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This 'Original instructions' document assumes that the operator carrying out any operation with this
product is trained and competent to do so. This manual does not attempt to cover all details or variations
in the equipment. Nor does this manual claim to provide for every possible contingency met in connection
with the installation, operation, or maintenance thereof. Should further information be desired, or should
a particular problem arise which is not covered in sufficient detail, the matter should be referred to
Hi-Force.
OPERATING INSTRUCTION MANUAL
STS SERIES | TOPSIDE BOLT TENSIONERS
Hi-Force STS series Topside Bolt Tensioners are designed for topside operation, covering a variety of bolt
tensioning applications. STS series bolt tensioners come in a range of sizes, covering imperial bolts
4" in diameter and metric bolt sizes from M16 to M100. Load Capacities range from 234 kN up to 2649 kN,
with a maximum working pressure on all models of 1500 bar (21,750 psi). Interchangeable accessories
allow load cells to be used on multiple stud sizes. This manual applies to Hi-Force STS series topside bolt
tensioners. It contains the latest product information available at the time of publication and approval. For
information relating to the servicing of a topside bolt tensioner, see the servicing instructions, which are
available on the Hi-Force website. Hi-Force reserves the right to make changes to this document at any
time without notice.
Operating Instruction Manual:
OM-STS-01
1
Serial Numbers:
All
" to
¾
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Summary of Contents for Hi-Force STS Series
- Page 1 1500 bar (21,750 psi). Interchangeable accessories allow load cells to be used on multiple stud sizes. This manual applies to Hi-Force STS series topside bolt tensioners. It contains the latest product information available at the time of publication and approval. For information relating to the servicing of a topside bolt tensioner, see the servicing instructions, which are available on the Hi-Force website.
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Page 2: Table Of Contents
Operating Instruction Manual: Serial Numbers: OM-STS-01 Table of Contents 1.0 Inspection upon Receipt ..............3 2.0 Safety Precautions ................3 3.0 Declaration of Incorporation / Conformity ........6 4.0 Component Identification ..............7 5.0 Installation/Setup ................8 6.0 Operation ..................12 7.0 Maintenance and Storage .............. -
Page 3: Inspection Upon Receipt
If in doubt on the correct use of any Hi-Force equipment, contact your nearest Hi-Force office or distributor. Only qualified personnel should be allowed to operate hydraulic equipment. If an operator has not been trained on high-pressure hydraulic equipment and its safe usage, consult your local Hi-Force sales office or distributor who can offer training courses for operators. - Page 4 NEVER attempt to solve, or clean up leaks in the system while the system is pressurised. Immediately replace any worn or damaged parts using genuine Hi-Force parts only. DO NOT remove any labels from the product. Replace any damaged or unreadable labels immediately.
- Page 5 A comprehensive bolting sequence and tensioning / de-tensioning procedure should be prepared and overseen by a trained professional with bolting experience. Hi-Force recommends that the entire tensioning / de-tensioning process be read and fully understood prior to tensioning. ...
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Page 6: Declaration Of Incorporation / Conformity
3.0 Declaration of Incorporation / Conformity Hi-Force declares that this product has been tested and complies with the standards set out in the relevant EU directives. The EU Declaration of Incorporation / Conformity is included as Annex A to this instruction... -
Page 7: Component Identification
Operating Instruction Manual: Serial Numbers: OM-STS-01 4.0 Component Identification Load Cell Male Coupler Bridge Female Coupler Bridge Window Nut Rotating Socket (Optional) Threaded Puller Tommy Bar (Optional) Piston Dust Caps Figure 4.1: Component Identification... -
Page 8: Installation/Setup
Connection to the hydraulic pump must ALWAYS be made to the male coupler on the tensioner. Hi-Force STS tensioners are fitted with dual quick-connect couplers. Connections between couplers (see figure 5.2) are made by [1] pulling back the spring collar on the female coupler. - Page 9 NOTE: The last tensioner in the system will have an unconnected female coupler. This is correct, and it can be left unconnected. Alternatively, this last coupler can be removed, and a suitable high-pressure blanking plug fitted. (Contact your local Hi-Force office or distributor for further details).
- Page 10 Operating Instruction Manual: Serial Numbers: OM-STS-01 Figure 5.3: Bolt Tensioner Installation...
- Page 11 Operating Instruction Manual: Serial Numbers: OM-STS-01 NOTE: The joint is tensioned in 2 Stages. 50% of the studs are tensioned in the first stage. remaining studs tensioned in the second stage. Figure 5.4: Bolt Tensioner Sequence (50% Coverage) Link hose – maximum working pressure = 1500 bar (21,750 psi) SAFETY NOTE:...
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Page 12: Operation
OM-STS-01 6.0 Operation Hi-Force STS bolt tensioners are operated by means of a suitable hydraulic pump. Make sure you read this manual in conjunction with the pumps operating instruction manual to ensure correct and safe operation of the hydraulic system. - Page 13 This allows the tensioner to be kept compact, for use in confined spaces. Hi-Force STS tensioners have a maximum stroke indicator in the form of a red band on the piston.
- Page 14 Operating Instruction Manual: Serial Numbers: OM-STS-01 6.4 Setting / Releasing the Nut/s. (Figure 6.2) Once the studs/bolts have been tensioned, and the system pressure is holding stable. Approach the tensioner/s and with a tommy bar, (through the bridge access window) (3) fully tighten the nut/s against the workpiece surface, or loosen the nut/s by rotating them a maximum of 4-flats.
- Page 15 Operating Instruction Manual: Serial Numbers: OM-STS-01 6.6 Removing the tensioner/s. (Figure 6.4) 1. Disconnect all hoses and fit dust caps (not shown) to the couplers. 2. Turn the threaded puller anti-clockwise until it disengages from the threads of the stud [A]. 3.
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Page 16: Maintenance And Storage
8.1 Oil Specifications Hi-Force cylinders/tools will use 1 of 2 grades of oil, dependant on the pump used. The tools are designed to operate at temperatures between -20°C and 80°C. Details of the oil used can be found in the pumps operating instruction manual, in the section: FILLING OF PUMP WITH OIL. - Page 17 Operating Instruction Manual: Serial Numbers: OM-STS-01 8.2 STS Specifications Refer to the engraved detail on the tensioner for model identification. STS - TOPSIDE BOLT TENSIONERS (METRIC) Bolt Thread Capacity Effective Area Stroke Model Thread Pitch Number (kN) (tonnes) (mm) Size (mm) STS1-M16B1 23.9...
- Page 18 Operating Instruction Manual: Serial Numbers: OM-STS-01 STS - TOPSIDE BOLT TENSIONERS (IMPERIAL) Bolt Capacity Effective Area Stroke Model Threads Thread Number per Inch (kN) (tonnes) (mm) Size ¾” STS1-075B1 23.9 15.6 ⅞” STS1-087B1 23.9 15.6 1” STS1-100B2 23.9 15.6 ⅛ ”...
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Page 19: Conversion Charts & Tables
Operating Instruction Manual: Serial Numbers: OM-STS-01... - Page 20 Operating Instruction Manual: Serial Numbers: OM-STS-01...
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Page 21: System Components / Accessories
Operating Instruction Manual: Serial Numbers: OM-STS-01 10.0 System Components / Accessories (Refer to the Hi-Force website or latest Hi-Force catalogue for further details) Tommy Bars for Tensioner Series STS1 - STS6 Optional Bridges for Load Cells STS1, STS3, STS4 & STS6 ... -
Page 22: Troubleshooting
Operating Instruction Manual: Serial Numbers: OM-STS-01 11.0 Troubleshooting Hi-Force STS topside bolt tensioners should be serviced and repaired only by authorised Hi-Force repair centres. The following table gives possible causes and solutions for common problems. TROUBLESHOOTING GUIDE Problem Possible Cause Solution 1. -
Page 23: Contact Details
Operating Instruction Manual: Serial Numbers: OM-STS-01 UK Head Office: Hi-Force Limited Prospect Way, Daventry, Northamptonshire NN11 8PL United Kingdom Tel: + 44 1327 301000 Fax: + 44 1327 706555 Email: daventry@hi-force.com... - Page 24 Baku Milano Azerbaijan Italy Tel: +994 124 474 100 Tel: +39 0257 607 174 Email: baku@hi-force.com Email: italy@hi-force.com Hi-Force Hydraulics (Asia) S.B. Hi-Force Nederland B.V. Selangor Numansdorp Malaysia Netherlands Tel: +603 5525 4203 Tel: +31 85 902 8111 Email: malaysia@hi-force.com Email: holland@hi-force.com...
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