INSTALLATION PROCEDURES

Transcription

1 MORE BITE FOR YOUR MONEY INSTALLATION PROCEDURES 207 edition

2 Installation procedure for cutting-edges A Preparations Note measurements A and B as indicated in figures above for excavator B FIG. and wheel loader buckets respectively. It is imperative that bucket tip radius and volume remain unchanged when new cutting-edge is installed. Remove old edge by flame cutting clear of existing weld. Cut and grind welding grooves. Remove paint, oil and or impurities as well as any remaining manganese steel from welding zone. Install new edge to measurements A and B and weld according to se instructions. Flame Cutting (also applies to KVX wear bar and wear products) Any flame cutting of edge requires following temperature precautions:. Preheat steel thicker than 0 mm to 0 C / 300 F. 2. Condition any cold stored steel 4mm or less to 00 C / 20 F before flame cutting. Preheating (also applies to KVX wear bar and wear products) For good welds use preheating temperatures in table. Plate thickness, mm Temperature in Celsius Interpass- Temperature CEV 0,7 0,66 0,74 CET 0,42 0,43 0,46 CEV = C + Mn (Mo + Cr + V) (Ni + Cu) CET = C + (Mn + Mo) (Cr + Cu) Ni Heat parts evenly with a suitable gas torch, minimum 0 mm into bucket bottom plate. Maintain recommended preheating temperature during complete welding operation, orwise cracks can develop in Heat Affected Zone. Let welded parts cool slowly.

3 Check preheating temperature by chromatic temperature crayons. Preheating and interpass temperatures in excess of 230 C / 40 F will reduce abrasive properties and strength of steel. For cutting edges from 80 mm thickness and up, we recommend preheating with electrical blankets. Temperature measuring is best performed with an infrared handheld gun. Welding rods: (also applies to KVX wear bars and wear products) Use only low hydrogen welding rods (H 2 O <ml/00g). Heat welding rods according to manufacturers instructions. Welding (also applies to KVX wear bars and wear products) Weld single beads alterning on eir side of plate as indicated in Fig. 4. Use only straight beads. Grind or gouge root string prior to welding from backside. Weld with smooth transitions to parent and without any welding defects. We recomend using Voltage, Ampere and weldingspeeds according to manufacturer spesifications. Recommended welding consumables (or brands can be used with same mechanical properties): MMA (Manual Metal Arc-Electrodes) ESAB OK 48. (AWS: A/SFA. E 708-) ESAB OK.00 (AWS: A/SFA. E 708-) GMAW (Mig/Mag Welding-Wire) ESAB OK Autrod 2. (AWS A.8-93 ER 70S-6) ESAB OK Autrod 6.9 (AWS A.9:ER307 mod) FILARC PZ60R (AWS: A.8-93 E70C-6M H4) HYUNDAI Supercored 70SB (AWS: A.20 E7T-C) *Use recomended polarity and gas as described in welding rod datasheet. Welding Sequence: Generally a welding sequence is favoured which minimises restraining forces between welded parts. This is ensured by giving parts freedom of movement during welding operation. When installing a cutting-edge to a bucket base Correct Welding Sequence: FIG. 2 plate must be welded prior to sides in order to minimise any tension in welding zones. Weld last bead on each side with a distance of 3 - mm. to parent, to anneal its Heat Affected Zone and reduce risk of cracks.

4 Max 3 mm Grinding (also applies to KVX wear bar and wear products) Grind weld as indicated in Fig. 3. and with grinding marks transverse to welding direction. 4º Direction grinding marks Side-edge Cutting-edge (excavator shown) Weld between cutting-edge and bottom plate Side-edge Surface to be ground in this area Cutting-edge FIG. 3 T Min 0,4xT Min 0,xT Grind Grind Max 3 mm Cutting Edge Center of Bucket > 22 FIG. 4

5 Typical crack patterns resulting from neglecting procedures for preheating and welding equence. Wrong welding sequence Bucketbottom not pre-heated Insufficient lip preheat FIG.. General notes:. All dimensions are min. values 2. Number of beads vary according to plate thickness. 3. All transitions shall be smooth and without defects, grind if nessary. These instructions provide specific guidance on welding of KVX plates, but assume that welding is carried out by suitably qualified personnel experienced in welding of hardened plate s. KVX bear no responsibility for damage to lip or bucket resultant from inexperienced personnel or poor welding practice/procedures. Areas suceptible to cold cracks in weld joints of high-strength wear steel. Edge of plate near weld In plate, close to weld on sides and under In weld, longditudal In weld, lateral FIG..2

6 will be annealed during welding of joint. This edge Welding of Highly constrained Joints, will reduce hardness and stresses in coars Weld between grained HAZ, reby reducing risk of hydrogenand Welding thicknesses > 00 mm l cutting-edge induced cracks (cold c racks), (see drawing ). When welding highly constrained and joints bottomand s plate with thickness of > 00 mm, itconstrained is best to coverjoints, Recommended for awelding Highly etween cutting edge and bottomprocedure plate: Cutting-edge mm technique surfacesshown) to be welded with weld deposit (butterit is generally beneficial to use a2,welding be (excavator welding thicknesses > 00 mm and/or welding across plate thickness weld bead on base beeading) prior to welding actual joint. In that doinginvolves first placing 9 0 to filling up weld deposit, see 2 4 with so, HAZ (Heat Affected of base> When welding Highly Constrained Joints, weldingzone) thicknesses 00 mmprior and/or welding across 3 Side-edge drawing 2. will be annealed during welding of joint. This The last weld bead on each side should be welded with plate thickness (fig 6.), it is best to cover surfaces to be welded with weld deposit hardness and stresses in coarsea distance of 3will reduce mm from base. This is also here to hammer (butter beeading) prior to welding reby actual joint. Inrisk doing so,it HAZbeneficial (Heat Affected Zone) weld using, Weld between reducing of hydrogened will temper grained HAZ in HAZ, base and reduce cutting-edge for instance, a pneumatic slag pick, in order to reduc cracksduring (cold c racks), (see drawing ).joint. of base beinduced annealed welding of This will reduce bottom riskwill of cracks. and shrinkage stresses in welded joints. plate hardness and stresses in coarse-grained reducing risk of hydrogenng-edge It is generally beneficial tohaz, use a reby welding technique drawing : vator shown) that involves first placing weld bead on base induced cracks7. (cold craks), (see fig. 6.2) It is generally beneficial to use a welding technique deposit Material totensile fillingstrength up with weld deposit, see Deposit with a prior lower that involves first placing weld bead on basethan prior to filling up with weld deposit drawing 2. used. In technical jargon will be ad on each side should be welded with (see fig 6.3). It is base also beneficial here to hammer weld using, for instance, a pneumatic mm from base.this Thisis called welding with under matched welding It is also beneficial here to hammer welded weld using, slag pick, in order to reduce shrinkage stresses in joints. For butter beeading.this yields at a relatively low stress level, HAZ in base and reduce for instance, a pneumatic slag pick, in order to reduce thus resulting in a6.9 reduction in internalwell stresses s. applications EASB OK Autrod is particulary suited. shrinkage stresses in welded joints , mm ( shrinkage stresses) in weld and base, after welding and cooling. drawing : This reduces risk of hydrogen cracks (cold cracks). t Material with a lower tensile strength than It is also important that welding has as l will be used. In technical jargon low a hydrogen content (water content) as possible lding with under matched welding (H2< ml/00 g welding ). lds at a relatively low stress level, a reduction in internal stresses tresses) in weld and base, d cooling. This risk of drawing 2: FIG.reduces 6. FIG , mm (cold cracks) drawing 2: 2, mm FIG. 6.3 Welding of Wear Bars ant that welding has as content (water content) as possible welding ). a It must be used several strings as 24thickness of bottom plate increases a = 0.7 x t (bottomplate) 4 a a t (bottomplate) 4 Customers choice 3 2 Welding is done from center out to sides 4 FIG. 7 Recommended welding pattern

7 Installation of teeth When se installation procedures are followed, KVX bolt-on wear parts will stand up to extreme loads without loosening. The procedures are applicable to all types of bolt-on wear parts even though teeth only are specifically mentioned. All surfaces must be clean and free of debris: Clean surfaces with a steel brush and remove any burrs. Check that adjoining surfaces are flat and that threads and cones are undamaged. Use only KVX recommended grease: Apply recommended grease on threads and cones. Use of or grease may cause bolts to become loose or bolts snapping. listed in table below. Smaller bolts, up to M6, can be tightened by means of any appropriate torque wrench and hand power. Bigger bolts require special KVX spanners. M20 bolts can be tightened by hitting spanner with a, kg sledgehammer until it stops. Consult table for bolts bigger than M20. Hit spanner until it stops, which gives a sufficient pre-torque value. Alternatively, use a torque wrench and apply % of final specified torque value as "pre-torque" value. The specified final torque can be achieved by turning bolts additional angle by means of hand tools, spanner stand or hydraulic tool. Various brands of hydraulic torque tools can be adapted for KVX bolts. Always assess procedures with reference to local safety regulations and guidelines. Install teeth: Place tooth in position on cutting edge and insert bolts. To ensure good contact in cone give tooth a couple of blows sideways. Tighten bolts to specified torque: Apply torque Spanner stand: When using KVX spanner stand make sure to consult KVX Spanner Stand Operating Instruction booklet. Follow safety procedures for torque-up of KVX bolts where safety regulations permit. Dimension Tool ) Instructions for KVX s own hydraulic tools available separately. DOWELLED PARTS NON-DOWELLED PARTS Angle Torque Angle Torque M6 Hand power Nm M20 Sledgehammer -2 kg Nm M27 Sledgehammer 3-4 kg º 00 Nm M36 Sledgehammer 8-0 kg/spanner stand º 3000 Nm M48 Spanner stand or Hydraulic tool ) º 700 Nm M2 Spanner stand or Hydraulic tool ) 0º 2000 Nm 0º 000 Nm M60 Spanner stand or Hydraulic tool ) 80º 8000 Nm 20º 000 Nm M68 Spanner stand or Hydraulic tool ) 80º 2600 Nm 20º 2200 Nm M80 Spanner stand or Hydraulic tool ) 80º Nm 0º Nm M90 Hydraulic tool ) 80º 6000 Nm 0º 2000 Nm M00 Hydraulic tool ) 80º Nm 0º Nm

8 All surfaces 2 3 must be clean and free of debris. Pre-torque with -2 kg hammer. Tighten all bolts to specified torque. 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 furr information! Hydraulic power pack and torque tool. Spanner stand GB 0/207 KOMATSU KVX LLC Plogfabrikkvegen 9, 433 Klepp Stasjon Tlf.: Faks: E-post: kvx@kvx.no