ESCO Toplok Mechanical Shrouds

Installation and Removal Instructions

Safety and Warnings

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 your
knowledge of the correct operating procedures.

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.

WARNING: A statement preceded by WARNING

is information that should be acted upon to prevent serious
injury.

CAUTION: A statement preceded by CAUTION

is information that should be acted upon to prevent
machine 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.

ESCO Toplok Mechanical Shrouds

Installation & Maintenance for Plate Lips
ESCO Toplok shroud system is an innovative system
proven in the field on front end loaders, face shovels,
draglines, hydraulic excavators, shovel dippers, and load
haul dump buckets. A mechanical lock provides secure
attachment in severe applications, requires no bolts and
no welding for attachment and removal.
Toplok shrouds are held on the lip with a pin that
is simple to install and remove. The pin locks in the
shroud behind a permanently installed boss on the lip.
This simple and effective design ensures the lip carries
the high stress loads of digging. The pin merely keeps
the shroud from falling off, for excellent reliability.
Toplok shrouds can be installed on almost any lip
new or used. Shrouds are available for both lips and
wings, and attach with one boss and pin for each
shroud. Shrouds can also be used together without
adapters!

Lips

Toplok lip shrouds are available for spade and straight lips. Type A shrouds are only for spade lips and must match
the actual spade angle of the lip. Type B shrouds can be used on spade or straight lips, including the center
position of semi-spade or duckbill spade lips. Type B shrouds are noted in the product specifications catalog with
a 0 degree spade angle. Type A shrouds provide slightly better lip coverage on spade lips between the shroud and
adapter than Type B shrouds.
Left and right hand shrouds are labeled based on the machine operators view of the bucket while sitting in the
machine. The exception is Hydraulic Face Shovels where left and right is determined by facing into the bucket.

Lip Shrouds for Spade and Straight

Type A

Type B

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.

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Wing Shrouds
Wing shrouds protect buckets from accelerated wear that reduces loading capacity and leads to premature failure,
and reduce spillage that can cause severe tire damage. Toplok wing shrouds install easily on ESCO, OEM or
aftermarket buckets. To select the correct shroud, first determine the bucket wing thickness and shroud width
for the desired wing coverage. Toplok wing shrouds are designed to be installed just above the corner adapter
(as shown above). A second shroud may be installed just above the first for increased coverage. ESCO strongly
recommends the use of thrust blocks (see illustration) when installing Toplok wing shrouds to help absorb the
multidirectional forces encountered in the digging cycle.

Thrust
blocks

Toplok Mechanical Shroud Template

ESCO has templates available to assist in the installation and
maintenance of Toplok lip shrouds. Templates provide specific fit criteria
for each shroud and should be used when possible. When retrofitting a
used lip, establishing correct fit at the shroud bearing pads is necessary
for a successful installation. See P6001GEN literature for a list of available
templates, or contact your ESCO representative.

General Fit Concept for Toplok Shrouds

The template must simultaneously contact the leading edge and the top
of the lip. The allowable gap for the lip ramp surface should not exceed
1.5mm/0.06 in. The allowable clearance between the template and the
bottom of the lip is marked on the template (the clearance is different
based on the shroud used).

Allowable gap Full contact

1.5mm/0.06 in. max. with lip
Contact
with lip
Gap allowed as noted
on template.

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Step 1. Prepare the Surface

In order to provide sufficient support for the
shroud, the boss mounting surface must:
Be relatively smooth and free of debris, weld
spatter, and other irregularities.
Have a profile that produces a gap no
greater than 1.5mm/0.06 in. at the boss
weld. Any gap greater than 1.5mm/0.06 in.
must be shimmed.

2a) Slide shroud into place on the lip,

centered between the adapters or onto
the wing just above the corner adapter.
Lip or wing (lip
shown)

Step 2. Position the Bosses

Toplok shrouds are secured to a lip or wing base
witha boss and pin. The boss is permanently
attached to the lip by welding on the perimeter
and/or in the plug holes as specified in the
welding guide table (see next page). With
correct location and installation the shroud is
quickly installed and securely held in place with
the pin.
For wing shrouds it is recommended that bosses
be installed on the outside of the bucket to allow
the bucket to dump clean. A shim may be used
to get the desired wing thickness, and should
be located on the same side of the wing as the
boss. However, it is recommended that a hole
be cut into the shim to allow the boss weld to
attach directly to the wing base. ESCO strongly
recommends the use of thrust blocks (see
illustration on page 1) when installing Toplok
wing shrouds to help absorb the multidirectional
forces encountered in the digging cycle. Proper
location and welding procedures of the boss are
critical to correct fit and bearing of the shroud on
the lip or wing.
Note: It may be necessary to modify the leading
edge of the wing to match the shroud fit area
(blunt and ramp angle), as shrouds should
contact the leading edge and not wedge on;
proper location of the boss; correct fit and
bearing of the shroud on the lip; and proper
welding procedures.
Call your ESCO representative for additional
information or assistance.

2b) Insert the tapered end of

the boss up and forward.

Side view
Lip or wing must make contact with 50% of
the shroud bearing pads. If the lip does not
make 50% contact with the shroud pads,
the lip or wing must be rebuilt to provide the
proper amount of bearing area. For lips, use
the template as previously noted.

2d) Remove the pin. Mark

the position of the boss
with pencil line.

2c) Make sure the

back of the boss
face is in contact
with the pin and
the back of the pin
face is in contact
with the shroud.

2e) Remove the shroud. Make

sure the boss is aligned
to your location mark
and tack weld it. Restore
the shroud and check
accuracy of fit on lip.

Location
mark

2f) Remove the shroud and

complete final welding as
shown on the next page.

Shroud
cavity

Tip: The pin should fit snugly in a new assembly

without binding. The shroud should not move off
the lip leading edge.

Pin
Boss

Shroud arm

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Step 3. Welding the Bosses

The weld surface must be clean and free of any contamination that might
prevent a good weld. Follow the preheat interweld and post heat guidelines
below. See P6000GEN for additional general welding instructions.
Summary of Welding Specifications
Electrodes: E7016 or E7018 low hydrogen (keep dry!)
Wires: E70T-5, E71T-1, or E70T-1 with CO2 gas.
Preheat: 200F/95C (350-400F/175-205C if air temperature is
40F/5C or lower.)
Interweld: Maintain interweld temperature less than 500F/260C.
Postheat: If air temperature is 40F/5C or lower, postheat 350-400F/175205C, then let air cool.
Remove slag after each pass and peen each bead.
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.

Welding Guide

Step 4. Installing the Mechanical Shrouds

Toplok mechanical shrouds offer a secure installation that is quick and easy. Follow these simple directions to derive
the maximum benefits from the product.
4a) Slide the shroud over the lip base or wing and
boss until it seats on lip leading edge.
Pin

Boss

Boss

4b) Position the pin in the shroud

cavity as shown.
Pin

Shroud

Shroud arm

Leading
edge

Latch

Insert this
end first

4c) A light blow with a 1-2 kg/2-4

lb hammer will engage the pin.

Butt fit
contact

4d) The shroud is now

securely attached.

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Step 5. Inspecting Worn Shrouds

Bottom of worn
Toplok shroud

Toplok shrouds protect the bucket lip and wings from

abrasive wear. Using ESCO 12S abrasion resistant alloy
assures long life before change-out.
Periodic inspection should be made to determine
when to replace a shroud.
Monitor high wear surfaces of the Toplok shroud for
wear. Special wear indicators are panels that will
wear through first to alert the user it is time to change
shrouds.

Wear indicators

Step 6. Removing the Mechanical Shrouds

6a) Place a pry bar or pinch bar behind the latch as shown, as a
lever to compress it.

The Toplok shroud system is engineered to make

change-out easy. Before following these simple steps
shown to the right, its important to clean fines from pin
area by tapping the shroud with a dead blow hammer
(brass or rubber) to loosen them, then scraping them
using a chisel or needle gun. If fines are heavily packed:
Use a small bar with flat end (19mm/.75 in. wide
maximum) to retract the latch and lift the pin out.
Pins can be reused if not worn below the locator flange
and the insert latch rubber is fully bonded to the steel tip
and fully seated in the pin body.

6b) Lift out and remove the pin. Slide the shroud off the lip base.

WARNING: Never hammer on an edge or a

corner of the shroud. Doing so could produce flying
shards of metal.
Tip: In severe applications or areas with high impacted
fines, assist removal by inserting a pry bar under the lock
from the rear of the shroud and lifting up the latch end of
the pin while prying.

Locator flange

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.

www.escocorp.com

.w

North America
2141 NW 25th Avenue
Portland, OR 97210
PH: 800.523.3795 | 503.228.2141
Latin America
Rua Engenheiro Gerhard Ett, 1215
Distrito Industrial Paulo Camilo Sul
Betim/MG CEP: 32669-110
Caixa Postal 256 - Betim, Minas Gerais Brasil
PH: 55 31.3539.1200

www.escocorp.com

ESCO Corporation is the preferred provider of

technically rich metal components and wear
solutions for industrial applications. ESCO has
over 40 locations and affiliates worldwide.

Europe, Africa, Middle East,

Commonwealth of Independent States
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P6014MIN01L0510