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Summary of Contents for NORD-LOCK BOLTIGHT TSR+
- Page 1 TSR+ Hydraulic Bolt Tensioners USER MANUAL Health & Safety Instructions 4 Operating Instructions Maintenance & Storage Technical Information Boltight Limited Tel: +44 (0) 1922 669222 Email: enquiries.boltight.uk@nord-lock.com www.nord-lock.com/Boltight...
- Page 2 Boltight Limited cannot accept any responsibility for any actions arising as a result of misuse of this equipment. The contents of this manual may periodically be subject to alteration. Boltight Limited reserves the right to alter or modify this manual without prior notification. Further copies of this manual can be downloaded from the website www.nord-lock.com/Boltight...
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Page 3: Table Of Contents
CONTENTS SECTION 1 – HEALTH & SAFETY INSTRUCTIONS 1.1 Safety notes 1.2 European pressure equipment directive 1.3 Using quick connectors 1.4 Hoses 1.5 Hydraulic bolt tensioning tools 1.6 Personal protective equipment (PPE) SECTION 2 – OPERATING INSTRUCTIONS 2.1 Main component parts 2.2 Recommended practices 2.3 Tensioning a bolt 2.4 De-tensioning a bolt... -
Page 4: Section 1 - Health & Safety Instructions
SECTION 1 – HEALTH & SAFETY INSTRUCTIONS 1.1 SAFETY NOTES Hydraulic bolt tensioning tools are very powerful and capable of inducing very high bolt stresses. This equipment will give many years of safe tensioning when used in accordance with these instructions. Anyone using hydraulic bolt tensioning equipment must be properly trained to use the equipment and must take adequate steps to ensure their own safety and the health and safety of others where bolt tensioning operations are being performed. -
Page 5: European Pressure Equipment Directive
1.2 EUROPEAN PRESSURE EQUIPMENT DIRECTIVE The TSR+ range of hydraulic bolt tensioning tools have been designed to operate at pressures up to 1500 bar with Group 2 liquid (hydraulic oil ISO 32 or ISO 46) with a volume less than 10 litres. This equipment aligns with: •... -
Page 6: Hoses
1.4 HOSES Boltight supply flexible hydraulic hoses which have a small plastic core tube surrounded by multiple high tensile steel spiral windings. The outside of the hose is molded with a coloured plastic coating. Most hoses also have a clear plastic cover which provides additional protection against damage when in use. Each hose is identified with a serial number. -
Page 7: Hydraulic Bolt Tensioning Tools
1.5 HYDRAULIC BOLT TENSIONING TOOLS Maximum pressure Do not exceed the maximum working pressure. The bolt being tensioned may have a maximum load less than that generated by the tensioner at The operational pressure for an application is maximum working pressure. The operator needs to confirm and check what the maximum pressure often not limited by the stud material yield. -
Page 8: Section 2 - Operating Instructions
SECTION 2 – OPERATING INSTRUCTIONS Introduction A hydraulic bolt tensioner is simply an annular jack with a hollow bore. Much like a jack, a hydraulic pushing force is generated, however instead of lifting a heavy object the force is transferred into stretching a bolt. To allow the transfer of force into the bolt a hydraulic tensioner utilises a threaded puller, bridge and nut rotating socket to effectively transfer and lock in the tensioned load within a joint. -
Page 9: Main Component Parts
2.1 MAIN COMPONENT PARTS Puller The puller consists of an internal female thread which mates with the bolts male thread. A knurled external flange allows for ease of rotation when assembling onto the bolt and several tommy bar holes allow for additional leverage when required. The outer flange of the puller reacts on the hydraulic load cells piston to allow transfer of the load directly into the bolt. -
Page 10: Tensioning A Bolt
2.3 TENSIONING A BOLT Step 1 ≥ D Ensure the joint has been assembled using the correct nuts and bolts required for tensioning. To ensure the safe and effective use of the hydraulic bolt tensioner ensure that a minimum of 2x bolt diameters of bolt length is protruding from the surface of the joint face. - Page 11 Step 3 Place the load cell and bridge assembly over the nut, bolt and socket. The load cell and bridge are assembled together using set screws positioned radially on the lower outside diameter of the load cell. The bridge and load cell can be rotated relative to each other.
- Page 12 Step 5 During the rotation of the puller, ensure that Continue to wind down the puller until the the bolt remains stationary as failure to do lower face of the pullers flange firmly contacts the top face of the load cells so could result in a reduced thread engagement in both the puller or application.
- Page 13 Step 7 Connect the tensioner to corresponding hydraulic hose and pump unit. Make sure the quick connect coupling is fully engaged. See Section 1.3 “Using quick connectors.” If required re-tighten the puller into position. Open the pumps oil return to tank valve and ensure the piston does not retract further. If it does then simply wind down the puller to regain piston engagement.
- Page 14 TENSIONING A BOLT – HEALTH & SAFETY The bolt tensioning tool is now ready to be pressurised. Before proceeding read the Health & Safety Instructions given in Section 1 of this manual then proceed as follows: — Ensure suitable PPE has been utilised prior to pressurisation. —...
- Page 15 Step 10 Use a tommy bar to turn the socket clockwise, to tighten the nut. Insert the tommy bar through the window in the bridge until it engages with the furthest right hole in the socket. Turn the socket clockwise as far as it will go. If the tommy bar comes into contact with the bridge, remove it and engage the next furthest right hole in the socket.
- Page 16 Step 12 ANTI-CLOCKWISE Remove the puller from the joint by rotating anti-clockwise. Use a tommy bar for added leverage if required. Step 13 Remove the load cell and bridge. TENSIONING A BOLT BOLTIGHT – TSR+ HYDRAULIC BOLT TENSIONERS...
- Page 17 Step 14 If it is not retained in the bridge, remove the socket. BOLTIGHT – TSR+ HYDRAULIC BOLT TENSIONERS TENSIONING A BOLT...
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Page 18: Tensioning A Bolt
2.4 DE-TENSIONING A BOLT Step 1 De-tensioning of a bolt follows many of the steps as shown in the previous section. There are however a few key differences in the process which are explained within the following section. ≥ D First visually inspect the bolts to be de-tensioned. - Page 19 Step 3 Place the load cell and bridge assembly over the nut, bolt and socket. The load cell and bridge are assembled together using set screws positioned radially on the lower outside diameter of the load cell. The bridge and load cell can be rotated relative to each other. This allows the self sealing quick connect hydraulic connection on the load cell to be positioned in the best position for connecting the flexible hydraulic hose.
- Page 20 Step 5 ANTI-CLOCKWISE IMPORTANT: Now turn back the puller at least one full revolution. This operation ensures the piston can retract into the load NOTE: PULLER WOUND cell when the bolt becomes free and needs BACK ONE FULL TURN to return to its original length. If this step is missed the load retained in the bolt will be transferred from the nut to the puller during the de-tensioning operation...
- Page 21 Step 7 If applicable fit a blank nipple to the quick connect coupling. Ensure the connector is fully engaged. Only when the second hydraulic connection has been plugged can the tool be pressurised. BLANKING PLUG QUICK BLANK PLUG CONNECTOR CORRECTLY FITTED DE-TENSIONING A BOLT –...
- Page 22 Ensure the stroke of the piston is A highly visible red line indicates when the piston observed during pressurisation. If the has reached its maximum stroke. Stop the pump as maximum piston stroke indicator soon as the red indicator can be seen. If the tool is becomes visible, STOP the pump and over stroked the valve will activate and oil will be wind down the nut as shown in Step 10.
- Page 23 Step 10 Once the desired tensioning pressure has been reached and the nut has been released from the surface of the joint. The pressure within the tool can be released. Release the pressure by slowly opening the pressure release valve on the hydraulic pump. The TSR+ has been supplied with an automatic piston return system.
- Page 24 Step 12 Remove the load cell and bridge. Step 13 If it is not retained in the bridge, remove the socket. DE-TENSIONING A BOLT BOLTIGHT – TSR+ HYDRAULIC BOLT TENSIONERS...
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Page 25: Simultaneous Bolt Tensioning
2.5 SIMULTANEOUS BOLT TENSIONING Ensure you have read and understood both the bolt tensioning and de-tensioning methods as shown in the previous sections prior to conducting a simultaneous bolt tensioning operation. Simultaneous bolt tensioning improves the speed and efficiency when performing a tensioning operation on a multi stud application. - Page 26 Daisy chain arrangement The daisy chain arrangement is an affordable method of connecting multiple tools. It is best for simplicity, as only one type of hose needs to be specified, however with this setup oil must pass through every hydraulic cylinder increasing the resistance for manual piston reset or increasing the time reset takes for auto return tensioners.
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Page 27: Section 3 - Maintenance & Storage
SECTION 3 – MAINTENANCE & STORAGE Introduction A hydraulic bolt tensioning tool will provide many years of trouble free service if used, maintained and stored correctly. Storage Each tool is surface treated before leaving the factory. This provides a degree of corrosion protection but additional protection should be applied when the tools are to be stored for any period of time. -
Page 28: Parts Breakdown
3.1 PARTS BREAKDOWN TSR+1 to TSR+2 diagram TSR+3 to TSR+7 diagram Item no. Description Part no. Qty. Item no. Description Part no. Qty. Cylinder body 1 TSRPx-CB-01* Cylinder body TSRPx-CB-01* Piston TSRPx-PT-01* Piston TSRPx-PT-01* Spring cap TSRPx-SC-01* Spring cap TSRPx-SC-01* Spring sleeve TSRPx-SL-01* Spring locking sleeve... -
Page 29: Disassembly Of Load Cell - Tsr+1 & Tsr+2
3.2 DISASSEMBLY OF LOAD CELL – TSR+1 & TSR+2 — Remove grip tape from the load cell. — Place the tool upside down on a flat surface. — Remove grub screw located on the outer body, using a suitable Allen key as shown. —... -
Page 30: Reassembly Of Load Cell - Tsr+1 & Tsr+2
3.3 REASSEMBLY OF LOAD CELL – TSR+1 & TSR+2 — Once the new seals have been fitted, assemble the piston into the body. — Use a soft end hammer or a press to gently push the piston into the body. —... -
Page 31: Disassembly And Assembly Of Load Cell - Tsr+3 & Tsr+7
3.4 DISASSEMBLY AND ASSEMBLY OF LOAD CELL – TSR+3 & TSR+7 — Place the tool upside down on a flat surface. — Carefully remove the screws by using a suitably sized Allen key. — Use a cross pattern as shown, unscrewing a small amount each time. -
Page 32: Hydraulic Seal Replacement
3.5 HYDRAULIC SEAL REPLACEMENT — To assist with changing the seals, a small flat screw driver and a picking hook should be utilised. — Each seal consists of two parts. A red polymer lip seal complete with an anti extrusion ring. —... - Page 33 — Inspect the new seal kit (inner and outer seal) and ensure it is free from damage. — Apply a thin layer of bearing grease to the surfaces of each of the seals. Outer seal installation: — Install the extrusion ring first. —...
- Page 34 Inner Seal Fitting: — First start with the lip seal. — Gently feed the seal into the seal housing ensuring the V section faces the top or into the hydraulic area of the tool. — Minimal force should be required for installation. —...
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Page 35: Tool Pressure Test
3.6 TOOL PRESSURE TEST Ensure the product instruction — Visual inspect the tooling by — Overall condition of tooling checking for defects which may and any signs of leaking oil. manual has been read and affect the tools operation that all safety instructions are —... -
Page 36: Section 4 - Technical Information
SECTION 4 – TECHNICAL INFORMATION 4.1 OIL PRESSURE CALCULATIONS Grip length The formula widely used to calculate the oil pressure to be used with a bolt tensioning tool is given below along with definitions of the terms used: Bolt load Residual Bolt Load required when the tensioning operation is complete. -
Page 37: Tool Specification And Dimensions
4.2 TOOL SPECIFICATION AND DIMENSIONS SECTION X-X BOD - BRIDGE OUTER DIAMETER TOD - TOOL OUTSIDE DIAMETER Do not use an oil pressure which will result in an initial bolt stress in excess of 95% of the minimum yield stress of the bolt material. Refer to pages 39 to 43 for specific tooling specification &... - Page 38 THD - THREAD DIAMETER TECHNICAL INFORMATION BOLTIGHT – TSR+ HYDRAULIC BOLT TENSIONERS...
- Page 39 TSR+ tools are designed to TSR+ tools are designed to following Imperial Nut Dimensions following Metric Nut Dimensions Imperial Metric Thread Thread Sizes inch inch Sizes inch inch 4 in 155.6 6.125 101.6 4.000 M100 5.71 3.94 3-3/4 in 146.1 5.750 95.3 3.750...
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Page 40: Technical Information - Imperial Bolt Sizes
4.3 TECHNICAL INFORMATION – IMPERIAL BOLT SIZES Hydraulic Max. Area Stroke Max. Load Bolt Tool No. Diameter inch inch 3.66 TSR+ 0 1,070 35,970 2.60 3.66 4.61 TSR+ 1 1,870 62,950 3.43 1-1/8 4.72 4.61 1-1/8 4.72 TSR+ 2 3,000 101,160 4.06 1-1/4... - Page 41 MXNH BAF* (inc. 2mm clearance) inch inch inch inch inch inch 4.69 62.5 2.46 1.42 62.5 2.46 3.86 0.75 4.69 62.5 2.46 1.42 62.5 2.46 3.74 0.87 5.71 2.68 1.50 2.68 4.61 1.02 5.83 77.5 3.05 1.61 77.5 3.05 4.61 1.14 5.71 2.95...
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Page 42: Technical Information - Metric Bolt Sizes
4.4 TECHNICAL INFORMATION – METRIC BOLT SIZES Hydraulic Max. Area Stroke Max. Load Bolt Tool No. Diameter inch inch 3.66 TSR+ 0 1,070 35,970 2.60 3.66 4.61 TSR+ 1 1,870 62,950 3.43 4.61 4.49 4.61 TSR+ 2 3,000 101,160 4.06 4.72 4.84 4.96... - Page 43 MXNH BAF* (inc. 2mm clearance) inch inch inch inch inch inch 4.69 62.5 2.46 1.42 62.5 2.46 3.82 0.83 4.69 62.5 2.46 1.42 62.5 2.46 3.74 0.87 5.71 2.68 1.50 2.68 4.69 0.94 5.71 2.68 1.50 2.68 4.57 1.06 5.59 2.95 1.50 2.95...
- Page 45 Boltight Limited Tel: +44 (0) 1922 669222 Email: enquiries.boltight.uk@nord-lock.com www.nord-lock.com/Boltight TSRP_Manual_2021_03_EN1/B...
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