DOC014120/1-EN / 27.02.

2015

TIGHTENING AND MAINTENANCE OF BOLTED JOINTS

Read the instructions supplied with the product before installation and
CAUTION
commissioning.

CAUTION Keep the instructions in a safe place for future reference.

Table of contents

1 GENERAL .................................................................................................................................................. 2
2 INITIAL TIGHTENING, TORQUE WRENCH PROCEDURE ..................................................................... 3
3 INITIAL TIGHTENING, HYDRAULIC TENSIONER PROCEDURE .......................................................... 4
3.1 Tool construction ............................................................................................................................... 4
3.2 Testing and calibration of tool ............................................................................................................ 5
3.3 Operating procedure .......................................................................................................................... 5
4 BOLTED JOINT MAINTENANCE ............................................................................................................. 7
4.1 General .............................................................................................................................................. 7
4.2 Frequency of bolt inspection .............................................................................................................. 7
4.3 Visual inspection ................................................................................................................................ 7
4.4 Bolt tightening procedure, torque wrench .......................................................................................... 8
4.5 Bolt tightening procedure, hydraulic tensioner .................................................................................. 9
4.6 Bolt and nut replacement ................................................................................................................. 10

Original instructions 1/10

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

1 GENERAL
All of the bolts used in the same joint must come from a single production batch. This concerns also the test
and calibration procedures of the tool.
In order to maintain reliable tightness in a joint, the same tightening tool should be used both for initial
tightening and for maintenance inspection.
The pre-tightening values of each particular bolted joint must be collected from the drawings or from the
specific maintenance instructions of the joint.

2/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

2 INITIAL TIGHTENING, TORQUE WRENCH PROCEDURE

Bolts up to the size M27 may be tightened to nominal torque value given in the KONECRANES drawings or
instructions. During actual tightening, torque values indicated by the tool are compared to this nominal value.

For bolts of size M30 or larger, the torque wrench must be calibrated by bolt elongation tests
according to maintenance instruction DOC001668. The final torque value for the wrench applied
in the actual tightening is achieved from this test. The nominal torque values shown in drawings
or in maintenance instructions are reference values, only for the calibration.

If bolts are certified according to EN14399 follow the tightening torque value given in the
certificates or manufacturer’s package. Refer to DOC001668.

In case there is any suspicion about the torque value elongation test shall be made also for
smaller than M30 EN14399 screw assemblies.

Tightening procedure is as follows:

 Check that the washers are exactly flat, and free of burrs and defects.
 Clean the bearing surfaces in the structure for washers and check that the surfaces are level.
 Clean and lightly oil the bolts and nuts.
 Set the washers so that beveled side is against bolt head or nut.
 Tighten the bolts first to 80 % of the full pre-tightening value. Start simultaneously on the opposite sides
of the joint and proceed according to figure 1, until the whole joint has been gone through.
 Tighten the bolts to the full pre-tightening value. Start simultaneously on the opposite sides of the joint
and proceed as shown in the figure, until the whole joint has been gone through.
Figure 1. Sequence of Tightening.

3/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

3 INITIAL TIGHTENING, HYDRAULIC TENSIONER PROCEDURE

3.1 Tool construction

The construction of a hydraulic tensioner varies according to actual make, but the principal parts shown in
the figure can always be found.

Figure 2. Hydraulic tensioner.

1. High pressure pump

2. Pressure gauge
3. High pressure hose
4. Hydraulic tensioner
5. Sleeve

4/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

3.2 Testing and calibration of tool

Operating method of the tool must be practiced in the work shop before the actual tightening work is started.
The correctness of the method is demonstrated by measuring the achieved bolt elongation (ΔL) and
comparing this to the design value.

Figure 3. Testing arrangement.

3
F
L

L
1

1. Steel block
2. Test bolt
3. Micrometer

Test procedure is as follows:

 Prepare a steel block with one bolt hole as the basement of the bolt tensioning. The test block must have
the common thickness of the flanges of the actual joint.
 Take 5 bolts with nuts and washers of the same batch as the actual bolts for the joint. Clean the heads of
the bolts and, if necessary, machine the heads level.
 Measure and record the bolt length by a micrometer.
 Tighten the bolt to the full design tension. Follow the procedure described in chapter 3.3.
 Remove the tensioner from the bolt and measure the elongated length of the bolt.
 Compare the measured elongation (ΔL) to the design value.
 Repeat the steps 3 to 6 for all 5 bolts. Tightening procedure is acceptable, when the measured values for
all bolts are within ±10 % of the design value.

3.3 Operating procedure

Both for the tool calibration and the actual bolt tightening, the following procedure must be used:
 Check the geometric shape of the nut:
Figure 4. Checking the geometric shape of the nut.

The eccentricity of the bore (E) must not be such that it disturbs the free rotation of the nut inside the
tensioner sleeve.

5/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

Figure 5. Checking the geometric shape of the nut.

The misalignment of the bore must not prevent the nut from settling flush on the basement, when the nut is
turned freely. No gap is accepted!
 Check that the washers are exactly flat, and free of burrs and defects.

For a hydraulic tensioner, the washers must be finished by grinding to exact flatness.

 Clean and lightly oil the threads of the bolts and nuts. Clean thoroughly the washers.
 Clean thoroughly the bearing surfaces in the structure for washers and check that they are level.
 Set the washers so that beveled side is against bolt head or nut.
 Tighten the bolts first to approximately 80 % of the full pre-tensioning value. Start simultaneously on the
opposite sides of the joint and proceed according to figure 1, until the whole joint has been gone through.
At this stage the aim is a rough tightness of the whole joint. A torque wrench can also be used, by a torque
value of 80 % of the nominal torque.
 Tighten the bolts to the full pre-tensioning value. Start simultaneously on the opposite sides of the joint
and proceed according to figure 1, until the whole joint has been gone through.
The tightening procedure in detail is as follows:
 Fit the tensioner to the bolt thread and apply the full tension force to the bolt.
 Tighten the nut so that it is hard against the washer.

Check the equipment so that nothing is preventing free rotating of the nut!

 Release the force from the tensioner, to allow the nut and washer faces to bed in.
 Apply the full tension force to the bolt.
 Re-tighten the nut so that it is hard against the washer.
 Release the force from the tensioner, and remove it from the bolt.

6/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

4 BOLTED JOINT MAINTENANCE

4.1 General
During the operation of the machine, the bolted joints are subjected to varying loads. To minimize the
differences in loads on these bolts, it is essential that they all remain at a high and even pre-tightening level.
In operation, these bolts can become loose through settling of the joint surfaces.
The purpose of the periodic bolt tightness check is to make sure that all bolts are carrying an equal share of
the loads, and to replace any elongated or suspect bolts, before fatigue fracture occurs.

4.2 Frequency of bolt inspection

For the main bolted joints, specific instructions of the inspection frequency may be given in the particular
instructions of these joints. This concerns e.g. the slew bearing bolts and major structural joints, which are
shown in the Structural Inspection Plan.
If other instructions do not exist, the following basic inspection frequency must be followed:

Table 1. Inspection intervals of bolted joints.

Inspection action Time of action (Years after start up)
Structural joints Slew bearing bolts
1–4
6 – 14
Visual inspection Every year
16 – 24
26 –>
5
Bolt tightening procedure 15 Every year
25, 30, 35
7, 14, 21 or when needed, see chapters 4.4
Replacement of all bolts When needed, see chapters 4.4 and 4.5
and 4.5

4.3 Visual inspection

For each joint, the visual inspection should include the following checks:
 The bolts and nuts are tight.
 Any locking devices that prevent the bolts and nuts from coming loose are in place and fitted correctly.
 There has been no relative movement between the joint faces.
If a bolted joint fails any of these checks, all bolts in the joint must be tightened to the required level using the
correct procedure, and then the locking devices must be fitted.
If there is any doubt that the bolt is seized or thread-bound and hence is not applying the force to the joint,
the bolt must be replaced.

7/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

4.4 Bolt tightening procedure, torque wrench

 The joint must be as unloaded as practical and the machine must be out of operation during the
inspection.
 Spray thin, oil-based corrosion release agent (CRC) onto all of the nuts and washers. Let it affect for
10…20 minutes.
 Record the initial position of each nut by stamping the nut and the structure next to the washer with
checking marks (M).
Figure 6. Stamping the nut and the structure.

 Apply a torque of 80 % of the nominal value onto each bolt.

 Check turning of the nut: If the nut has turned, mark this bolt by paint to be replaced.
 Repeat the above steps 3…5 for all of the bolts in the joint.
 Count how many bolts are marked to be replaced.
If more than 20 % of the nuts in the joint have been marked, all of the bolts and nuts in the joint must be
replaced by new ones.
If less than 20 % of the nuts in the joint have been marked to be replaced, the marked bolts and also one
nearest bolt on either side of the marked ones must be replaced by new ones.
 Also mark these adjacent bolts by paint to be replaced!
 Nuts which, have not turned must be retightened by following method bolt by bolt:
 First loosen the nut by turning it 30 degrees.
 Retighten the nut by the full pre-tightening torque.

8/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

4.5 Bolt tightening procedure, hydraulic tensioner

 The joint must be as unloaded as practical and the machine must be out of operation during the
inspection.
 Clean all of the exposed bolt threads. Spray thin, oil-based corrosion release agent (CRC) onto all of the
nuts, bolt threads and washers. Let it affect for 10…20 minutes.
 Record the initial position of each nut by stamping the nut and the structure next to the washer with
checking marks.
Figure 7. Recording the initial position of each nut.

 Fit the tensioner to the bolt thread and apply the full tension force to the bolt.
 Loosen the nut on the bolt under tension.
 Re-tighten the nut so that it is hard against the washer.

Check the equipment so that nothing is preventing free rotating of the nut!

 Release the force from the tensioner, and remove it from the bolt.
 Check how much the nut has turned.
 If it is less than 30 degrees, the bolt is acceptable.
Figure 8. Checking how much the nut has turned.

9/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.
DOC014120/1-EN / 27.02.2015

 If the nut has turned by more than 30 degrees, mark this bolt by paint to be replaced.
Figure 9. Checking how much the nut has turned.

 Repeat the above steps 3…8 for all of the bolts in the joint.
 Count how many bolts are marked to be replaced.
If more than 20 % of the nuts in the joint have been marked, all of the bolts and nuts in the joint must be
replaced by new ones.
If less than 20 % of the nuts in the joint have been marked to be replaced, the marked bolts and also one
nearest bolt on either side of the marked ones must be replaced by new ones.
 Also mark these adjacent bolts by paint to be replaced!

4.6 Bolt and nut replacement

All of the bolts used in the same joint must come from a single production batch. This concerns also the tool
operating and/or tool calibration tests.
Before the tightening work, carry out the described tool operating and/or tool calibration tests.

For the replacement procedure, it is essential that only one bolt and nut is
CAUTION
slackened and removed from the joint at any time.

Carry out the check procedures for the fitting material, as described in the chapters 2 or 3 of Initial
Tightening.
Tighten each new bolt immediately after fitting to 80 % of the full pre-tightening value.

Damage deliberately each removed bolt to prevent its reuse!

After replacing all of the marked bolts, carry out the Initial Tightening Procedure of chapters 2 or 3,
depending on the type of the tool.

10/10
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2015)
Konecranes Plc. All rights reserved.