Hydrajaws 2000 User manual

Operating Instructions
HYDR AJAWS
LIMITED
2000 Model Tester

2000 Model Tester
Model 2000 Parts
1. Gauge - Analogue with
QR Hydraulic Coupler
2. Gauge - Digital with
QR Hydraulic Coupler
(optional)
3. Quick release
 couplingwhentted
or gauge (1 & 2)
4. Tester body with
50mm/scale indicator
5. Load jaw
6. Turning handle with
integrated nut
7. Grab Handle
8. Displacement sensor
(Bluetooth option)
9. Level bubble
10. Threaded Legs
11. 75mm Hexagonal
Extension Legs
(optional)
12. 100mm Hexagonal
Extension Legs
(optional)
13. Tester bridge
1
2
4
78
9
3
6
10
11 12
5
2
TECHNICAL SPECIFICATIONS
• Pull-out load range 0-25kN/lb/f
• Weight
Tester only 2.2kg
Packaged weight 8kg (will vary)
• Stroke scale 0-50mm
• Effective stroke 50mm
• Loadgauge xedorInterchangeable
• Casing Aluminium
• Loading jaw Pivotable through
360° with Spring
return
• Operating handle Standard size with
integrated 22mm
operating nut for
  connedspaces
Load Gauges
• Ranges available: Digital: 0-30kN
Analogue: 0-5, 0-10, 0-15, 0-20
and 0-25kN/lb/f (5600lbf).
• Accuracy: Analogue to +/-2.5% fsd
Digital to +/-0.5% fsd
• Indicationofpull-outload
• Calibrated in kN
• TraceableUKAScalibrationcerticate
supplied with each gauge
• Protective rubber cover (analogue only)
• Impactresistantglass
• Protection against sudden load relief
 (i.e.suddenfailureofxing)
• Analogue and Digital: peak hold memory
• Working Temperature:
Analogue: -20°C to +60°C
Digital: -30°C to +85°C
13
See section 8 on tting
Hex Extension legs.

3
SAFETY RULES
•Modicationofthetester,ortampering
with its parts is not permissible.
• Observe the information printed in the
operating instructions applicable to
operation care and maintenance.
• The tester and its accessories may
present hazards when used incorrectly
by untrained personnel or not as
directed.
• Use only the genuine Hydrajaws
accessories or ancillary equipment
listed in the operating instructions.
The model 2000 pull-out tester is
a purpose made system for testing
xings, fasteners and anchors. It
consists of a mechanical screw
arrangement acting through a
hydraulic load cell, which measures
the load applied to the xing directly.
The resulting load value is then
indicated on the dial type analogue
gauge or optional digital gauge.
The tester has a built in movement
indicatorscale50mmtoshow“rst
movement”onthexingpriortothe
test load being applied. The tester and
bridge are supplied as an integral part
of all the 2000 tester kit ranges.
A comprehensive range of accessories
is also available, further increasing the
scope of possible testing applications.
USE OF THE TESTER AS DIRECTED
The tester is intended for use by skilled
personnel with the appropriate training
and knowledge of the applicable safety
precautions.
GENERAL DESCRIPTION
It is essential that the
operating instructions
are read before the tester is
operated for the rst time.
Always keep these operating
instructions together with
the tester.
Ensure that the operating
instructions are with the
tester when it is given to
other persons.
CONTENTS
Page
Model 2000 Parts 2
TechnicalSpecications 2
General description 3
Kit contents 4
1. GENERAL TESTING
PROCEDURE 5
2. PULLING ADAPTORS 8
2.1 The bolt test adaptor
Slotted button adaptors
Threaded button adaptors
2.2 Threaded stud adaptors 9
2.3 The insulation adaptor
2.4 Threaded rod adaptors 10
2.5 The clevis adaptor
3. SCAFFOLD TESTER KIT 11
4. SAFETY HARNESS EYEBOLT
TESTER KIT 14
5. WALL TIE TESTER KIT 16
6. MATERIAL BOND TESTER KIT 18
7. OPTIONAL LOAD
SPREADING BRIDGES 21
8. FITTING HEX EXTENSION LEGS 21
9. CARE OF TESTER
9.1 Lubrication 22
 9.2 Oilrellinginstructions 23
9.3 Calibration

4
FULL KIT CONTENT RANGE:
1. Model 2000 tester attached to
150 load spreading bridge
2. Oil bottle (Detachable gauge only)
3. Analogue load gauge(s)
4. Digital load gauge(s)
5. Button adaptors slotted set.
4.5, 5.5, 6.5, 8.5, 10.5 & 12.5mm
6. Button adaptors metric set.
M4, M5, M6, M8, M10 & M12
7. Hex socket wrench set 2.5mm
and spare screws
8. M12 ringbolt adaptor clevis
9. M5 threaded rod adaptor
10. M6 threaded rod adaptor
11. M8 threaded rod adaptor
12. M10 threaded rod adaptor
13. M10 threaded stud adaptor
14. M12 threaded stud adaptor
15. M16 threaded stud adaptor
16. M20 threaded stud adaptor
17.Insulationadaptor
18. Bolt tester adaptor
19. 50mm hexagon extension legs
20. 75mm hexagon extension legs
21. 100mm hexagon extension legs
22. 3mm Ball driver
23. 10mm single wrench
24. 22m ratchet spanner
25. M12 locking adaptor (inside tester)
26. Piston key
27.Carryingcasewithfoamller
28.OperatingInstructions
29.CerticateofCalibration
Optional Accessories:
For illustration purposes, this tester kit features
many optional accessories.
TESTER AND ACCESSORIES
1
24
22
19
16
12
14
15
2
11
8
18
7
4
17
9
13
3
21
20
29
10
Operating Instructions
HYD R AJ A W S
LIMITED
2000 Model Tester
28
27
5 6 25
23
26

5
1. GENERAL TESTING PROCEDURE
SETTING UP THE TESTER
1 Fit the appropriate adaptor to the tester.
Example shown is a bolt tester adaptor.
(Forttingofotheradaptorspleasesee
individual instructions in this manual).
2. The tester is supplied with a locking
adaptorttedintothetesterbody.
This locking adaptor can be removed
forttingofdifferentadaptorsbyusing
the 3mm Ball Driver. When replacing
back in ensure it is fully engaged into
the tester body before tightening
(g 1). Thread the bolt tester adaptor
into this, until it is fully engaged, using
a quarter turn for position (g 2).
3.Makenaladjustmentssothatthebolt
testeradaptor,testerandxingare
aligned (g 3).
4. Position the tester so that the gauge
can be easily read.
5. Adjust the length of the threaded legs
so that all three are in contact with the
base material and the load spreading
bridge is aligned and level by referring
to the bubble levels on each face.
Fig 3
Fig 2
Fig 1

6
Inconnedspacestheintegratednutcan
be used with a 22mm ratchet spanner for
betteraccessinconnedspacesandfor
easier operation (g 5).
Remove the handles by unscrewing from
the base using the 10mm wrench (g 6).
Ensure when re-attaching handles that
they are tight on and secure.
TESTING PROCEDURE
6. Set the red pointer on the gauge to zero
- hold the tester by the grip handle and
proceed to load the fastener by turning
the operating handle clockwise (g 4).
7.Increasetheloaduntiltherequired
test load is attained. Hold this load and
observe any falling back of the readings
which would indicate movement and
possible failure of the fastener. Record
the satisfactory result.
8. Release the load on the fastener
by turning the operating handle
anti-clockwise and allowing the test
jaw to return to the original position.
9. Remove the tester and bolt tester
adaptor.
Fig 5
CAUTION!
Hold the fastener securely by the grip
handle as long as the fastener is under
load. When the load increases, note
the reading on the displacement scale
onthetester.Indicationoffailureofthe
fastener may be obtained by comparing
the current reading with the original
reading.
Fig 4
Fig 6
Using the integrated nut
in conned spaces
1. GENERAL TESTING PROCEDURE continued..

7
It is recommended
when testing on ceilings
(inverted) and/or vertically,
that a safety line is
attached around the tester body to
a suitable solid xing point. This will
stop the tester falling and prevent
injury to personnel and/or damage
to test unit.
If no suitable xing point is available
then attach to safety harness on
personnel.
Adjusting the handle position (g 7)
Fig 7
The top part of the unit can be rotated if the handle or gauge becoming obstructed by the
unit legs or other objects.
This is achieved by loosening the three grub screws (a) on the body using the allen key
provided. Rotate the top until the handle and gauge are clear of obstacles and re-tighten
the screws.
a
a

8
2. PULLING ADAPTORS
2.1 THE BOLT TEST ADAPTOR
Using the bolt test adaptor directly
Using the bolt test adaptor with the slotted button adaptor
Using the bolt test adaptor with
the threaded button adaptor
For M16 nuts, (g 8) the bolt tester
adaptor (a) directly engages the nut (b) in
the pulling jaw.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
Fig 8
Fortestingxingswhereaconnectionis
madeunderneaththeheadofthexingor
anchor the slotted button adaptor is used.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
The slotted button adaptor (a) slots into
the bolt tester adaptor (b) and engages the
xing(c) (g 10).
Fortestingthreadedxingsthethreaded
button adaptor is used.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
The threaded button adaptor (a) threads
ontothexing(c) and then slots into the
bolt tester adaptor (b) (g 11). Ensure the
button adaptor has at least 2 complete
threadturnsonthexingandissecure.
Fig 10
Fig 11
Fig 9
b
ca
b
c
a
a
b

9
Remove the insulation around the fastener.
Mount the locking adaptor into the tester (see
Section 1 General testing procedure). Thread
the insulation adaptor into the locking adaptor
fully then back off until horizontal.
By holding the tester, slide the head of the
insulation fastener (a) between the two plates
withthestemofthexingrestingintheslotin
the lower plate (b) and adjust the legs on the
load spreading bridge to suit the base material.
Ensure that the pull-out force acts along the
axisofthexingbeingtested(g 15).
Hexagonal leg extensions may be required to
reach an insulation fastener that is raised.
2.3 THE INSULATION ADAPTOR
2.2 M10, M12, M16 AND M20 THREADED STUD ADAPTORS
Fig 12
Suitable for testing sleeve and stud anchors.
(g 12) After the anchor has been set
in accordance with the manufacturers
recommendations, a suitable threaded
rod (a) is screwed into the anchor and the
adaptor (b)thentted.Thelengthofthe
threaded rod to be screwed into the anchor
must be at least equal to the diameter of the
anchor.
Removethelockingadaptoriftted(see
Section 1 General testing procedure).When
theadaptorissecurelyttedtotheanchor
thread position, place the tester over the
adaptor, passing the head through the hole
in the bridge and engage it in the pulling
jaw of the tester (g 13). Level the load
spreading bridge with the adjustable legs
before commencing the application of
the load.
Fig 13
b
a
1 2 3
Fig 15
b
a
Note: (g 14) To use
the optional M30 HD
Threaded stud adaptor,
rstattach45mmM20
thread piece (c) into
adaptor (e) and attach to
thexing.Thenthread
the M20 Adaptor (d)
and proceed as above.
Hexagonal leg extensions
may be required.
d
c
e
Fig 14

10
For testing ringbolts the Clevis adaptor is used.
Mount the locking adaptor into the tester (see Section 1 General testing procedure). Then
thread the clevis adaptor into the tester body until it is fully engaged, using a quarter turn
for positioning (g 18).
Remove crosspin from the clevis adaptor and offer the tester and bridge to engage eye of
the anchor in the clevis. Some adjustment will be required on the swivel feet, so that this
tisachieved.Pushclevispinthroughtheclevisandeyebolt,ensuringthattheballonthe
pin clicks into place, having passed through the second fork (g 19).Oncettedsecurely
commence testing (see Section 1 General testing procedure).
Fig 19
Fig 18
2.5 THE CLEVIS ADAPTOR
2.4 M5, M6, M8 AND M10 THREADED ROD ADAPTORS
Fig 16
The M5 and M6 threaded rod adaptors are
equipped with an external M12 thread for
use in conjunction with the M12 threaded
button adaptor. They are used primarily
for testing remedial wall ties. The M8 and
M10 threaded rod adaptors are equipped
with an M16 external thread and the M16
nutttedwithconnectstothepullingslot
in the tester or bolt tester adaptor.
Connect the threaded rod adaptor
complete with the M12 button adaptor to
thethreadonthexing(g 16).
Removethelockingadaptoriftted(see
Section 1 General testing procedure).
Adjust the length of the bridge legs and
the height of the button adaptor/nut so that
the adaptor can pass through the hole in
the bridge and engage it in the pulling jaw
of the tester (g 17).
Level the load spreading bridge with the
adjustable legs before commencing the
application of the load.
Fig 17
b
a
1 2 3 4