riverhawk IM-150 User manual

Repairs – Rentals
Field Service
215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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INSTRUCTIONMANUALIM‐150
ForGas/SteamTurbineTensionedStudsandNuts


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Fr.6CTurbineto6A8GeneratorGE381A6851
SteamTurbineto6A8GeneratorGE382A4352
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
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 
GEPower&Water
GENERALELECTRICCOMPANY
MLI: ____ OF ____
DATE

CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
ISSUED:
THISDOCUMENTSHALLBEREVISEDINITSENTIRETY.ALLSHEETSOFTHISDOCUMENTARE
THESAMEREVISIONLEVELASINDICATEDINTHISVENDORSUPPLIEDDRAWINGAPPLIQUE.
REV
373A4006
GEDRAWINGNUMBER
VENDORSUPPLIED
THISDOCUMENTISFILEDUNDERTHEGEDRAWINGNUMBER.
GENOTTOREVISE.GEREVISIONLEVELISSHOWNONTHISAPPLIQUE.
GESIGNATURES
CHECKED:
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TheRiverhawkCompanyreservestherighttoupdatethisdocumentwithoutdisseminationornotice.The
latestrevisionmaybeobtainedbycontactingRiverhawkCompanyorthruwww.riverhawk.com.

Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4006
GEDRAWINGNUMBER
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RevisionG
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TableofContents
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Section Description PageNumber
1.0 CautionsandSafetyWarnings 3
2.0 Scope 4
3.0 QuickCheck‐List 4
4.0 GeneralPreparations 7
5.0 PreparationofHardware 9
6.0 NutandStudAssembly 11
7.0 AssemblyofHydraulicTensionerEquipment 11
8.0 AssemblyofTensioneronStud 12
9.0 StudPullingandTensioning 14
10.0 ThreadLocking 16
11.0 Stud/NutRemoval 16
12.0 FrequentlyAskedQuestions 17
13.0 RevisionHistory 19
AppendixA1 ECDeclarationofConformity 20
AppendixA2 UKCADeclarationofConformity 21


Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4006
GEDRAWINGNUMBER
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RevisionG
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1.0CautionsandSafetyWarnings
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WARNING
Impropertooluseandthefailuretofollowthecorrectproceduresaretheprimaryrootcauses
oftoolsfailuresandpersonalinjuries.Alackoftrainingorinexperiencecanleadtoincorrect
hardwareinstallationorincorrecttooluse.Onlytrainedoperatorswithcareful,deliberate
actionsshouldusehydraulictensioners.ContactRiverhawkwithanytrainingneeds.
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WARNING
Riskofhighpressurehydraulicfluidinjection.Riverhawktoolsoperateunderhighpressure.
Thoroughlyinspectallhosesandconnectionsfordamageorleakspriortousingthisequipment.

CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandtheTensionerAssemblyisfreetorotate.

WARNING
Theproperpersonalprotectiveequipmentmustbewornatalltimes.Riverhawkrecommends
ataminimum,safetyglasses,longsleeveshirt,hardhat,heavyworkgloves,andsteeltoe
shoes.

WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhenthe
tensionerispressurizedotherwisepersonalinjurycanoccur.

CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.

WARNING
FireHazard!DONOTheatwhenthepullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended.

NOTICE
DonotusemorethreadlockingcompoundthanspecifiedorthenutmaybeVERYdifficultto
removeatdisassembly.

CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandpullerscrew

Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]

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REV
373A4006
GEDRAWINGNUMBER
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Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.
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2.0 Scope
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Thisdocumentdescribestheproceduretobeusedtoinstallthestudandnutsetssuppliedby
theRiverhawkCompanyintheflangesattheTurbine/Coupling,Coupling/Gearand
Gear/Generatorconnections.

ThevariousframeconfigurationscoveredinthismanualarelistedinSections2.1through2.2
withdifferencesasrelatedtoconnectivehardwaredefined.Listedalsoarethepertinent
hardwaredrawings(HF‐).Thesedrawingsaswellastoolingdrawings(HT‐)formpartofthis
manual.
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2.1Fr.6CTurbineto6A8GeneratorGE381A6851
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HF‐2267,HT‐2268,HT‐2286
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ThehardwaredrawingdepictsthestudandnutsetforbothTurbinetoLoadCouplingand
CouplingtoGearbox(11/8”[29mm]size,Qty48)aswellasGearboxtoGenerator(15/8”[41
mm]size,Qty40)

2.2SteamTurbineto6A8GeneratorGE382A4352
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HF‐2312,HT‐2268
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ThehardwaredrawingdepictsthestudandnutsetforbothTurbinetoGenerator(15/8”[41
mm]size,Qty40)
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3.0QuickChecklist

ThefollowingchecklistisintendedasasummaryofthestepsneededtousetheRiverhawk‐
suppliedequipment.Newpersonnelorthoseexperiencedpersonnelwhohavenotusedthe
Riverhawkequipmentrecentlyareencouragedtoreadtheentiremanual.


Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4006
GEDRAWINGNUMBER
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RevisionG
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EQUIPMENTINSPECTION
□Checkoillevelinhydraulicpump.
□Checkairpressureat80psi[5.5bar]minimum.(Forair‐drivenpumps)
□Checkhydraulichosefordamage.
□Testpump.
□Inspecttensionerforanydamage.
NUTANDSTUDPREPARATION
□Inspectstudandnutsforanydamage.
□Measurestudlength.
□Cleanthestudsandnuts.
□Installstudsandnuts(off‐center)intotheflange.
□Setstick‐outdimensiononstudendwiththeinternal,conicalthread.
□Handtightenallstuds.
□Verifystick‐outmeasurement(VERYIMPORTANT)

Tensioning(Boltinstallation)
□Matchthetensionersetuptotheflangejoint.
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.

Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]

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REV
373A4006
GEDRAWINGNUMBER
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RevisionG
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□Mountthetensioneronthestudinflangeandinstallspannerringontonut.
□Insert3/8”hexAllenwrenchintothebacksideofthestud.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Tensionto50%.Consultmanualforcorrectpressure.
□Usethepinwrenchinspannerringtotightennut.
□Releasepressure,movetonextstudinpattern.
□Repeatabovestepsatfinalpressure.
□Measurefinalstudlengthandrecordonstretchdatasheets.Calculatestretch.
□Torquenuts'setscrews.

Detensioning(Studremoval)
□Loosennuts'setscrews
□Inspectandcleanstuds'conicalthreads.DonotcontinueuntilALLdebrisisremoved
fromthethreads!Donottrytousethetensionertoremoveadamagedstud!
□Applyalightcoatofcleanturbineoilorspraylubricanttothepullerscrew.DONOTUSE
“NEVERSEIZE”ONTHECONICALTHREADS.
□Slidespannerringoverthepullerscrew.

Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4006
GEDRAWINGNUMBER
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RevisionG
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□Mountthetensioneronthestudandinstallspannerringintonut.
□Tightenthepullerscrew.Thenbackoffpullerscrew1/2aturn.
□Retightenthepullerscrewandleavetight.DONOTBACKOFFPULLERSCREW.
□Tightenpullernutandthenbacknutofftwoflatsor120degreestoallowforstudstretch.
□Bleedthetensioner.DoNOTbleedtensioneroffofastud!Damagetothetoolwill
result!
□Applyfinalpressure.
□Loosennutwiththespannerringandpinwrench.
□Movetonextstudinpattern


4.0GeneralPreparations

Readandunderstandallinstructionsbeforeinstallingandtensioningstuds.

Thisequipmentproducesveryhighhydraulicpressuresandveryhighforces.Operatorsmust
exercisecaution,wearsafetyglassesandhardhatswhenusingthisequipment.

High‐pressurefluidfromtheHydraulicPressureKitsystempressurizesthetensionerwhich
generatesastretchingforcethatactuallystretchesthestud.Asthestudisstretchedthenut
liftsofftheflange.Thenutisthenreseatedintopositionontheflangebyturninganutdriver
byhand.Whenthenutistightagainsttheflange,thepressureinthetensionerisreleased
leavingthestudloadedtoitspredeterminedvalue.

4.1MachinePreparation

Theflangetobetensionedmustbefullyclosedpriortopositioningthestudsintheflanges.
Theremustbeprovisionsforturningtheshaftsoftheturbine,coupling,gearboxandgenerator.
Also,itwillbeadvantageoustoremoveasmanyobstructionsaspossiblefromtheflangearea,
suchasspeedprobesandconduit.



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Tel:+13157684855
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
4.2Hardware–Balance

 Hardwareissuppliedinweightbalancedsets
 StudsandNutsareinterchangeablewithinsets
 Donotmixwithothersets
 Saveweightcertificationdatasuppliedwitheachsetforpurchaseofspares

4.3Tensioner–CareandHandling

 Whennotinuse,thetensionershallbemaintainedinacleanenvironmentandallcapsand
plugsforhydraulicopeningsandfittingsmustbeinplace.
 UseISO32gradeoil.
 Wheninuse,thetensionershallbeprotectedfromsandandgrit
 Longtermstorage–coattensionerwithoil,returntooriginalcontainer,sealcontainerand
protectfrommoisture.
 Shipment–coattensionerwithoilandshipinoriginalcontainer

4.4 HandTools

Severalhandwrenchesandmicrometerswillberequiredtoperforminstallationand
measurementofthestuds:

5/8”openendwrench
15/16"open‐endwrench
1”wrench
AsetofAllenWrenches
3’–4’BreakerBar
5”to6”micrometerorcaliper
6”to7”micrometerorcaliper


4.5SpecialTools

HydraulicTensionerKit: HT‐2268HydraulicTensioner,1‐5/8”
 HT‐2286HydraulicTensioner,1‐1/8”
(referenceGE364B3422)

HydraulicPumpKit: MP‐0130ManualHand‐Operated
HydraulicPump
(recommended)
(referenceGE359B2506)

Instruction Manual IM-150
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
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
 AP‐0532Air‐OperatedHydraulicPump
(referenceGE359B2502)


5.0PreparationofHardware

5.1NutPreparation

Fornewinstallationsthenutsshouldcomesealedfromthefactoryandwillneednocleaning.

Previouslyinstallednutsrequirecleaningasfollows:Wirebrushusingapetroleumbased
solventtoremoveanyforeignmaterialontheexternalsurfacesandthreads.

Ifpreviousinstallationemployedathreadlockingcompound,whichwillbevisibleasagrayish‐
greenresidue,removeasmuchofthiscompoundaspossible.

Donotapplythreadlubricantstothethreads.

Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.

5.2StudPreparation

Checkthestudforanyvisibledamage.Ifthereisanyvisibledamage,donotusethestudand
contacttheRiverhawkCompanyforareplacementstud.Pleasebepreparedtosupplythe
turbinenumber,weightcertification,anddigitalphotographsforevaluation.

Theconicalthreadsofeachstudmustbecleanbeforeinstallationorremoval.Thisensuresthe
properseatingofthepullerscrew.

5.2.1StudCleaning‐NewInstallations

Fornewinstallations,thestudsshouldcomesealedfromthefactoryandwillneednocleaning.

5.2.2StudCleaning‐OldInstallations

Previouslyinstalledstudsmayrequirecleaning.Cleanconicalthreadsshouldhaveabrightand
shinyappearance.

Ifcleaningisrequired,followthesesteps:


Instruction Manual IM-150
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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215ClintonRoad
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Tel:+13157684855
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1. Blowoutthethreadswithcompressedairtoremoveloosedebrisanddryconical
threads.Donotapplyasolventorothercleaningsolutiontothethreadsasthismay
chemicallyattackthestud.

2. UseStudCleaningKit,GT‐4354orasimilar1/2"diameterBrasspowerbrush.


PictureofBrassPowerBrush

3. Insertthebrushintoanelectricdrillandsetdrilltoruninacounterclockwisedirection
athighspeed.


4. Workthedrillinacircularmotionwhilemovingthebrushinandouttocleanallofthe
threads.Trynottoholdthebrushinoneplacetoolong,soasnottoremovethestud's
protectivecoating.

5. Blowoutthethreadswithcompressedairtoremovelooseneddebris.

6. Visuallyinspectthreadsforcleanliness.Threadsshouldbebrightandshiny.

7. Repeatifanydirtcanbeseeninthethreads.

8. Inspectthreadsforanydamagethatmayhavebeencausedbypreviousinstallation.

Donotapplythreadlubricantstothethreads.

Finishthecleaningprocessbyrinsinginavolatilesolventsuchasacetoneandallowtodry.

5.3StudLengthMeasurement

Measureandrecordtheinitiallengthofthestuds.Thefollowingsuggestionswillimproveyour
results:

 Plantostartandfinishanyflangeinthesameday.
 Studsandflangemustbeatthesametemperature
 Numbereachstudwithamarker.
 Markthelocationofthemeasurementonstudendwithapermanentmarker.
 Measureeachstudtonearest0.001inch.

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215ClintonRoad
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
 Recordeachmeasurementonthesuppliedcharts.
 Donotallowthemeasuringinstrumentstosetinthesun


6.0StudandNutAssembly

RefertotheHardwareAssemblyDrawing(HF‐)listedinSection2.0ofthismanual.
1. Assemblethecylindricalnuttothetaperedthreadend(PullEnd)ofthestud.
2. SlidethestudandcylindricalnutassemblyintotheflangeasshowninFigures1,2&3
andinstalltheothernutonthebackside.
3. Adjustnut/studassemblysothatthestudprotrudesfromthefaceofthecylindrical
nuttheamountdepictedonthehardwaredrawing(HF‐).SETTINGTHISPROTRUSION
OFSTUDTONUTISCRITICALFORPROPERTENSIONEROPERATION.
4. Handtightentheassemblytoasnugfit.


7.0AssemblyofHydraulicTensionerEquipment

7.1KitAssembly

Assemblethehydraulicpumpwithitshosetothepullertoolandbleedthesystemofairper
followinginstructions.

7.1.1Fittings

Makesurebothmaleandfemalepartsarecleanandfreeofdebris,seeFigure4forfitting
configuration.Holdfemalepartsecurelywhentighteningsoastopreventdamagetothe
adjacenttubing.Ifthefittingleaksfirsttryretighteningasneeded.Ifleakingcontinuesthen
disassembleandcheckforscratchesordebrisontheseatingconicalsurfaces.Cleanas
required.Replaceplasticprotectivecapswhenfinishedwiththetooling.

7.2Pump

Pumpkitisshippedfullofhydraulicoil.Thepumpreservoircapissealedforshipment.Touse
turncaptotheventposition.Topreventoilspillageclosecapwhennotinuse,duringstorage
andshipment.LostoilshouldbereplacedwithEnerpacHydraulicOil.ISO32MineralOilmaybe
substituted,ifnecessary.



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215ClintonRoad
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7.3BleedingHydraulicSystem

FollowthetensionerassemblyinstructionsofSection8.0.

TOAVOIDFAILURE,ENSURESAFETYANDPROPEROPERATIONTHETENSIONERASSEMBLY
MUSTBEMOUNTEDONTHESTUDBEFOREBLEEDINGTHESYSTEMANDTENSIONINGBEGINS.

MounttensioneronastudpertheassemblyinstructionsofSection8.0.Makesurethepumpis
situatedbelowthetensionerassembly.Thetensionerassemblyhastwoports,onefor
pressurizingandoneforbleedingthesystem.Theseportsserviceacommonchamberand
thereforemaybetreatedinterchangeability.Thebleedportmustalwaysbeorientedinthe
uppermostposition.Thepullertoolisshippedwitha5/8in.[16mm]hexconedstembleeder
fittinginstalled.Withthisfittingloosenedstrokethepumprepeatedlyuntilthestreamofoil
exitingthetoolisfreeofairthenretightenthefitting.

Note:Thehoseisstiff,useofthistoolingcanbesimplifiedbytemporarilymountingthepuller
toolononestudpriortofinaltighteningoffittings.Thiswillreducethetendencyforthe
fittingstoloosenduringuse.


8.0AssemblyofTensioneronStud

TwotypesofTensionerKitswillbeencounteredinthefield.Thetwoassembliesaredepictedin
Figures5&6.

Cleanpullerscrewandcheckforanydebrisanddents.

Pullerscrewshouldbefreetorotateandmovebackandforth.

Inspecttensionerguardforanysignsofdamage.Bentguardsshouldbereplaced.

Alltensioning(pulling)willbeperformedfromthetaperedthreadendofthestudwith
orientationofthestudtotheflangeasshowninFigures1,2,&3.

8.1AssemblyofTensionerKitwithIntegralSafetyCage.

RefertoTensionerAssemblydrawingandFigure5fortensionertoflangemounting.This
assemblyhasthefollowingfeatureswhichshouldmakestudtensioningsaferandeasier.

 Thesafetycageisintegral(bolted)tothepullertool
 Thehydraulicpistonisspringloadedtoretract

Instruction Manual IM-150
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CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL
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215ClintonRoad
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Tel:+13157684855
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
 Thepullerscrewisa2‐piecedesign,Thisrequiresthattheoperatortightenthepullerscrew
intothestudandtheninstallapullernut.

Assemblysequenceisasfollows:

1. Openthehydraulicreturnvalveonthepumptoallowhydraulicfluidtobepushedback
fromthepullertoolintothepumpreservoir.(Thisisautomaticwiththeair‐operated
hydraulicpump)
2. Placethespannerringonthepullersidecylindricalnut.
3. Applyalightcoatofcleanturbineoiloraspraylubricanttothepullerscrew.Donotuse
“NeverSeize”ontheconicalthreads.
4. Placeandholdthepullertoolovertheendtobetightened.
5. Insertthepullerscrewthroughthepullertoolintothetaperedthreadofthestudandtighten.
6. Besurenottocross‐threadtheassembly.
7. TightenthepullerscrewusingAllenwrenchesonthepullerscrewandthestud.DONOT
wrenchontheHexnutoppositethepullertool.
8. Installthepullernutuntilitseatssnuglyonthepistonandthenback‐off2flats.Thisis
particularlyimportantforremovalbecausethestudshortensduringdisassemblyandthe
tensionermaythenbind.
9. AtthispointtheTensionerAssemblyMUSTBEFREETOROTATE,thepullerscrewistightin
thestudandthepullernuthasbeenbacked‐offthe2flats.

Note:Ifthetoolisnotfreetorotateitismostlikelythatthenutsmustberepositionedsothat
thestudmaybeshiftedslightlytothepullertoolsideoftheflange.Thiscanbeaccomplishedas
follows:

1. Backoffthepullernutandslightlyloosenthepullerscrew.
2. BackofftheHexnutoppositethepullertoolabout1/2turn.
3. Tightenthepullerscrewsidecylindricalnuttotakeuptheslack
4. Retightenthepullerscrewperaboveandcheckfortoollooseness

Note:Donotoverextendthestud.Overextensioncancausethepistontoloseitssealandleak
oil.



Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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REV
373A4006
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
CAUTION
Personalinjuryandequipmentdamagecanoccurifthepullerscrewisnotsecurelyengaged
withthetaperedthreadsofthestud.Properengagementisachievedwhenthepullerscrewis
tightinthestudandthetensionerassemblyisfreetoturn.


9.0StudPullingandTensioning

Thestudswillbetensionedintwosteps,atapproximately50%pressureandatfinalpressure.
Followthetensioningsequenceforeachflangejointasdefinedonthedatasheetsfoundatthe
endofthismanual.

Note:Beforethreadingthepullerscrewintothestud,carefullycheckthecleanlinessofboth
thestud'sandthepullerscrew'sconicalthreads.Applyalightcoatofcleanturbineoilora
spraylubricanttothepullerscrew.Donotuse“NeverSeize”ontheconicalthreads.This
procedurewilleaseassemblyandassurepositivematingofthethreadsbeforetightening.

WARNING
ThesafetycageMUSTbeinplaceandhandskeptoutofdesignatedareasatalltimeswhen
thepullertoolispressurizedotherwisepersonalinjurycanoccur.

9.1Tensioningat50%pressure

Afterthetensionerisproperlyinstalledapplyhydraulicpressuretothetool.Bringthepressure
tothe50%levelinaccordancewiththefollowingtable.

FlangePosition StudSize 50%Pressure 50%Stretch
TurbinetoCoupling 1‐1/8"
[29mm]
9000psi
[620bar]
Donotmeasure
Donotuse
CouplingtoGear 1‐1/8"
[29mm]
9000psi
[620bar]
Donotmeasure
Donotuse
GeartoQuillShaft 1‐5/8”
[41mm]
7500psi
[520bar]
Donotmeasure
Donotuse
QuillShaftto
Generator
1‐5/8”
[41mm]
7500psi
[520bar]
Donotmeasure
Donotuse



Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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
9.1.1Tighteningof1‐1/8”Nuts

Tightenthecylindricalnutshandtightusingthepinwrenchandspannerring(seefigure5).

9.1.2Tighteningof1‐5/8”Nuts

Tightenthecylindricalnutshandtightusingthepinwrenchandspannerring(seefigure6).

9.2RemovingtheTensionerfromanInstalledStud

Pullertoolremovalistobeaccomplishedasfollows:

1. Releasethepullertoolpressurebyopeningthevalveonthepump.Leavevalveopen.(Thisis
automaticwiththeair‐operatedhydraulicpump)
2. Unscrewthepullerscrewusingawrench.
3. Tappingthewrenchwithahammermaybenecessarytoloosenthepullerscrew
4. Movethetooltothenextstud/nutassemblytobetensioned,followingthesequence/pattern
asdefinedonthesupplieddatasheets

9.3TensioningatFinalPressure

Repeatthepullingandtighteningprocedurestatedaboveatfullpressure.Measuresthelength
ofthestudsafterallhavebeentensioned.Thefinalpressureandrequiredstretchvaluesare
listedinthefollowingtable

FlangePosition StudSize FinalPressure FinalStretch
TurbinetoCoupling 1‐1/8"
[29mm]
18000psi
[1250bar]
0.009"‐0.011"
[0.23mm‐0.28mm]
CouplingtoGear 1‐1/8"
[29mm]
18000psi
[1250bar]
0.008"‐0.010"
[0.20mm‐0.25mm]
GeartoQuillShaft 1‐5/8”
[41mm]
15000psi
[1035bar]
0.007"‐0.009"
[0.18mm‐0.23mm]
QuillShaftto
Generator
1‐5/8”
[41mm]
15000psi
[1035bar]
0.007"‐0.009"
[0.18mm‐0.23mm]



Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]
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
CAUTION
DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.

Excessivestretchvariationsorlowstretchvaluescanbecorrectedbyretensioningallor
selectedstudstothepressurevaluesstatedintheabovetable.Havefinalstretchvalues
approvedbythesupervisorresponsiblefortheinstallation

10.0ThreadLocking

Mechanicallocknutshavetwosetscrewslocatedinthetopface,seeFigure7.Before
threadingthenutontothestudchecktobecertainthesetscrewsarefreetoturn.Oncethe
nutisseatedtorquethesetscrewstothevaluesspecifiedinthefollowingtable.Whenseated
andtorquedtothevaluesspecifiedtheloadcreatedbythesetscrewdisplacesthethreadof
thenutintheareaofthewebcreatingthedesiredlockingaction.

StudSize SetScrewSize Torque
1‐1/8"
[29mm] #10‐32UN 30in∙lbs‐36in∙lbs
[3.4N∙m–4.1N∙m]
1‐5/8"
[41mm] 1/4"‐28UN 65in∙lbs‐87in∙lbs
[7.3N∙m–9.8N∙m]

CAUTION:

DONOTEXCEEDTHEMAXIMUMPRESSUREVIBROSCRIBEDONTHEPULLERBODY.Excessive
pressurecandamagethestudandthepullerscrew.

WARNING:
FireHazard,DONOTheatwhenpullerassemblyisinplace.Personalinjuryorequipment
damagemayoccur.UseofanOxy‐Acetylenetorchisnotrecommended


11.0Stud/Nutremoval

Forthoseassemblieswhichhavebeenlockedusingmechanicallocknuts,removalis
accomplishedasfollows:


Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
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
1. Usingawirebrushandshopaircleantheinternaltaperedthreadofthestudtoremoveany
debris/depositswhichmayhaveaccumulatedduringservice.(seesection5.2.1)
2. WithanAllen‐wrenchloosenthetwolockingsetscrewsbutdonotremovefromnutsee
Figure5.
3. InstalltheappropriatepullertooltothestudasdescribedinSection8.0.
4. ApplytheappropriatehydraulicpressureperthetableofSection9.3andusingthespanner
ringandspannerwrenchesshowninFigure6loosenthenut,thenreleasethepressureand
removethepullertool.


13.0FrequentlyAskedQuestions

Thissectioncontainssomefrequentlyaskedquestionsandproblems.Ifthestepslistedheredo
notsolveyourproblem,contacttheRiverhawkCompanythruourwebsite,email,orphonecall.

Q: Atensionerhaspulleditselfoutofthestud'sconicalthreads.CanIcontinueusinga
tensioneronthisstud?

A: No.Boththetensionerandthestudmayhavebeendamaged.Ifthestudistensioned,a
NutBusterrepairkit,fromRiverhawk,mustbeusedtoremovethedamagedstudby
drillingoutthenut.Riverhawkcansupplyareplacement studandnutbasedonthe
initialweightcertificationsuppliedwiththehardwareset(seesection4.2).The
damagedtensionershouldalsobereturnedtoRiverhawkforinspectionandrepair.


Q: Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlength
isshortofthefinalstretchtarget.Whatisthenextstep?

A: Donotincreasethehydraulicpressure.Checkifthehydraulicpumpissettotheright
pressure.Installthetensionerandre‐pressurizethetensionertothefinalpressurethen
recheckthestretchmeasurement.Ifthestretchvalueisstillshort,removethestud
fromtheholeandre‐measurethestud'sinitiallengththentrytoinstallthestudagain.


Q: Thehydraulictensionerhasbeentakenuptoitsfinalpressure.Thefinalstretchlength
islargerthanthefinalstretchtarget.Whatisthenextstep?

A: Removethestudfromthebolthole.Checkifthehydraulicpumpissettotheright
pressure.Re‐measurethestud'sinitiallengththentrytoinstallthestudagain.


Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]

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373A4006
GEDRAWINGNUMBER
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RevisionG
Page18of32
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Q: Isthereaneasierwaytosupportormovethetensioneraroundthecouplingshaft?

A: Usetwostraps.Onearoundthecouplingshaftandtheotherattachtoanyoverhead
support.Strapsmustbeslackduringmountingtensionertostudandduringtensioning.


Q: Thetensionerisatitsfinalpressure,butthenutcannotbeloosen.

A: Ifthenutscannotbeloosenedatthefinalpressure,continuallyincreasingthepressure
willnothelpandcanbedangerousandinsomecasesmakeithardertoremovethenut.
Checkthenuttoseeifitssetscrewshavebeenloosened.Checkforandremoveany
corrosionaroundthenut'sthreads.


Q: HowdoIcleantheconicalthreadsonastud?

A: Theconicalthreadsarebestcleanedusingaspiralwoundbrassbrushinadrillas
describedinsection5.2.2


Q: Duringtheinitialstepsofremovingatensionedstud,thestick‐outlengthisfoundtobe
wrong.

A: Donotproceed.ContactRiverhawkforassistance.Withthewrongstick‐outlength,the
hydraulictensionerhasalimitedstrokeandmaynotworkproperlyandcanbe
damaged.


Q: Thehydraulicpumpappearstobeleaking.

A: Checkthehoseconnectiontothehydraulicpump.Ifthe1/4"highpressurefittingisnot
assembledcorrectly,itmaylooklikethepumpisleaking.Iftheproblemcontinues,it
maybenecessarytoopenthepumpkit.ContactRiverhawkforguidance.


Q: Thehydraulichosehasacollaronitthatcan'tbemovedbyhand

A: Thehydraulicfittingisshowninsection7.1.1.Thecollarissometimesheldinplacewith
athreadlockingcompound.Thispreventsthecollarfrommovingtooeasily.Itmaybe

Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4006
GEDRAWINGNUMBER

RevisionG
Page19of32
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necessarytoadjustthiscollarwithasetofvise‐grippliers.Becarefultonotstripthe
threadsoffthetubeorhoseend.


14.0RevisionHistory

Revision
Letter
EffectiveDate Description
G May18,2022 UpdatedECDeclarationofConformity;AddedUKCA
DeclarationofConformity
F Jan15,2015 Updatedsections1.0,4.3,and15.0.
E Jun12,2014 AddedECDeclarationofConformity
D Jun10,2009 Addedturbineoilandremoved“NeverSeize”from
sections1.0,3.0,8.0,and9.0
C Mar25,2009 Addedsections3and13
B Sept19,2003 AddedGE382A4352andHF‐2312
A Sept10,2003 Drawings
‐ Aug11,2003 Released




Instruction Manual IM-150
CUSTOMER'SINFORMATIONBOX
CONTENTSAREINDEPENDENTOFRIVERHAWKDOCUMENTCONTROL

215ClintonRoad
NewHartford,NY13413
Tel:+13157684855
Fax:+13157684941
Email:[email protected]


REV
373A4006
GEDRAWINGNUMBER

RevisionG
Page20of32

AppendixA1

ECDeclarationofConformity


Manufacturer: RiverhawkCompany
Address: 215ClintonRoad
NewHartford,NY13413,USA


Thehydraulicpumpandbolttensioningtooldescribedinthismanualareusedforinstallingand
applyingtensiontolargeboltsthatarespecificallydesignedbyRiverhawkCompanytobe
tensionedhydraulically.

AllapplicablesectionsofEuropeanDirective2006/42/ECformachineryhavebeenappliedand
fulfilledinthedesignandmanufactureofthehydraulicpumpandbolttensioningtool
describedinthismanual.ReferencealsoISO12100:2010,ISO4413:2010,andISO4414:2010.

Furthermore,thisequipmenthasbeenmanufacturedundertheRiverhawkqualitysystemper
ENISO9001:2015

ConsulttheDeclarationofConformanceincludedwiththeshipmentofthisequipmentthat
identifiestheauthorizedRiverhawkrepresentative,applicableserialnumbers,andappropriate
signature.
