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Tool No 21

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1. DO NOT exceed the maximum stroke This is indicated by a red line around the piston A DO NOT exceed the 1500 bar maximum pressure for the tool P e SE d ax ei ee S CA rx ae Ge e V Ge Ki P b XX b KX b Ee ges B 77 C Jl _ Observe the piston If the maximum piston stroke indicator is seen you MUST stop the pump and go to STEP 9 then STEP 12 then back to STEP 8 A A highly visible red line indicates when the piston has reached its maximum stroke Stop the pump as soon as the red indicator can be seen Section 3 Page No 16 e E Kam E Job No Q620 Copyright November 2006 STEP9 TIGHTENING A BOLT Use a tommy bar to turn the SOCKE T clockwise to tighten the nut Insert the tommy bar through the window in the BRIDGE until it engages with a hole in the SOCKET Turn the SOCKET clockwise as far as it will go If the tommy bar comes into contact with the BRIDGE remove it and engage the next hole in the SOCKET Continue turning the SOCKET until the nut is tight X EXC II ORI D PAYS Ce A ALA LUSH FL JM Ed Clockwise TOMMY BAR Section 3 Page No 17 RARoO TORE Job No Q620 Copyright November 2006 STEP 10 TIGHTENING A BOLT Release the pressure slowly Section 3 Page No 18 e RAPID TORE Job No Q620 Copyright November 2006 STEP 11 TIGHTENING A BOLT Apply the correct hydraulic pressure again Observe
2. The pressure should be steady and not fall to show the seals are working When satisfied the seals are functioning release the oil pressure The seals are now energised and the tool is ready for use If the seals will not energise the tool must be taken apart again because the seals have not been correctly fitted The seals may not energise if the pump is unable to deliver oil quickly enough Section 5 Page No 17 e RAPID TORE Job No Q620 Copyright November 2006 Fitting a Quick Connector To fit a quick connect nipple or coupling to the hydraulic cylinder you will need a quick connector T 1501 or T 1502 and a male male threaded adaptor T 1503 and a suitable spanner Fitting either the quick connect nipple or coupling can be achieved by following the simple steps shown below Check the internal and external threads are clean and free from damage Screw the adaptor into the hydraulic cylinder The adaptor is identical at each end so it does not matter which end is inserted into the cylinder Tighten the adaptor firmly onto the cylinder using a spanner Section 5 Page No 18 e RAPIO TORE Job No Q620 Copyright November 2006 Fitting a Quick Connector Screw the Nipple or Coupling onto the adaptor Using a spanner firmly tighten the quick connector onto the adaptor oection 5 Page No 19 D E Job No Q620 Copyright November 2006 Fitting a Quick Connector Tool No 21 To fit a quick connect nipple
3. Job No Q620 Copyright November 2006 f 71 Ran Tore Hydraulic Bolt Tensioning Equipment Health amp Safety Operating and Maintenance Instruction Manual Customer Name TITAN Technologies Korea Customer Order No Titan Job No Q620 Date November 2006 Job No Q620 Copyright November 2006 Copyright Statement This Health amp Safety Operating and Maintenance Manual has been prepared by the company Titan Technologies Inc All of the material in this manual is the property of the company and is subject to copyright No part of this manual may be copied or reproduced without the prior written consent of the company Further copies of this manual may be purchased from Titan Technologies Inc e RAPI D TORC 1 2 co 4 D CONTENTS Technical Information List of equipment supplied Technical Information Test Certificate Parts Lists for each Tool Size Oil Pressure Calculation Table of Oil Pressure Graphs Oil Pressure Graphs Health and Safety Important Notice Working with Quick Connectors Working with Hoses Working with Bolt Tensioning Tools Operating Instructions How to tighten a bolt Steps 1 to 16 How to loosen a bolt Steps 1 to 14 Returning the Pistons Simultaneous Bolt Tensioning Connecting tools together for simultaneous operation Maintenance Instructions Introduction Changing the Seals Fitting the Piston Energising the Seals Fitting the Quick Connectors Removing and Fittin
4. Tommy Bar 14 mm dia Tommy Bar 12 mm dia Tommy Bar 10 mm dia Tommy Bar 8 mm dia Tommy Bar 6 mm dia Pressure Test Certificate Operating Manual section 1 Page No 2 Job No Q620 Copyright November 2006 T 4000 127 T 3 50 127 T 3500 T26 T 3000 T25 T 2750 125 T 2500 T24 T 2250 124 T 18759 123 T 1625 123 1 1500 122 T 1125 T21 T 1000 T21 T 0875 T21 T 1540 1 5 T SK T27 T SK T26 T SK T25 T SK T24 T SK T23 T SK T22 T SK T21 T TB 20 T TB 16 T TB 14 T TB 12 T TB 10 T TB 8 T TB 6 Job No Q620 Copyright November 2006 e RAPI D TORC Technical Information Tool No 21 Pressure Area 1 555 mm Maximum Working Pressure 1500 bar Maximum Load 233 kN Tool No 22 Pressure Area 2 884 mm Maximum Working Pressure 1500 bar Maximum Load 433 kN Tool No 23 Pressure Area 5 271 mm Maximum Working Pressure 1500 bar Maximum Load 91 kN Tool No 24 Pressure Area 8 445 mm Maximum Working Pressure 1500 bar Maximum Load 1 267 kN Tool No 25 Pressure Area 12 197 mm Maximum Working Pressure 1500 bar Maximum Load 1 830 kN Tool No 26 Pressure Area 16 682 mm Maximum Working Pressure 1500 bar Maximum Load 2 502 kN Tool No 27 Pressure Area 17 530 mm Maximum Working Pressure 1500 bar Maximum Load 2 629 kN Section 1 Page No 3 e Job No 620 Copyright November 2006 Technical Information Fatigue Life The Puller of the Bolt Tensioning Tool is subject to fatigue loading during normal operat
5. 1 1 1 1 1 3 1 1 1 1 1 1 4 UN8 Puller T 3092 00 4 inch Bridge T 3609 00 section 1 Page No 24 4 inch Socket T 3096 00 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 27 Quick Connect Nipple T 1502 id T 3094 00 Cylinder Body T 3093 00 Male male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly No 27 Stroke Indicator T IR T27 Seal Kit T SK T27 Section 1 Page No 25 Job No Q620 Copyright November 2006 PICTURE of 1 5 m long 1500 bar hose ii Guick Connect Nipple Pd Quick Connect Coupling High Pressure Flexible Hose complete with self sealing quick connectors at each end 1 5 m Long Part No T 1540 1 5 Section 1 Page No 26 e RAPIO TORE Job No Q620 Copyright November 2006 PICTURES of tool fittings for Tool TRM 22 to 29 Male Male adaptor Quick Connect Nipple Magie T 1502 PICTURES of tool fittings for Tool TRM 21 T 1533 T 1524 Bonded Male Male Washer T 1502 Adaptor Seal Quick Connect Nipple T 1510 Dust Cap section 1 Page No 27 e Job No Q620 Copyright November 2006 OIL PRESSURE CALCULATION AND GRAPHS The formula used to calculate the Oil Pressure to be used with a bolt tensioning too are given below along with definitions of the terms used Bolt Load Residual Bolt Load required when the tensioning operation is complete
6. Ou O Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 26 3500 0091 0070 eg 41155644 IO 0060 0021 DOLL DOOL 006 008 004 009 00S OO 00 ooz DOL 0 0 0S OOL 00c r osc 00 Jenayew yoq ay jo 01003415 pjer uunuuluruJ BU JO 94506 JO Sseoxe ul ssaijjs 10 Jelu ue ul nsa jim UDIUM eunssaud jio ue aen zou OG DuIUJeM Segoe 1109 111 A 9JnSS9Jg NO 60111 8NN Z L 103 97 ON 1 1 Buluoisu l yog 09 00r 09 Lu 668 uw 0089 JO 4 55415 ay uo 0 55 45 0004 sseas 1109 Section 1 Page No 46 cO e e N 6 O Ou gt le lt re O Kal Q O O e N cO g le lt fe le Graph TRM 27 L 9002 1uBliu doO bagda INSS ld pi DOS OOVL OU L 00cL OOLL 0001 009 00r 00 OU 001 0 cts NA 6Z9Z 99104 Buiuorisue uinuurxeJA Jeq 0091 eunssaJg WC WNWIXEN WW DEG AL eeJy eunsseJg oineJp H 90104 Buiuoisuo9 29139109Y A INSS ld NO ZZ ON 1 1 Buluo sa 1 00077 0922 0092 0547 Np 8 992 04 010015061 Section 1 Page No 47 Job No Q620 Copyright November 2006 Graph TRM 27 3750 00 1 LA Cc Hi O O S N H N O N c c c NN WN e e e gt O Hi O o O o Hi LA N O E HA N oO Fe O oO uU N e O 11111111111
7. _ O gt L D C KS D 2 O D 0 Section 3 Page No 38 D RAPID TORC Job No Q620 Copyright November 2006 STEP 12 LOOSENING A BOLT Use the Tommy Bar to release and remove the PULLER Anti Clockwise NNN Wl Ge ZZZ S Ki Ka DN GE BC KN EN SEN RSS O 5492040400 0 20 5294040 OOO SELLOS A dm LE 22 Section 3 Page No 39 z e RAPID TORC Job No Q620 Copyright November 2006 STEP 13 LOOSENING A BOLT Remove the CYLINDER and BRIDGE Section 3 Page No 40 e RAPID TORC Job No Q620 Copyright November 2006 STEP 14 LOOSENING A BOLT Remove the SOCKET The nut is now loose Z Section 3 Page No 41 e RAPID TORE Job No Q620 Copyright November 2006 Returning the Pistons The small bore of the oil pressure release valve on the pump is the most significant restriction to the flow of oil back to the oil reservoir The oil pressure release valve Attempting to return the pistons manually using a tommy bar on the Puller will be difficult when pushing the oil through the pump pressure release valve To greatly reduce the force time and effort necessary to return the pistons TITAN has provided a direct return to tank coupling on the top of the oil reservoir immediately next to the oil filler cap A quick connector is provided on the top of the oil reservoir to bypass
8. lt Hydraulic 27 Hose 2 Quick Connect Coupling Section 3 Page No 32 e Fear Tra Job No Q620 Copyright November 2006 AN MOST IMPORTANT HEALTH amp SAFETY THINK SAFETY The bolt tensioning tool is now ready to be pressurised Before proceeding read the Health amp Safety Instructions given in this manual then proceed as follows Clear all personnel from the area where the bolt tensioninq operation is to be performed Position the pump a safe distance away from the bolt tensioning tools Set up barriers and warning signs or make other adequate arrangements to prevent unauthorised personnel from accidentally straying into the bolt tensioning area Make certain that nobody is allowed to stand near to a bolt tensioning tool during the pressurisation process At no time should anyone allow any part of their body to be positioned over the PULLER of a bolt tensioning tool whilst the pressure is rising or when it is pressurised Do not allow anyone to stand anywhere near a direct line with the long axis of a bolt during the tensioning operation In the case of studbolts with nuts at each end it is important that nobody stands in line with the long axis of the bolt at either end during the tensioning operation Do not approach a bolt tensioning tool whilst it is being pressurised Remember that bolt or tool failure is most likely to happen at this critical time When the operating pressure has been reached approa
9. the Health and safety Instructions AN DO NOT exceed the maximum stroke This Is indicated by a red line around the piston A DO NOT exceed the 1500 bar maximum pressure for the tool Use the tommy bar to turn the Socket until it is tight again 2 E Clockwise 11 an TOMMY BAR A A highly visible red line indicates when the piston has reached its maximum stroke Stop the pump as soon as the red indicator can be seen Section 3 Page No 19 D NETO Job No Q620 Copyright November 2006 STEP 12 TIGHTENING A BOLT Release the pressure slowly Fully open the oil pressure release valve on the pump Use the tommy bar to tighten the PULLER until the Piston is fully returned into the CYLINDER See oection 3 Page 42 for more information on returning the pistons Clockwise 2 Stroke 0 mm LA ISI ZO ISS AA AA A AAA EE RSS SSL WEIT OI SRF Kan ESS VSS RH BEASLEY SRE RK SSF ki RISER Ex n Dh RR NEE MLN dee JA O DO ate DO Ge Ge RSA im BH p t EA Bua S 222 Section 3 Page No 20 cO e e N i Ou 2 Ou gt le lt re O gt Q O O e N cO g le lt fe le STEP 13 TIGHTENING A BOLT D 62 O L O 5 DO Kn O gt L D e KS D 2 O E D 0 Section 3 Page No 21 D RAPID TORC Job No Q620 Copyright November 2006 STEP 14 TIGHTENI
10. 0 41155644 IO 0011 0001 006 008 004 009 009 007 00 002 001 NA Z 92104 Buiuoisue wnuwixeyy Jeq 0091 4154 IO 0 0 UW SSS Belly eJnsseJg 9INEIP H 9910 4 Duiuoisuo 891391094 A 41155644 IO LZ ON 1 1 DBuruoisue 31 GE r OS gl 001 920 r 69 r SZL r 004 NA 392104 Buiuoisu 1 Section 1 Page No 30 cO e e N i Ou 2 Ou gt le lt re O gt Q O O e N cO g le lt 2 le Graph TRM 21 0875 009 00 00 eg 41155 44 NO 0020 0010 000 006 008 002 009 009 007 00 UO euajeu oq 110 u Bu ns pjar 01 0 BU JO 9666 JO Sseoxe ul ss ns YOQ ue ul 1 nS 1 jim yolym einssaiJd io ue BSN jou OG DuluJeAA SS9J S 11 eIIU A INSS ld NO 60111 INN 8 2 103 LZ ON 1 1 Buruoisue 1 000 00v OST 009 r 099 009 099 004 000 5 415 Og 1 Section 1 Page No 31 Ul Z9py 0 uw 0 JO Bale ss ns 0 uo peseq ss xs yog cO e e N 6 2 Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 21 1000 0090 007 0061 4 0 41155 44 NO 0001 0011 0001 006 008 007 009 006 00 00 002 001 0 euajeu yoq ay jo 1603415 pjer uunuululuu 110 96 JO ssooxe ul 55 41 JOG eniui ue ul 1
11. 2006 STEP8 LOOSENING A BOLT Use the tommy bar to turn the SOCKE T anti clockwise to loosen the nut Insert the tommy bar through the window in the BRIDGE until it engages with a hole in the SOCKET Turn the SOCKET anti clockwise When the tommy bar comes into contact with the BRIDGE remove it and engage the next hole in the SOCKET Continue turning the SOCKET until the nut has been undone one full turn Do not let the nut come into contact with the PULLER 2 ee S EXC II ELA ES A I3 Ge 7 RH Ji x lt LL Anti Clockwise TOMMY BAR Section 3 Page No 35 e RAPID TORC Job No Q620 Copyright November 2006 STEP 9 LOOSENING A BOLT Release the pressure slowly When the pressure has fallen to zero fully open the oil pressure release valve on the pump p s ISR PSII SIS IIS IKI S SG ee lt KX se Ge Section 3 Page No 36 D RAPID TORC Job No Q620 Copyright November 2006 STEP 10 LOOSENING A BOLT Use the tommy bar to tighten the PULLER until the Piston is fully returned into the CYLINDER See Section 3 Page 42 for more information on returning the pistons Clockwise 22 Section 3 Page No 37 Stroke 0 mm 2 S E D TCE d cO e e N i Ou 2 Ou gt le lt re O gt Q O O e N cO g le lt fe le LOOSENING A BOLT STEP 11 D V O L O 5 DO
12. BRIDGE and this step can be ignored In some circumstances and applications the hexagon nuts are pre drilled with tommy bar holes in the flats of the nut Sometimes circular or ring nuts are used instead of hexagon nuts and these will also be pre drilled with tommy bar holes In these circumstances the SOCKET is not required and this operation can be ignored SOCKET 22 22 Section 3 Page No 27 e as Job No Q620 Copyright November 2006 STEP A LOOSENING A BOLT Place the CYLINDER and BRIDGE assembly over the nut bolt and SOCKET The CYLINDER and BRIDGE are assembled together using small spring loaded screws around the outside of the base of the CYLINDER The BRIDGE and CYLINDER can be rotated relative to each other This allows the self sealing quick disconnect hydraulic connection on the CYLINDER to be positioned in the best position for connecting the hydraulic hose In applications where space is limited above the bolt it may be helpful to separate the BRIDGE and the CYLINDER placing them individually onto the bolt The BRIDGE has a recess to accept the SOCKET nut and bolt A window in the front of the BRIDGE allows access to the SOCKET with a tommy bar The BRIDGE may have flats on each side to clear the adjacent nuts The BRIDGE and CYLINDER may have an angled flat at the back to clear any obstruction behind the bolt and nut such as the hub of a weld neck flange CYLINDER BRIDGE Flat to clear adjacent I hexa
13. Check there is no pressure in the system before attempting to connect or disconnect the couplings ROU SR EE LS x DOS lt RRR SEA SRK ee lt gt gt x gt x gt J KO EE OOOO LILLI lt lt 2 262 P To connect the Quick Connect Coupling and Nipple first check there is no pressure in the system Then pull back the shroud by hand and push the coupling onto the nipple When together release the shroud which will spring back to lock the Coupling and Nipple together To disconnect first check there is no pressure in the system Pull back the shroud by hand and pull the coupling and nipple apart Release the shroud when apart Shroud VOD SORRY gt Gei e KRX 5522 LX Pull the shroud back to retract KX 9 KOS ORK SxS SKS 9 9 COCO KX XX lt gt XXX Coupling and Nipple with the shroud retracted KXXX 6 SLRS BOR CC 252 Y ee Ge X e SS 5 S LLS SZ XJ KX ROS Coupling and nipple pushed together with the shroud still retracted 4503450207050 4503450204050 OO DS E CN NS Shroud released Coupling and Nipple are now locked together and safe to use AAAAAAAAAZ RRR SSR RRS ODO OOD SZ d DO XS be 2626 G x y Section 3 P
14. No 14 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 24 for 2 1 4 inch UN8 Part No Description Quantity T 3021 00 No 24 Cylinder Body 1 T 3022 01 No 24 Piston 1 T 0682 00 No 24 Puller for 2 1 4 inch UN8 1 T 3464 00 No 29 Socket for 2 1 4 inch 1 T 3682 00 No 24 Bridge for 2 1 4 inch 1 T BRSDP M512 Bridge Retaining Screw 3 T SK T24 Seal Kit for Tool No 24 1 T IR T24 Red Plastic Stroke Indicator for Tool No 24 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T24 Label for Tool No 24 1 Hydraulic Cylinder No 24 2 1 4 Bridge T 3682 00 Section 1 Page No 15 2 1 4 UN8 Puller T 0682 00 2 1 4 Socket T 3464 00 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 24 for 2 1 2 inch UN8 Part No Description Quantity T 3021 00 No 24 Cylinder Body 1 T 3022 01 No 24 Piston 1 T 0681 00 No 24 Puller for 2 1 2 inch UN8 1 T 3024 00 No 24 Socket for 2 1 2 inch 1 T 3223 01 No 24 Bridge for 2 1 2 inch 1 T BRSDP M512 Bridge Retaining Screw 3 T SK T24 Seal Kit for Tool No 24 1 T IR T24 Red Plastic Stroke Indicator for Tool No 24 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T24 Label for Tool No 24 1 Hydraulic Cylinder No 24 2 1 2 Bridge T 3223 01 2 1 2 UN8 Puller T 0681 00 2 1 2 Socket T 3024 00 Section 1 Page No 16 e RAPID TORE Job No Q620 Copyright Novemb
15. Seal Kit T SK T21 Section 1 Page No 9 9 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 22 for 1 1 2 inch UN8 Part No Description Quantity T 1985 00 No 22 Cylinder Body 1 T 1998 00 No 22 Piston 1 T 0589 02 No 22 Puller for 1 1 2 inch UN8 1 T 0816 01 No 22 Socket for 1 1 2 inch 1 T 0592 03 No 22 Bridge for 1 3 8 inch and 1 1 2 inch 1 T BRSDP M510 Bridge Retaining Screw 2 T SK T22 Seal Kit for Tool No 22 1 T IR T22 Red Plastic Stroke Indicator for Tool No 22 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T22 Label for Tool No 22 1 Hydraulic Cylinder No 22 1 3 8 inch and 1 1 2 inch Bridge T 0592 03 section 1 Page No 10 1 1 2 UN8 Puller T 0589 02 1 1 2 Socket T 0816 01 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 22 Quick Connect Nipple T 1502 Piston T 1998 00 Cylinder Body T 1985 00 Male male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly No 22 Stroke Indicator T IR T22 Seal Kit T SK T22 Section 1 Page No 11 e RAPID TORC Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 23 for 1 5 8 inch UN8 Part No Description Quantity T 1989 01 No 23 Cylinder Body 1 T 0622 01 No 23 Piston 1 T 0809 01 No 23 Puller for 1 5 8 inch UN8 1 T 0813 01 No 23 Socket for 1 5 8 inch 1 T 0804 02 No 23 Bridge for 1 5 8 inch and 1 3 4 1 T BRSDP M512 Bridge
16. T SK T21 Seal Kit for Tool No 21 1 T IR T21 Red Plastic Stroke Indicator for Tool No 21 1 T 1502 Quick connect nipple 1 T 1524 Male male adaptor 1 T 1533 Bonded Washer Seal 1 T 1510 Plastic dust cap for nipple 1 T L1 T21 Label for Tool No 21 1 Hydraulic Cylinder No 21 1 inch and 1 1 8 inch Bridge T 3546 00 Section 1 Page No 7 1 UNC Puller T 1738 00 1 Socket T 0398 00 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 21 for 1 1 8 inch UN8 Part No Description Quantity T 3650 00 No 21 Cylinder Body 1 T 3651 00 No 21 Piston 1 T 1737 01 No 21 Puller for 1 1 8 inch UN8 1 T 0399 02 No 21 Socket for 1 1 8 inch 1 T 3546 00 No 21 Bridge for 1 inch and 1 1 8 inch 1 T BRSDP M506 Bridge Retaining Screw 2 T SK T21 Seal Kit for Tool No 21 1 T IR T21 Red Plastic Stroke Indicator for Tool No 21 1 T 1502 Quick connect nipple 1 T 1524 Male male adaptor 1 T 1533 Bonded Washer Seal 1 T 1510 Plastic dust cap for nipple 1 T L1 T21 Label for Tool No 21 1 Hydraulic Cylinder No 21 1 inch and 1 1 8 inch Bridge T 3546 00 Section 1 Page No 8 1 1 8 UN8 Puller T 1737 01 1 1 8 Socket T 0399 02 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 21 Piston T 3651 00 Bonded Washer Seal T 1533 Quick Connect Nipple T 1502 Cylinder Body T 3650 00 Plastic Dust Cap T 1510 Male male adaptor T 1524 Cylinder Assembly No 21 Stroke Indicator T IR T21
17. TRM 24 L 0091 0070 00 0001 4 0 eunssaJg NO DOLL 000 006 008 004 009 009 00r 00 00 amp 000 e STEIN NA 992 99104 Buiuoisue 001 1 0 Jeq 0091 amssald ro unuurxelA E 004 Otto Bd ejynssoJg DINPIP H E AAA 5 5 99104 Duiuoisuo e9133109y A inss id IO yz ON 1 1 6010015061 31 e 001 UO 00 NJ 939104 Buiuoisu y Section 1 Page No 39 e e N i 6 Q Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 24 2250 009 oop L ueq eunssauJgd 110 00 L 00cl 00LL 0000 006 008 004 009 009 00v 00 UO 001 euajeu yoq 110 ulBu u s pJaer uunuululuu BU JO GE JO sseoxe ul ss ns YO Jegu ue Ul nS 1 yotym nSs 1d io ue BSN jou og BulUJeM SS9JJS 1 09 110 A 4155644 NO Bunioq 8NN YoU FILS 103 pZ ON 1 1 BuluoIsua yog 0S 001 090 00 OSC 00 OSE 00r OSV 00S OSS Lu JG uw gogz JO 4 sseJis yoq uo peseq ss ns yog WIW N sseas 1109 10 Section 1 Page No 40 cO e e N 6 O Ou gt le lt re O gt Q O O e N cO O O lt fe le Graph TRM 24 2500 0091 00v L 4 90 eunssaJg IO UO L 00cl OOLL 000L 006 008 004 009 009 O07 00 002 004 0 leuajew eui jo 160 415 pjer wnwiulu BU JO 9566 JO Sseoxe ui sseij
18. Tensioning Force The load that will be applied by the bolt tensioner during the tensioning operation Load Loss Allowance The ratio of Tensioning Force to Bolt Load Load Loss Allowance Tensioning Force 1 01 Bolt Diameter Bolt Load Grip Length If the Load Loss Allowance calculates to less than 1 10 then use 1 10 Tensioning Force Bolt Load x Load Loss Allowance Always check that the tensioning force will not exceed 90 of the yield strength of the bolt material If it does the grip length of the bolt must be increased Contact TITAN for advice on this Oil Pressure bar 10 x Tensioning Force Newtons Tool Pressure Area mm Oil pressure graphs are provided for each bolt size One graph shows the theoretical tensioning force developed by the tool against the oil pressure applied The next graphs show the initial bolt stress developed by the tool against the oil pressure applied for each bolt size This graph is provided to assist with the check that the tensioning force does not exceed 90 of the yield strength of the bolt material Users who require highly accurate residual bolt stresses should perform a bolt extension measurement before and after tensioning In this way residual bolt stresses can be calculated from the actual bolt extensions measured oection 1 Page No 28 Job No Q620 Copyright November 2006 TABLE OF OIL PRESSURE GRAPHS Tool No 21 Graph No 21 L Graph No 21 0875 Graph No 21 1000 G
19. helpful to separate the BRIDGE and the CYLINDER placing them individually onto the bolt Pull the BRIDGE away from the CYLINDER to remove it Push the two back together again afterwards The BRIDGE has a recess to accept the SOCKET nut and bolt A window in the front of the BRIDGE allows access to the SOCKET with a tommy bar The BRIDGE may have flats on each side to clear the adjacent nuts The BRIDGE and CYLINDER may have an angled flat at the back to clear any obstruction behind the bolt and nut such as the hub of a weld neck flange CYLINDER BRIDGE Flat to clear adjacent Yj hexagon nuts SOCKET aa es Flat to clear hub of weld neck flange or Z other obstruction yA Section 3 Page No 9 2 e as Job No Q620 Copyright November 2006 STEP A TIGHTENING A BOLT Place the PULLER into the centre of the CYLINDER and BRIDGE and engage the PULLER thread with the end of the bolt The PULLER has a nose to assist this operation Take care the PULLER and bolt threads are properly engaged and do not become crossed Do not force the PULLER onto the bolt The PULLER should turn freely on the bolt PULLER Y N Tommy bar holes Sd EXPO SS PLI 22 Section 3 Page No 10 e RAPID TORC Job No Q620 Copyright November 2006 STEP 5 TIGHTENING A BOLT Screw the PULLER fully down onto the top surface of the CYLINDER The PULLER will normally be turned by hand but the f
20. in RED on Page 2 and Page 7 Important Notice Page 2 Using the Quick Connectors Page 3 Using the Hoses Page 4 Using the Tools Page 5 Section 2 Page No 1 e SE Job No Q620 Copyright November 2006 A HEALTH amp SAFETY INSTRUCTIONS THINK SAFETY IMPORTANT NOTICE Thank you for purchasing or renting your hydraulic bolt tensioning equipment from TITAN Bolt tensioning tools are very powerful and capable of inducing very high bolt stresses This equipment has been designed to give many years of safe tightening of bolted connections when used in accordance with these instructions Persons using hydraulic bolt tensioning tools must be properly trained in the correct use of the equipment and must take adequate steps to ensure their own safety and the Health and Safety of others working in the area where bolt tensioning operations are being performed TITAN will be pleased to quote for the provision of training courses either at its base or on site anywhere in the world Operators must read all of this instruction and maintenance manual before attempting to use the equipment Do not use the equipment if you are not already an experienced user of hydraulic bolt tensioning tools or if you have not already received proper training Your attention is particularly drawn to the notes in RED Tightening a bolt with a hydraulic bolt tensioning tool is like lifting a heavy weight with a crane or lifting a car with a hydraulic jack Everyone knows it i
21. male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly Stroke Indicator T IR T26 Seal Kit T SK T26 oection 1 Page No 22 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 27 for 3 3 4 inch UN8 Part No T 3093 00 T 3094 00 T 3091 00 T 3098 00 T 3099 00 T BRSDP M612 T SK T27 T IR T27 T 1502 T 1503 T 1510 T L1 T27 Description Cylinder Body Piston Puller No 27 for 3 3 4 inch UN8 Socket for 3 3 4 inch Bridge for 3 3 4 inch Bridge retaining screw Seal Kit for Tool No 27 Red Plastic Stroke Indicator for Tool No 27 Quick connect nipple Male male adaptor Plastic dust cap for nipple Label for Tool No 27 Hydraulic Cylinder No 27 Quantity 1 1 1 1 1 3 1 1 1 1 1 1 3 3 4 UN8 Puller T 3091 00 3 3 4 inch Bridge T 3099 00 section 1 Page No 23 3 3 4 inch Socket T 3098 00 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 27 for 4 inch UN8 Part No T 3093 00 T 3094 00 T 3092 00 T 3096 00 T 3609 00 T BRSDP M612 T SK T27 T IR T27 T 1502 T 1503 T 1510 T L1 T27 Description Cylinder Body Piston Puller No 27 for 4 inch UN8 Socket for 4 inch Bridge for 4 inch Bridge retaining screw Seal Kit for Tool No 27 Red Plastic Stroke Indicator for Tool No 27 Quick connect nipple Male male adaptor Plastic dust cap for nipple Label for Tool No 27 Hydraulic Cylinder No 27 Quantity
22. the pressure release valve Section 3 Page No 42 e as Job No Q620 Copyright November 2006 Returning the Pistons Remove the 5m link hose from the pump outlet and connect it directly to the connector on the top of the oil reservoir Oil will now be returned to the reservoir without passing through the oil pressure release valve The top of the Puller can be tapped with a rubber or plastic mallet at the same time as effort is applied to a tommy bar to turn the puller This will assist the return of the piston Section 3 Page No 43 Job No Q620 Copyright November 2006 SECTION 4 OPERATING INSTRUCTIONS SIMULTANEOUS BOLT TENSIONING In flanged applications TITAN strongly recommends simultaneous tensioning of 100 of the bolts if space allows If insufficient space is available it is usually possible to simultaneously tighten 50 of the bolts The time required to complete the bolt tensioning operation will be a minimum when 100 tensioning is used In a gasket and flange application 5096 tensioning will take more than twice the time when compared with 100 tensioning This is because the gasket is not always fully compressed by tightening only half the bolts Tightening the second half will cause the gasket to compress further reducing the tension in the first bolts tightened and necessitating a return to the first bolts If the gasket compresses further a return to the second set of bolts may also be necessary Even so this met
23. to a minimum of two bolt diameters is protruding from the surface of the flange or joint on the side the operation is to be performed The bolt tensioner is designed to cope with thread lengths in excess of two diameters If the bolts have been tightened with a bolt tensioner it is most likely that sufficient thread length will be available however it is very important this check is performed otherwise the thread engagement between the bolt tensioner and the bolt might be less than one diameter which could cause the bolt and or bolt tensioner threads to be stripped AN HEALTH amp SAFETY WARNING If only a few threads protrude and an attempt is made to appl tension the bolt threads will strip and components of the tensioner could be launched with the possibility of serious iniury 2 IE BM L d CORRECT and SAFE WRONG and DANGEROUS Section 3 Page No 26 e SE Job No Q620 Copyright November 2006 STEP 2 LOOSENING A BOLT Place the SOCKET over the nut to be loosened When loosening bolts with hexagon nuts it is normal to use the SOCKET which is drilled with tommy bar holes as the method for turning the nut when the load from the tool is applied On some tools there is a circular groove in the BRIDGE to fit a socket retaining ring which gives the option of captivating the SOCKET within the BRIDGE lf this option is chosen there is no need to place the SOCKET over the nut separately to the
24. tool being Used Clear all personnel from the area where the bolt tensioning operation is to be performed Position the pump a safe distance away from the bolt tensioning tools Set up barriers and warning signs or make other adequate arrangements to prevent unauthorised personnel from accidentally straying into the bolt tensioning area Make certain that nobody is allowed to stand near to a bolt tensioning tool during the pressurisation process At no time should anyone allow any part of their body to be positioned over the PULLER of a bolt tensioning tool whilst the pressure is rising or when it is pressurised Do not allow anyone to stand anywhere near a direct line with the long axis of a bolt during the tensioning operation In the case of studbolts with nuts at each end it is important that nobody stands in line with the long axis of the bolt at either end during the tensioning operation Do not approach a bolt tensioning tool whilst it is being pressurised Remember that a damaged bolt or tool is most likely to fail at this critical time When the operating pressure has been reached approach a pressurised bolt tensioning tool only for as long as it takes to turn the permanent nut always keeping away from the axis of the bolt and the PULLER Section 2 Page No 7 e RAPI TOrC Job No Q620 Copyright November 2006 HEALTH amp SAFETY INSTRUCTIONS Bolt Tensioning Tools gt gt b b b b p
25. 1 T 1510 Plastic dust cap for nipple 1 T L1 T25 Label for Tool No 25 1 Hydraulic Cylinder No 25 3 Bridge T 1977 00 3 UNS Puller T 0830 01 section 1 Page No 19 3 Socket T 0353 02 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 25 Quick Connect Nipple T 1502 Piston T 1654A 01 Cylinder Body T 1654B 01 Male male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly No 25 Stroke Indicator T IR T25 Seal Kit T SK T25 oection 1 Page No 20 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 26 for 3 1 2 inch UN8 Part No T 07 37 00 T 0729 00 T 0727 01 T 0732 00 T 0736 00 T BRSDP M612 T SK T26 T IR T26 T 1502 T 1503 T 1510 T L1 T26 Description Cylinder Body Piston Puller No 26 for 3 1 2 inch UN8 Socket for 3 1 2 inch Bridge for 3 1 2 inch Bridge retaining screw Seal Kit for Tool No 26 Red Plastic Stroke Indicator for Tool No 26 Quick connect nipple Male male adaptor Plastic dust cap for nipple Label for Tool No 26 Hydraulic Cylinder No 26 Quantity 1 1 1 1 1 3 1 1 1 1 1 1 3 1 2 UN8 Puller T 0727 01 3 1 2 inch Bridge T 0736 00 section 1 Page No 21 3 1 2 inch Socket T 0732 00 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 26 Quick Connect Nipple Piston T 1502 T 0737 00 Cylinder Body T 0729 00 Male
26. 111 N KI co _ 3 o Y B Q N o ES 2 62 x b 8 c N Y en 5 z O x N m 0 N e Y 1 T eo 8 I m e x X S 0 O 5 um 4 yA EM o T O gt 295 Z E K gt 252 E O Y 3027 0 O o0 EE s 8 0 SES lt eo t ESE e n s gt E S 9 lt n 00 z 5 lt 9 cO 6 O 2255 a Y lt 9 Z 3 0 c 2053200 eo E AT 0 E j 2 5 s D S m 2 i O CH D i AN I o D 0 6 03 MIN 55435 1 Section 1 Page No 48 e RAPID TORE Job No Q620 Copyright November 2006 Graph TRM 27 4000 o O O t a S 6 S lt c l O e 00 v 5 8 l lt E on c O C I O S A o Ss O Qc 2g I mm 0 N c o 0 Oo D lt gt 295 03 ZED O O a voL o 00 s SS D Y QS o o 2 6 5 6 S C wc fg O TTE E D Se E O Q 350 on wO iii i c SEKKE e Ka 20355 8 9 O e e 2 e 2 11111 9 Ee OV o 9 e CN O un e CH CH 0 BAI ssens 1108 en Z O e Section 1 Page No 49 Job No Q620 Copyright November 2006 SECTION 2 HEALTH amp SAFETY INSTRUCTIONS Persons using hydraulic bolt tensioning tools must read and understand this section before starting to use the equipment Your attention is particularly drawn to the instructions
27. 15 4 IM YOIUM 94nssaid io ue aen jou OG DulUuJeAA SS9J S 31 09 10 A 9JnSS9Jg O bunioq INN You 8 2 103 LZ ON 1 1 Buruoisue yog 0 OS 00 091 002 OSC 00 ose 00y OSV 00S OSS 009 099 004 094 008 9 0 uw 0 JO Bale 55415 yoq ay uo 0 5 5545 Og WW N 5 415 Og 10 Section 1 Page No 32 cO e e N 6 O Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 21 1125 00SL 00tL ueq INSS ld IO OOEL 0021 0011 0001 006 008 004 009 006 006 00 oog 00L Jeuuejeuu oq au jo y Buans pal unuururuJ y JO 9466 JO SS39X3 ui ssaiJjs 10 Jenlul ue ul 15 4 jim U9IUM 9Jnssaiud jio ue esn zou OG DuiuJeAA SS9J JS 1 1 10 A 41155644 IO 5u 104 8Nf You 8 1 1 104 LZ ON JOO Buruoisue yog OSC GLC 00 9 096 GLE 00 SCV OST GLY 2 862 0 WW 9 19 JO Bale ss ns 1 uo paseq ss ns yog WIWW N S9 IS 1109 10 Section 1 Page No 33 cO e e N Ou 2 Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 22 L 0090 0060 00 0 00cl ueq INSS ld 110 OOLL 0001 006 008 002 009 009 oor 00 00 000 NA py 2403 Buluoisu uinuuixeJy Jeq 0091 2 nssald WC WNWIXeEN WW 788 Z 4 einssaJg 9INEIPp H 9910 4 Buluoisu 29139109
28. 250H Wes O Wi DIr eee cO e e N Ou 2 Ou gt le lt re O Kal Q O O e N cO G le lt fe le _ Es a a E ALL if VN eg v Se AZ MM d KA m d d i i 4 k A i d b p d EA d VM L d pF d A ff d d Be M A lie ene 001 uiv Joo pJe loo pug JOO 151 section 4 Page No 3 Job No Q620 Copyright November 2006 SECTION 5 MAINTENANCE AND STORAGE INSTRUCTIONS Introduction Page 2 Changing the Seals Page 3 Fitting the Piston Page 14 Energising the Seals Page 17 Fitting a Quick Connector Page 18 Removing and Fitting the Bridge Page 20 Section 5 Page No 1 e as Job No Q620 Copyright November 2006 MAINTENACE AND STORAGE INSTRUCTIONS Introduction A hydraulic bolt tensioning tool will provide many years of trouble free service if used maintained and stored correctly Storage Each tool is chemically blacked before leaving the factory This provides a degree of corrosion protection but additional protection should be applied when the tools are to be stored for any period of time It is recommended that before storage the tools should be dismantled into their four major components 1 Puller 2 Cylinder 3 Bridge 4 Socket Each of these items should be checked for damage and if OK lightly oiled and the tool reassembled The reassembled tool must have t
29. 4 l A inss id NO ZZ ON 1 1 DBuruoisue 3jog r 00 OSC 00 OSE oor OSV Nx 92404 Buiuoisu 1 Section 1 Page No 34 e e N i 6 Q Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 22 1500 0091 007 4 9 4155644 IO 00 0 0020 0010 0001 006 008 004 009 009 00 00 002 000 1 1 4 1 ay jo ulBu ns pjer 00100010 BU JO 94566 JO SSeoxe ul 99 419 JOG eniui ue ul 115 4 JIAA YOIUM eJnsseJd io ue aen jou oq BuiUuJeAA SS9J S 3 09 81 1U A DINSSDJd NO Dunjoq SNN YOU 2 1 1 10 ZZ ON 1 1 Buruoisue 1 08 0G 00L 091 00c OSC 00 ose oor OSV WW N sses 1109 jeniuj Lu 09 uw 696 JO Bale sseus oq y peseq ss ns jog Section 1 Page No 35 cO e e N 6 2 Ou gt le lt re O Kal Q O O e N cO G le lt fe le wl Graph TRM 23 L 4 0 41155644 110 009 OOF 00 L 00cl 001 000 006 008 004 009 009 OOF 00 ef NEN Jeq 0091 INSS ld ro unuuixe A UW ZZ S Bally einsseJg ouneJpAH 92104 DBuiuoisue9 e91 93109y A 94nsSaJg IO Z ON 1 1 Buruoisue 11 NA L62 99104 Buruoisue uinullXelN NA 32104 Buiuoisu Section 1 Page No 36 cO e e N 6 O Ou gt le lt re O gt Q O O e N cO g le lt fe l
30. BOLT Place the SOCKET over the nut to be tightened When tensioning bolts with hexagon nuts it is normal to use the SOCKET which is drilled with tommy bar holes as the method for turning the nut when the bolt tension is applied On some tools there is a circular groove in the BRIDGE to fit a Socket retaining ring which gives the option of captivating the SOCKET within the BRIDGE If this option is chosen there is no need to place the SOCKET over the nut separately to the BRIDGE and this step can be ignored Also in some circumstances and applications the hexagon nuts are pre drilled with tommy bar holes in the flats of the nut Sometimes circular or ring nuts are used instead of hexagon nuts and these will also be pre drilled with tommy bar holes In these circumstances the SOCKET is not required at all and this step can be ignored SOCKET 2 E m Section 3 Page No 8 7 e as Job No Q620 Copyright November 2006 STEP A TIGHTENING A BOLT Place the CYLINDER and BRIDGE assembly over the nut bolt and SOCKET The CYLINDER and BRIDGE are assembled together using spring loaded ball screws around the outside of the base of the CYLINDER The BRIDGE and CYLINDER can be rotated relative to each other This allows the self sealing quick connect hydraulic connection on the CYLINDER to be positioned in the best position for connecting the flexible hydraulic hose In applications where space is limited above the bolt it may be
31. Coupling and Nipple first check there is no pressure in the system Then pull back the shroud by hand and push the coupling onto the nipple When together release the shroud which will spring back to lock the Coupling and Nipple together To disconnect first check there is no pressure in the system Pull back the shroud by hand and pull the coupling and nipple apart Release the shroud when apart Shroud VOD SORRY gt Gei e KRX 5522 LX Pull the shroud back to retract KX 9 KOS ORK SxS SKS 9 9 COCO KX XX lt gt XXX Coupling and Nipple with the shroud retracted KXXX 6 SLRS BOR CC 252 Y ee Ge X e SS 5 S LLS SZ XJ KX ROS Coupling and nipple pushed together with the shroud still retracted 4503450207050 4503450204050 OO DS E CN NS Shroud released Coupling and Nipple are now locked together and safe to use AAAAAAAAAZ RRR SSR RRS ODO OOD SZ d DO XS be 2626 G x y Section 3 Page No 31 e Job No 620 Copyright November 2006 STEP6 LOOSENING A BOLT Connect the hydraulic hose Make sure the quick connect coupling is fully engaged DO NOT tighten the PULLER with the tommy bar DN wv JK p a LI SA d oles d LX gt
32. ER when the bolt becomes free and needs fo return to its original length If you do not do this the load in the bolt will simply be transferred from the nut to the PULLER during the untightening operation It will be impossible to remove the bolt tensioning tool from the bolt If this happens re tighten the bolt using the bolt tensioner tighten the nut using the tommy bar and release the oil pressure The PULLER can then be wound back the one full turn necessary to avoid this situation arising again The tool is now ready for the hydraulic hose to be connected Note PULLER wound back one full turn Anti Clockwise NS XX ee RAS Li OO lag Wav ate 029242929 Geteste Ka p RR b d b d d b d b d SR RISA d P b d d DX 4 q d ae ere D d D d D d D d D d D d D d D 029242920 SSA b IZ K ve xl Li O o SLISI 252528 ada P xo Ko S09 RSX qu TT Section 3 Page No 30 NY e as Job No Q620 Copyright November 2006 Using the Quick Connect Couplings DO NOT pressurise the connectors when they are disconnected Check there is no pressure in the system before attempting to connect or disconnect the couplings ROU SR EE LS x DOS lt RRR SEA SRK ee lt gt gt x gt x gt J KO EE OOOO LILLI lt lt 2 262 P To connect the Quick Connect
33. NG A BOLT Use the Tommy Bar to release and remove the PULLER Anti Clockwise zS z d Ge Ge Ge KKK SOK d e lt d Ge d d SS WS Ge 2 Y PT P4 KX d Ge q OOO SSNS da vi Kc ss XY ROO PRESSION SE SOON XK Kee ES ALY RLS 9 9 SOROLLA H dm LE Section 3 Page No 22 e RAPID TORC Job No Q620 Copyright November 2006 STEP 15 TIGHTENING A BOLT Remove the CYLINDER and BRIDGE a Section 3 Page No 23 e RAPID TORC Job No Q620 Copyright November 2006 STEP 16 TIGHTENING A BOLT Remove the SOCKET The bolt is tight 22 Section 3 Page No 24 Job No Q620 Copyright November 2006 OPERATING INSTRUCTIONS HOW TO LOOSEN A BOLT oection 3 Page No 25 e RAPID TORC Job No Q620 Copyright November 2006 STEP 1 LOOSENING A BOLT Loosening bolts with a bolt tensioning tool is almost the reverse of the tightening operation but there are a couple of very important additions to the procedure Failure to observe them will leave the nut loose but the tensioning tool locked onto the bolt which remains tight Check the bolts to be loosened Make sure there is sufficient thread length protruding through the nut and the thread is not damaged Any bruising of the thread should be rectified with a thread file or die nut before attempting to assemble the hydraulic bolt tensioning tool onto the bolt Make sure a thread length equal
34. R transfers the force Vo developed by the CYLINDER into tension in the bolt CYLINDER The CYLINDER is an annular hydraulic jack The bolt and PULLER pass through the centre of the CYLINDER A recess is provided in the base of the CYLINDER to accept the BRIDGE One or two self sealing quick disconnect nipples are provided for connecting the hydraulic hoses BRIDGE The BRIDGE supports the CYLINDER over the bolt nut and SOCKET A circular groove has been added to fit a socket retaining ring which optionally retains the SOCKET within the BRIDGE Flats on each side of the BRIDGE give clearance for adjacent nuts An angled flat at the rear clears the welding neck of a flange or other obstruction A cut out in the front of the BRIDGE allows access to the SOCKET with a tommy bar to turn the nut when the bolt is tensioned SOCKET The SOCKET fits over the hexagon nut and inside the BRIDGE It has tommy bar holes to avoid the need to drill holes in the flats of the hexagon nut BOLT amp NUT An extra length of thread must protrude through the nut for the tensioner to screw onto and apply the bolt tension The length of bolt is very important Details are given in the instructions to follow Good quality bolts and nuts will make the tensioning operation quicker and more accurate Do not use washers under the nut when using a bolt tensioner FULLY ASSEMBLED TOOL This diagram shows a tool with single hydraulic connection fully assemble
35. Retaining Screw 2 T SK T23 Seal Kit for Tool No 23 1 T IR T23 Red Plastic Stroke Indicator for Tool No 23 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T23 Label for Tool No 23 1 Hydraulic Cylinder No 23 1 5 8 inch and 1 3 4 inch Bridge T 0804 02 oection 1 Page No 12 1 5 8 UN8 Puller T 0809 01 1 5 8 Socket T 0813 01 e RAPID TORC Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 23 for 1 7 8 inch UN8 Part No Description Quantity T 1989 01 No 23 Cylinder Body 1 T 0622 01 No 23 Piston 1 T 0807 01 No 23 Puller for 1 7 8 inch UN8 1 T 0811 01 No 23 Socket for 1 7 8 inch 1 T 0805 03 No 23 Bridge for 1 7 8 inch and 2 inch 1 T BRSDP M512 Bridge Retaining Screw 2 T SK T23 Seal Kit for Tool No 23 1 T IR T23 Red Plastic Stroke Indicator for Tool No 23 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T23 Label for Tool No 23 1 Hydraulic Cylinder No 23 1 7 8 inch and 2 inch Bridge T 0805 03 Section 1 Page No 13 1 7 8 UN8 Puller T 0807 01 1 7 8 Socket T 0811 01 e RAPID TORE Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 23 Quick Connect Nipple T 1502 Piston T 0622 01 Cylinder Body T 1989 01 Male male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly No 23 Stroke Indicator T IR T23 Seal Kit T SK T23 section 1 Page
36. SSDJd 10 60111 8Nf p e z 103 GZ ON JOO bDuruoisue 0 0 OS OOL 09 00 r OSe 00 OSE 00v OS 00S 099 Qui vv S 264 4 609 JO Bale sseJs yoq uo paseq ss ns yog uuu N 55415 3jog en Ju Section 1 Page No 43 cO e e N i Ou O Ou gt le lt re O gt Q O O e N cO g le lt 2 le Graph TRM 25 3000 0090 0071 0001 eg 41155644 NO DOC DOLL 0001 006 008 QOL 009 009 oor 00 00 amp 000 0 ElJ9 EUJ 3100 au JO y Bual s p 04110411004 1 JO 96 JO sseoxe ul 55415 OQ Jeniui ue ul nsa jim UDIUM alnssald ro ue aen zou OG DulUuJeAA SS9J S 1 1 1110 A 341155644 NO Bunioq 8NN 104 GZ ON OO Buruoisue og 0 0S OOL 090 002 osc 00 OSE 007 OSV ES 9 uw EL zy JO 4 ss ns 1 0 ay uo paseq ss ns yog WIW N ssedJs 1109 1 0 Section 1 Page No 44 e e N i 6 Q Ou gt le lt re O Kal Q O O e N cO g le lt fe le Graph TRM 26 L 00S 1 0071 MII UO L vane oJnsSaJd pd 0074 0011 0001 006 e Jeq 0091 eunssaJg NO WNWIXEN WW 28991 Bally eunsseJg 11 40 0 8 ue 009 Z 9910 4 DBuiuoisue 8913931094 A 41155644 NO 92 ON 1 1 Buruoisue 1 NDI 99104 Huluoisua L section 1 Page No 45 cO e e N i
37. age No 13 Job No Q620 Copyright November 2006 STEP 7 TIGHTENING A BOLT Connect the hydraulic hose Make sure the quick connect coupling is fully engaged Tighten the PULLER with the tommy bar Clockwise fo 7 3 e H Ms HH GC Hydraulic Hose Quick Connect Coupling DARAN O 1024202424 get QR Sd GL P 0 Ges 9 C Ne EN p Seah PRR 4 LU RSS e DXX XX 024202426 Section 3 Page No 14 e Fear Tra Job No Q620 Copyright November 2006 AN MOST IMPORTANT HEALTH amp SAFETY THINK SAFETY The bolt tensioning tool is now ready to be pressurised Before proceeding read the Health amp Safety Instructions given in this manual then proceed as follows Clear all personnel from the area where the bolt tensioninq operation is to be performed Position the pump a safe distance away from the bolt tensioning tools Set up barriers and warning signs or make other adequate arrangements to prevent unauthorised personnel from accidentally straying into the bolt tensioning area Make certain that nobody is allowed to stand near to a bolt tensioning tool during the pressurisation process At no time should anyone allow any part of their body to be positioned over the PULLER of a bolt tensioning tool whilst the pressure is rising or when it is pressurised Do not allow anyone to stand anywhere near a direct line with the lon
38. ay cause the PISTON to score the CYLINDER BODY The HYDRAULIC CYLINDER may be so badly damaged that it cannot be used again 2 PS PRESS m TEL Dk m When extending the piston under zero load do so only in 6mm stages Section 3 Page No 5 Job No Q620 Copyright November 2006 OPERATING INSTRUCTIONS HOW TO TIGHTEN A BOLT Section 3 Page No 6 e RAPID TORC Job No Q620 Copyright November 2006 STEP 1 TIGHTENING A BOLT Assemble the joint with the bolts and nuts to be tightened Do not use WASHERS under the nuts Make sure thread length equal to a minimum of two bolt diameters is protruding from the surface of the flange or joint on the side the bolt tensioning operation is to be performed The bolt tensioner is designed to cope with thread lengths in excess of two diameters It is very important this operation is performed properly otherwise the thread engagement between the bolt tensioner and the bolt will be less than one diameter which could cause the bolt and or bolt tensioner threads to be stripped AN HEALTH amp SAFETY WARNING If only a few threads protrude and an attempt is made to appl tension the bolt threads will strip and components of the tensioner could be launched with the possibility of serious iniury X Pp ql 2 D CORRECT and SAFE WRONG and DANGEROUS Section 3 Page No 7 e as Job No Q620 Copyright November 2006 STEP 2 TIGHTENING A
39. b Never leave a pressurised bolt tensioning tool unattended Keep the bolt tensioning tools under pressure for the minimum time necessary to complete the bolt tightening job Wear SAFETY GLASSES and GLOVES when using bolt tensioning tools The tools should only be used as a bolt tensioning tool DO NOT use the tools as hydraulic jacks or for any other purpose Take care when handling the tools Large tools may be heavy and require the use of lifting equipment The BRIDGE and CYLINDER of the larger tools are not held together The CYLINDER and BRIDGE are easily taken apart When handling the tools always support the BRIDGE and the CYLINDER otherwise the BRIDGE may become detached from the CYLINDER and fall Do not pick up or carry bolt tensioning tools around using the flexible hydraulic hoses as a handle Do not try to tighten a leaking hydraulic connection when itis under pressure First release the pressure then repair the leak Section 2 Page No 8 SECTION Job No Q620 Copyright November 2006 3 OPERATING INSTRUCTIONS Introduction Main Components Parts Operating Instructions How to Tighten a Bolt Step 1 to 16 How to Loosen a Bolt Step 1 to 14 Returning the Pistons oection 3 Page No 1 Page 2 Page 3 Page 5 Page 6 Page 25 Page 42 e as Job No Q620 Copyright November 2006 Introduction A hydraulic bolt tensioning tool provides a quick and easy method for tightening large diameter bolts to hi
40. ch a pressurised bolt tensioning tool only for as long as it takes to turn the permanent nut always keeping away from the axis of the bolt and the PULLER Wear eye protection gloves overalls and a hard hat Never leave a pressurised bolt tensioning tool unattended Release the oil pressure immediately if any unauthorised person moves into the bolt tensioning area and especially if anyone stands in front of the PULLER of a bolt tensioning tool under pressure or stands in line with the long axis of a bolt being tensioned Determine the correct working pressure for the bolts to be tightened Proceed with the following operations keeping the bolt tensioning tools under pressure for the minimum time necessary to complete the bolt tightening job Section 3 Page No 33 Job No Q620 Copyright November 2006 STEP 7 LOOSENING A BOLT Apply the hydraulic pressure observing the Health and Safety Instructions Insert a tommy bar into a hole in the permanent nut and loosen the nut by turning it anti clockwise DO NOT exceed the maximum stroke This A is indicated by a red line around the piston DO NOT exceed the 1500 bar maximum pressure for the tool 10 10 Anti N Clockwise TOMMY BAR A highly visible red line indicates when the piston has reached its maximum stroke Stop the pump as soon as the red indicator can be Seen Section 3 Page No 34 e Fear r core Job No Q620 Copyright November
41. d onto a bolt and nut ready for the hydraulic hose to be connected and the tensioning operation to commence Through the BRIDGE the tommy bar holes in the SOCKET are seen The following pages describe fully each stage of the tool assembly and bolt tightening operation Section 3 Page No 3 e D Job No Q620 Copyright November 2006 Main component parts Puller Hydraulic Cylinder Bridge Socket Section 3 Page No 4 e as Job No Q620 Copyright November 2006 Operating Instructions To obtain the best results from your bolt tensioning equipment you should carefully follow the operating instructions given in the following pages You should also observe the instructions given below DO NOT try to pressurise the HYDRAULIC CYLINDER unless it is properly seated on its BRIDGE and the PULLER has been correctly fitted onto the bolt to be tightened or released If the HYDRAULIC CYLINDER is pressurised when it is not on a BRIDGE or when a PULLER is not properly fitted the HYDRAULIC CYLINDER may be so badly damaged that it cannot be used again DO NOT try to use the pump to push the PISTON out of the HYDRAULIC CYLINDER at zero load by more than 6 mm before it comes into contact with the a PULLER If you do want to push out the PISTON by more than 6 mm do so only in 6 mm stages and ensure the PISTON is brought back into alignment with the HYDRAULIC CYLINDER by the use of the PULLER at the end of each 6 mm of travel Failure to do so m
42. e Graph TRM 23 1625 009 00 eg eunssaJg 110 00 O0cl 001 000 006 008 004 009 009 oor 00 UO 000 euejeui yoq ayy jo y Buans pjei 00100000 y 40 95656 JO SS99K9 Ul SSO S JOY 10 ue Ul nsa jim YOIUM nss 1d ue esn jou oq DuiuleAA SS9J S 1 09 jeljiu A INSS ld JO Bunjoq 8NN YOU 8 9 1 4 1 Z ON OO Bujuorsua r OS OOL OSL 00 amp 0SC 00 OSE 00r 09 009 OSS 009 099 004 u 6 1 uw SSL JO Bale 59419 jog uo peseq ss ns 0404 14 55415 1109 1 11 Section 1 Page No 37 cO e e N 6 O Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph TRM 23 1875 009 00 eg eunssaJg IO 000 000 DOLL 000L 006 008 007 009 009 oor 00 ooz 001 0 euajewu yoq ay jo u Bu us Dia 001000 4 BU JO 9 66 JO SSAIXA ul ss 1 s YO emt ue ul nS 1 YDIUM eJnssauJd io ue BSN jou OG DulUuJeAA SS9J S 1 09 1001 A 94nSS9Jg O bunioq 8Nf 8 2 1 103 Z ON 1 1 20100150 1 yog 0 09 001 090 002 OSC 00 OSE 00v ost 009 099 UI 2 uw 2991 JO 4 sseJis ay uo peseq ss ns 40g 0004 0 55415 Og 1 1 Section 1 Page No 38 cO e e N 6 O Ou gt le lt re O gt Q O O e N cO g le lt fe le Graph
43. e piston is not aligned correctly with the cylinder Once the puller is fully down the piston is fitted Remove the open quick connect coupling The seals can now be energised and the tool tested as it stands see next page The cylinder with a correctly fitted piston Section 5 Page No 16 e Job No Q620 Copyright November 2006 Energising the Seals After fitting new seals and before the Bolt Tensioning Tool can be used the new seals must be energised Observing the safety instructions give in Section 2 and Section 3 of this manual proceed as follows Make sure the PISTON is fully returned into the CYLINDER Body Using a test bolt or an actual bolt to be tensioned lower the bolt tensioning tool onto the bolt ocrew the Puller onto the bolt Centralise the tool if necessary to allow the Puller to fit into the centre of the tool Turn the Puller by hand until it comes into contact with the top of the Puller Wind back the Puller ONE FULL TURN Connect the tool to the pump Run the pump quickly and pump oil into the tool Air and oil may escape from the seals during this operation and the pressure gauge may indicate rising and falling pressure at each stroke of the pump If the seals have been properly fitted the seals will quickly energise Any leakage from the seals will stop and pressure will start to be generated in the tool otop the pump when the pressure reaches 1000 bar
44. er 2006 PARTS LIST FOR TOOL TRM 24 Quick Connect Nipple T 1502 Piston T 3022 01 Cylinder Body T 3021 00 Male male adaptor T 1503 Plastic Dust Cap T 1510 Cylinder Assembly No 24 Stroke Indicator T IR T24 Seal Kit T SK T24 Section 1 Page No 17 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 25 for 2 3 4 inch UN8 Part No Description Quantity T 1654A 01 No 25 Cylinder Body 1 T 1654B 01 No 25 Piston 1 T 0831 01 No 25 Puller for 2 3 4 inch UN8 1 T 1976 00 No 25 Socket for 2 3 4 inch 1 T 1975 01 No 25 Bridge for 2 3 4 inch 1 T BRSDP M512 Bridge Retaining Screw 3 T SK T25 oeal Kit for Tool No 25 1 T IR T25 Red Plastic Stroke Indicator for Tool No 25 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor 1 T 1510 Plastic dust cap for nipple 1 T L1 T25 Label for Tool No 25 1 Hydraulic Cylinder No 25 2 3 4 Bridge T 1975 01 2 3 4 UN8 Puller T 0831 01 Section 1 Page No 18 2 3 4 Socket T 1976 00 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 25 for 3 inch UN8 Part No Description Quantity T 1654A 01 No 25 Cylinder Body 1 T 1654B 01 No 25 Piston 1 T 0830 01 No 25 Puller for 3 inch UN8 1 T 0353 02 No 25 Socket for 3 inch 1 T 1977 00 No 25 Bridge for 3 inch 1 T BRSDP M512 Bridge Retaining Screw 3 T SK T25 Seal Kit for Tool No 25 1 T IR T25 Red Plastic Stroke Indicator for Tool No 25 1 T 1502 Quick connect nipple 1 T 1503 Male male adaptor
45. g axis of a bolt during the tensioning operation In the case of studbolts with nuts at each end it is important that nobody stands in line with the long axis of the bolt at either end during the tensioning operation Do not approach a bolt tensioning tool whilst it is being pressurised Remember that bolt or tool failure is most likely to happen at this critical time When the operating pressure has been reached approach a pressurised bolt tensioning tool only for as long as it takes to turn the permanent nut always keeping away from the axis of the bolt and the PULLER Wear eye protection gloves overalls and a hard hat Never leave a pressurised bolt tensioning tool unattended Release the oil pressure immediately if any unauthorised person moves into the bolt tensioning area and especially if anyone stands in front of the PULLER of a bolt tensioning tool under pressure or stands in line with the long axis of a bolt being tensioned Determine the correct working pressure for the bolts to be tightened Proceed with the following operations keeping the bolt tensioning tools under pressure for the minimum time necessary to complete the bolt tightening Job Section 3 Page No 15 e RARID TORE Job No Q620 Copyright November 2006 STEP 8 TIGHTENING A BOLT Apply the correct hydraulic pressure observing the Health and Safety Instructions The Piston will move out of the Cylinder as the bolt is stretched and the bolted joint is compressed
46. g the Bridge Job No Q620 Copyright November 2006 Section 1 Page 2 Page 3 Page 5 Page 6 27 Page 28 Page 29 Page 30 49 Section 2 Page 2 Page 3 Page 4 Page 5 Section 3 Page 1 Page 25 Page 42 Section 4 Page 2 Section 5 Page 2 Page 3 Page 14 Page 17 Page 18 Page 20 Job No Q620 Copyright November 2006 SECTION 1 TECHNICAL INFORMATION Section 1 Page No 1 e RAPI D TORC Technical Information Summary of Equipment Supplied 2 off 6 off 4 off 6 off 4 off 10 off 4 off 4 off 4 off 4 off 4 off 8 off 4 off 5 off 5 off 5 off 5 off 5 off 5 off 5 off 5 off 4 off 4 off 4 off 4 off 4 off 4 off 4 off 1 off 1 off All above equipment designated for 1500 bar maximum working pressure Tool No 27 for 4 inch UN8 bolting Tool No 27 for 3 3 4 inch UN8 bolting Tool No 26 for 3 1 2 inch UN8 bolting Tool No 25 for 3 inch UN8 bolting Tool No 25 for 2 3 4 inch UN8 bolting Tool No 24 for 2 1 2 inch UN8 bolting Tool No 24 for 2 1 4 UN8 bolting Tool No 23 for 1 7 8 inch UN8 bolting Tool No 23 for 1 5 8 inch UN8 bolting Tool No 22 for 1 1 2 inch UN8 bolting Tool No 21 for 1 1 8 UN8 bolting Tool No 21 for 1 inch UNC bolting Tool No 21 fore 7 8 UNC bolting Link Hose 1 5 m long Seal Kit for Tool No 27 Seal Kit for Tool No 26 Seal Kit for Tool No 25 Seal Kit for Tool No 24 Seal Kit for Tool No 23 Seal Kit for Tool No 22 Seal Kit for Tool No 21 Tommy Bar 20 mm dia Tommy Bar 16 mm dia
47. gh and accurate pre loads Unlike conventional methods It does not use torque and does not require any forceful turning of the nut or bolt like impact wrenches flogging spanners or hydraulic torque wrenches All of these methods have one common enemy FRICTION Overcoming thread friction and friction between the nut and the washer uses up over 80 of the torque energy applied to the nut or bolt leaving less than 20 of the energy to produce useful tension in the shank of the bolt Variations in this friction loss from bolt to bolt causes non uniform tension in bolts that have been tightened to the same torque or impact wrench setting Z Hydraulic Bolt Tensioning Tool IWS a D N NSN Annular jack Za NE OO V4 d SSC i t Ha High pressure oil i oe ERE I Nut IL A hydraulic bolt tensioner is an annular jack which fits over the bolt and nut to be tightened The jack pushes against the bolted joint and pulls on the end of the bolt which needs to be at least one diameter longer to accommodate the bolt tensioning tool Because the force produced by the jack is applied directly to the end of the bolt a tension equal to the load generated by the jack is developed in the shank of the bolt With the jack applying the tension it is possible to turn the nut with zero torque until it is tight The load applied by the jack is then relaxed and a high percentage depending on the length of the bolt and i
48. ghtly lubricate the O ring with grease and fit it over the narrow end of the piston Carefully stretch the ring over the retaining lip and snap it into the seal groove Now pack the O ring with grease Fit the plastic seal over the bottom end of the piston making sure the chamfered side of the seal is facing towards the smallest diameter Carefully manipulate one side of the seal into the seal groove until it sits on the O ring Push the seal as far into the seal groove as possible Carefully ease the seal over the seal retaining lip starting from the point where the seal is already in the groove Work both ways around the piston simultaneously The process will slightly stretch the seal Use only your hands to stretch the seal Do not insert anything between the seal and the piston to force the seal into place as this may damage or cause excessive stretching of the seal Take care not to twist the seal When the seal is in place the last part to be fitted may protrude beyond the piston a greater distance than the rest of the seal Centralise the seal using your fingers to manipulate the it Wipe away any excess grease The outer seal is now correctly fitted to the Piston Section 5 Page No 9 e as Job No Q620 Copyright November 2006 Changing the outer piston seal Lubricate the O Ring with grease Place the O ring onto the piston Stretch 0 ring over seal retaining lip Snap O ring int
49. gon nuts Z Z WAA ch ET 22 Flat to clear hub of weld neck flange or other obstruction Section 3 Page No 28 e at Job No Q620 Copyright November 2006 STEP A LOOSENING A BOLT Place the PULLER into the centre of the CYLINDER and BRIDGE assembly and engage the PULLER thread with the end of the bolt The PULLER has a nose to assist this operation Take care the PULLER and bolt threads are properly engaged and do not become crossed Do not force the PULLER onto the bolt The PULLER should turn freely on the bolt Screw the PULLER fully down onto the top surface of the CYLINDER The PULLER will normally be turned by hand but the final nip onto the CYLINDER may require the help of a tommy bar Once the PULLER has been screwed down the tool is locked in place and cannot fall off PULLER Y N Tommy bar holes A O X d DORSO 49 19 L d d b 4 q d A DO SS SS SSI X gt gt gt x gt gt gt gt gt gt gt gt gt gt gt gt gt x gt gt gt gt x gt x gt gt gt gt gt gt gt x gt gt gt x gt gt dE Ju SH r Yi section 3 Page No 29 e Job No Q620 Copyright November 2006 STEP 5 LOOSENING A BOLT Now turn back the PULLER at least one full revolution The bolt tensioning tool will still be captive on the end of the bolt but it will be free to slide along the PULLER This operation ensures the PISTON can retract into the CYLIND
50. he piston returned to the zero stroke position and the hydraulic connection must have it s plastic protective cap fitted The hydraulic bolt tensioner should be stored upright in a clean dry environment Maintenance Very little maintenance is required for a bolt tensioning tool The only items which may require changing will be the seals and the quick connect fittings Changing seals Each bolt tensioning tool has an inner and an outer seal set Each seal set consists of a rubber O ring and an elastomeric seal If the seals are damaged or badly worn the complete set CO ring and seal must be changed It is recommended that both inner and outer sets are changed at the same time To change the seals the piston must be withdrawn from the cylinder If the seals are not badly damaged this may be achieved by carefully blowing compressed air into the cylinder through the quick connect nipple All applicable Health and Safety precautions relating to the use of compressed air must be observed In addition suitable safe provision must be made to catch the piston and any escaping oil when it leaves the cylinder If the seal damage is too great to allow air to be used the piston may be removed by making a simple piston extraction tool from a bar of steel The bar must be drilled with two holes to align with the threaded holes found in the top of the piston Two screws can be used to secure the bar to the piston The piston can then be pulled f
51. hod is far quicker and superior to conventional tightening methods which suffer even more from the gasket compressing as each bolt is tightened The method for simultaneous tensioning is similar to tightening one bolt but requires an additional operation This involves using flexible hoses to gang the tools and the hydraulic pump together so that oil under pressure will be supplied to all of the tools simultaneously oection 4 Page No 1 e as Job No Q620 Copyright November 2006 Connecting for Simultaneous Operation The diagram on the next page shows how four tools can be connected together for simultaneous operation using an air driven pump flexible hoses and tee blocks The 5m long and 1 5 m long hoses may be interchanged at will to construct the hydraulic ring main that best suits the users application There is no right or wrong way to connect the tools together Titan provides a wide range of block and hose assemblies to enable any number of tools to be connected together for simultaneous operation no matter how far apart they might be The user is free to construct the ring main that best suits his application it is only necessary to ensure that oil can flow to all of the tools simultaneously Section 4 Page No 2 S 0bSL L S 0bSL 1 S OvS L L soH uu S esoH uu sor ul 9 JO JO JO 9 0691 3 SSH 9 1 0691 3 sor 5 06913 43 13 OPSEL asoH W sg 90 g Sel asoH ul Ss 490 g Sel asoH ul sS 2 18
52. ial No s RS450 RS452 RS453 RS455 RS456 The above equipment was successfully pressure tested at 1800 bar Tested using hydraulic oil ISO 10 We certify the above equipment was subject to inspection and test according to the company standard procedures The maximum working pressure for this equipment is 1500 bar Authorised Signature Test Engineer Section 1 Page No 5 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 21 for 7 8 inch UNC Part No Description Quantity T 3650 00 No 21 Cylinder Body 1 T 3651 00 No 21 Piston 1 T 1739 00 No 21 Puller for 7 8 inch UNC 1 1 0417 00 No 21 Socket for 7 8 inch 1 T 3545 00 No 21 Bridge for Ya and 7 8 inch 1 T BRSDP M506 Bridge Retaining Screw 2 T SK T21 Seal Kit for Tool No 21 1 T IR T21 Red Plastic Stroke Indicator for Tool No 21 1 T 1502 Quick connect nipple 1 T 1524 Male male adaptor 1 T 1533 Bonded Washer Seal 1 T 1510 Plastic dust cap for nipple 1 T L1 T21 Label for Tool No 21 1 Hydraulic Cylinder No 21 3 4 inch and 7 8 inch Bridge T 3545 00 Section 1 Page No 6 7 8 UNC Puller T 1739 00 7 8 Socket T 0417 00 Job No Q620 Copyright November 2006 PARTS LIST FOR TOOL TRM 21 for 1 inch UNC Part No Description Quantity T 3650 00 No 21 Cylinder Body 1 T 3651 00 No 21 Piston 1 T 1738 00 No 21 Puller for 1 inch UNC 1 T 0398 00 No 21 Socket for 1 inch 1 T 3546 00 No 21 Bridge for 1 inch and 1 1 8 inch 1 T BRSDP M506 Bridge Retaining Screw 2
53. idge Dog Point Bridge Retaining Screw with Dog Point Hexagon Key The screws remain in the Bridge but the Dog Point can be advanced into the groove machined in the recess in the base of the Hydraulic Cylinder A hexagon key is used to advance or withdraw the Bridge Retaining Screws working from the inside of the Bridge Itis not necessary to remove the screws for the Bridge and Cylinder to be separated The screws need only be withdrawn into the Bridge wall by 2 to 3 mm to disengage the dog point from the groove Hydraulic Cylinder Bridge Retaining Screw with Dog Point A 9 9 9 9 9 9 9 9 9 9 9 9 0 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 0 SS Ge Bridge Section 5 Page No 20 e ea TONE Job No Q620 Copyright November 2006 Removing and Fitting the Bridge Hexagon Key Bridge showing radial bridge retaining screw with dog point and hexagon key Dog Point When refitting the Bridge the Retaining Screws need only be advanced enough for the dog points to locate into the groove in the Hydraulic Cylinder If they are fully advanced and tightened the Bridge will be locked into the Hydraulic Cylinder which is not recommended If the screws are advanced but not tightened the Bridge and the Cylinder will be permanently joined but the two components will rotate relative to each other This can be useful as the Hydraulic Cylinder can be rotated until the quick connectors are in the best position f
54. inal nip onto the CYLINDER may require the help of a tommy bar Take extra care to stop the bolt turning with the PULLER which would reduce the thread engagement on the bolt In the worst case the PULLER could be left with only one or two threads engaged even though two diameters of thread were initially protruding through the bolted joint Clockwise gt 7 Z OS as 0 DE EE EE atat OI SOI DOS b S DOS MORRIS DIODOS ged KA e E R dA dH 1 LI LS 22 The PULLER is not fully in contact with the top of the CYLINDER Section 3 Page No 11 e SE Job No Q620 Copyright November 2006 STEP TIGHTENING A BOLT Once the PULLER has been screwed down double check the thread engagement with the bolt is still correct AN The bolt tensioner is now locked in place and cannot fall off The tool is now ready for the hydraulic hose to be connected 7 N Tu WA CORRECT Y WRONG and DANGEROUS ZA N A The BOLT has turned with H the PULLER and the thread SL HAHR engagement between the BOLT and the PULLER has been reduced D Yk SN 4 i If pressure is applied the PULLER threads might strip and cause injury NS Section 3 Page No 12 e as Job No Q620 Copyright November 2006 Using the Quick Connect Couplings DO NOT pressurise the connectors when they are disconnected
55. into seal groove Now pack the O ring with grease Section 5 Page No 5 RAPID TORC Job No Q620 Copyright November 2006 Changing the inner piston seal Chamfered edge of seal on the inside and at the top Place the seal into the groove on one side Using finger pressure only press the seal until it snaps into the groove Section 5 Page No 6 Job No Q620 Copyright November 2006 Changing the inner piston seal m Lubricate the O Ring with grease Place the Piston on a clean surface and insert the Rubber O Ring into the seal groove Fit the O Ring into the seal groove Pack the O ring with grease Al Section 5 Page No 7 e STORE Job No Q620 Copyright November 2006 Changing the inner piston seal Y Insert the green plastic seal into the seal groove Make sure the chamfer is at the top Work the seal into the groove using hand force only The seal will snap into the seal groove Wipe away any excess grease Section 5 Page No 8 e Job No Q620 Copyright November 2006 Changing the outer piston seal These instructions should be read in conjunction with the drawings and photographs on the following pages The old seal set must be removed by cutting through the seal with a knife The O ring can be removed by cutting or by levering it out Both items should be discarded Ensure the seal groove is clean Li
56. ion of the equipment The Pullers provided have a fatigue life of between 10 000 and 20 000 cycles at full operating pressure Provision should be made to replace the Pullers at 10 000 pressure cycles Section 1 Page No 4 e RAPID TORC Job No Q620 Copyright November 2006 Test Certificate T an agar T crec N u T ZS G E At J a is WP WP ERES E gt I I T I F lt co p wn FALLIXOQUANC ILJI VL IV2FA I L Date Issued 22nd November 2006 Certificate No 285 Job No Q620 Equipment covered by this certificate 2 off Tool No 27 for 4 UN8 Serial No s RN793 and RN797 6 off Tool No 27 for 3 3 4 UN8 Serial No s RN791 RN792 RN794 to RN796 RN799 4 off Tool No 26 for 3 1 2 UN8 Serial No s RN529 RN773 RN804 RN806 6 off Tool No 25 for 3 UN8 serial No s RN604 to RN607 RN609 RN610 4 off Tool No 25 for 2 3 4 0148 Serial No s RN936 to RN939 10 off Tool No 24 for 2 1 2 UN8 Serial No s RN875 to RN878 RN881 to RN886 4 off Tool No 24 for 2 1 4 0048 Serial No s RN549 RN551 RN749 RN752 4 off Tool No 23 for 1 7 8 UN8 Serial No s RN835 to RN838 4 off Tool No 23 for 1 5 8 UN8 Serial No s RN655 RN657 RN658 RN659 4 off Tool No 22 for 1 1 2 UN8 Serial No s RN787 RN789 RN853 RN860 4 off Tool No 21 for 1 1 8 UN8 Serial No s RN815 to RN818 8 off Tool No 21 for 1 UNC Serial No s RN814 RN823 to RN828 4 off Tool No 21 for 7 8 UNC Serial No s RN819 to RN822 5 off 1 5m Flexible Hoses ser
57. mum Working Pressure lt 1500 bar b b lt gt lt gt d q BSE V SRA iw RSS 026056 ACEC OO BA A Zoo IO ANO OA Z Sii S SC SOS SAA ORAL OI S SO SO MS IS 1 e RR ERROR BC OX XX 0X X 0X 0X X XX 0X 0X X X OX X X X OX X XX X X X X XO BA Section 2 Page No 5 e RAPID TORC Job No Q620 Copyright November 2006 HEALTH amp SAFETY INSTRUCTIONS TA L Bolt Tensioning Tools DO NOT exceed the maximum Stroke Tool No 21 12 mm Other Tools 15 mm Stroke 15 mm Tool No 21 12 mm SC NC Y NA S NC NC N N N N N N N N N N N NX X N N N N N N SN N S S S INS a dS IS AANA QQ Ka 2 x e za DXX QL AAN Le N TI KA UH Stroke gt 15 mm Tool No 21 gt 12mm A highly visible red line indicates when the piston has reached its maximum stroke Stop the pump as soon as the red indicator can be seen Section 2 Page No 6 e Job No Q620 Copyright November 2006 HEALTH SAFETY INSTRUCTIONS Bolt Tensioning Tools Bolt tensioning tools MUST always be used with a hydraulic pump which has a pressure limiting device The pump supplied with this equipment has a pressure limit device Always check that the pump stall pressure is set at or below the maximum working pressure for the
58. nd photographs shown on the following pages The old seal set must be removed by cutting through the seal with a knife The O ring can be removed by cutting or by levering it out Both items should be discarded Ensure the seal groove is clean Lubricate the O ring with grease Fit the O ring into the centre of the body folding the ring slightly to fit itin Manoeuvre the O ring into the seal groove Ensure the O ring is firmly in the groove and seated in the bottom of the groove Now pack the 0 ring with grease Place the plastic seal in the groove working from the bottom and smallest diameter end of the Piston ensuring the chamfered face of the seal faces towards the bottom of the Piston Enter the seal into the seal groove and ensure that it is as far into the groove as possible Carefully fit the rest of the seal into the groove using only hand force Work around the Piston Take care not to twist the seal When the seal is in place the last section to be fitted may protrude beyond the Piston a greater amount than the rest of the seal Centralise the seal using only hand force Wipe away any excess grease The inner seal is now correctly fitted to the Piston Section 5 Page No 4 EGO TOR Job No Q620 Copyright November 2006 Changing the inner piston seal Lubricate the O Ring with grease Fit the O ring into one side of the groove KXXX ZZS RSRS Snap the O ring
59. ng that the test block has been manufactured from the appropriate grade of steel it can also be used to pressure test the tools once the pistons are fitted Stud Bolt M 3713311111 L Nut not required TH C Steel Base Alternatively the piston could be fitted using an application bolt on a flange that is to be tensioned The principal remains the same To fit the piston proceed as follows Firstly make sure the cylinder and piston are clean and free from foreign objects and dirt Lubricate the cylinder walls and the seals of the piston with hydraulic oil Section 5 Page No 14 D E Job No Q620 Copyright November 2006 Fitting the Piston Cont Assemble the tool on the bolt as normal bridge followed by cylinder Ensure that you fit an open quick connect coupling to the hydraulic connection to enable air to be expelled from the cylinder as the piston is pushed in Place the piston over the cylinder Ensure that the piston Is correctly aligned with the cylinder Section 5 Page No 15 D E Job No Q620 Copyright November 2006 Fitting the Piston Cont Now wind the puller down onto the bolt until it is in contact with the piston Once again check that the piston is aligned correctly with the cylinder Using a tommy bar gently wind the puller down the bolt easing the piston into the cylinder This should not require much force The seals can be easily damaged if th
60. o seal groove Now pack the O ring with grease Section 5 Page No 10 D RAPID TORC Job No Q620 Copyright November 2006 Changing the outer piston seal Chamfered edge of seal 4 Place the seal over the end of the piston otretch the seal over the seal retaining lip Snap the seal into the seal groove Section 5 Page No 11 e an TOR Job No Q620 Copyright November 2006 Changing the outer piston seal Place the Piston on a clean surface Lubricate the O Ring with grease Insert the Rubber O Ring into the seal groove Stretch the O Ring until it Snaps into the seal groove Pack the O Ring with grease section 5 Page No 12 e STORE Job No Q620 Copyright November 2006 Changing the outer piston seal Insert the green plastic seal into the seal groove Make sure the chamfer is at the top otretch the seal over the outer lip of the piston by working around both sides of the piston simultaneously Work the seal into the groove using hand force only Wipe away any excess grease oection 5 Page No 13 D RAPID TORC Job No Q620 Copyright November 2006 Fitting the Piston BOLTIGHT recommends that the easiest and safest method of fitting a piston into any of our standard tools is by using a test block such as the one shown below This can be easily manufactured with a steel base threaded through the centre to accept the correct stud bolt for the tool in question Assumi
61. or both ends Section 2 Page No 3 e RAPID TORC Job No Q620 Copyright November 2006 HEALTH amp SAFETY INSTRUCTIONS You must observe the following Health amp Safety instructions when using hydraulic hoses e Discard and do not use any hose that does not have an identifying serial number e Discard and do not use any hose that shows any sign of damage either a to the coloured moulded plastic coating b where the spiral windings are exposed C where the spiral windings are damaged or broken d where there is damage to the swaged metal ends e Do not allow any hose to be kinked or knotted Hoses which have been kinked or knotted will have suffered damage to the windings and must be discarded e Do not allow heavy objects to fall on rest on or roll over the hoses e Do not allow hoses to be subjected to temperatures higher than 60 deg C e Discard and do not use any hose which has been subjected to heat or fire e Do not bend the hose tighter than the minimum bend radius of the hose or it will be kinked e Do not exceed the maximum working pressure of 1000 bar for the GREEN colour hose 1500 bar for BLUE colour hose and 2500 bar for RED colour hose e Only use the hoses for their intended purpose for use with TITAN hydraulic equipment e After use check the hoses for damage wipe to remove dirt and oil refit dust caps and prepare for storage e When not in use store the hoses in a safe place where they cannot easil
62. or the flexible hoses to be connected whilst the window in the Bridge is in the best position for access to the nuts with a tommy bar Bridge retaining screw being advanced or retracted with the hexagon key Section 5 Page No 21
63. raph No 21 1250 Tool No 22 Graph No 22 L Graph No 22 1500 Tool No 23 Graph No 23 L Graph No 23 1625 Graph No 23 1875 Tool No 24 Graph No 24 L Graph No 24 2250 Graph No 24 2500 Tool No 25 Graph No 25 L Graph No 25 2750 Graph No 25 3000 Tool No 26 Graph No 26 L Graph No 26 3500 Tool No 27 Graph No 27 L Graph No 27 3750 Graph No 27 4000 Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 7 8 inch bolts Oil Pressure v Initial Bolt Stress 1 inch bolts Oil Pressure v Initial Bolt Stress 1 1 8 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 1 1 2 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 1 5 8 inch bolts Oil Pressure v Initial Bolt Stress 1 7 8 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 2 1 4 inch bolts Oil Pressure v Initial Bolt Stress 2 1 2 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 2 3 4 inch bolts Oil Pressure v Initial Bolt Stress 3 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 3 1 2 inch bolts Oil Pressure v Theoretical Load Oil Pressure v Initial Bolt Stress 3 3 4 inch bolts Oil Pressure v Initial Bolt Stress 4 inch bolts Section 1 Page No 29 e e N i 6 O Ou gt le lt re O gt Q O O e N cO g le lt 2 le Graph TRM 21 L 0091 007 00 00 1 4
64. rom the body using the bar oection 5 Page No2 e nm s TC Job No Q620 Copyright November 2006 Changing the Seals The seals used do not run dry They are self lubricating and will always exhibit a small amount of oil around the inner and outer edges of the piston The presence of a small volume of oil around the piston is NOT a signal the seals need to be changed It is normal and to be expected The oil lubricates the cylinder wall reduces the force required to return the piston and helps to prevent corrosion After extensive use as much as 5 ml of oil may be present around the piston Simply wipe away any oil when the tools have been used The seals will need to be changed only if the tool will not pressurise or a very large volume of oil escapes whilst the oil pressure is being increased or if the tool will not hold pressure Each bolt tensioning tool has an inner and an outer seal kit Each seal kit consists of a rubber O ring and a plastic seal If the seals are damaged or badly worn the complete set O ring and seal must be changed It is recommended that both inner and outer sets are changed at the same time To change the seals the piston must be withdrawn from the cylinder Plastic Inner Seal Kit Rubber Outer Seal Kit Section 5 Page No 3 e Job No Q620 Copyright November 2006 Changing the inner piston seal These instructions should be read in conjunction with the drawings a
65. rs when they are disconnected Check there is no pressure in the system before attempting to connect or disconnect the couplings Hoses The flexible hydraulic hoses supplied by TITAN have a small plastic core tube surrounded by multiple high tensile steel spiral windings The outside of the hose is moulded with a coloured plastic coating Most hoses are also given a clear plastic cover to provide additional protection against damage when in use Each hose is identified with a serial number All hoses are pressure tested when manufactured and test certificates can be issued TITAN supplies three types of high pressure flexible hydraulic hose and they are easily identified by the colour of the moulded plastic coating beneath the clear plastic cover The maximum working pressure for the hose is sometimes marked on the outside of the coloured plastic coating however this is the working pressure of the hose ONLY and not the hose ASSEMBLY The maximum working pressure of a hose assembly is often limited by the pressure rating of the quick connect couplings and or the fittings on the end of the hose Although the hose may be capable of operating at higher pressures the limit you must observe is shown below along with the minimum bend radius Colour Max Working Pressure Min Bend Radius GREEN 1000 bar 95 mm BLUE 1500 bar 130 mm RED 2500 bar 200 mm Each type of hose is fitted with self sealing quick connect couplings at one
66. s JOG Jeu ue ul 115 4 YOIUM eJnssaJd io ue asn jou oq DuiuJeMA SS9J S 1109 E3Iu A INSS ld IO bunjoq 8NN You Z L Z 46 pz ON JOO Buruo sua 1 0 0S 001 091 002 osz 00 OSE OOF OST ul bs 97 uw 8 z JO 4 ss ns yoq e uo peseq ssas WIWW N 55415 1 1 Section 1 Page No 41 e REPID TORE Job No Q620 Copyright November 2006 Graph TRM 25 L 1500 1400 i e Latt a 0 Ep wau manus EAT wami us SS NEN HEN ENS SN O LI AAA 1200 1300 900 1000 1100 800 Oil Pressure bar 700 600 500 400 300 Bolt Tensioning Tool No 25 Oil Pressure v Theoretical Tensioning Force 200 ximum Tensioning Force 1 80kN 00 1 Hydraulic Pressure Area 12 197 mm Maximum Oil Pressure 1500 bar e o CH S e CO LO 1 900 1 800 1 700 1 600 1 500 1 400 1 300 1 200 1 100 1 000 ae 99104 010015061 section 1 Page No 42 cO e e N Ou 2 Ou gt le lt re O gt Q O O e N cO g le lt 2 le Graph TRM 25 2750 009 00 4 0 41155644 NO 00 00cl 0010 0001 006 008 004 009 009 00v 00 002 001 Euejeui Og ay jo yyBua ns Dau 001000104 94110 9566 JO SS39X3 ul 533419 1 Eu ue ul 15 4 jim YOIUM 4153 40 jio ue aen jou OG DuiUJeAA SS9J S 3 09 Jel IU A DIN
67. s not safe to stand underneath a load on a crane or to work under a car supported only by a jack However not everyone will immediately know that standing in line with the long axis of a bolt during the bolt tensioning operation is the same as standing under a weight during a lifting operation or working under a car supported only by the jack When using bolt tensioners loads of many hundreds of tonnes and even thousands of tonnes can be induced If the bolt material is incorrect or faulty or the tool is incorrectly installed the broken bolt could be launched at high speed along the axis of the bolt This is a very rare occurance However if there is a failure anyone standing near to the bolt tensioning tool or in line with the axis of the bolt during the tensioning operation will suffer critical injury or even be killed It is therefore essential that anyone operating this equipment is properly trained in its safe use and takes every precaution to ensure that nobody is allowed to stand work or stray near to or into line with the axis of any bolt tensioning tool during the bolt tensioning operation Bolt tensioning tools are powerful and use high pressure hydraulics it is essential that you are trained in the correct use of the equipment and adhere fully with the Health and Safety Instructions Section 2 Page No2 e as Job No Q620 Copyright November 2006 HEALTH amp SAFETY INSTRUCTIONS Quick Connectors DO NOT pressurise the connecto
68. to the hydraulic cylinder for Tool No 21 you will need a quick connector T 1502 a male male threaded adaptor T 1524 a bonded washer seal T 1533 and a suitable spanner Fitting elther the quick connect nipple or coupling can be achieved by following the simple steps shown below Apply Loctite 542 here N T CB1 T21 T 1533 T 1524 T 1502 T 1510 Check the internal and external threads are clean and free from damage Hold the adaptor T 1524 in a vice Screw the quick connect nipple T 1502 onto the 74 BSP end of the adaptor and tighten with a spanner Now place the 1 8 BSP bonded washer seal T 1533 onto the 1 8 BSP end of the adaptor T 1524 Apply Loctite hydraulic sealant No 542 onto the 1 8 BSP thread of the adaptor screw the adaptor into the hydraulic cylinder body and tighten with a spanner Fit the plastic dust cap T 1510 T CA1 T21 Section 5 Page No 19a D RAPID TORC Job No Q620 Copyright November 2006 Removing and Fitting the Bridge The Bridge and the Hydraulic Cylinder can be held together as one piece When using the tools it is sometimes advantageous to work with three separate parts however when it is better for the Hydraulic Cylinder and the Bridge to be joined Bridge Retaining Screws are used Depending on the tool two or three Bridge Retaining Screws may be used The screws are Socket Head Screws with Dog Points They are located in radial drilled and tapped holes near the top of the Br
69. ts diameter is retained in the shank of the bolt Flange or bolted joint Bolt tensioning tools can be ganged together to enable multiple bolts to be tightened simultaneously to the same high and accurate pre load This is particularly useful when compressing gaskets in pipeline or pressure vessel flanged connections The high load developed by the multiple bolt tensioning tools is evenly distributed around the Joint causing the gasket to flow into the surface irregularities of the flange giving a much better seal Flexible hoses with self sealing quick connect couplings are used to gang the bolt tensioning tools together to form a hydraulic ring main The ring main and tensioning tools are pressurised using an air driven pump working from a compressed air supply Section 3 Page No 2 e RAPID TORC Job No Q620 Copyright November 2006 Main component parts The diagrams below show the component parts of a typical bolt tensioning tool and the order in which they are assembled together onto the bolt and nut to be tightened The last diagram shows the tool fully assembled PULLER TRA e usus Eh The PULLER has an internal thread to suit the bolt The NAAA A ADA AAA X lt O gt O gt gt gt gt lt gt X outside edge is knurled to assist rotation by hand and tommy bar holes are provided for final tightening The PULLER has a nose to assist location into the centre of the CYLINDER and onto the bolt The PULLE
70. y be damaged e Do not mix the GREEN BLUE RED colour coded hoses The end fittings and quick disconnect couplings on these hoses have different pressure ratings e Never move hose end connectors or quick disconnects from BLUE hoses to any other colour hose e Never move hose end connectors or quick disconnects from RED hoses to any other colour hose e Never move hose end connectors or quick disconnects from GREEN hoses to any other colour hose e Use GREEN colour coded hoses for 1000 bar System Tools and Equipment e Use BLUE colour coded hoses for 1500 bar System Tools and Equipment e Use RED colour coded hoses for 2500 bar System Tools and Equipment e Check the bolt tensioning tools you are using are compatible with the hoses you are using All TITAN tools are marked with the maximum operating pressure e Never pressurise a quick disconnect coupling or nipple when disconnected e Do not take apart any ring main harness component or hose assembly These are filled with oil and pressure tested after assembly When taken apart the integrity of the assembly is lost and the pressure test invalidated Return any parts that need attention to TITAN where the correct specification parts will be used to effect repairs followed by pressure testing and certification before return Section 2 Page No 4 EGO TOR Job No Q620 Copyright November 2006 HEALTH amp SAFETY INSTRUCTIONS Bolt Tensioning Tools NOT exceed the 1500 bar Maxi

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