedure could result in serious
injury or death.
In some cases the adapter sticks in the epoxy well
enough that using a pry bar does not create enough
force. Weld a bar across the adapter to use wedges.
 WARNING: Be sure adapter and bar have
an electrical ground before welding. Gases from
warm epoxy or steam created by an arc going
to ground can create enough pressure to eject
the adapter. Failure to keep personnel away
from the front of the adapter could result in
serious injury or death. In some cases the adapter
breaks off at the shank when the weld fails during
severe impact or as a result of too much time
between maintenance cycles. Weld a tee to the
shank face to use wedges. See illustration.
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 protec-
tion 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.

See section on epoxy removal for cases where it is

advised to replace part or all of the epoxy.
WARNING: Do not use heat to soften the
epoxy. The fumes may cause nausea, serious
illness or death.

Step 4 – Clean Surface

Grind the face of the socket to clean it from arcing
residue and check the face of the socket to see if
it needs rebuilding. Make a half ball fitting tool from
drawing PDE50277 (in cutter document pack or
available from ESCO). If weld buildup is required,
follow the welding procedures in this document.

Step 5 – Check Epoxy

Clean all dirt and grime from the socket. If the epoxy
is damaged pour new epoxy; refer to “Replacing
Epoxy.” Epoxy should only be replaced if it is
cracked full length or a significant section is
damaged or missing.

Step 6 – Seat Adapter

Apply a thin coat of Anti-Seize, a release material, to
the shank of the replacement adapter. DO NOT coat
the ball of the adapter beyond 25mm / 1in. from the
shank. Slip the new adapter in place, being careful to
align the adapter locator surfaces correctly. Seat the
adapter all the way into the socket with a hammer. A
solid hammer rebound defines when the adapter is
correctly seated.

Step 7 – Preheat and Weld

Refer to ESCO Welding Procedures P6000GEN for
preheat, weld and post heat treat procedures. Make
the root pass, as shown in the diagram, to ease
adapter replacement. Use E7018 or E8018 low-
hydrogen electrodes from the drying oven and weld
root welds all around the adapter as shown.

12
Improving Fatigue Resistance with
Spherilok Adapters
®

Testing has shown that the fatigue life of the

ESCO Spherilok adapter welds can be increased
significantly over that of an as-welded surface by
Polish corners of
peening the toe of the weld. chisel point to
4mm radius.
All welds have a microscopic notch at the toe of the
weld, regardless of sound welding practices. When
subjected to repeated cyclic loading that exceeds Using a pneumatic slag hammer with the
the Endurance Limit of the weld materials, this notch prepared chisel, peen the toe of the weld
to produce a 0.50mm / 0.02in. depression.
can grow, eventually resulting in failure of the weld.
Continue this completely around each adapter.
Peening will induce compressive residual stresses
which lower the peak tensile stresses experienced
during cyclic loading. Also, peening imparts a radius
on the edge at the toe of the weld which reduces the Peening detail
amount of stress concentration. Weld
0.50mm /
Using a specially prepared slag chisel with a 4mm / 0.02in.
0.16in. radius at the end (see below), and polished
to eliminate all sharp edges, peen only the toe of the
weld using the specially prepared chisel. This chisel NACELL
Peened
should have a tip hardness at least 55 Rc. Preserve depression
the geometry of the chisel by using it only for the Adapter
peening operation. Any defects or undercut in the
toe of the weld should be ground or weld repaired
prior to the peening process. During peening, the By applying the above technique longer periods
temperature of the work piece should be below between adapter weld repair may be experienced.
205°C / 400°F.
CAUTION: Failure to properly peen welds
may result in premature cracking of the
assembly welds.

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 require-
ments (e.g. OSHA, MSHA) when performing
maintenance work. To avoid injury to others, keep
bystanders well out of the way.

13
Temper Beads Weldment after placing last bead
In some cases, application of temper beads may Low-temperature
heat-affected zone
be required to reduce the risk of hydrogen assisted
cracking. Temper beads are small, additional beads High-temperature
placed on the weld deposit after completion of the heat-affected zone
weld. They are located on the weld deposit, a short Last weld bead
distance from the toe of the weld. It is important to
place temper beads on the weld material and not
the base metal. If temper beads are applied to the
base metal, a new heat affected zone (HAZ) will
be formed and no tempering will have occurred. If
temper beads are placed too far from the toe of the
weld an insufficient amount of tempering will occur
near the toe of the weld.
Temper beads should be between 6.5-9.5mm/0.25- Weldment after placing temper bead
0.375in wide. They must be placed between Low-temperature
2-4mm/.080-.160in from the toe heat-affected zone
of the weld. High-temperature
heat-affected zone
Temper beads are to be employed on adapter sizes
of 48DS or larger. Standard post-weld mechanical Temper bead
dressing is recommended after the weld has had
sufficient time to cool.
CAUTION: Failure to follow this recommen-
dation may result in premature cracking of the
assembly welds.

Temper bead
full circumferance

14
Replacing Epoxy
There are a number of different reasons
to replace Epoxy:
1. Adapters require reorientation or a large portion
of the epoxy has broken down and does not
support the shank anymore.
2. In some difficult projects in the larger sizes
of sockets, 642D, 700D, 787D, replacing the
epoxy back to the pour hole can be an advantage
in supporting the adapter in the socket, which
reduces weld failure.
3. New epoxy can be poured around old epoxy. If
possible keep the epoxy that supports the shank
as this orients the adapter correctly without having
to use an Adapter Positioning Fixture
(Sweep Board).
4. ESCO MAXBAK® Epoxy and ITW Polymer
CHOCKFAST® Orange are the two most popular
epoxies. ESCO MAXBAK can be ordered.
CHOCKFAST Orange is available from marine
supply companies in many countries of the world.
Note: Other epoxies may be used, but they must
have a minimum compressive strength of 124 N/
mm2/12,000 psi.
Step 1 – Remove Old Epoxy
Break out the epoxy with a chisel and remove the
loose pieces. A roto-hammer can be a useful tool
both with a chisel bit or drill bit when removing
epoxy. The drill bit should be tungsten carbide for
longer life.
WARNING: Do not heat the epoxy with a
torch. The fumes may result in nausea, serious
illness or death.
Step 2 – Clean Socket
Clean the socket and coat the shank of the
replacement adapter with an anti-seize or release
material. DO NOT coat the ball of the adapter
beyond 25mm / 1in. from the shank.
WARNING: Coating the ball of the adapter will
place anti-seize or release material too close to
the heat of the weld and may generate fumes or
flames which may result in nausea, serious ill-
ness, serious injury or death.
15
Step 3 – Add Pad to Bottom of Socket
It is strongly recommended to add a disk of non-
flammable fabric (mineral wool insulation) to the
bottom of the socket to exclude epoxy from the
end of the cavity and to have the adapter seat in
the socket more consistently. 25mm/1.0 in thick
material has been found to compress tightly and
still allow the adapter sphere to seat firmly into the
shank as desired. For 3G and smaller sizes it may be
necessary to peel some layers of pad off to reduce
the thickness and allow good material compression
and still allow the adapter to seat properly in
the socket.
It is important that both the pad material and the
socket itself are dry prior to welding in the adapter.
Damp pad material or socket increases the risk of
expanding steam causing forceful adapter ejection
during subsequent steps or future adapter removal.
WARNING: Failure to keep personnel away
from front of adapter during the arcing process
could result in serious injury or death.
Trim diameter so that it holds itself in place while
installing adapter. If the socket already has a dry pad,
do not remove it.
Step 4 – Install Adapter
Install the adapter so the ball fits firmly against the
spherical surface of the socket. Make sure the adapter
is rotated with the lock in the correct orientation.
Orient the adapter by using a sweep board.
Step 5 – For complete details read the ESCO
Welding Procedures; P6000GEN01L
Step 6 – Assembly Sequence Options (two)
1. Weld a root-pass nearly all around the socket/
adapter junction, leaving a small air-escape hole at
the highest point of the weld. In order to avoid air
bubbles or possible epoxy combustion, DO NOT
pour epoxy if the temperature of the socket
exceeds 50°C / 125°F. If adapter is left sitting
prior to pouring epoxy, cover the air escape hole to
keep out moisture and dirt. Slowly pour the mixed
epoxy into the pouring hole, filling to the top of the
hole. After the epoxy has set 20 minutes, remove
any epoxy that may have escaped through the hole
in the root-pass, then preheat and weld the adapter.
OR
2. Cover pour hole to keep moisture and dirt
out. Weld adapter completely. Clean weld,
remove pour hole cover. In order to avoid air
bubbles or possible epoxy combustion, DO NOT
pour if the temperature of the socket exceeds
50°C / 125°F. Slowly pour the mixed epoxy into
the pouring hole, filling to the top of the hole.
Check that hole remains full.
CAUTION: The second process requires cutter
to sit 36 hours before use to allow the epoxy to
cure. Failure to allow adequate time for curing can
result in system failure.

Replacing Sand/Clay
Winged Adapters
Adapters are replaced because of damage in various
areas. They may be worn beyond repair, cracked, or
broken. Proper procedures in removal will minimize
replacement time.

Step 1 – Preheat Area Preheat

region
Mark the arm to show the location of the adapter.
Before cutting the welds preheat the cutter
arm adjacent to the adapter to be removed to
95°C/200°F. During adapter removal be sure to
minimize damage to the arm surfaces to reduce
repair time.

16
Step 2 – Contour and Weld Repair
Grind or weld the cut area to the contour of the
fit area of the adapter and adjacent arm shape as
required. Weld repair any cracks or deep gouges. Outside wing
Be sure to preheat the area thoroughly if welding. surface
(Refer to table below.) Weld using short stringer
beads with a single bead or a weave not to exceed
20mm/0.75in. Remove slag completely after
each pass. Do not exceed 260°C/500°F
interpass temperature.

Step 3 – Position and Contour Leg

Position the adapter according to the locator tab or
markings. Preheat the adapter per the table above
and flame cut to fit between existing wing adapters.
Tack weld in place. Bevel wing as needed to achieve
10mm weld depth between wings.
IMPORTANT: After an adapter has been replaced
multiple times, a new adapter should be checked
for alignment with a sweep gage and setup point
to insure adapters are accurately positioned.

Step 4 – Tack-Weld Adapter

Ensuring that preheat per P6000GEN01L is
achieved, weld adapters using E7018 or E8018 low
hydrogen electrodes. Apply root layers to all the weld
joints. DO NOT weld any one joint completely before
moving to another weld joint of the adapter; doing
this will help minimize distortion.

Step 5 – Weld Sequence

Weld rod size should be chosen to minimize the weave.
One pass, full size welds are not acceptable. Begin with
a single pass on the inside wing-to-arm joint. Move to a
2-pass weld on the outside of the wings. Continue with
a single pass on the leg of the adapter.
IMPORTANT: DO NOT stop and/or start welds in
corners of wing and adapter body. Weld around
corners staggering the starts and stops. Make
final weld passes on the outside of the wings WARNING: When performing the work
and then the inside. Weld the leg of the adapter described in these instructions, always work
being careful to alternate sides until fully welded. safely and use proper safety equipment to help
Before the welds cool, apply a temper bead, as avoid injury. Always wear hard hat, gloves,
described above, to the welds around the leg of safety shoes, eye protection, hearing protec-
the adapter using E7018. tion 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.
17
Replacing Single Leg Adapters, WARNING: When performing the work
Weld-on Noses described in these instructions, always work
Adapters are replaced because of damage in various safely and use proper safety equipment to help
areas. They may be worn beyond repair, cracked, or avoid injury. Always wear hard hat, gloves,
broken. Proper procedures in removal will minimize safety shoes, eye protection, hearing protec-
tion and fall protection per regional, national
replacement time.
and site requirements (e.g. OSHA, MSHA)
Step 1 – Reference Location when performing maintenance work. To avoid
injury to others, keep bystanders well out of
Mark the cutter arm with weld to show the correct the way.
orientation of the adapter.

Step 2 – Preheat Area

Preheat the cutter arm, adjacent to the adapter, to be
removed with a torch to 95°C / 200°F before arcing
the welds. During arcing, minimize damage to reduce
repair time and to leave the surface for remounting a
new adapter.

Step 3 – Contour/Weld Repair

Grind the arced area to the contour of the fit area of
the adapter. Weld repair any cracks or deep gouges
per procedures in this manual.

Step 4 – Position
Position the adapter according to the locator tab and
tack in place.
Note: After an adapter has been replaced a num-
ber of times, a new adapter should be checked
for alignment with a sweep gage to insure that the
adapters are maintaining consistency. For weld-
on noses add bars in two directions to maintain
the orientations during welding.
Step 5 – Weld
Weld adapters, using E7018 or E8018 low hydrogen
electrodes from the drying ovens, from the rear
of the leg forward, alternating weld locations to
minimize stress concentration. For weld-on
noses, alternate weld sides after each four layers
of weld material.

Step 6 – Weld Finish

For single leg adapters and weld-on noses, grind
the weld at the leading edge of the arm to reduce
stress concentrations.

18
Helilok Nose Weld
Rebuild Instructions
If point loss continually occurs from a particular
adapter, ESCO recommends the adapter be
replaced with a new one, or the adapter be rebuilt
using the following procedures.

Step 1 – Clean and Inspect Nose

Clean the nose thoroughly and examine for cracks,
especially in the rear areas of the nose. A cracked
nose is generally not worth rebuilding.

Step 2 – Weld Nose

Refer to P6000GEN01 for preheats. Weld the
nose end as squarely as possible to about 1.5mm
/ 0.06in. longer than the repair template (use low-
hydrogen E9018 or E11018 electrodes). (A repair
template was sent with your ESCO cutterhead.
Template drawings come with your cutter document
pack or are available from ESCO).

Step 3 – Rebuild Corners

If the corners are worn, rebuild them to the original
shape using a new adapter nose as a guide. Grind
the end of the nose until the template contacts the
end of the nose and slides into the pin slot.

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 protec-
tion 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.
19
Step 4 – Check Fit
Lightly cover the end of the nose with wet chalk
or paint, then thrust a new point in place. Insert
a bayonet into the pin slot, engaging the ears on
both sides. Remove the point and insure contact at
the end of the nose. Grind or add additional weld
until both a contact fit exists between the point and
nose and the bayonet inserts into the pin slot. (One
bayonet is shipped to the dredge with each cutter.
Additional bayonets are available from ESCO).
Note: This procedure is designed to stop point
loss in normal service. Eventually, wear in other
areas of the nose will become significant. In this
case, ESCO recommends adapter replacement.
However, if you wish to attempt to extend adapter
service life even further, do so according to the
following procedures.
Step 5 – Preheat and Weld Band
With the end of the nose restored, heat the nose
so the areas just ahead of the pin slot reach Weld band
150-205°C / 300-400°F. Weld the stabilizing
surface as shown to buildup a 13mm / 0.5in.
wide band. (Use low-hydrogen E7018 or
E8018 electrodes).

Step 6 – Grind
Grind as required until a new point contacts the end
of the nose and the bayonet fits in the pin slot. DO
NOT produce a wedge-fit that requires hammering
to remove the point.

20
Rebuilding Worn Sockets
A socket worn to 50% or less of its original
thickness at the adapter weld face should be rebuilt
to the original contour. Preheat to 120°C/250°F and
weld stringer beads. Rebuild the worn socket with
stringer beads extending around the socket. Finish
the rebuild with hardfacing. See the Cutterhead
Hardfacing procedures.

Rebuilding Heavily
Damaged Sockets
A heavily damaged socket can be repaired by the Burn line around leading
installation of a weld-on socket sphere designed to edge of blade at this location.
replace the forward spherical portion of the socket. If
socket damage extends behind the spherical portion,
direct weld-rebuilding is necessary.
Dimension C
Step 1 – Remove Epoxy
Remove the epoxy from the socket. (See Replacing
Epoxy procedures).

Step 2 – Burn Line

Carefully mark and punch a burn line around the
damaged socket according to the accompanying Dimension B
diagram and table. Depending on the amount of
Weld-on Socket Burn Burn
damage, it may be necessary to refer to other
Sphere Part No. Dimension B Dimension C
undamaged sockets to locate the
burn line. WN 430D 50mm / 2.0in. 12mm / 0.47in.
WN 490D 56mm / 2.2in. 14mm / 0.55in.
WN 580D 70mm / 2.8in. 16mm / 0.63in.
WN 640D 75mm / 3.0in. 16mm / 0.63in.
WN 700D 75mm / 3.0in. 16mm / 0.63in.

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 protec-
tion 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.
21
Step 3 - Cutting and Fitting Weld land positioned for best
Preheat the burn area to 95ºC / 200ºF and overall weld accessibility
carefully burn off the forward part of the socket
along the burn line. Maintain the burn face as flat
and smooth as possible. Clean slag and foreign
matter from the burned surface. Grind the surface
as required so the weld-on socket sphere repair part
fits as shown. Tack-weld the repair socket sphere to
the burned socket face.

Step 4 – Weld in Place

Weld the repair socket in place. Refer to procedure
P6000GEN01. Distribute the weld continuously
around the joint to minimize stress.
Trim flush with
Step 5 – Drill Epoxy Hole surrounding socket
Drill a 25mm/1in diameter hole for epoxy
addition (use other sockets as a reference).
Refer to “Replacing Epoxy in ESCO Sockets”
for filling instructions.

22
Sweep Board Sweep
Using a Sweep Board for Positioning Adapters and board
Weld-On Noses.
When the epoxy on a Spherilok adapter is replaced
®

or when other adapter types or a weld-on nose is

installed or replaced, a special gage called a sweep
board should be used to ensure proper adapter
positioning (a sweep board is NOT required when
installing Spherilok adapters if the epoxy is intact).
Drawings to build a sweep board were included with
the cutterhead documentation. To obtain a sweep
board or a price quotation for one, contact your
nearest ESCO sales office and provide the ESCO
cutterhead serial number.
Install the sweep board and use it as a gage
according to the following instructions:

Step 1 – Install Plug

Install a plug into the cutterhead shaft opening to
protect the threads, be sure it fully seats and is
firmly held in place.

Step 2 – Remove Points

Remove the points from the adapters adjacent
to the adapter that is to be repaired.

Step 3 – Install Post

Install the post of the sweep board in the plug.

23
Step 4 – Install Setup Point Leading
Install a setup point onto the adapter that is edge
being replaced.

Step 5 – Set Adapter to Gage

With the replacement adapter or weld-on nose in
place, pivot and /or roll it until the plate on the setup
point rests flat against the appropriate gage plate on
the sweep board. Tack-weld the adapter or weld-on
nose firmly in place.

Step 6 – Recheck Setup Point

Recheck the setup point plate against the sweep
board prior to final welding. As a final check
for accuracy, use the sweep board and setup
point to check the position of corresponding
points on other arms of the cutterhead (the
point arrangement on most ESCO cutterheads
is staggered on alternate arms). The location of
the point on the replacement adapter or weld-
on nose should be within 12mm/0.50in of the
corresponding points on other blades.
CAUTION: Failure to properly position each
point to the sweep board may result in uneven
point wear and reduce point service life.

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 protec-
tion 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.
24
NOTES:

25
NOTES:

26
 escocorp.com

P6000DRG01A0415 © 2015 ESCO Corporation. All Rights Reserved.