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L4371 Rev. B 10/19

Instruction Sheet

HydraMax® Series Hydraulic Tensioners

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Summary of Contents for HydraMax HM01

Page 1: ...L4371 Rev B 10 19 Instruction Sheet HydraMax Series Hydraulic Tensioners ...

Page 2: ... ovat osoitteessa www enerpac com Pour toutes les autres langues rendez vous sur www enerpac com Per altre lingue visitate il sito www enerpac com Ga voor de overige talen naar www enerpac com For alle andre språk henviser vi til www enerpac com Inne wersje językowe można znaleźć na stronie www enerpac com Para outros idiomas consulte www enerpac com För andra språk besök www enerpac com ...

Page 3: ...t covered by the Enerpac warranty Warranty Enerpac guarantees the product only for the purpose for which it is intended Refer to the Enerpac Global Warranty document for terms and conditions of the product warranty Any misuse or alteration invalidates the warranty Observe all instructions as communicated in this manual When replacement parts are needed use only genuine Enerpac replacement parts Mo...

Page 4: ... HM05 HM06 HM07 HM08 HM09 HM10 HM11 HM12 HM13 HM14 HM15 These tools conform with the requirements for CE 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 WARNING CAUTION and NOTICE Indicates a hazardous situation tha...

Page 5: ...load to a bolt than the maximum capacity of the tensioner Overloading may cause equipment failure and possible personal injury Failure to observe and comply with the following precautions could result in minor or moderate personal injury Property damage could also occur Be careful to avoid damaging hydraulic hoses Avoid sharp bends and kinks when routing hydraulic hoses Do not bend beyond the mini...

Page 6: ...es visible may result in high pressure hydraulic oil leakage Serious personal injury could result if a stream of pressurized hydraulic oil penetrates the skin Damage to tensioner components and joint may also occur if maximum stroke is exceeded Maximum Stroke Indicator FIGURE 3 MAXIMUM STROKE INDICATOR WARNING 3 0 SPECIFICATIONS Major tensioner specifications such as maximum working pressure maxim...

Page 7: ...l will be contained inside hoses and fittings 5 0 SETTING UP 5 1 Hydraulic Oil Oil requirements will vary depending on pump model and type Refer to your pump instruction manual for oil specifications Failure to use genuine Enerpac hydraulic oil may void warranty 5 2 Hoses and Fittings All hydraulic hoses and fittings used in the circuit must be rated at or above the maximum working pressure of the...

Page 8: ...connection of hydraulic hoses 5 Locate the end of the stud with the threaded puller Using a tommy bar screw down the threaded puller on the stud until the puller shoulder seats firmly against the piston See Figure 5 View B 6 Assemble any additional tensioners in the system in the same manner following steps 3 through 6 of this section 7 Check that the pump pressure release valve is OPEN See Figure...

Page 9: ... 2019 Enerpac All Rights Reserved 7 FIGURE 5 HYDRAULIC TENSIONER INSTALLATION A C PRESSURE RELEASE OPEN D 0 E 0 B PRESSURE RELEASE OPEN ...

Page 10: ...Pump 8 2019 Enerpac All Rights Reserved 6 3 Tensioner Arrangements typical Hydraulic tensioners can be mounted on either one or both sides of the joint depending on available clearance and work room Whenever possible all studs on the joint should be tensioned at the same time Typical examples of 100 and 50 tensioner coverage are shown in Figure 6 Contact Enerpac for additional information regardin...

Page 11: ... before continuing Refer to Section 4 1 for additional information IMPORTANT If any leaks occur immediately stop the pump and open the pressure release return to tank valve Be sure that the oil pressure gauge indicates zero 0 psi bar Make repairs as required before continuing with tensioning procedures Note For improved illustration clarity only one hydraulic hose is shown connected to the tension...

Page 12: ...n the threaded puller until the piston is fully retracted into the tensioner body See Figure 11 11 Repeat steps 4 through 10 a second time 12 Repeat steps 4 through 10 a third time 13 As an optional check apply hydraulic pressure a fourth time and attempt to tighten the nuts again If the nuts cannot be turned then tensioning is complete Relieve hydraulic pressure Go to Step 14 If the nuts can stil...

Page 13: ...future reference 3 Assemble the tensioner s to the studs marked 1 and connect the hydraulic hoses See Figure 12 for typical tensioner arrangement Also refer to sections 6 1 and 6 2 for additional tensioner installation and hook up instructions 4 Determine the first pass pressure A value This value must be calculated by a qualified engineer with bolting experience Note The pressure A value used to ...

Page 14: ...hed stop the pump Recheck the oil pressure gauge after pump has stopped Be sure the pressure remains stable not increasing or decreasing Threads may be visible between the nut and the joint surface at each tensioner See Figure 7 19 While holding the pressure constant use a tommy bar to turn down the first socket and nut by hand Continue tightening until the nut is firmly seated against the joint s...

Page 15: ...15 3 Operate the pump to pressurize the tensioners up to approximately 1000 psi 70 bar Check for oil leaks In the following de tensioning steps be certain that the hydraulic pressure remains below the maximum allowable hydraulic pressure of 21 750 psi 1500 bar and that the load applied does not exceed the tensile strength of the stud 4 If no leaks are found continue operating the pump Slowly raise...

Page 16: ...sing the hydraulic pressure tension in the stud has caused the puller to become locked on the ram To release the puller the hydraulic pressure must be re applied and the nut rotated via the socket until the nut seats on the flange joint face Depressurise the system the puller should now be free to be turned by hand CAUTION 7 4 De tensioning Instructions 50 Coverage tensioner installed on every oth...

Page 17: ...are found upon Enerpac s inspection not to be Enerpac s genuine spare parts will invalidate any operative warranty or guarantee Note It is strongly recommended that in the event of seal failure the tensioners are returned to Enerpac for seal replacement however if this is not possible then the enclosed procedure should be followed 8 1 Pre Use Maintenance Assemble the tensioner onto a suitable bolt...

Page 18: ...s cover thread areas Remove all dust dirt swarf and foreign particles Do not use sharp edged tools Lubricate all components before assembly Hydraulic seal replacement must only be carried out should the seals become damaged The seals should not be removed during routine maintenance 16 2019 Enerpac All Rights Reserved 2 Ram Legend for Figures 1 Seal 2 Ram 3 Anti Extrusion Ring AER 4 Pliers 5 Blunt ...

Page 19: ...tion of installing the ram Push the ram into the body bore ensuring that the seal does not become nipped The outer seal will be the first to enter and can be used as a guide to square up the ram prior to entering the inner seal Should difficulty be encountered in entering seals a slight rotation of the ram whilst pushing the ram into the body may aid the installation 5 Coupler Seals 5a 1 4 BSP Fit...

Page 20: ... from the tensioner body using the hexagon of the adaptor not the coupler Clean any dirt and debris from the tensioner body counterbore and the sealing face on the adaptor Do not lubricate the 1 8 BSP thread on the adaptor it is important that the adaptor is installed dry to prevent overloading the threads thread sealant should not be used Screw the adaptor into the tensioner body and tighten to a...

Page 21: ...eturn to tank valve 2 Tap the pump head ligtly with a hide hammer If this fails the pump must be stripped down Pump stalls prior to reaching required pressure 1 Insufficient air supply 2 Air pressure regulator 1 Increase air supply 2 Adjust air regulator Maximum pressure cannot be achieved even when pump is running continuously 1 Leaking couplers 2 Leaking tensioner seals 3 Hydraulic oil return va...

Page 22: ...ic hose is not connected properly to the tool 2 The bolt thread may be damaged 1 Release the pressure and check the hose connec tion 2 Release the pressure remove the tool and rectify When detensioning the bolt the tool becomes locked onto the bolts 1 Puller locked on nut 2 Puller locked on ram 1 See Section 7 3 2 See Section 7 3 The tensioner head assembly will not retract 1 Oil return to tank va...

Page 23: ... 2019 Enerpac All Rights Reserved 21 11 0 TECHNICAL DATA 11 1 HydraMax Tensioner Specifications FIGURE 22A FIGURE 22B X X minimum socket rotation 60 D B F A E Nearest obstruction ...

Page 24: ... 105 15 81 211 28 58 1 1 2 2 HM03BPM NRS02430 M24 x 3 1628 244 1 120 105 20 81 211 28 59 1 1 2 2 HM03BP NRS0750U10 10un 1628 244 1 120 105 15 81 211 28 56 1 1 2 2 HM03BP NRS0875U09 9un 1628 244 1 120 105 18 81 211 28 58 1 1 2 2 HM03BP NRS1000U08 1 8un 1628 244 1 125 110 20 81 216 33 60 1 1 HM04 LC 2 7 HM04BPM NRS02225 M22 x 2 5 2159 323 8 128 112 18 90 230 28 62 1 6 2 7 HM04BPM NRS02430 M24 x 3 21...

Page 25: ...5 HM06BPM NRS03035 M30 x 3 5 4162 624 1 143 126 23 118 246 36 80 2 8 4 5 HM06BPM NRS03335 M33 x 3 5 4162 624 1 146 129 27 118 249 39 82 2 9 4 5 HM06BPM NRS03640 M36 x 4 4162 624 1 149 132 32 118 252 42 83 3 0 4 5 HM06BPM NRS03940 M39 x 4 4162 624 1 152 135 33 118 255 45 85 3 1 4 5 HM06BP NRS1125U08 1 8un 4162 624 1 143 126 23 118 246 36 79 2 8 4 5 HM06BP NRS1250U08 1 8un 4162 624 1 146 129 27 118 ...

Page 26: ... 1 158 142 39 137 261 51 97 4 4 6 3 HM08BP NRS1375U08 1 8un 5869 880 1 149 133 32 137 252 42 92 3 9 6 3 HM08BP NRS1500U08 1 8un 5869 880 1 152 136 33 137 255 45 94 4 0 6 3 HM08BP NRS1625U08 1 8un 5869 880 1 155 139 34 137 258 48 95 4 1 6 3 HM08BP NRS1750U08 1 8un 5869 880 1 158 142 39 137 261 51 97 4 4 HM09 LC 6 5 HM09BPM NRS03940 M39 x 4 6834 1024 9 152 136 33 145 255 45 98 5 0 6 5 HM09BPM NRS042...

Page 27: ...08 1 8un 7868 1179 8 165 149 42 156 272 54 108 6 0 8 3 HM10BP NRS2000U08 2 8un 7868 1179 8 169 153 44 156 276 58 109 6 3 HM11 LC 10 5 HM11BPM NRS04545 M45 x 4 5 10 152 1522 5 167 146 39 175 274 51 116 7 4 10 5 HM11BPM NRS04850 M48 x 5 10 152 1522 5 170 149 42 175 277 54 118 7 9 10 5 HM11BPM NRS05250 M52 x 5 10 152 1522 5 174 153 44 175 281 58 120 8 1 10 5 HM11BPM NRS05655 M56 x 5 5 10 152 1522 5 1...

Page 28: ...9 42 194 281 54 127 9 6 13 3 HM12BP NRS2000U08 2 8un 12 722 1907 7 174 153 44 194 285 58 128 9 8 13 3 HM12BP NRS2250U08 2 8un 12 722 1907 7 182 161 50 194 293 66 132 10 4 13 3 HM12BP NRS2500U08 2 8un 12 722 1907 7 186 165 56 194 297 70 135 10 8 HM13 LC 17 6 HM13BPM NRS06460 M64 x 6 16 964 2544 0 195 173 56 219 310 70 148 14 5 17 6 HM13BPM NRS06860 M68 x 6 16 964 2544 0 195 173 56 219 310 70 150 16...

Page 29: ...9 259 337 96 181 23 3 25 8 HM14BP NRS3000U08 3 8un 23 451 3516 7 207 186 69 259 324 82 174 20 4 25 8 HM14BP NRS3250U08 3 8un 23 451 3516 7 216 164 70 259 302 91 177 22 7 25 8 HM14BP NRS3500U08 3 8un 23 451 3516 7 221 199 79 259 337 96 184 23 9 HM15 LC 32 5 HM15BPM NRS09060 M90 x 6 31 008 4650 0 221 199 79 296 337 96 199 30 0 32 5 HM15BPM NRS09560 M95 x 6 31 008 4650 0 226 205 81 296 343 101 202 33...

Page 30: ...3 2 8 3 1 1 2 3 2 4 4 9 HM03BPM NRS02430 M24 x 3 2 52 27 4 4 7 4 1 0 8 3 2 8 3 1 1 2 3 2 4 4 9 HM03BP NRS0750U10 10un 2 52 27 4 4 7 4 1 0 6 3 2 8 3 1 1 2 2 2 4 4 9 HM03BP NRS0875U09 9un 2 52 27 4 4 7 4 1 0 7 3 2 8 3 1 1 2 3 2 4 4 9 HM03BP NRS1000U08 1 8un 2 52 27 4 4 9 4 3 0 8 3 2 8 5 1 3 2 4 2 4 HM04 LC 6 0 HM04BPM NRS02225 M22 x 2 5 3 35 36 4 5 0 4 4 0 7 3 5 9 1 1 1 2 4 3 5 6 0 HM04BPM NRS02430 ...

Page 31: ...PM NRS03035 M30 x 3 5 6 45 70 2 5 6 5 0 0 9 4 6 9 7 1 4 3 1 6 2 9 9 HM06BPM NRS03335 M33 x 3 5 6 45 70 2 5 7 5 1 1 1 4 6 9 8 1 5 3 2 6 4 9 9 HM06BPM NRS03640 M36 x 4 6 45 70 2 5 9 5 2 1 3 4 6 9 9 1 6 3 3 6 6 9 9 HM06BPM NRS03940 M39 x 4 6 45 70 2 6 0 5 3 1 3 4 6 10 0 1 8 3 3 6 8 9 9 HM06BP NRS1125U08 1 8un 6 45 70 2 5 6 5 0 0 9 4 6 9 7 1 4 3 1 6 2 9 9 HM06BP NRS1250U08 1 8un 6 45 70 2 5 7 5 1 1 1 ...

Page 32: ...0 3 2 0 3 8 9 7 13 9 HM08BP NRS1375U08 1 8un 9 10 98 9 5 9 5 2 1 3 5 4 9 9 1 6 3 6 8 6 13 9 HM08BP NRS1500U08 1 8un 9 10 98 9 6 0 5 3 1 3 5 4 10 0 1 8 3 7 8 8 13 9 HM08BP NRS1625U08 1 8un 9 10 98 9 6 1 5 5 1 3 5 4 10 1 1 9 3 7 9 0 13 9 HM08BP NRS1750U08 1 8un 9 10 98 9 6 2 5 6 1 5 5 4 10 3 2 0 3 8 9 7 HM09 LC 14 3 HM09BPM NRS03940 M39 x 4 10 59 115 2 6 0 5 4 1 3 5 7 10 0 1 8 3 9 11 0 14 3 HM09BPM ...

Page 33: ...U08 1 8un 12 20 131 9 6 5 5 9 1 6 6 1 10 7 2 1 4 2 13 2 18 3 HM10BP NRS2000U08 2 8un 12 20 131 9 6 7 6 0 1 7 6 1 10 8 2 3 4 3 13 9 HM11 LC 23 1 HM11BPM NRS04545 M45 x 4 5 15 74 171 1 6 6 5 7 1 5 6 9 10 8 2 0 4 6 16 3 23 1 HM11BPM NRS04850 M48 x 5 15 74 171 1 6 7 5 8 1 6 6 9 10 9 2 1 4 6 17 4 23 1 HM11BPM NRS05250 M52 x 5 15 74 171 1 6 8 6 0 1 7 6 9 11 0 2 3 4 7 17 9 23 1 HM11BPM NRS05655 M56 x 5 5...

Page 34: ...7 6 11 0 2 1 5 0 21 2 29 3 HM12BP NRS2000U08 2 8un 19 72 214 4 6 8 6 0 1 7 7 6 11 2 2 3 5 1 21 6 29 3 HM12BP NRS2250U08 2 8un 19 72 214 4 7 2 6 3 2 0 7 6 11 5 2 6 5 2 22 9 29 3 HM12BP NRS2500U08 2 8un 19 72 214 4 7 3 6 5 2 2 7 6 11 7 2 7 5 3 23 8 HM13 LC 38 8 HM13BPM NRS06460 M64 x 6 26 29 285 9 7 7 6 8 2 2 8 6 12 2 2 7 5 8 32 0 38 8 HM13BPM NRS06860 M68 x 6 26 29 285 9 7 7 6 8 2 2 8 6 12 2 2 7 5 ...

Page 35: ... 13 3 3 8 7 1 51 4 56 9 HM14BP NRS3000U08 3 8un 36 35 395 3 8 1 7 3 2 7 10 2 12 7 3 2 6 8 45 0 56 9 HM14BP NRS3250U08 3 8un 36 35 395 3 8 5 6 5 2 7 10 2 11 9 3 6 7 0 50 0 56 9 HM14BP NRS3500U08 3 8un 36 35 395 3 8 7 7 8 3 1 10 2 13 3 3 8 7 2 52 7 HM15 LC 71 6 HM15BPM NRS09060 M90 x 6 48 06 522 7 8 7 7 8 3 1 11 7 13 3 3 8 7 8 66 1 71 6 HM15BPM NRS09560 M95 x 6 48 06 522 7 8 9 8 1 3 2 11 7 13 5 4 0 ...

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Page 38: ...http www enerpac com ...

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