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ESCO Kwik-Lok® Wear ProtectionInstallation and Removal Guide

P6002UWS01L0509

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SafetyGeneral Safety InformationThe 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 WordsThroughout 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. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

IntroductionThe ESCO Kwik-Lok® and Kwik-Lok II wear protection systems provide protection for high wear areas in a wide variety of applications on both flat and curved surfaces. Depending on the demands of the application, multiple Kwik-Lok or Kwik-Lok II wear runners may be used to protect large surfaces, or a single wear runner may be installed to protect a specific high wear area.

The original Kwik-Lok system has been used extensively in fixed plant applications. Where gravity and or material flow are sufficient, runners may be installed without stops, making the system change-out 100% mechanical. Where some method of runner retention is required, a separate stop block is welded in place to retain the runner.

Kwik-Lok II system, with its own integral mechanical lock and reversible runner, offers even greater flexibility and benefits. Also featuring the ability to be gravity retained, the mechanical lock allows the runner to be secured in place without additional welding. The reversible runner also ensures you maximize protection and minimize throw-away in areas of uneven wear.

IMPORTANT: In crushing and conveying applications, a lock or stop is generally not required if the surface being covered is upright at an angle greater than 45° from horizontal and material strikes the surface at less than 60° from the surface. However, if material tends to backup into the runners, or the surface is located in an area of heavy vibration, then Kwik-Lok II systems should be used and a lock should be installed in every runner.

For more information consult your ESCO representative.

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 1 Surface PreparationIn order to provide sufficient support for the base and the lock, the mounting surface must:

• Be relatively smooth and free of debris, weld spatter, and other irregularities.

• Be at least 3/4 the thickness of the base.

• Have a profile that produces a gap no greater than 3mm/0.13in. at the weld and lock slots – flat surfaces, as well as, curved.

If the gaps between the surface and the bottom of the base are too great and cannot be corrected through repositioning, the mounting surface must be arced or welded to provide the appropriate contour (see Figure 2).

If mounting surface preparation cannot reduce gaps to the 3mm/0.13in. maximum, select a Kwik-Lok II base that more closely matches the profile of the surface.

Lightweight runners

Moderate weight runners

Heavier weight runners

weld slot

lock slot

raised pads

Figure 2

Kwik-Lok Base (side view)Gap between weld slot and surface must be no more than 3mm/0.13in. at each end.

If the mounting sur-face is concave, the gap between the lock slot and the surface must be no more than 3mm/0.13in.

The gap at both ends (convex surfaces) must be nearly equal. If necessary, one end of the base should be shimmed to equalize any gap at the weld slots without increasing the gap at the lock slot.

Tip: If a curved base must be made flatter, the raised pads on the bottom of the base may be ground to produce correct clearances with the mounting surface.

Figure 1

Installing Kwik-Lok®II Mechanical Wear Protection

WARNING: To make handling easier, heavier Kwik-Lok II wear runners feature lifting handles or lifting eyes (see Figure 1). Prior to handling, obtain an appropriate lifting device (hoist, crane, etc.) with a capacity sufficient to lift the runner’s weight. Refer to specification literature for weights.

IMPORTANT: Familiarize yourself with the procedures by reading all the steps prior to beginning the installation.

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 2 Base InstallationIf runners are to be grouped on the wear surface, bases should be located to provide sufficient clearance for individual runner installation and removal.

ESCO provides several standard layouts to accommodate various wear pattern requirements. To simplify installation and help ensure sufficient wear protection, use these layouts or consult an ESCO representative to find out if there’s a layout pattern for your application.

The following details show three basic alternative methods for locating bases. Use the method suits your particular application.

CAUTION: Bases must be located so that primary load forces flow in the direction of the arrow on the base.

Location Method AIn order for runners in a group to be changed out individually, bases should be placed no closer than the dimensions obtained by the following (see Figure 3).

Determine Dimension ARunner Length _______________

plus Runner End Gap* ________

*MA Series, 63mm/2.50in. min. *MB Series, 38mm/1.50in. min. *MC Series, 32mm/1.25in. min.

Equals Dimension A __________ Determine Dimension BRunner Width ________________ plus 13mm/0.50in. min. _______Equals Dimension B _________

DimensionA

Dimension B

RunnerFinal

Location

Flow ofPrimary

LoadForces

First, lay out the pattern…

…then position bases.

Match arrow on bases with primarydirection of material flow.

Chalk lineson the mounting

surface

DimensionA

Example:

KLR12MB Length: 14.00in.

Runner End Gap + 1.50in.

Equals Dimension A: 15.50in.

Example:

KLR12MB Width: 10.00in.

Runner Side Gap + 0.50in.

Equals Dimension B: 10.50in.

Figure 3

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

IMPORTANT: In crushing and conveying applications, load forces can come from all directions. Assemblies are normally installed so that the primary load force (force of highest magnitude) is directed onto the front of the runner forcing it against the base dovetails (see Figure 4).

Where multidirectional loading is unavoidable, the assembly should be positioned so that the lowest impact loads are on the back side of the assembly. When reverse loads are present, a weld-on stop or mechanical lock must be used.

Location Method BLocate the runner assemblies in their final positions on the mounting surface, then trace around the base lock slots onto the surface using chalk or some other appropriate marker (see Figure 5).

Remove the runner, then locate the bases using the lock slot marks on the surface.

IMPORTANT: Ensure minimum distances required for runner removal (disen-gagement) are maintained (see Figure 6).

MA Size MB Size MC Size 63mm/2.50in. 38mm/1.50in. 32mm/1.25in.

Primary Load

Front of runner

Back of runner

Figure 4

Base dovetail

Reverse load (a stop or lock must be used)

Runner can be at edge, if no side plate

13mm/0.50in. min. distance

between runners

6mm/0.25in. min. distance between runner and side

plate

Figure 6

Mark through runnerlock slots to locate

base positions

Flow ofPrimary

LoadForces

Figure 5

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Tight SpacingIn applications where a tight layout is required a minimum spacing of 6mm/0.25in. can be used between all runners. When spacing is this tight:

1. Runners cannot be individually installed or removed. To remove one runner, all runners in front must be removed first.

2. When installing bases the installation must be held to very tight tolerances.

3. When using the following method of installation the end of the bases must be trimmed along the pre-marked burn line (see Figure 7).

4. When reverse loads are present (loads that could push the runner off the base), the Kwik-Lok II system should be used with a lock installed in each runner.

Location Method CWhen installing general purpose runners, bases can be located front-to-back by tack welding the first base in place, then spacing the next base a minimum of 3mm/0.13in. behind.

Side-to-side spacing (see Figure 8) must be defined using either Method A or B.

When installing general purpose style runners end-to-end on a curved surface, there must be a gap of at least 3mm/0.13in. between bases to provide sufficient clearance for runner disengagement.

Figure 7

Side-to-side location;

see Method A or B.

Front-to-back location; see

Figure 8.

0.13in minimum

Figure 8

Kwik-Lok® II bases

Burn line is cast in base

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 3 Weld BasesThe weld surface must be clean and free of any contamination that might prevent a good weld.

Weld bases onto the surface according to ESCO recommendations for welding ESCO 12E or 12F low hydrogen alloys, refer to P6000GEN01L, “ESCO Welding Procedures”.

Do not weld any base surface that will interfere with the runner during installation and removal.

• On low alloy surfaces, use E7016 or E7018 rod or E70T-5 wire. On manganese surfaces, use E309-16 stainless steel rod. Always keep electrodes dry.

• Working in temperatures above 40°F/5°C, preheat sections 38mm/1.50in. or greater to 200°F/95°C; no post heat required. Do not preheat if welding on manganese surfaces.

• Working in temperatures at or below 40°F/5°C, preheat to 350-400°F/175-205°C; post heat the entire part uniformly to 350-400°F/175-205°C, then slowly air cool. Do not preheat or post heat if welding on manganese surfaces.

• Keep interpass temperature below:500°F/260°C on low alloy surfaces. 200°F/93°C on manganese surfaces.

• To make sure the base remains flat against the surface, weld short stringer beads in each weld slot.

• Weld beads applied inside the weld slots must be multi-pass with the final bead on the Kwik-Lok II base.

2

3

4

5

6 WeldHeight

1

MOUNTING SURFACE

KWIK-LOK BASE

KWIK-LOKBASE

• Weld full fillets or plug weld as follows. Measure full fillet and plug weld heights as shown in (see Figure 9).

MC Series – 10mm/0.38in. min.

MB Series – 19mm/0.75in. min.

MA Series – 25mm/1.00in. min.

Plug weld (severe duty applications)

Fillet weld (general duty applications)

Exterior weld Additional

weld slot

Figure 9

IMPORTANT: MA size bases have a third weld slot for increased system strength. MA & MB bases also have exterior weld grooves for increased system strength in extreme duty applications.

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 4 Install the Wear Runner A. Position the wear runner

over the base. Use a lifting device when appropriate for the weight of the wear runner.

Viewed as though the

runner were transparent

Top view

B. Lower the runner over the base so the dovetails engage.

C. Slide the runner into position to interlock it onto the base.

Viewed as though the

runner were transparent

Top view

D. Look into the runner’s lock slot to make sure it is correctly aligned with the slot in the base

E. Locate the lock, “foam” end first, into the slot (either side will do), then push the lock in as far as possible with your thumb or finger.

IMPORTANT: Make sure this end of the lock slips well into the undercut in the base slot. Every runner must have its own lock.

Runner

Lock slot

The base should extend slightly into

the lock slot

The lock bears on this surface

End view

F. Insert the removal tool (or other prying device) to engage the lip.

G. Lever the lock down with the tool...

H. until the lock is firmly seated.

End view

End view

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 6 Remove the Wear RunnerLoosen fines completely and make sure the lock moves freely back and forth in the slot. Wedge out the lock and slip the runner off the base.

A. Loosen fines by tapping around the wear runner and the lock slot with a dead hammer (brass).

Step 5 Continuously Monitor RunnerWatch for wear indicators to show through worn runners.

IMPORTANT: DO NOT PERMIT THE RUNNER TO WEAR INTO THE BASE!

It’s time to rotate or replace runners at the first indication that the base will be exposed due to runner wear. At the first sign of surface breakthrough, rotate or replace the runner with a new one. If the base wear should occur, carefully inspect it for damage or deformation and replace if necessary.

In applications where the majority of wear is in one direction, reversible runners can be rotated to extend life, provided there is sufficient wear material on the opposite end.

Note: Tapered runners are not reversible

All runners are reversible except tapered runners for maximum wear life.

B. Thoroughly remove fines until the lock moves freely back and forth in the slot. If fines are heavily packed, a hand-held chisel or needle gun will remove them quickly.

The lock must be able to move back and forth

C. Insert the removal tool (or other appropriate prying device) under the ear of the lock and wedge it out of the lock slot.

D. Tap around the runner with a dead hammer to break the runner loose from the base, then slide it off the base.

WARNING: DO NOT HAMMER ON EDGES.

An arrow points to the pry lip

IMPORTANT: Before installing a new wear runner, make sure the base lock slot is thoroughly clean for new lock installation. ESCO recommends that a new lock be installed with each new runner.

Tip: If you encounter a bit of loose material in the lock slot, push it to the side opposite the lock’s foam end and orient the lock for easy removal later.

Lock slot must be clean

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WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Installing Kwik-Lok®

Semi-Mechanical Wear Protection

WARNING: To make handling easier, heavier Kwik-Lok wear runners feature lifting handles or lifting eyes. Prior to handling, obtain an appropriate lifting device (hoist, crane, etc.) with a capacity sufficient to lift the runner’s weight. Refer to specification literature for weights.

IMPORTANT: Familiarize yourself with the procedures by reading all the steps prior to beginning the installation.

Step 1 Surface Preparation 1. Remove all weld material and debris from the

mounting surfaces where the Kwik-Lok wear runner bases are to be installed.

2. Proper fit-up of bases is essential to ensure good performance. Bases should be mounted on surfaces at least 3/4 the thickness of the base. It may also be necessary to add plate or weld buildup under curved bases to obtain proper base fit-up. The space between bases and mounting surfaces prior to welding should be no more than 3mm/0.13in. The above illustration shows typical welds required to install weld-on bases. Avoid locating base welds over structural welds if possible.

Weld in plug holes only

Typical welds required to install weld-on bases

3. On the mounting surface, draw center lines for each column of Kwik-Lok bases. Figure 10 illustrates a typical installation pattern. For multiple side-by-side rows of runners, base center lines should be the width of the runner plus 6mm/0.25in minimum.

4. Make sure that all weld surfaces are free of grease, paint, air arc surface, etc. Locate the leading bases on their center lines and tack weld in place. Position the next-in-line bases and tack-weld in place. (see Figure 11).

Center lines

Mat

eria

l Flo

w

Stop

Base

Runner

Runner

Stop

BaseMaterial

Flow Minimum spacing centerline to center-line is the width of the runner +0.25in.

Figure 10

Burn line is cast into the base

Figure 11

AA/AB style bases

WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

Step 2 Base Installation 5. Weld the bases in place.

• On low alloy surfaces, use E7016 or E7018 rod or E70T-5 wire. On manganese surfaces, use E309-16 stainless steel rod. Always keep electrodes dry.

• Working in temperatures above 40ºF/5ºC, preheat heavy sections 38mm/1.50in or greater to 200ºF/95ºC. No post heat required. Do not preheat if welding on manganese surfaces.

• Working in temperatures at or below 40ºF/5ºC, preheat to 350-400ºF/175-205ºC, post heat the entire part uniformly to 350-400ºF/175-205ºC, then slowly air cool. Do not preheat or post heat if welding on manganese surfaces.

• Keep interpass temperature below: 500ºF/260ºF on low alloy surfaces 200ºF/93ºC on manganese surfaces.

• All fillet welds should be at least 7/8 x base thickness, up to 19mm/0.75in. fillet leg maximum.

6. To ensure a proper fit of the runners, carefully clean fit surfaces and tops of plates to remove weld splatter, slag, etc.

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Step 3 Install Runners 7. Position runners in place and slide them as far

back on the bases as possible.

Plug weld in (4)

places

1. Position the runner over the base...

2. then slide the runner to the final position

Step 4 Install Stops 8. Install stop blocks tightly against the runners.

Use ESCO cast alloy steel stop blocks for the most secure installation.

9. Weld stops in plug holes. Follow same welding instructions as in Step 5.

Step 5 Removing Runners 1. Burn stop locks off from behind the runner.

2. Lift worn runner from base.

3. Inspect base for damage prior to installing new base.

© 2009 ESCO Corporation. All Rights Reserved. All other brand or product names are trademarks of their respective holders.

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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.

North America2141 NW 25th AvenuePortland, OR 97210PH: 800.523.3795 | 503.228.2141

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P6002UWS01L0509