Enerpac CAT 3600 Series User manual
Instruction Sheet
CAT 3600 Series Engines
Connecting Rod Tensioner
L4163
Rev. C 06/17
English (EN)
• Part No. 498-6547
• Bolt Size M19 x 1.5
• 40 mm Bolt Centers
NEHS1281
Instruction Sheet
Cat 3600 Series Engines
Connecting Rod Tensioner
© 2017 Enerpac, All Rights Reserved
Table of Contents
1.0 SAFETY ...........................4
1.1 Introduction ...................4
1.2 General Hydraulic Safety
Precautions ...................4
1.3 Hydraulic Tensioner Safety
Precautions -
CAT 3600 Connecting
Rod Tensioner .................5
2.0 PRODUCT DATA ....................6
2.1 Maximum System Pressure ......6
2.2 Maximum Tensioner Force .......6
2.3 Additional Specifications ........6
2.4 Dimensions (for reference only) ...6
3.0 PRODUCT DESCRIPTION ............7
3.1 Overview......................7
3.2 Additional Tensioner Features ....7
3.3 Maximum Working Pressure -
CAT 3600 Tensioning Application..7
3.4 Conformance to National &
International Standards ...........7
4.0 IMPORTANT RECEIVING
INSTRUCTIONS ....................7
5.0 SETTING UP .......................8
5.1 Tensioning Group Contents ......8
5.2 Pump Information ..............8
5.3 Tensioner Operational Checks ....9
5.4 Hydraulic Oil..................10
5.5 Hydraulic Couplers ............10
5.6 Hose and Cable Assemblies.....11
5.7 Preparation for Tensioning
Procedures...................11
6.0 TENSIONING PROCEDURES.........12
7.0 ADDITIONAL PRODUCT FEATURES...12
7.1 Maximum Stroke Indicator ......12
7.2 Over-Stroke Protection System ..12
7.3 Cycle Counter ................13
8.0 ROUTINE MAINTENANCE ...........13
9.0 STORAGE ........................13
9.1 Tensioners ...................13
9.2 Hoses, Flow Divider and
Electrical Cables ..............13
10.0 TROUBLESHOOTING ..............13
Troubleshooting Chart .............14
• Part No. 498-6547
• Bolt Size M19 x 1.5
• 40 mm Bolt Centers
NEHS1281
4
1.0 SAFETY
1.1 Introduction
Read all instructions carefully. Follow all recommended safety
precautions to avoid personal injury as well as damage to the
pump and/or damage to other property. Enerpac cannot be
responsible for any damage or injury from unsafe use, lack of
maintenance or incorrect operation. Do not remove warning
labels, tags, or decals. In the event any questions or concerns
arise, contact Enerpac or a local Enerpac distributor for
clarification.
If you have never been trained on high-pressure hydraulic safety,
consult your dealer training representative for a hydraulic safety
course.
This manual follows a system of safety alert symbols, signal
words and safety messages to warn the user of specific hazards.
Failure to comply with these warnings could result in death or
serious personal injury, as well as damage to the equipment or
other property.
The Safety Alert Symbol appears throughout this
manual. It is used to alert you to potential physical
injury hazards. Pay close attention to Safety Alert
Symbols and obey all safety messages that follow this symbol
to avoid the possibility of death or serious personal injury.
Safety Alert Symbols are used in conjunction with certain
Signal Words that call attention to safety messages or property
damage messages and designate a degree or level of hazard
seriousness. The Signal Words used in this manual are DANGER,
WARNING, CAUTION and NOTICE.
DANGER
Indicates a hazardous situation that, if not
avoided, will result in death or serious
personal injury.
WARNING
Indicates a hazardous situation that, if not
avoided, could result in death or serious
personal injury.
CAUTION Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
personal injury.
NOTICE
Indicates information considered important,
but not hazard related (e.g. messages relating
to property damage). Please note that the
Safety Alert Symbol will not be used with this
signal word.
1.2 General Hydraulic Safety Precautions
WARNING
Failure to observe and comply with the following precautions
could result in death or serious personal injury. Property
damage could also occur.
• Do not remove or disable the pump relief valve.
• Never set the relief valve to a higher pressure than the
maximum rated pressure of the pump.
• Do not handle pressurized hoses. Escaping oil under pressure
can penetrate the skin. If oil is injected under the skin, see a
doctor immediately.
• Do not pressurize disconnected couplers.
• The system operating pressure must not exceed the pressure
rating of the lowest rated component in the system.
• Do not exceed equipment ratings. Never attempt to pressurize
a hydraulic device above its rated maximum pressure (or
above the maximum allowable pressure for the CAT 3600
connecting rod tensioner application). Overloading causes
equipment failure and possible personal injury.
CAUTION
Failure to observe and comply with the following precautions
could result in minor or moderate personal injury. Property
damage could also occur.
• Do not use or repair damaged hydraulic hose. Avoid sharp
bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure. Sharp
bends and kinks will internally damage the hose, leading to
premature hose failure.
• Do not drop heavy objects on hose. A sharp impact may cause
internal damage to hose wire strands. Applying pressure to a
damaged hose may cause it to rupture.
• Do not lift hydraulic equipment by the hoses or swivel
couplers. Use the carrying handle or strap.
• Keep hydraulic equipment away from flames and heat.
Excessive heat will soften packings and seals, resulting in
fluid leaks. Heat also weakens hose materials and packings.
For optimum performance, do not expose equipment to
temperatures of 140˚F [60˚C] or higher. Protect all hydraulic
equipment from weld spatter.
• Immediately replace worn or damaged parts with genuine
Enerpac parts. Enerpac parts are designed to fit properly and
to withstand high loads. Non-Enerpac parts may break or
cause the pump to malfunction.
NOTICE
• Hydraulic equipment must only be serviced by a qualified
hydraulic technician. For repair service, contact the Enerpac
Authorized Service Center in your area.
5
1.3 Hydraulic Tensioner Safety Precautions -
CAT 3600 Connecting Rod Tensioner
WARNING
Failure to observe the following precautions may result in
death or serious personal injury.
Hydraulic tensioners must be installed, operated and
maintained only by trained and skilled personnel familiar
with the safe operation of high pressure tensioning devices
and related equipment.
• Always wear eye protection, gloves and boots when working
near a pressurized hydraulic system.
• When working on site, the work area should be roped-o and
all non essential personnel not involved with the site operation
should be kept clear of the working area.
• Before starting tensioning procedures, be sure that all
personnel are aware that pressurization of high pressure
hydraulic equipment is about to occur.
• Never exceed the maximum working pressure of the hydraulic
tensioner (21,750 psi or 1500 bar).
• Do not exceed the maximum allowable stroke of the tensioner
pistons. An indicator (located on each tensioner sleeve) will
appear when the sleeve piston has reached its maximum
stroke. STOP pressurizing the tensioners immediately if this
indicator becomes visible.
• Never stand in-line with the bolt axis while tensioning or de-
tensioning is in progress. If the bolt or stud should fail, serious
personal injury or death could result if loose or broken parts
become projectiles. All personnel must be aware of this
potential hazard at all times.
• Allow personnel to be near pressurized hydraulic tensioners
only when absolutely necessary and only when the pressure is
steady. Continually observe the pump pressure gauge and the
touchscreen HMI pressure readout.
• Keep hands, fingers and other body parts clear of the
tensioner during tensioner operation. Do not attempt to move
or reposition the tensioner while it is pressurized.
• High pressure hydraulic equipment can be very dangerous if
misused. Keep away from oil leakages at high pressure. Liquid
escaping from highly pressurized equipment has sucient
power to penetrate the skin, which can cause blood poisoning.
In the case of such an accident, seek IMMEDIATE medical
attention.
• Never attempt to repair leaks while the system is pressurized.
Be sure system pressure gauge and the touchscreen HMI
pressure readout both indicate zero (0) psi/bar before
tightening fittings or beginning any repairs.
• Never attempt to disconnect a hydraulic coupler while it is
under pressure.
• Do not move or lift the hydraulic tensioners using the hydraulic
hoses and fittings.
• Hoses should not be twisted or bent too sharply. The bend
radius should not be less than the manufacturer’s specified
minimum bend radius for your hose type.
• Before pressurizing the system, carefully inspect all hydraulic
hose assemblies. Replace any damaged, crushed or kinked
hoses immediately.
• Before pressurizing the system, be sure that all hydraulic
hoses are connected. Each male coupler must be connected
to a corresponding female coupler. Verify that each coupler is
fully engaged and securely locked into position by physically
pulling on the connection.
• Never pressurize the back of a disconnected male coupler.
Male couplers cannot withstand high pressures when
disconnected. Serious personal injury could result if the
coupler fails while it is disconnected and under pressure.
• Use caution when pressurizing a system. Pressure can rise
faster than anticipated. Continuously monitor the pressure
gauge and the touchscreen HMI pressure readout during
pressurization. Be prepared to stop the pump immediately at
any time.
• Never leave a pressurized system unattended. If you must
leave the area, stop the pump and ensure that the hydraulic
pressure gauge and the touchscreen HMI pressure readout
both indicate zero (0) psi/bar.
• Use only the Smart Tensioning Pump (model No. 498-6540
or 498-6541) to power the tensioners. The tensioners are
designed for use only with this pump.
• Any maintenance or repairs to the tensioners, the pump or
related components must be performed with the equipment in
the unpressurized state (0 psi/bar).
6
Maximum rated working
pressure of tool:
bar psi
1500 21,750
2.0 PRODUCT DATA
2.1 Maximum System Pressure
Maximum rated load that tensioner can
generate @ 1500 bar [21,750 psi]
kN lbf
264
(± 3 kN)
59,350
(± 675 lbf)
2.2 Maximum Tensioner Force
2.3 Additional Specifications
Puller Thread
Size
Hydraulic Area
(per stud)
Maximum Stroke
(per stud) Puller Free-Float Distance Between
Stud Centers
Tensioner Square Drive
(4 locations)
metric bolt mm2in2mm in mm in mm in mm in
M19 x 1.5 1760 2.728 8 0.315 19.5 0.768 40 1.575 14 3/8
Hydraulic
Connection
Operating
Temperature Range
Weight
(each tensioner)
Qty. of tensioners
required per
connecting rod
Required Smart Tensioning Pump
°C °F kg lb 115 VAC 230 VAC
Quick-
Disconnect
(male)
0 to 60 32 to 140 7.9 17.4 2 Model No.
498-6540
Model No.
498-6541
2.4 Dimensions (for reference only)
Item mm inch
A
B C
D
E
F
G
H
J
K
A99 3.89
B 36 1.41
C 108 4.25
D 176 6.92
E 40 1.57
F 80 3.14
G 182 7.16
H M19 x 1.5
I 3/8" 14
J 3/8" 14
K 3/8" 14
7
1 2 3 4
5
6
7
8
9
10
11
12
Figure 1, Major Features and Components
Key:
1. Coupler, Male
2. Electrical Connector
3. Puller Sleeves *
4. Thumb Wheel, 3/8 in.**
5. Top Cap
6. Tensioner Body
3.0 PRODUCT DESCRIPTION
3.1 Overview
The Enerpac Model 498-6547 hydraulic tensioner is designed to
precisely tension the connecting rod studs used on CAT 3600
Series engines. It includes the following features:
• Application specific design - custom engineered to precisely
fit CAT 3600 connecting rods.
• Overstroke protection.
• Twin stud tensioning
• Fast castle nut spin down using standard 3/8" square drive.
The tensioner is part of a complete tensioning system that
includes a specially programmed Smart Tensioning Pump. This
pump oers the following advanced features:
• Convenient touchscreen HMI (human-machine interface).
• Automated GO/NO-GO operation with transducer feedback.
• Quality record (Includes: system pressure, tensioner piston
travel, operator ID, serial number and time stamp).
7. Drive Gears*
8. Gearbox
9. Nut Rotating Sockets
10. Tensioner Bridge
11. Cycle Counter
12. Swivel Manifold
* 3/8 inch drive. ** Item included in tensioning kit.
3.2 Additional Tensioner Features
• The tensioner mounts and operates quickly, since it is
especially designed for the CAT 3600 tensioning application.
• The puller sleeves and drive gears contain standard 3/8
inch female square drives. This allows the technician to easily
complete various operations that are part of the tensioning
process.
• Built-in electrical transducers help ensure that proper
tensioning procedures are followed.
• Cycle counter indicates tool cycles, and can be used to
determine when routine inspection and maintenance activities
are required.
• Durable black oxide finish helps protect the tensioner from rust
and corrosion, prolonging its life.
See Figure 1 for a diagram of the tensioner's major features and
components.
3.3 Maximum Working Pressure -
CAT 3600 Tensioning Application
The maximum working pressure for the CAT 3600 tensioning
application is regulated by the Smart Tensioning Pump, when the
pump is operated in the automatic program (P) mode. Note that
this pressure can be less than the maximum working pressure
(“WP”) stamped on the side of the hydraulic tensioners. This
pressure can also be less than the maximum pressure shown on
the pump data plate.
Program (P) mode limits the pump's maximum working
pressure to a setting determined by the Caterpillar Engine
Products Group. The pressure is automatically optimized for the
selected application, to help prevent bolt failure due to over-
pressurization.
The pump also contains a manual (M) mode. The manual mode
should be used only for troubleshooting or diagnostic purposes
while the tensioner is not mounted on the connecting rod, and
with use of appropriate fixturing to prevent over-stroke of the
tensioners.
CAUTION Use of the pump in manual mode with the
model 498-6547 Smart Tensioners may result in incorrect
clamp load and/or failure of the connecting rod studs.
Tensioner could drop if studs break, possibly injuring
persons in the work area. Property damage could also result.
3.4 Conformance to National & International Standards
Enerpac declares that the Enerpac Smart Tensioner
has been tested and conforms to applicable standards
and is approved to carry the CE certification mark. An
EU Declaration of Conformity is enclosed separately.
4.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping
damage is not covered by warranty. If shipping damage is found,
notify carrier at once. The carrier is responsible for all repair and
replacement costs resulting from damage in shipment.
8
1
2
34
56
7
10
8
9
Figure 2, Tensioners and Related Components
5.0 SETTING UP
5.1 Tensioning Group Contents
The complete CAT 3600 connecting rod tensioning group
includes two tensioners, three hydraulic hoses, five electrical
cables and various other components. All components are
stored in a travel case. See Figure 2.
WARNING If other hydraulic hoses, fittings and
components are used in the system, they MUST be rated at
or above the maximum rated working pressure of the
tensioner - 1500 bar [21,750 psi].
5.2 Pump Information
The Smart Tensioning Pump, model No. 498-6540 (115 VAC) or
498-6541 (230 VAC). is specially designed and programmed for
the CAT 3600 connecting rod tensioning application. See Figure
3.
Detailed information regarding Smart Pump set-up, operation
and maintenance are included in the pump instruction sheet
(document No. L4186).
CAUTION The tensioners are designed to be used ONLY
with the Smart Tensioning Pump. Use of any other pump
with the tensioners may result in improper clamp load and/
or connecting rod stud damage. Serious personal injury
may result. Property damage may also occur (refer to
section 3.3 for additional information).
Figure 3, Smart Tensioning Pump
Key:
1. Socket Kit (service tool)
2. Tensioner
3. Thumbwheel
4. Travel Case
5. Hose Assy. - Junction Box to Tensioner
6. Hose Assy. - Pump to Flow Divider.
7. Flow Divider
8. Cable Assy. - Junction Box to Tensioner
9. Junction Box
10. Cable Assy. - Pump to Junction Box
Note: Chafe gear protective covering
(three pieces) not shown.
9
5.3 Tensioner Operational Checks
The following checks and inspections should be performed
before placing the tensioner into service, with the hydraulic hose
and electrical cables disconnected.
• Visually inspect the tensioner for any signs of damage or
excessive amounts of oil (which could indicate a potential
leak).
• Operational Check #1: Hold the tensioner upside down and
ensure that the puller sleeves freely retract by approximately
20 mm [0.78 in]. See Figure 4.
20 mm
[0.78 in.]
Figure 4, Checking Puller Sleeve Retraction
• Operational Check #2: With the tensioner still in the upside
down position, depress the nut rotating sockets by hand
by approximately 5-10 mm [0.20 - 0.39 in.] to ensure they
move freely and are returned to their original position by the
compression springs. See Figure 5.
20 mm
[0.78 in.]
Figure 5, Checking Spring Return
• Operational Check #3: Use a 3/8 inch drive extension to
rotate the drive gears on the gearbox at least one complete
revolution in both directions. Check that they rotate freely
without binding, and that they rotate the nut rotating sockets.
See Figure 6.
20 mm
[0.78 in.]
Figure 6, Checking Drive Gear Rotation
• Operational Check #4: Rotate the swivel manifold by hand at
least one complete revolution in both directions. Check that it
rotates freely without binding. See Figure 7.
20 mm
[0.78 in.]
Figure 7, Checking Puller Sleeve Retraction
If the tensioner is unable to successfully perform one or more of
the operational checks, it should be inspected and repaired by
an Enerpac Authorized Service Center before being placed into
service.
10
5.4 Hydraulic Oil
The hydraulic oil shown in the following table is approved for use
with the pump.
Temperature Range Approved Hydraulic Oil
°C °F
15 to 60 60 to 150 ADV Hydo 10 (SAE 10W)
NOTICE
Failure to use the specified oil may result in damage to
pump and other hydraulic components and will void the product
warranty.
Be sure that the oil is clean and that it is poured from a clean
container. The oil cleanliness should be maintained to a minimum
cleanliness level of 18/16/13 per the ISO4406 standard. If the oil
has a milky, cloudy or dark appearance, it should be changed
immediately as described in the pump maintenance instructions.
Use only a high quality hydraulic oil that meets the specifications
shown in the approved hydraulic oil table. Add oil only when all
system components are fully retracted, or the system will contain
more oil than the reservoir can hold.
For detailed instructions explaining how to add oil to the pump
reservoir, refer to the Smart Tensioning Pump instruction sheet
(document L4186).
5.5 Hydraulic Couplers
Each tensioner includes a male quick-disconnect style hydraulic
coupler. The Smart Tensioning Pump, and the connecting hoses
include similar male and female couplers.
WARNING
Failure to observe the following precautions may result in
death or serious personal injury.
• On the Smart Tensioning Pump, pressure is automatically
relieved and directed to the pump reservoir when the motor
is stopped. However, as a precaution after stopping the motor
and before disconnecting electrical power, always verify that
zero (0) psi/bar is indicated on both the pump pressure gauge
and on the pump touchscreen HMI pressure readout.
• Be sure that pump motor is OFF before connecting or
disconnecting any couplers.
• Do not pressurize disconnected couplers. All couplers must
be correctly and completely fastened together before applying
pressure.
• Never disconnect any couplers without first unloading the
tensioners and releasing hydraulic pressure.
• Never attempt to relieve pressure by loosening a fitting or by
unseating a coupler check ball or seat.
NOTICE
All system pressure must be released prior to making
connections. If there is any pressure trapped in the hydraulic
components, it will be not possible to connect or disconnect
hoses using the couplers.
To Connect Couplers:
See Figure 8.
1. Before making any connections, be sure that the pump
pressure gauge and the touchscreen HMI pressure readout
both indicate (0) psi/bar.
2. Be sure that couplers are free of dirt and debris.
3. On the female coupler, be sure that the locking collar is
completely backed-o (unscrewed). Then, hold back the
main collar and push the male coupler into the female
coupler.
4. Release the main collar on the female coupler and push the
male coupler further into the female coupler until a “click” is
heard and engagement is felt.
5. Thread down the locking collar so it makes contact with the
main collar and locks the couplers together. There should be
NO GAP where the collars meet. Tighten by hand only. Do
not use tools.
6. At each coupler connection, firmly tug the hose to verify that
the couplers are securely connected. Verify the couplers
are locked by attempting to pull back the main collar on the
female coupler.
GAP
NO GAP
1
Hand Tighten
Loosen
Pull Back
Pull BackLoosen
Connect
Disconnect
2
1
2
3
3
Figure 8, Hydraulic Couplers - Connect and Lock
To Disconnect Couplers:
See Figure 9.
1. Before disconnecting any couplers, be sure that the pump
pressure gauge and the touchscreen HMI pressure readout
both indicate (0) psi/bar.
2. On the female coupler, fully back-o (unscrew) the locking
collar to unlock the connection.
3. Pull back the main collar on the female coupler to disconnect
the couplers.
11
GAP
NO GAP
1
Hand Tighten
Loosen
Pull Back
Pull BackLoosen
Connect
Disconnect
2
1
2
3
3
Figure 9, Hydraulic Couplers - Unlock and Disconnect
5.6 Hose and Cable Assemblies
See Figure 10 for an overall view of the hoses, cables, flow-
divider and junction box.
For detailed hose and cable connection instructions, refer to the
Smart Tensioning Pump instruction sheet (document L4186).
Before connecting or disconnecting hydraulic couplers on hoses,
tensioner, pump and other hydraulic devices:
• Be absolutely certain that any pressure is completely relieved.
Verify that both the pump hydraulic pressure gauge and the
touchscreen HMI pressure readout indicate zero (0) bar/psi.
• Be certain that the pump motor is o and that the pump control
valve is not energized
WARNING All hoses, fittings and components used in the
system, MUST be rated at or above the maximum rated working
pressure of the tensioner - 21,750 psi [1500 bar]. Failure to
observe this instruction could result in dangerous high pressure
oil leakage. Death or serious personal injury could result if a high
pressure oil stream penetrates the skin.
5.7 Preparation for Tensioning Procedures
• Be sure all personnel involved in this procedure are trained
in tensioning procedures and in the equipment being used.
Ensure that all personnel read and understand the safety
information contained in Section 2 of this document.
• Read and completely follow the additional pump setup
instructions contained in pump instruction sheet L4186. Be
sure that the pump reservoir is filled with oil.
• Be sure all personnel are familiar with the use of the Smart
Pump and its HMI screens. Refer to the Smart Tensioning
Pump instruction sheet (document number L4186) for
additional information.
• Inspect the connecting rod studs to verify that they contain no
Figure 10, Hose and Cable Assembly
Notes:
• Refer to smart tensioner pump manual
(document No. L4186) for detailed hose and
cable connection diagrams.
• For illustrative purposes, touchscreen HMI and
chafe gear protective coverings are not shown
in this graphic.
12
obvious damage or defects, and that they appear capable of
withstanding the force that will be applied by the tensioners.
• Ensure that the connecting rod caps are correctly and firmly
seated, and that the nuts are fully threaded onto the studs
until they firmly contact the connecting rod cap surface.
There should be a total of 26 mm [1.02 inch] above each nut.
Absolute minimum stud protrusion required to safely tension
the studs is 21 mm [0.83 inch]. See Figure 11.
20 mm
26 mm
[1.02 in.]
M19 x 1.5
Figure 11, Checking Stud Protrusion
• Before installing each tensioner, be sure that the threaded
portions of the studs and puller sleeves are clean and free of
damage.
• Before using the tensioner and pump, use the pump's oil flush
feature to remove any trapped air from the system. Refer to
the pump instruction sheet (document No. L4186) for oil flush
procedure.
6.0 TENSIONING PROCEDURES
• Refer to the Caterpillar 3600 connecting rod Disassembly and
Assembly instructions (available from Caterpillar) for detailed
tensioner installation and operation procedures.
• Refer to the Smart Tensioning Pump instruction sheet
(document No. L4186) for detailed pump set-up instructions
and user-level pump troubleshooting information.
• If oil leaks occur or if abnormal operation is noticed, STOP the
pump immediately and determine the source of the problem
before resuming the tensioning procedure.
7.0 ADDITIONAL PRODUCT FEATURES
7.1 Maximum Stroke Indicator
Maximum allowable tensioner stroke is visually indicated
by a yellow painted groove located on the puller sleeve’s
circumference. See Figure 12.
Continually watch for the maximum stroke indicator during
tensioning procedures. Stop pressurizing the system immediately
if the indicator becomes visible at one or both puller sleeves.
The maximum stroke indicator groove can be felt by hand. If
the view of the tensioner is restricted or obstructed, periodically
check for the groove by hand as tensioning procedures are
performed.
Reaching maximum stroke is a possible indication of a problem
with the connecting rod assembly.
If the maximum stroke indicator appears before the desired
hydraulic pressure is reached, always stop the pump and verify
that pressure is fully relieved (0 psi/bar).
Check for obvious problems, such as broken connecting rod
studs or worn threads. Also check for correct assembly of parts.
Reassemble and/or replace parts as required. Then, repeat the
tensioning process.
NOTICE
If the maximum stroke indicator appears before the
desired hydraulic pressure is reached, no additional load will be
transferred to the connecting rod studs, and the studs and nuts
will not be tensioned to the correct values.
Figure 12, Maximum Stroke Indicators
7.2 Over-Stroke Protection System
The tensioner contains an over-stroke protection system. This
feature helps reduce the risk of damage to both the tensioner and
the connecting rod studs.
The over-stroke protection system is activated after the maximum
stroke indicator (on either one or both puller sleeves) is fully
exposed. Oil leakage will be visible in the top cap area when
pressure relief occurs.
NOTICE
Clean-up any leaked or spilled oil. Dispose of this oil in
accordance with all applicable regulations and laws.
13
7.3 Cycle Counter
A cycle counter is mounted on the side of the tensioner. This
tracks the life of the tool and can be used to determine when
routine service intervals or parts replacement is required. See
Figure 13.
Figure 13, Cycle Counter
8.0 ROUTINE MAINTENANCE
The tensioner puller assemblies have an average expected life of
1800 cycles. However, it is recommended that puller assemblies
be replaced every 1500 cycles to avoid possible failure occurring
during a tensioning operation.
The puller assemblies are not user-serviceable and must
be replaced by an Enerpac Service center or other qualified
hydraulic repair facility. Other internal wear items, such as seals,
should also be inspected by the service technician, after the
puller assemblies have been disassembled and removed.
9.0 STORAGE
Perform the following operations after completing tensioning
procedures, and before placing the tensioner in storage.
9.1 Tensioners
• Inspect the tensioner for obvious damage or wear. Perform the
operational checks as shown in Section 5.3.
• Apply a light coating of oil or rust inhibitor to all metal surfaces
prior to storage. Ensure that the internal threads of the pullers
are also coated.
• Store the tensioner inside the travel/storage case in which it
was originally received. Be sure that the puller sleeves are fully
retracted inside the tensioner body.
• Install the dust cap over the hydraulic coupler. To prevent dirt
entry, always keep dust cap installed on the coupler when the
tensioner is not being used.
• Install dust caps over the tensioner electrical connections.
9.2 Hoses, Flow Divider and Electrical Cables
• Wipe all hoses clean.
• Remove the chafe gear covering (secured with Velcro) and
inspect the entire length of all hoses for damage. Damage to
the chafe gear covering (hose and cable protective covering)
could indicate additional damage to the hoses or electrical
cables.
• Check for oil leaks. Tighten or replace fittings and couplers as
required.
• Inspect the flow divider manifold. Repair if damaged, or if oil
leakage is visible.
• Inspect all electrical cables for wear or damage. Replace
cables if worn, frayed, cut or otherwise damaged. Note that
if an electrical plug is damaged, the entire cable must be
replaced.
• Check condition of electrical junction box. Replace if damaged.
10.0 TROUBLESHOOTING
For tensioner troubleshooting information, refer to the
troubleshooting chart on the following page. Also refer to the
troubleshooting chart in the Smart Tensioning Pump instruction
sheet (document number L4186).
WARNING
Failure to observe and comply with the following precautions
during could result in death or serious personal injury.
Property damage could also occur.
• Never tighten or loosen hydraulic fittings while the pump
hydraulic system or connected components are pressurized.
Escaping oil under pressure can penetrate the skin, causing
serious personal injury.
• Keep hands, fingers and other body parts clear of pinch
points and moving parts when observing operation during
troubleshooting.
• Always disconnect the pump electrical power cord before
performing any maintenance or repair procedures.
• Be sure that pump pressure gauge and touchscreen HMI
pressure readout both indicate zero (0) psi/bar before
disconnecting any hydraulic couplers or performing any
maintenance or repair procedures.
14
Troubleshooting Chart
Symptom Possible Cause Remedial Action
Puller sleeves not moving when they
should be moving.
Bad hydraulic connections. Check ALL hydraulic couplers for debris and
proper engagement.
Pump not building pressure. Check if pressure is increasing, using:
1) mechanical pressure gauge, 2) touchscreen
HMI readout, 3) amber LED on proportional relief
valve driver.
Oil leaking from tensioner. Over stroke protection activated. Press “motor o” button on hydraulic pump
pendant. Reinstall tensioner.
Nut rotating socket will not spin. Over torqued gearbox bolts. Loosen gearbox bolts until nut rotating socket
spins.
Transducers not providing feedback. Loose cable connection. Check ALL electrical cable connections for
debris, bent pins, and proper engagement.
Puller sleeves not returning to flush with
the top cap.
Bad hydraulic connections. Check ALL hydraulic couplers for debris and
proper engagement.
Puller sleeve not returning to flush with
the top cap.
Weak return spring force. With hose assembly connected, use ratchet to
manually bring puller sleeve to flush. Replace
broken or weak return springs.
For setup, applica�on, or how‐to ques�ons; please use the following resources:
Global Dealer Solu�on Network
Phone: 18772282420(NorthAmerica)
13092664421(Interna�onal)
Dealer Service Tools Website
hps://dealer.cat.com/dealerservicetools
Connec�ng Rod Training Video
CATU1269(locatedonCaterpillarChannel1)
For service, warranty, or troubleshoo�ng, please use the following resources:
Country/Region Enerpac Academy or Regional Office
U.S./Canada Enerpac|199GatewayCourt,Columbus,WI53925
La�n America
Europe
EnerpacB.V.|Galvanistraat115|6716AEEde,TheNetherlands
Northern Africa
Sub Sahara Africa
Middle East
India
Australia /
New Zealand
EnerpacAustralia|BlockV:Unit3,RegentsParkEstate,391ParkRd,
RegentsPark,NSW2143
hp://www.enerpac.com/enau/contactus
Southeast Asia ActuantAsiaPte.Ltd.|83JooKoonCircle#0103,Singapore629109
CountriescoveredbytheEnerpacSoutheastAsiaoffice:
Brunei,Cambodia,HongKong,Indonesia,LaoPDR,Malaysia,MongoliaSingapore,Pakistan,
Philippines,Taiwan,Thailand,TimorLesteandVietnam
Korea
ActuantKoreaEnerpac|
48,Mayuro20beongil,Siheungsi,Gyeonggido|15116|Korea
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