Enerpac CAT 3600 Series Repair Parts And Maintenance Manual
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Enerpac CAT 3600 Series Repair Parts And Maintenance Manual

Enerpac CAT 3600 Series Repair Parts And Maintenance Manual

Engines connecting rod tensioner
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L4164 Rev. C 06/17
• Part No. 498-6547
• Bolt Size M19 x 1.5
• 40 mm Bolt Centers
Repair Parts Sheet and Maintenance Plan
CAT 3600 Series Engines
Connecting Rod Tensioner

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Summary of Contents for Enerpac CAT 3600 Series

  • Page 1 Repair Parts Sheet and Maintenance Plan CAT 3600 Series Engines Connecting Rod Tensioner L4164 Rev. C 06/17 • Part No. 498-6547 • Bolt Size M19 x 1.5 • 40 mm Bolt Centers...

  • Page 3: Table Of Contents

    CONTENTS 1.0 RECOMMENDED TOOL KIT ....................2 2.0 GENERAL MAINTENANCE PLAN ................... 3 2.1 Preventative Maintenance ..................... 3 2.2 Full Maintenance ........................ 3 3.0 PREVENTATIVE MAINTENANCE ................... 5 3.1 Tensioners .......................... 5 4.0 FULL MAINTENANCE ......................7 4.1 Removable Sub-Assemblies .................... 8 4.2 Cover ............................ 1 1 4.3 Electronics .......................... 1 3 4.4 Top Cap and Return Springs .................... 1 6 4.5 Bridge and Nut Rotating Sockets .................. 2 1 4.6 Puller Assemblies .

  • Page 4: Recommended Tool Kit

    RECOMMENDED TOOL KIT • 4 mm Open-End Wrench (qty. 2) • 7mm Open-End Wrench • 13 mm Open-End Wrench • 22 mm Open-End Wrench • 24 mm Open-End Wrench • 1.5 mm Allen Key • 2 mm Allen Key • 2.5 mm Allen Key • 3 mm Allen Key • 5 mm Allen Key • 6 mm Allen Key • 3/8” Square Drive Ratchet • ø 4 mm x 5 mm LG x 27.5 mm PCD Pin Face Spanner • Circlip Pliers • Seal Picks • Relief Valve Tool (Part No. M140003816) • Bench Vice with Soft Grip Jaws • Small Hydraulic Press or Arbor Press • Loctite 243 Thread Sealant • Multipurpose Lithium Grease, Shell Gadus S2 V100 2 or equivalent •...

  • Page 5: General Maintenance Plan

    GENERAL MAINTENANCE PLAN Sections 2.1 and 2.2 contain a general overview of the Maintenance activities which must be performed to ensure that the equipment remains in good working condition throughout its usable life. Preventative Maintenance There are a number of basic maintenance steps that should be performed before and after each period of use of the tensioner. These steps will help to maintain the life of the tensioner, and will help identify any problems or issues before the tool is either fitted to the application or placed into storage. 2.1.1 Pre-Use Always perform basic checks on the tensioner features before installing the tensioner on the application. This will ensure the tool is functioning correctly and will avoid any unforeseen problems during the tensioning procedure. See Section 3.1.1 for a description of the recommended basic checks. If a test-stand is available, a pressure check can be performed before installing the Tensioner on the application to ensure there are no leaks. See Section 3.1.2 for a description of the pressure check. 2.1.2 Post-Use At the end of each period of use, all system components should be inspected and prepared for storage. Perform all Preventative Maintenance steps as per Section 3.0. Full Maintenance If any problems are noted during any Pre-Use or Post-Use Preventative Maintenance steps, then refer to the Trouble Shooting Section (Section 5.0) to help diagnose the problem. Repairs can be made by following the necessary steps in the Full Maintenance Section (Section 4.0). Tensioners that see high usage will need to undergo certain Full Maintenance steps after a specified number of cycles. NOTE: If any full maintenance is being undertaken, ensure that all electronics are fully removed from the Tensioner before removing the Top-Cap to access internal parts. 2.2.1 Puller Assemblies The Puller Assemblies on the tensioners have an average expected life of 1800 Cycles. However, it is recommended that Puller Assemblies be replaced every 1500 cycles to avoid a failure from occurring while a tensioning operation is in progress. To change the Puller Assemblies, follow all disassembly steps in Section 4 up to Section 4.6. (It will not be necessary to remove the Cycle Counter unless a leak from this area has been identified).
  • Page 6 2.2.2 Seals Hydraulic seal replacement must only be performed if the seals become damaged. The seals should not be removed during any Preventative Maintenance Steps. See Sections 4.1.1 & 4.8 for Swivel Manifold Seals. To change the Piston & Rod Seals, follow all disassembly steps in Section 4 up to Section 4.7. (It will not be necessary to remove the Cycle Counter unless a leak from this area has been identified). 2.2.3 Relief Valves The Mechanical Relief Valves within the Piston should never need removing unless a fault has been identified. If the Tensioners ever reach over-stoke during a tensioning procedure, then a Pressure Check as per Section 3.1.2 should be done to check that the tools still hold pressure. If they do not, it could indicate a problem with the Relief Valves which will need inspecting for any signs of damage. Refer to Section 4.7. If a Puller Assembly fails during tensioning procedures, there is a possibility of damage being caused to the Relief Valves and the Spring Pins that activate them. Both components will need inspecting for any signs of damage when replacing Puller Assemblies. Refer to Sections 4.4 & 4.7.

  • Page 7: Preventative Maintenance

    PREVENTATIVE MAINTENANCE In order to keep the equipment in good working condition, it is important that preventative maintenance be performed at the end of each period of use, prior to the equipment being placed into dry storage. Basic Tensioner Checks (as described in Section 3.1.1) should always be performed prior to any use of the Tensioners. Tensioners 3.1.1 Basic Checks • Visually inspect the Tensioner for any signs of damage or excessive amounts of oil (which could indicate a potential leak). • Hold the Tensioner in the inverted position (with puller sleeves facing down). Ensure that the Puller Sleeves freely retract by approximately 20mm. • With the Tensioner still in the inverted position, depress the Nut Rotating Sockets by hand by approximately 5-10mm to ensure they move freely and are returned to their original position by the Compression Spring. • Use a 3/8” drive tool to rotate the Drive Gears on the Gearboxes at least one complete revolution in both directions to ensure they rotate freely without binding, and that they rotate the Nut Rotating Sockets. • Rotate the Swivel Manifold by hand at least one complete revolution in both directions to ensure it rotates freely without binding.
  • Page 8 3.1.2 Storage Apply a light coating of oil or rust inhibitor to all metal surfaces prior to storage, ensuring the internal threads of the Pullers are also coated. Store the Tensioner(s) in the travel case in which they were received, with the Puller Sleeves and Pistons fully retracted inside the body. Always keep dust caps installed on couplers and connectors when the Tensioner is not being used.

  • Page 9: Full Maintenance

    FULL MAINTENANCE This Section contains Disassembly Steps in sequential order which are required to access the desired components of the Tensioner. (i.e. if Puller Assemblies are being changed, all ‘Disassembly’ steps up to Section 4.6 will need to be followed. And if Piston & Rod Seals are being changed, all ‘Disassembly’ steps up to Section 4.7 will need to be followed.) Details of inspections and reassembly procedures are also included for each disassembly step. Refer to the Trouble Shooting Section (Section 5.0) to help diagnose the problem before following the necessary steps in this section. Note: Item Numbers in the Parts Lists refer to the main parts list table included in the Repair Parts List Section at the end of this document. (Section 6.0) FULL MAINTENANCE CONTENTS: 4.1 Removable Sub-Assemblies ....................8 4.2 Cover ..........................11 4.3 Electronics ........................13 4.4 Top Cap and Return Springs ....................16 4.5 Bridge and Nut Rotating Sockets ..................21 4.6 Puller Assemblies ......................23 4.7 Pistons, Seals and Relief Valves ..................25 4.8 Swivel Manifold Sub-Assembly ..................29 4.9 Gearbox Sub-Assembly ..................... 31...

  • Page 10: Removable Sub-Assemblies

    Removable Sub-Assemblies There are three Sub-Assemblies that can easily be removed from the complete Tensioner if and when required. These are the Swivel Manifold Assembly, Cycle Counter Assembly and Gearbox Assembly. 4.1.1 Swivel Manifold Assembly The Swivel Manifold Assembly should always be removed prior to any full- maintenance steps on the internal components. It will allow for any remaining oil to vent from the Tensioner and will make it possible to remove the Pistons in later maintenance steps. To remove the Swivel Manifold Assembly: • Use a 24mm Open-End Wrench on the hex of the Manifold Pin to remove the assembly from the Body. If there were no problems with the Swivel Manifold Assembly, it can be left to one side and remain assembled. If problems were noted with the assembly, it can be replaced as a complete unit or it can be dismantled to replace the seals. See Section 4.8 for Swivel Manifold Assembly Maintenance. To re-install the Swivel Manifold Assembly: • Apply Hydraulic Oil to the threads and cone of the Manifold Pin and re- install the assembly onto the Body. Use a 24mm Open-End Wrench on the hex of the Manifold Pin to tighten to a torque of 30 – 35 Nm (22 – 26 lbf.ft).
  • Page 11 4.1.2 Cycle Counter Assembly IMPORTANT: The Cycle Counter Assembly should never be removed from the Body unless a leak from this area has been identified. It should only be removed to replace the seal and must be re-installed to the same Tensioner assembly that it came from. To remove the Cycle Counter Assembly: • Use a 5mm Allen Key to undo and remove the two M6x40 Screws. • Carefully remove the cycle counter while keeping it in the orientation as shown (piston and seal at the top). The Piston will be free to remove from the Cycle Counter Assembly (or it may have stayed within the Body upon removing the Cycle Counter, in which case, carefully remove it from the Body). Note: Underneath the Piston is a series of spring washers. Keeping the Cycle Counter in the orientation shown will ensure these remain within the Cycle Counter Body. Do not disturb the spring washers. • The damaged seal can then be removed from the Piston and replaced with a new one. • Apply Hydraulic Oil to the new Seal and Back-Up Ring before installation. To re-install the Cycle Counter Assembly: • Assemble the Cycle Counter to the Body. (It is recommended to install the Piston into the bore in the Body first and then position the Cycle Counter Assembly on the Body). Apply a thin film of Copper Grease or similar anti-seize compound to the threads of the two Socket Head Cap Screws and tighten to a torque of 13 – 15 Nm (10 – 11 lbf.ft).
  • Page 12 4.1.3 Gearbox Assembly The Gearbox Assembly needs to be removed before disconnecting the Body from the Bridge (Section 4.5) to allow access to the Bridge-Body Mounting Screws. To remove the Gearbox Assembly: • Use a 5mm Allen Key to undo and remove the two M6x50 Screws and remove the Gearbox Assembly from the Bridge. If there were no problems with the Gearbox Assembly, it can be left to one side and remain assembled. If problems were noted with the assembly, it can be dismantled to inspect and replace individual parts as necessary. See Section 4.9 for Gearbox Assembly Maintenance. Before re-installing the Gearbox, apply Lithium Grease to the exposed gear teeth while rotating the gears to ensure an even coating over all gear teeth. To refit the Gearbox Assembly: • Apply a thin film of Copper Grease or similar anti-seize compound to the threads of the two Socket Head Cap Screws, assemble the Gearbox to the Bridge, and tighten the two Socket Head Cap Screws to a torque of 13 – 15 Nm (10 – 11 lbf.ft).

  • Page 13: Cover

    Cover Parts Required: Item Part Number Description Qty No. 3600CRT020-1 Sealing Cap CAE1030108-1A Flat Washer M3 CBA311028-1E Button Head Screw M3 x 6 M1400030981 Cover...
  • Page 14 4.2.1 Disassembly • Using a high quality 2mm Allen Key (to prevent round-off), remove all eight screws (item 11) holding the Cover (item 25) to the Tensioner. The top two screws are used with washers (item 9), and the front two screws retain the Sealing Cap (item 2) lanyards to the Tensioner. Remove the Sealing Caps from the connectors before attempting to remove the Cover. • Slide the Cover upwards to remove it from the top of the Tensioner. 4.2.2 Inspection • Visually inspect the cover for signs of damage, and check the fit of the Cover on the Tensioner. • Should a damaged cover need replacement, a ‘Cover Kit’ (498-6553) is available. Refer to the Repair Parts List (Section 6.0) at the end of this document for additional information. 4.2.3 Assembly • Fit the Cover over the Tensioner from the top. • Apply a thin film of Copper Grease or similar anti-seize compound to the threads of the screws, re-install (including washers and Sealing Cap lanyards) and tighten to a torque of 1 – 1.5 Nm (0.7 – 1.1 lbf.ft). Do not over tighten screws.

  • Page 15: Electronics

    Electronics Parts List: Item Part Number Description Qty 3600CRT383 Sensor Mount 3600CRT384 Sensor and Connector Assembly CBA315028-1B Countersunk Screw M3 x 10 CCA215028-1A Socket Head Cap Screw M2 x 10 CCA417028-1A Socket Head Cap Screw M4 x 12 M150032103 Offset Arm 4.3.1 Disassembly • Use a high-quality 2mm Allen Key (to prevent round-off), undo and remove the two Countersunk Screws (item 12). Use a thin 4mm Open-End Wrench to undo and remove the two M2 Sensor Nuts (part of item 6) from the top of the Offset Arms (item 26). Lift the Offset Arms off the Tensioner.
  • Page 16 • Use a 3mm Allen Key to undo and remove the two Socket Head Cap Screws (item 15) holding the Sensor Mount to the tensioner. • Slide the Sensor Mount complete with Sensor and Connector Assemblies (item A, comprising items 5, 6, 14) out from the front of the tensioner while the Connectors are still attached to the Top Cap. • Remove the Connector Nuts using a 13mm Open-End Wrench while holding the Connector Body with a 7mm Open-End Wrench. • If required, the Sensor and Connector Assemblies (item 6) can be removed from the Sensor Mount (item 5) by simply loosening the two M2 Screws (items 14). 4.3.2 Inspection • Visually inspect all components for signs of damage. • Sensor and Connector Assemblies that have failed any testing will need replacing. • A ‘Sensor Kit’ is available comprising one Sensor and Connector Assembly should any need replacing. See Section 6.0.
  • Page 17 4.3.3 Assembly • If the Sensor and Connector Assemblies have been removed from the Sensor Mount, then start by re-installing them into the mount and only loosely clamping the M2 Screws for now, leaving approximately 2-3mm of the Sensors protruding from the top of the Sensor Mount. (This does not need to be accurate as it will be adjusted in the next assembly steps). • Remove the ‘Connector Nuts’ from the connectors and position the Connectors into the holes in the Top Cap. Loosely install the ‘Connector Nuts’ to hold the Connectors in place. • Then position the Sensor Mount, ensuring it sits square to the Body, and secure it with the two M4 Screws. Ensure that a thin film of Copper Grease or similar anti-seize compound is applied to the threads of the screws and tighten to a torque of 4 – 5 Nm (3 – 3.7 lbf.ft). • Adjust the Connectors so that both Red Alignment Marks are facing forward and tighten the Connector Nuts with a 13mm Open-End Wrench. (The sensors can be held with a 7mm Open-End Wrench if necessary). • Adjust the Sensors within the Sensor Mount using the M2 Screws to slide the Sensors as far upward as they go (so they contact the Top Cap) and tighten the M2 Screws so that the Sensors cannot move. • Remove the two M2 Nuts from each Sensor. Apply Loctite 243 to the threads of one Nut and thread it as far down on the Sensor as it can go. • Install the Offset Arms over the Push-Rods and Sensors. • Apply Loctite 243 to the M3 Countersunk Screws. Install these screws and tighten them to a torque of 1 – 1.5 Nm (0.7 – 1.1 lbf.ft). Apply Loctite 243 to the remaining M2 Sensor Nut and install it on the Sensor above the Offset Arm. • Adjust both M2 Nuts on each Sensor so that the tip of the Sensor is at the same height as the top of the Offset Arm and tighten the nuts.

  • Page 18: Top Cap And Return Springs

    Top Cap and Return Springs Parts List: Item Part Number Description Qty 3600CRT020 Top Cap 3600CRT110 Compression Spring CAE1050108-1A Flat Washer M5 CCA1019028-1E Button Head Screw M10 x 16 Grade 12.9 M140003061 Spring Pin 4.4.1 Disassembly • Use a 6mm Allen Key to loosen the six Top Cap Screws (item 13) in a star- pattern. Continue removing the screws bit by bit in a star-pattern, ensuring the Top Cap remains even as it is backed off from the Body by the Return Springs. • The Top Cap (item 1) can now be removed from the Tensioner. The Compression Springs (item 4) should stay within the Top Cap due to the presence of grease, but may remain on top of the Pistons. These should be removed and kept with the Top Cap. The Spring Pins (item 20) can be found above two of the Compression Springs within the Top Cap.
  • Page 19 • Remaining on the Pistons will be the Washers above the Relief Valves (items 10). These should be removed and kept to one side so they do not get lost. 4.4.2 Inspection • Clean and visually inspect all components for signs of damage. Replace damaged parts as necessary. • Check the Compression Springs for straightness and measure the Free Length. They should be between 36.5 and 39.5mm. Replace any springs that are less than 36.5mm long. • Measure the length of the Spring Pins. They should be between 18 and 18.6mm. Replace any Spring Pins that are less than 18mm long.
  • Page 20 4.4.3 Assembly • Re-install the Washers (item 10) above the Relief Valves. Note: Applying a small amount of Lithium Grease to the washers should help them stay in place while re-installing the Compression Springs and Top Cap.
  • Page 21 • Brush a thin coat of Molybdenum Disulphide Grease on the two main bores of the Top Cap (item 1). • Fit the Compression Springs (item 4) into the Top Cap along with the two Spring Pins (item 19). IMPORTANT: The Spring Pins are both mounted on the same side, in the central holes as shown. These pins will sit above the Relief Valves when the Top Cap is mounted on the Tensioner. Note: Applying a small amount of Lithium Grease to the end of the springs and pins will help hold them in place ready for assembling the Top Cap to the Body.
  • Page 22 • To install the Top Cap, springs and pins to the main assembly, lay the tool on its side and gently position the Top Cap onto the Assembly, ensuring all the springs correctly align with their corresponding recesses in the Pistons. • Keeping the Top Cap in position, sit the tool upright. Apply a thin film of Copper Grease or similar anti-seize compound to the threads of the six M10 Screws (items 10) and tighten to a torque of 45 – 50 Nm (33 – 37 lbf.ft). Note: Thread the screws down by small increments in a star pattern to ensure the Top Cap remains level. The Top Cap will need to be depressed slightly to engage the first threads of the screws.

  • Page 23: Bridge And Nut Rotating Sockets

    Bridge and Nut Rotating Sockets Note: The Gearbox Assembly must be removed prior to this step to provide access to the four M4 Screws holding the Bridge to the Body. Removal of the Bridge can be done at any stage during disassembly provided the Gearbox has been removed (previous disassembly steps are not a necessity). Parts List: Item Part Number Description Qty CCA417028-1A Socket Head Cap Screw M4 x 12 M140003036 Nut Rotating Socket (NRS) M1400030541 Bridge M140003110 Compression Spring 4.5.1 Disassembly • The Bridge (item 19) can be disconnected from the Body by using a 3mm Allen Key to undo and remove the four M4 Screws (items 15). • The Nut Rotating Sockets (item 17) and Compression Springs (item 20) will then be free to remove from the Bridge. 4.5.2 Inspection • Clean and visually inspect all components for signs of damage. Replace damaged parts as necessary. • Check the Compression Springs for straightness and measure the Free Length. They should be between 44.5 and 47mm. Replace any springs that are less than 44.5mm long. • Check the fit of the Nut Rotating Sockets within the Bridge and ensure that they rotate and slide freely within the bores.
  • Page 24 4.5.3 Assembly • Brush a small amount of Lithium Grease onto the teeth of the two Nut Rotating Sockets and install them into the Bridge, followed by the two Compression Springs. • Install the Body Assembly onto the Bridge Assembly, ensuring the top coils of the Compression Springs do not get trapped. • Apply a thin film of Copper Grease or similar anti-seize compound to the threads of the four M4 Screws and tighten to a torque of 4 – 5 Nm (3 – 3.7 lbf.ft).

  • Page 25: Puller Assemblies

    Puller Assemblies Parts List: Item Part Number Description Qty 3600CRT950 Puller Assembly M19x1.5 (each comprising): 7a 3600CRT145 Puller Bar M19x1.5 7b M140003021 Puller Nut 7c CCA309028-5A Set Screw Flat Point M3 X 5 4.6.1 Disassembly • The Puller Assemblies will need dismantling to remove them from the Pistons: Remove the two M3 Set-Screws, and then unscrew the Puller Nut from the Puller Bar. IMPORTANT: Puller Bars and Puller Nuts are made as matching pairs and must be kept together. Always re-install the Puller Nuts to the same Puller Bars they came from. (Puller Bars and Puller Nuts from the same pair will each be engraved with identical serial numbers).
  • Page 26 4.6.2 Inspection • Clean and visually inspect all components for signs of damage. Replace damaged parts as necessary. • Puller Assemblies should always be replaced every 1500 Cycles. 4.6.3 Assembly • New Puller Assemblies will need dismantling prior to installation into the Tensioner. Undo and remove the two M3 Set-Screws, and then unscrew the Puller Nut from the Puller Bar. • Install the Puller Bars up through the bottom of the Pistons and thread the Puller Nuts back onto the corresponding Puller Bars, ensuring the Bars and Nuts remain as a matched pair (they should both have the same Serial Number in the engravings). • Ensure the M3 holes line up correctly. Apply Loctite 243 to the threads of the M3 setscrews and reinstall them. ...

  • Page 27: Pistons, Seals And Relief Valves

    Pistons, Seals and Relief Valves Note: The Swivel Manifold Assembly must be removed prior to this step to allow the Pistons to be removed. Parts List: Item Part Number Description Qty 3600CRT051 Piston M140003476 Rod Seal with Back-Up Rings M1400034764 Piston Seal with Oval Back-Up Rings M1400030301 Body M150032107 Push Rod Y70 Relief Valve Assembly M140003816 Relief Valve Tool 4.7.1 Disassembly • The Piston Assemblies (items 3, 27, 28) can be pushed out of the Body (item 24) by using a suitable sized drift (round bar, O.D. 26-28mm). IMPORTANT: Relief Valve Assemblies should never be removed from the Pistons unless a problem has been detected or they are visibly damaged. • Seals can then be inspected and replaced as necessary: • Carefully remove the Seals with a Seal-Pick by first removing the Back- Up Rings, followed by the main seal element. Be careful not to mark any surfaces of the Body or Piston.
  • Page 28 • If required, the Push Rods (item 27) can be removed from the Pistons (item 3) using a 4mm Open-End Wrench. • If Relief Valve Assemblies require replacing, a ‘Relief Valve Kit’ (498-6557) is available which includes the necessary parts along with the Relief Valve Tool: • Use a 5mm Allen Key in conjunction with the Relief Valve Tool (item 36) to locate around the flats of the Relief Valve Assembly (item 28) and remove the valve from the Piston (item 3). 4.7.2 Inspection • Clean and visually inspect all components for signs of damage. • Check the fit of the Piston within the Body without any Seals installed to ensure there is no binding due to damaged components. • Check the operation of the Relief Valve Assemblies by depressing the pin to ensure it springs back to its original position.
  • Page 29 4.7.3 Assembly • If the Push Rods have been removed, they should be re-installed with Loctite 243. Tighten with a 4mm Open-End Wrench and ensure the Push Rod is fully seated against its shoulder – it should protrude from the top face of the Piston by 21.5mm. • If new Relief Valve Assemblies are being fitted: • Ensure that the flat bottom hole in the Piston is free from defects, has a good surface finish and is spotlessly clean. • Hold the Piston (item 3) in a soft-jaw vice. Apply Hydraulic Oil to the threads of the Relief Valve Assembly (item 28) and thread into the Piston. Using a 5mm Allen Key in conjunction with the Relief Valve Tool (item 36), tighten to a torque of 15 Nm (11 lbf.ft).
  • Page 30 • To install new Seals and re-install the Pistons into the Body: • Liberally apply Hydraulic Oil to all Seals prior to installation. • Install the Rod Seal with Back-Up Rings (item 21) into the Body (item 24). Note: Ensure the skive-cuts of the two Back-Up Rings are situated on opposite sides. • Install the Piston Seals with Oval Back-Up Rings (item 22) onto the Piston Assemblies (items 3, 27, 28) Note: Ensure the skive-cuts of the two Back-Up Rings are situated on opposite sides of the Piston, and that the chamfered edges of the Back- Up Rings are facing the inside of the T-Seal. • The Piston Assemblies with Seals can now be pressed back into the Body by hand, ensuring that the Relief Valve Assemblies are furthest from the main port on the Body. Note: Before installation, apply a thin coat of hydraulic oil to the Piston, Seals and Body Bores. This will help aid installation. (ENLARGED VIEW)

  • Page 31: Swivel Manifold Sub-Assembly

    Swivel Manifold Sub-Assembly Note: Item Numbers in this section refer to the Swivel Manifold Sub-Assembly parts list included in Section 6.0 at the end of this document. Parts List: Item Part Number Description Qty M1400030611 Manifold Pin M1400034762 Manifold Piston Seal with Back-Up Rings M1400034763 Manifold Rod Seal with Back-Up Rings M140003840 Manifold Block CCA1014044-1A External Circlip 14mm Dia SY45 Male Coupler 4.8.1 Disassembly • Use Circlip Pliers to carefully remove the Circlip (item 9). • Hold the Manifold Block (item 4) in a soft-jaw vice and use a suitable sized drift (round bar, O.D. 12-14mm) to press out the Manifold Pin (item 1) by hand. • Seals can then be inspected and replaced as necessary: • Carefully remove the Seals with a Seal-Pick by first removing the Back- Up Rings, followed by the main seal element. Be careful not to mark any surfaces of the Block or Pin. Note: The Male Coupler (item 6) does not require removing from the Manifold Block (item 4) unless it requires replacing. 4.8.2 Inspection • Clean and visually inspect all components for signs of damage. •...
  • Page 32 4.8.3 Assembly • Liberally apply Hydraulic Oil to all Seals prior to installation. • Install the Manifold Rod Seal with Back-Up Rings (item 3) into the Manifold Block (item 4). • Install the Manifold Piston Seal with Back-Up Rings (item 2) onto the Manifold Pin (item 1). • Press the Pin through the Manifold Block and install the External Circlip (item 5) into the groove in the Pin. • If the Coupler has been removed from the Manifold Block, or if it is being replaced: assemble the Coupler (item 6) onto the Manifold Block in a dry condition (do not apply any lubricant or thread sealant) and tighten to a torque of 40 – 50 Nm (30-37 lbf.ft).

  • Page 33: Gearbox Sub-Assembly

    Gearbox Sub-Assembly Note: Item Numbers in this section refer to the Gearbox Sub-Assembly parts list included in Section 6.0 at the end of this document. Parts List: Item Part Number Description Qty CBA411028-1E Button Head Screw M4 x 6 E4852 External Circlip 22mm Dia E4855 Socket Head Cap Screw M6 x 50 M122013059 Dowel Pin M122013061 Intermediate Gear Location Pin M1220132281 Bushed Intermediate Gear M1220132282 Drive Gear M140003001 Gearbox Housing M140003098 Gearbox Cover 4.9.1 Disassembly • Remove the Button Head Screw (item 1). • Gently pry the Gearbox Cover (item 9) over the Intermediate Gear Location Pins (item 5) and slide it out of the Gearbox Housing (item 8). • Remove the two External Circlips (item 2) and then remove the two Drive Gears (items 7). • Remove the two Dowel Pins (item 4) from inside the bores of the housing. • Using a suitable sized drift (Round Bar, O.D. 9-11mm) and a Small Hydraulic Press or Arbor Press, press out the two the Intermediate Gear Location Pins (item 5) and remove the Bushed Intermediate Gears (item 6) from the Pins.
  • Page 34 4.9.2 Inspection • Clean and inspect all components for damage and replace parts as necessary. • During assembly, check the meshing of gear teeth and ensure that all gears rotate smoothly. 4.9.3 Assembly • Brush a small amount of Lithium Grease onto the teeth of the two Bushed Intermediate Gears (item 6) and install them onto the Intermediate Gear Location Pins (item 5) in the orientation shown. • Carefully install the Pins and Gears into the Gearbox Housing (item 8). This step may require a press. Ensure the top of the Pin comes flush with the top of the Gearbox Housing, and that the Idler Gears rotate freely. • Install the two Dowel Pins (item 4) into Gearbox Housing by locating them through the main bores as shown, ensuring that they are fully engaged against the Intermediate Gear Location Pins (item 5). • Brush a small amount of Lithium Grease onto the teeth of the two Drive Gears (items 7) and install them into the Gearbox Housing. • Install the two External Circlips (item 2) to retain the Drive Gears. • Slide the Gearbox Cover (item 9) over the Intermediate Gear Location Pins and into the Gearbox Housing (item 8). Fix the cover in place with the Button Head Screw (item 1). • Ensure that the gears turn freely and that all gear teeth are coated with a thin film of Lithium Grease. • Apply a thin film Copper Grease or similar anti-seize compound to the threads of the two Socket Head Cap Screws (item 3) and install them into the Gearbox Housing ready for assembling back onto the tensioner.

  • Page 35: Troubleshooting

    TROUBLESHOOTING Symptom Cause Remedy Oil leaking on test Maximum Stroke reached and Re-install the Tensioners on the Relief Valve Activated: test-stand and ensure Puller and/or Tensioner not correctly installed Sleeves are fully threaded down to test-stand. and Pistons are fully retracted. Tensioner will not reach Leaking Couplings Replace faulty Couplings max. pressure Leaking/burst Hose Replace faulty Hose Seal Leak Replace faulty Seals Relief Valve Leak Replace faulty Relief Valve Defective Pump Unit Refer to Pump Manual Smart Pump does not pick Faulty Electrical Connections Check that Electrical Connectors up sensor readings on test are properly installed and connected. Replace faulty Connectors. Faulty Sensor Assembly Replace faulty Sensor Assembly Swivel Manifold does not Components jammed due to Disassemble Swivel Manifold, swivel Seal failure check fit without seals. Replace Seals if main components are OK, or alternatively, replace whole...

  • Page 36: Repair Parts List

    REPAIR PARTS LIST 3600CRT020 Top Cap 3600CRT020-1 Sealing Cap 3600CRT051 Piston 3600CRT110 Compression Spring 3600CRT338 Sensor Mount 3600CRT384 Sensor and Connector Assembly 3600CRT950 Puller Assembly M19x1.5 3600CRT950-1 Swivel Manifold Assembly CAE1030108-1A Flat Washer M3 10 CAE1050108-1A Flat Washer M5 11 CBA311028-1E Button Head Screw M3 X 6 12 CBA315028-1B Countersunk Screw M3 X 10 Button Head Screw M10 X 16 13 CCA1019028-1E Grade 12.9 14 CCA215028-1A Socket Head Cap Screw M2 X 10 15 CCA417028-1A Socket Head Cap Screw M4 X 12 16 M132022750 Cycle Counter Assembly 17 M140003036 Nut Rotating Socket (NRS)
  • Page 39 Swivel Manifold Sub-Assembly, comprising: Item Part Number Description Qty M1400030611 Manifold Pin 2 (37) M1400034762 Manifold Piston Seal with Back-Up Rings 3 (38) M1400034763 Manifold Rod Seal with Back-Up Rings M140003840 Manifold Block 5 (30) CCA1014044-1A External Circlip 14mm Dia SY45 Male Coupler Note: All items in this table are included in the Swivel Manifold Assembly. See main parts list, page 34, item 8. Alternate item numbers used in the main parts list are shown in parenthesis (. . . ).
  • Page 40 Gearbox Assembly, comprising: Item Part Number Description Qty 1 (29) CBA411028-1E Button Head Screw M4 x 6 2 (33) E4852 External Circlip 22mm Dia 3 (34) E4855 Socket Head Cap Screw M6 x 50 M122013059 Dowel Pin M122013061 Intermediate Gear Location Pin M1220132281 Bushed Intermediate Gear M1220132282 Drive Gear M140003001 Gearbox Housing M140003098 Gearbox Cover Note: All items in this table are included in the Gearbox Assembly. See main parts list, page 34, item 23. Alternate item numbers used in the main parts list are shown in parenthesis (. . . ).

  • Page 41: Maintenance Record

    MAINTENANCE RECORD Tensioner Cycle Performed Maintenance undertaken & parts replaced Date: Count by: Serial No.
  • Page 42 7.0 MAINTENANCE RECORD (CONTINUED) Tensioner Cycle Performed Maintenance undertaken & parts replaced Date: Count by: Serial No.
  • Page 43 7.0 MAINTENANCE RECORD (CONTINUED) Tensioner Cycle Performed Maintenance undertaken & parts replaced Date: Count by: Serial No.
  • Page 44 Connec ng Rod Training Video        CATU1269  (located on Caterpillar Channel 1) For service, warranty, or troubleshoo ng, please use the following resources:  Country/Region Enerpac Academy or Regional Office U.S./Canada Enerpac | 199 Gateway Court, Columbus, WI 53925  1‐800‐558‐0530 op on #2 | techservices@enerpac.com   La n America Europe Northern Africa Enerpac B.V. | Galvanistraat 115 | 6716 AE Ede, The Netherlands  Sub Sahara Africa Office +31 (0)318 535 911 | EAINFO@ENERPAC.COM ...

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