Installation of teeth –SPANNER STAND PROCEDURES · Ideally, position the spanner horizontally...

2015 edition

www.kvx.no

MO

RE B

ITE F

OR

YO

UR

MO

NEY Installation of teeth –

SPANNER STANDPROCEDURES

Before starting removal or installation

of any GET product, read all instructions

completely. Be sure to follow all standard safety

procedures and wear appropriate protective equipment

including a hard hat, safety glasses and safety footwear.

HSE!

Identification of items: The KVX Spanner stand will have the Spanner attached to the stand on the same side as the Safety Bracket.

Before you start: ■ Ensure that the stand is placed on ‘firm’ level ground. Do not work on muddy or steel sur-faces. Make sure the bucket teeth are perpendicular to the ground.

■ Make sure you have communication with the machine operator during the procedure and also use the correct hand signals

■ Ensure the spanner is a good, tight fit ■ Use KVX recommended grease for this procedure ■ Importantly, do not stand directly in front of the bolts during ‘torque up’ ensuring that you are standing a minimum of 3 meters when torque is being applied.

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The Spanner should be at-tached to the Stand according to the illustra-tion above, on the same side as the safety bracket.

Follow safety procedures for the torque-up of KVX bolts where safety regu-lations permit.

Handle pointing away from bucket during torque-up.

Safety bracket.

No hand in this area!

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01/

2017

MONTERING AV TENNER

Komatsu KVX LLC Plogfabrikkvegen 9, 4353 Klepp stasjonTlf.: 51 78 50 80, faks: 51 78 50 81

Internett: www.kvx.no | E-post: [email protected]

2

3

Fortrekk med 1-2 kg slegge.

Trekk boltene med korrekt moment (se tabell).

Alle overflater må være rene og fri for smuss. Bruk alltid fett anbefalt av KVX. Bruk av annet fett vil kunne medføre bortfall

av reklamasjonsrett.

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Til tross for at den manuelle metoden for å finne rett moment til KVX-bolter er både sikker og trygg, kan dette sikres ytterligere ved bruk av hydraulisk verktøy med måler eller andre alternative måter å måle moment med høy nøyaktighet.

1) Hydraulisk verktøy levert fra KVX har egen instruksjonsveiledning.

Dimen-sjon

1-bolt (med kuler)Verktøy

2-boltVerktøy

Vinkel Moment Vinkel Moment

M16 - - Håndkraft - 250 Nm Håndkraft

M20 - - Slegge 1-2 kg - 500 Nm Slegge 1-2 kg

M27 - - Slegge 3-4 kg 60º 1500 Nm Slegge 3-4 kg

M36 - - Slegge 8-10 kg/SF 60º 3000 Nm Slegge 8-10 kg/SF

M48 - - SF eller HV 1) 90º 7500 Nm SF eller HV 1)

M52 150º 12000 Nm SF eller HV 1) 105º 10500 Nm SF eller HV 1)




M90 180º 65000 Nm Hydraulisk verktøy 1) 150º 52000 Nm Hydraulisk verktøy 1)

M100 180º 89000 Nm Hydraulisk verktøy 1) 150º 73000 Nm Hydraulisk verktøy 1)

SF = Skrufot | HV = Hydraulisk verktøy

INSTA

LLATIO

N O

F T

EETH

Kom

ats

u K

VX L

LC P

logfa

brik

kvegen 1

0, 4

353 K

lepp s

tasjo

n, N

orw

ay

Tel: +

47 5

1 7

8 5

0 8

0, fa

x: +

47 5

1 7

8 5

0 8

1W

eb: w

ww.k

vx.n

o | E

mail: k

vx@

kvx.n

o

23

Pre

-torq

ue

with

1-2

kg

ham

mer.

Tig

hte

n

all b

olts

to

the

specifie

d

torq

ue

(see ta

ble

).

503101 02/2014

All c

onta

ct

surfa

ces m

ust b

e

cle

an a

nd fre

e o

f debris

. Alw

ays u

se

KVX re

com

mended

gre

ase. F

ailin

g to

use th

is

will m

ost lik

ely

cause a

syste

m fa

ilure

for w

hic

h K

VX

can n

ot b

e h

eld

responsib

le.

While

the to

rque t

urn

method o

f tensio

nin

g is

a re

liable

and s

afe

means o

f torq

uin

g K

VX b

olt

s, accura

cy c

an b

e fu

rther e

nhanced

by u

se o

f a h

ydra

ulic

tool (

and a

ssocia

ted p

ressure

/to

rque re

fere

nce) o

r an a

ltern

ativ

e m

eans o

f accura

tely

measurin

g to

rque.

1Dim

en-

sio

n

1-b

olt

Tool

2-b

olt

Tool

Angle

Torq

ue

Angle

Torq

ue

M16

- -

Hand p

ow

er

- 250 N

mH

and p

ow

er

M20

- -

SH

1-2

kg

- 500 N

mSH

1-2

kg

M27

- -

SH

3-4

kg

60º

1500 N

mSH

3-4

kg

M36

- -

SH 8

-10 k

g o

r SS

60º

3000 N

mSH 8

-10 k

g o

r SS

M48

- -

SS o

r HT 1)

90º

7500 N

mSS o

r HT

1)

M52

150º

12000 N

mSS o

r HT 1)

--

SS o

r HT 1)

M60

180º

18000 N

mSS o

r HT 1)

120º

15000 N

mSS o

r HT 1)

M68

180º

26500 N

mSS o

r HT 1)

120º

22500 N

mSS o

r HT 1)

M80

180º

44000 N

mSS o

r HT 1

)150º

37000 N

mSS o

r HT 1)

M90

180º

65000 N

mH

ydra

ulic

tool

1)

150º

52000 N

mH

ydra

ulic

tool

1)

M100

180º

89000 N

mH

ydra

ulic

tool

1)

150º

73000 N

mH

ydra

ulic

tool

1)

1)

Instru

ctio

ns f

or K

VX

’s o

wn

hy

dra

ulic

to

ols

av

aila

ble

se

pa

ra

te

ly.

SH

= S

ledgeham

mer | S

S =

Spanner s

tand | H

T =

Hydra

ulic

tool

SAFETY PRECAUTIONS

Komatsu KVX LLC Plogfabrikkvegen 9, 4353 Klepp stasjon, Norway

Tel: +47 51 78 50 80, fax: +47 51 78 50 81Web: www.kvx.no | Email: [email protected]

5031

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01/

2015

• Tightening and loosening of bolts must be in accordance with instructions given in the leafl et “Installation Procedures” and where local regulations permit!

• Wear safety glasses!

• Wear hard hat!

• Use safety footwear!

• Use KVX recommended grease only!

• Always use a good tight spanner!

• Do not stand directly in front of the bolts during torque-up!

• Stand well clear of the spanner stand (minimum 3 meters) when force is applied!*)

• Always make sure the stand foot is on fi rm and level ground!*)

• Keep constant contact with driver during torque-up procedure!*)

• Always use correct hand signals to communicate with driver!*)

*) Where local regulations permit

SAFETY PRECAUTIONS


Tel: +47 51 78 50 80, fax: +47 51 78 50 81Web: www.kvx.no | Email: [email protected]

• Tightening and loosening of bolts must be in accordance with instructions given in the leafl et “Installation Procedures” and where local regulations permit!

• Wear safety glasses!

• Wear hard hat!

• Use safety footwear!

• Use KVX recommended grease only!

• Always use a good tight spanner!

• Do not stand directly in front of the bolts during torque-up!

• Stand well clear of the spanner stand (minimum 3 meters) when force is applied!*)

• Always make sure the stand foot is on fi rm and level ground!*)

• Keep constant contact with driver during torque-up procedure!*)

• Always use correct hand signals to communicate with driver!*)

*) Where local regulations permit

.

Spanner shown with the spanner retainer plate.

www.kvx.no

Removal – loosening the bolt:Place the stand to the right of the bolt. The spanner wrench and stand should be positioned such that when downward pressure is exerted, the bolt rotates in a counter-clockwise direction.

Ideally, position the spanner horizontally when starting the first cycle. This gives maximum torque to the bolt. Tap the spanner to make sure that it is located securely on the bolt hex. Have the operator lower the bucket until the stand touches the ground.

Important! With the stand on the ground step back, 3 meters away from the bucket, staying visible to the operator. Maintain periodic eye contact with him, while you watch the bolt.

Direct his actions to continue lowering the bucket until the Spanner wrench is in a one o’clock position to the bolt. Further lowering of the bucket may damage the stand.

If the bolt is not sufficiently loose, repeat the above steps. With repeat cycles, however, attach the spanner in the 5 o'clock position for maximum turn angle per cycle.

Once the bolt is loose, remove it by hand or wrench. Loosen each bolt in this manner.

Begin removing the bolts and teeth, taking care not to let teeth slip off and cause damage or injury. Heavier teeth may require the use of two people or a lifting device.

Use of tooth-turn shaft (for reversible 1-bolt dowelled parts only)

If you are loosening 1-bolt (dow-elled) teeth and intend to turn them for their second life, use of the appropriate KVX tooth rotation shaft is recommended. This will require that the bucket is tilted slightly forward of vertical after bolts have been loosened with spanner stand, so that the teeth sit on the ball dowels when the bolt is removed, and the rotation shaft is inserted in their place.

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2

2

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Once the rotation shaft is screwed into the bolt hole:a. Return the bucket to vertical, b. Pull the tooth away from the lip and ball dowels on to the shaftc. Rotate the tooth 180 degrees so that the other end of the tooth is now in the digging position.

Beware that the unworn end of the tooth is heavier than the worn end, so the unworn end will tend to fall to the final position unless held and carefully lowered by the person carrying out the rotation.

d. Push the tooth back on to the ball dowels, ensuring that none of the dowels have fallen out of their sockets during the procedure (if they have, clean off any dirt/grit and apply a small amount of KVX recommended grease to the dowel when inserting it back in the lip socket…this will act like a glue to hold it in place)

e. Tilt the bucket slightly forward of vertical again so that the tooth is sitting on the dowels rather than the rotation shaft

f. Remove the shaft, then proceed with installation and tightening of bolt as per following instructions.

Installation – tightening the bolt:Ensure the bolt is clean of any dirt or grit. Use KVX prescribed grease to thoroughly lubricate the bolt threads and the bolt cone, as well as the lip threads and the tooth cone.

Insert the bolt by hand.

It is important to pre-torque the bolt and this can be done in a variety of ways:

a. The most common method is to simply use the spanner wrench, tapping it to ensure it locates securely on the bolt. Hit the wrench with a small 1-2 kg hammer until the rotation stops.

b. Alternatively, the bolt can be pre-torqued using a con-ventional torque wrench. Simply set a torque equivalent to 5% of the final prescribed torque for the bolt you are tightening , as listed in the torque table found in the KVX Installation Procedures or Spanner Stand Booklet.

After pre-torquing is completed mark the bolt and tooth in preparation for the final torque. Refer to the Torque Table in the KVX Installation Procedures and Spanner Stand booklets, to determine how much rotation is required for the bolt size you are using.

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www.kvx.no

Draw a straight line with a marker through the centre of the bolt to one corner of the hex head. Draw a second line on the tooth/wearpart or lip to the specified number of degrees away from the line you’ve marked on the bolt.

Re-pin the spanner wrench to the stand if it was removed for the pre-torquing rocedure.

Position the stand on the left hand side of the bolt to tighten.

Position the wrench in a seven o’clock position to the bolt tapping to ensure it locates securely on the bolt.

Have the operator lower the bucket until stand contacts ground and make sure bucket teeth are perpendicular to the flat firm surface. Then stand at least 3 meters away maintaining eye contact with the operator. Direct the machine operator to lower the bucket until the line on the bolt reaches the line on the tooth. In most cases this will take two cycles with the spanner wrench ranging from a seven o’clock to an eleven o'clock position relative to the bolt.

Bolts from M27 size and up are progressively being updated to include either a small threaded hole or a hole right through the middle of the bolt. These holes enable the attaching of a lifting hook/eye to the bolt, enabling it to be used as a lifting system when inserted into a threaded lip or wearpart. The primary purpose of these holes, however, is to enable tooling sockets and spanners to be physically attached to the bolt during torquing operations. In the case of a standard red KVX spanner (as used with spanner stand), simply attach the spanner to the bolt head in the normal way and then attach the spanner retainer plate. This optional extra measure can be of assistance, especially when bolt heads have been partially worn in service and good spanner-to-bolt contact is difficult to achieve.

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1) Instructions for KVX’s own hydraulic tools available separately.

Dimen-sion Tool

DOWELLED PARTS NON-DOWELLED PARTS

Angle Torque Angle Torque

M16 Hand power - - - 250 Nm

M20 Sledgehammer 1-2 kg - - - 500 Nm

M27 Sledgehammer 3-4 kg - - 60º 1500 Nm

M36 Sledgehammer 8-10 kg/Spanner stand - - 60º 3000 Nm

M48 Spanner stand or Hydraulic tool 1) - - 90º 7500 Nm

M52 Spanner stand or Hydraulic tool 1) 150º 12000 Nm 105º 10500 Nm




M90 Hydraulic tool 1) 180º 65000 Nm 150º 52000 Nm

M100 Hydraulic tool 1) 180º 89000 Nm 150º 73000 Nm

1 2 3

KVX is a Norwegian based

company that has gained

worldwide recognition for its

highly wear resistant bolt-on

ground engaging tool system

for Excavators, Front Shovels

and Wheel Loaders. Feel free

to contact us for further

information!

All surfaces must be clean and free of debris.

Pre-torque with 1-2 kg hammer.

Hydraulic power packand torque tool.

www.kvx.no

KOMATSU KVX LLC

Plogfabrikkvegen 9, 4353 Klepp Stasjon, NORWAYTel.: +47 51 78 50 80Fax: +47 51 78 50 81E-mail: [email protected]

Tighten all bolts to the specified torque.

Spannerstand

503007

05/2

017

IMPO

RTANT!

The cylinder stroke must alw

ays reach end position

before reversing, both in Auto and Manual m

ode.

La carrera del cilindro siempre debe llegar a la posición

fi nal antes de invertir, tanto en Auto y Manual.

Le cylindre doit toujours atteindre sa position

d’ouverture ( ou fermeture ) m

aximale avant la

réversion, tant en mode Auto que M

anuel.Sylinderstaget m

å alltid gå til endestilling før

sylinder reverseres, både i Auto og Manuell betjening!


Web: www.kvx.no | Email: kvx@

kvx.no

Installation of teeth –SPANNER STAND PROCEDURES · Ideally, position the spanner horizontally...

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Transcript of Installation of teeth –SPANNER STAND PROCEDURES · Ideally, position the spanner horizontally...