riverhawk MP-0130 Instruction Manual

For hydraulic pump kits used with gas and steam turbine's hydraulic tensioners

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Applicable Riverhawk Part Numbers

MP‐0130 Manual Hydraulic Pump Kit

MP‐6809 Manual Hydraulic Pump Kit

AP‐0532 Air‐Driven Hydraulic Pump Kit

AP‐6048 Air‐Driven Hydraulic Pump Kit

Applicable GE Ordering Sheet Part Numbers

No Specific Ordering

Sheet Part Numbers

MLI:

CHECKED:

ISSUED:

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.

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Field Service

INSTRUCTION MANUAL IM‐293

For Hydraulic Pump Kits used with Gas and

Steam Turbine's Hydraulic Tensioners

CUSTOMER'S INFORMATION BOX

CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL

GE Power & Water

VENDOR SUPPLIED

GE NOT TO REVISE. GE REVISION LEVEL IS SHOWN ON THIS APPLIQUE.

THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER.

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.

GE SIGNATURES

DATE

215 Clinton Road

New Hartford, NY 13413

Tel: +1 315 768 4855

Fax: +1 315 768 4941

Email: info@riverhawk.com

GENERAL ELECTRIC COMPANY

____ OF ____

GE DRAWING NUMBER

373A4058

REV

Revision F

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Summary of Contents for riverhawk MP-0130

Page 1 INSTRUCTION MANUAL IM‐293 For Hydraulic Pump Kits used with Gas and Steam Turbine’s Hydraulic Tensioners Applicable Riverhawk Part Numbers MP‐0130 Manual Hydraulic Pump Kit MP‐6809 Manual Hydraulic Pump Kit AP‐0532 Air‐Driven Hydraulic Pump Kit AP‐6048 Air‐Driven Hydraulic Pump Kit Applicable GE Ordering Sheet Part Numbers No Specific Ordering Sheet Part Numbers CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE Power & Water GENERAL ELECTRIC COMPANY VENDOR SUPPLIED GE NOT TO REVISE. GE REVISION LEVEL IS SHOWN ON THIS APPLIQUE. THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER. 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. MLI: ____ OF ____ GE SIGNATURES...
Page 2 Appendix A2 UKCA Declaration of Conformity 17 Figure 1 MP‐0130 Manual Pump Kit 18 Figure 2 MP‐0130 Manual Pump Kit 18 Figure 3 AP‐0532 Air‐Driven Pump Kit 19 Figure 4 AP‐6048 Air‐Driven Pump Kit 20 Figure 5 MP‐6809 Manual Pump Kit 21 Figure 6 MP‐6809 Manual Pump Kit 21 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 2 of 21 ...
Page 3 Instruction Manual IM‐293 1.0 Cautions and Safety Warnings WARNING Improper tool use and the failure to follow the correct procedures are the primary root causes of tool failures and personal injuries. A lack of training or experience can lead to incorrect equipment installation or incorrect pump use. Only trained operators with careful, deliberate actions should use hydraulic pumps and hydraulic tools. CAUTION Personal injury and equipment damage can occur if the proper health and safety codes and procedures are not followed. Contact the site’s health and safety office to determine all applicable safety rules and regulations. WARNING The proper personal protective equipment must be worn at all times. CAUTION Riverhawk recommends that the hydraulic pumps should be returned to Riverhawk for periodic inspections. Replacement of obsolete hydraulic pumps is recommended. Functional upgrades are also recommended. The Riverhawk Service Returns Coordinator should be notified 3‐6 months prior to a planned outage to schedule an inspection service. CAUTION Air can become trapped in the hydraulic system when connecting hoses and tensioners to a hydraulic pump. Refer to the hydraulic tensioner’s instructions to determine if bleeding the air out of the hydraulic system is required. CAUTION Depending on the amount of air present in the connected hoses or tensioners, it may be necessary to refill the pump with hydraulic oil. WARNING Check the maximum working pressures of the hoses and tensioners connected to the pump. Do not exceed the maximum working pressure of the pump, hose, or tensioner. CUSTOMER'S INFORMATION BOX ...
Page 4 359B2502 Air‐Driven Hydraulic Pump Kit AP‐6048 269B8768 Air‐Driven Hydraulic Pump Kit The figures at the end of this manual depict the location of the components used to operate the hydraulic pump kits. 3.0 Quick Checklist The following checklist is intended as a summary of the steps needed to use the Riverhawk‐ supplied hydraulic pump kits. New personnel or those experienced personnel who have not used the Riverhawk equipment recently are encouraged to read the entire manual. □ Check oil level in the hydraulic pump. (Refer to section 6.2 for more information) For the air‐driven hydraulic pump, insure that the pump’s air pressure is set between □ 80 psi [5.5 bar] to 100 psi [6.9 bar]. □ Check hydraulic pressure gage for any damage. ...
Page 5 Instruction Manual IM‐293 □ Connect the hydraulic hose to the tensioner in accordance with the tensioner’s instructions 4.0 General Preparations before Use 4.1 Check Hydraulic Pump Kit 4.1.1 Check Manual Hydraulic Pump Kit CAUTION Riverhawk recommends that the hydraulic pumps should be returned to Riverhawk for periodic inspections. Replacement of obsolete hydraulic pumps is recommended. Functional upgrades are also recommended. The Riverhawk Service Returns Coordinator should be notified 3‐6 months prior to a planned outage to schedule an inspection service. Check the pump kit for any visible signs of damage. Do not use if the pump is damaged. The pump kit is shipped from the Riverhawk factory full of hydraulic oil. Verify oil level as described in section 6.2.1. Check hydraulic pressure gage for any damage. Review section 5.1 for operating instructions prior to testing the pump. Test pump by dead‐heading (leave port plug in place) and pump the lever arm. The pressure gauge should build pressure and then hold the steady pressure when the lever is motionless. 4.1.2 Check Air‐Driven Hydraulic Pump Kit CAUTION Riverhawk recommends that the hydraulic pumps should be returned to Riverhawk for periodic inspections. Replacement of obsolete hydraulic pumps is recommended. Functional upgrades are also recommended. The Riverhawk Service Returns Coordinator should be notified 3‐6 months prior to a planned outage to schedule an inspection service. Check the pump kit for any visible signs of damage. Do not use if the pump is damaged. ...
Page 6 The pump reservoir cap is sealed for shipment. Replace the grey shipping plug with the red plastic reservoir cap. A supply of clean, dry air is required. Lubricated air is not required. Attach the male air fittings to the pump’s air filter‐regulator. Attach the female air fitting to the air hose. Couple the air hose to the air filter‐regulator and adjust the air filter‐regulator knob until the air pressure gage reads the pressure level marked on the pump. For most air‐driven pumps, the air supply pressure should be set to within the range of 80 psi [5.5 bar] to 100 psi [6.9 bar]. Review section 5.2 for operating instructions prior to testing the pump. Test pump by dead‐heading (leave port plug in place) and activate the pump. The pressure gauge should build pressure and then hold the steady pressure when the pump stops. 4.2 Check Hydraulic Hose Check the hydraulic hose for any damage including bent hose ends, kinked hose and split outer lining. If any damage is found, replace the hose immediately by contacting Riverhawk Company. 4.2.1 The 1/4” High Pressure Fitting Assembly The Riverhawk hydraulic hose may use a 1/4" High Pressure Fitting to connect to a tensioner. The hose connector is made from a three piece assembly: a gland nut, a collar, and a 1/4” tube or 1/4” hose end. (See Illustration 1) To assembly the fitting, slide the gland nut over the 1/4” tube or 1/4” hose end. Turn the collar counter‐clockwise (left hand thread) on to the tube or hose end as shown in Illustration 1. Illustration 1 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL ...
Page 7 N‐m). Tips:  Make sure all parts are clean and free from debris.  Protect the cone on the end of the 1/4” tube or 1/4” hose end from scratches as this is the sealing surface.  Replace red plastic caps when finished to Illustration 3 protect the threads and cone. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 7 of 21 ...
Page 8 Instruction Manual IM‐293 4.2.2 The 3/8” High Pressure Fitting Assembly The Riverhawk hydraulic hose may use a 3/8" High Pressure Fitting to connect to a tensioner. The hose connector is made from a three piece assembly: a gland nut, a collar, and a 3/8” tube or 3/8” hose end. (See Illustration 4) To assembly the fitting, slide the gland nut over the 3/8” tube or 3/8” hose end. Turn the collar counter‐clockwise (left hand thread) on to the tube or hose end as shown in Illustration 4. Illustration 4 The collar should be placed .250” (6.4 mm) from the tip of the cone. (See Illustration 5) It may be 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. Illustration 5 CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 ...
Page 9 Before connecting the hydraulic hose to the pump or tensioner, check the hydraulic port for grit, dirt, and other debris. Clean with a brush and, if necessary, with a volatile solvent such as acetone. Do not force the debris deeper into the port. 4.4 Check Hydraulic Tensioner Refer to the hydraulic tensioner instruction manual for inspection procedure. 5.0 Operation 5.1 Manual Pump Operation The figures 1 and 2 at the end of this manual depict the location of the components used to operate the manual pump kits. Step #1: Connect the pump to the tensioner with the appropriate hydraulic hose and open the release knob. WARNING Check the maximum working pressures of the hoses and tensioners connected to the pump. Do not exceed the maximum working pressure of the pump, hose, or tensioner. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 9 of 21 ...
Page 10 Step #6: To relieve the hydraulic pressure, open the release knob to allow the tensioner to fully retract. The tensioner will take approximately 30 seconds to retract. It is the best practice to leave the release knob in the open position while the tensioner is connected to the pump. Even though the pump’s pressure gage reads no pressure, the tensioner can still be retracting. 5.2 Air‐Driven Pump Operation The figures 3 and 4 at the end of this manual depict the location of the components used to operate the hydraulic pump kits. Refer to the inside cover of the pump for instructions that are specific to the pump. The following sections are generic instructions that may be superseded by the instructions inside the pump. Step #1: Connect the pump to the tensioner with the appropriate hydraulic hose. WARNING Check the maximum working pressures of the hoses and tensioners connected to the pump. Do not exceed the maximum working pressure of the pump, hose, or tensioner. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 10 of 21 ...
Page 11 Step #5: Activate the pump’s switch. Step #6: Slowly turn the hydraulic pressure knob clockwise until the target hydraulic pressure is reached. Step #7: Once the target pressure is reached, perform the steps required by the tensioner’s instructions. Step #8: Deactivate the pump’s switch to release the hydraulic pressure. It is the best practice to leave the air‐driven pump connected to the tensioner. Even though the pump’s pressure gage reads no pressure, the tensioner can still be retracting. 6.0 Service and Maintenance 6.1 Replacement Hydraulic Oil Lost oil should be replaced with Enerpac Hydraulic Oil. ISO 32 or equivalent hydraulic oil may be substituted. Do not overfill the pump’s oil reservoir. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 11 of 21 ...
Page 12 6.2.2 Oil Level for MP‐6809 Manual Pump Kits The filler hole on the hydraulic oil reservoir is also used to check the level. The oil level is correct when the oil reaches the bottom edge of the filler hole. Refit the filler plug and tightened by hand until cap stops. 6.2.3 Oil Level for Air‐Driven Pump Kits Place the pump kit on a flat level surface and remove the grey shipping plug or the red plastic reservoir cap. The oil level is correct when the oil is approximately 1 inch (25 mm) below the top of the reservoir. A flashlight may be helpful to see the oil level. Refit the grey shipping plug or the red plastic reservoir cap. 6.3 Maintenance Lubricate the moving parts on the manual pump. Check the air filter on the air‐driven pump kit for excessive dirt and debris buildup. Examine the pump’s hydraulic pressure gage for damage. In the absence of a site’s preventative maintenance schedule, Riverhawk recommends a gage calibration every two years. Check the hydraulic ports for grit, dirt, and other debris. Clean with a brush and, if necessary, with a volatile solvent such as acetone. Do not force the debris deeper into the port. Check the hydraulic hose for any damage including bent hose ends and split outer lining. If any damage is found, replace the hose immediately by contacting the Riverhawk Company. Place the plastic end caps on the hose ends to protect the hose ends from damage. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 ...
Page 13 Instruction Manual IM‐293 7.0 Storage Instructions 7.1 MP‐0130 and MP‐6809 Manual Hydraulic Pump Kit Disconnect the hose from pump and place the metal plug into pump port. Place the plastic end caps on the hose ends to protect the hose ends from damage. Check the hydraulic hose for any damage including bent hose ends and split outer lining. If any damage is found, replace the hose immediately by contacting the Riverhawk Company. Wind the hydraulic hose around the pump and secure in place with the hose clamps. Make sure the pump has not suffered any external damage as the result of impacts, mishandling, etc. Clean pump and check that there are no external hydraulic oil leaks. If any leaks are observed, contact Riverhawk for repair options. Lubricate the pump’s moving parts before returning the pump to storage. Place the hydraulic pump kit into the original shipping container. 7.2 AP‐0532 and AP‐6048 Air‐Driven Hydraulic Pump Kits Disconnect the hose from pump and place the metal plug into pump port. Place the plastic end caps on the hose ends to protect the hose ends from damage. Check the hydraulic hose for any damage including bent hose ends and split outer lining. If any damage is found, replace the hose immediately by contacting the Riverhawk Company. Wind the hydraulic hose into a circle no smaller than 14" (360mm) in diameter and place into the original shipping container. Make sure the pump has not suffered any external damage as the result of impacts, mishandling, etc. Clean pump and check that there are no external hydraulic oil leaks. If any leaks are observed, contact Riverhawk for repair options. ...
Page 14 Instruction Manual IM‐293 The red oil reservoir cap should be removed and stored inside the pump box with the extra air hose fittings. Place the grey and black storage plug into the oil reservoir opening and tighten to secure the oil from spillage Place the hydraulic pump kit into the original shipping container. 8.0 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: Can I rent a hydraulic tensioner kit? A: Yes, Riverhawk has rental tensioner kits available for most of our hydraulic tensioners. Q: The hydraulic pump appears to be leaking or does not build pressure. A: Check the hose connection to the hydraulic pump. If the hose’s high pressure fitting is not assembled correctly to the pump, it may look like the pump is leaking. Refer to sections 4.2.1 or 4.2.2 for the correct use of the high pressure fittings. Inspect and clean the male cone at the end of the hose, the cone must be free of damage and debris. Also, inspect and clean the female cone at the bottom of the hydraulic port, the cone must also be free of damage and debris. Check pump by dead heading as described in section 4.1.1 or section 4.1.2. If the problem continues, contact Riverhawk for guidance. Q: ...
Page 15 Declaration of Conformity E Nov 14, 2017 Section 4.1.2, Section 6.2.3 was Section 6.2.2 D Jul 11, 2016 Added hydraulic pressure gage references to sections 3, 4.1.1, 4.1.2, and 6.3 C May 5, 2015 Added MP‐6809 Manual Pump Kit B Mar 26, 2014 Added AP‐6048 Air‐Driven Pump Kit, Added Appendix A1 A Oct 22, 2012 Reformatted, general update to warnings and cautions ‐ Aug 16, 2012 Released CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 15 of 21 ...
Page 16: Ec Declaration Of Conformity
Instruction Manual IM‐293 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. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 ...
Page 17 Instruction Manual IM‐293 Appendix A2 UKCA 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 Supply of Machinery (Safety) 2008 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. CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 ...
Page 18 Hydraulic Port Plug Filler Plug Figure 1 – Sample Picture of MP‐0130 Hydraulic Pump with the Hydraulic Port plugged for testing (Right Side) Flexible Hose Release Knob Figure 2 – Sample Picture of MP‐0130 Hydraulic Pump with the Hydraulic Port plugged for testing (Left Side) CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 18 of 21 ...
Page 19 Port Gauge Regulator Hydraulic Red Reservoir Hand Switch Hydraulic Pressure Pressure Gauge Cap Control Knob Figure 3 ‐ Sample Picture of AP‐0532 Hydraulic Pump with the Hydraulic Port plugged for testing (Top View) CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 19 of 21 ...
Page 20 Gauge Regulator Hand Switch Red Reservoir Hydraulic Hydraulic Pressure Cap Pressure Gauge Control Knob Figure 4 ‐ Sample Picture of AP‐6048 Hydraulic Pump with the Hydraulic Port plugged for testing (Top View) CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 20 of 21 ...
Page 21 Instruction Manual IM‐293 Pressure Gauge Lever Arm Filler Plug Hydraulic Port Figure 5 – Sample Picture of MP‐6809 Hydraulic Pump with the Hydraulic Port plugged for testing (Right Side) Flexible Hose Release Knob Hydraulic Port Plug Figure 6 – Sample Picture of MP‐6809 Hydraulic Pump with the Hydraulic Port plugged for testing (Left Side) CUSTOMER'S INFORMATION BOX CONTENTS ARE INDEPENDENT OF RIVERHAWK DOCUMENT CONTROL GE DRAWING NUMBER 215 Clinton Road 373A4058 New Hartford, NY 13413 Tel: +1 315 768 4855 Fax: +1 315 768 4941 Revision F Email: info@riverhawk.com Page 21 of 21 ...

This manual is also suitable for:

Mp-6809 Ap-0532 Ap-6048