Bolt Tensioner Manual

Operating manual
Bolt tensioner
Article-no. A67420000
02/2009
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Inhaltsverzeichnis:
1. Foreword .........................................................................................................4
2. General safety instructions ...........................................................................5

2.1 Typical warnings in this manual .................................................................................5
2.2 Caution: high-pressure hydraulics..............................................................................5
2.3 Employee qualifications and training..........................................................................5
2.4 Safety instructions for operators/users.......................................................................5
2.5 Safety instructions for maintenance, inspection and installation work........................7
2.6 Dangers of not following safety instructions ...............................................................7
3. Safety instructions for bolt tensioner...........................................................8
4. Abbreviations ..................................................................................................9
5. Operation .......................................................................................................10
5.1 Screwing on the SSV before the Tensioning Procedure ..........................................10
5.2 Tensioning Procedure ..............................................................................................10
5.3 Screwing on the SSV before the Loosening Procedure ...........................................11
5.4 Loosening Procedure ...............................................................................................11
5.5 Tensioning Procedure in Several Steps ...................................................................12
5.6 Loosening Procedure in Several Steps with Large Loosening Distances ................12
6. Piston return stroke......................................................................................13

6.1 Piston return stroke by reset elements.....................................................................13
7. Positioning and reversing the nut...............................................................13

7.1 Positioning with socket (tightening) ..........................................................................13
7.2 Reversing with socket (releasing) ............................................................................13
8. Attaching the pressure connector ..............................................................14

8.1 Coupling the Quick-Release Coupling Sleeve and Nipple .......................................14
8.2 Uncoupling the Quick-Release Coupling Sleeve and Nipple....................................14

9. Bolt tensioner wear ......................................................................................15
10. Maintenance, storage and transport...........................................................16

10.1 General ....................................................................................................................16
10.2 Changing seal (above 1,600 bar) .............................................................................16
10.3 Changing seal – angle connector.............................................................................17
10.4 Bleeding ...................................................................................................................17
10.5 Troubleshooting .......................................................................................................18
10.6 Storage ....................................................................................................................19
10.7 Transport..................................................................................................................19
11. Guarantee ......................................................................................................19
12. Disposal .........................................................................................................19
13. Technical data Item no. A67420000 ............................................................19
14. Drawing SSV M72x6 A6742..........................................................................20
15. Parts list.........................................................................................................21

1. Foreword
Thank you for choosing a SCHAAF product.
You’ll find SCHAAF GmbH & Co. KG a knowledgeable partner for all questions and
problems in the areas of high-pressure tools and tensioners. Our experts are ready
to advise you in the planning and execution of your projects and commissions.
Experience in our areas of expertise since 1954 is your guarantee of top-quality,
state-of-the-art performance. We even have the right solution for those unusual
problems.
Just send us your problem and we’ll get back to you immediately.
Product quality and collaboration, the way you want it!
SCHAAF GmbH & Co. KG

Bruesseler Allee 22
41812 Erkelenz – Germany
Phone: +49 - 2431 - 97770-0

Fax: +49 - 2431 - 97770-77
Email: [email protected]
Internet: www.schaaf-gmbh.com
Service:
Phone: +49 - 2431 - 97770-0
Fax: +49 - 2431 - 97770-77
You’ll find your closest national or regional representative on the Internet.
This operating manual contains basic details on operation and maintenance. Please
read all instructions, warnings and safety instructions carefully. Follow these
instructions to prevent accidents and property damage as you work. Make sure all
users have read and understood this manual.

2. General safety instructions
2.1 Typical warnings in this manual
Danger
Dangerous electrical voltage
Environmental hazard warning
2.2 Caution: high-pressure hydraulics

The safe handling of hydraulic high-pressure tools, pumps and accessories
requires close observation of the generally applicable legal and other
regulations for avoiding accidents and protecting the environment,
especially the following instructions.
2.3 Employee qualifications and training

Operating, maintenance, inspection and installation personnel must have
appropriate qualifications for this work.
Areas of responsibility, competences and the supervision of personnel must be

closely controlled by the operator. If employees do not possess the required
knowledge they should receive instruction and training. If required, this can be
provided to the machine owner by SCHAAF.
The operator must ensure that employees fully understand the contents of this
operating manual.
2.4 Safety instructions for operators/users

Wear protective clothing, a helmet with visor or safety
goggles, protective gloves and safety boots.
The operator must ensure that the product is always in perfect operating condition.
Always install and operate the product on a secure and rigid base. Leave sufficient
room for movement by operators and maintenance personnel.
Danger! Do not exceed the maximum permitted pressure (see Technical

data).

The pressure gauge used must be filled with glycerine. If the glycerine has leaked
out, the gauge must be replaced immediately. Gauges must be calibrated at least
once a year or as needed. We recommend a monthly check with a reference
pressure gauge. A faulty gauge can result in components being overloaded and/or
incorrectly tensioned.
A faulty pressure gauge is a risk to life!
Monitor the level on the pressure gauge on the pressure generator during the entire
work process.
Replace high-pressure hoses at the latest every 5 years or after 10,000 load cycles.
This applies even if there are no defects that could affect safety.
Check the quick-release coupling nipples and coupling sleeves after 500
connections at the most and replace after a maximum 10,000 load cycles. This
applies even if there are no defects that could affect safety.
Pressure must never be applied to the quick-release coupling nipple if it is not

connected.
Faultless operation is only guaranteed at the prescribed ambient temperature (see

Technical data).
Do not make any modifications, additions or alterations to the product. This applies
especially to the installation and adjustment of safety devices, pushbuttons,
pressure limiters and other valves.
Before pressurisation, check that all connections (e.g. hose couplings) are attached
correctly and securely (see “Pressure connections”).
All attached elements must be rated for the desired operating pressure.
Make sure all persons present remain at a safe distance when the system is
pressurised. It is forbidden to stand in the path of travel of screw or clamping axes
when using hydraulic high-pressure tools.
Check all components for damage before pressurisation. Damaged components

must be replaced with new ones immediately.

Release the pressure immediately if leaks occur during pressurisation. Squirting
liquid can cause life-threatening injuries. Seal the source of the leak and/or replace
defective parts. Original replacement parts from SCHAAF must be used for repairs.
Ensure that hydraulic fluid does not escape into the environment.
Hydraulic fluid can damage the environment.
2.5 Safety instructions for maintenance, inspection and installation work

Use only the hydraulic fluids specified in the Technical data.
Depressurise the equipment before carrying out maintenance work..
Equipment must be disconnected from the power supply before any work
is carried out. Only qualified electricians should work on electrical
equipment.
2.6 Dangers of not following safety instructions

Not following the safety instructions can put people’s lives at risk and represent a
danger to the environment and to property.
Serious health risks and property damage can occur through:
Improper use of the product

Incorrect operation
Product breakdown
Inadequate maintenance
Electrical, mechanical or chemical risks to personnel
Damage to the environment through leaks
Improper waste disposal.

3. Safety instructions for bolt tensioner
Check all parts for damage before each pressurisation. Damaged parts must be
replaced immediately by new parts.
Make all connections only with the system unpressurised.
The instructions in this operation manual must be followed for best results with one
or more SSVs.
Before each tensioning procedure, check the thread quality of the bolt and the SSV.
The SSV must not be installed if there is any damage.
The threaded bolt must be at right angles to the surface (Fig. 1). Fig. 1
Exposed length of bolt must be at least 1.0 x the thread diameter

(Fig. 2).
Fig. 2
The piston must not be driven above the maximum stroke limit (optical stroke
gauge). The maximum stroke is reached when the signal ring is fully visible.
Zero stroke Maximum stroke 1 Cylinder

2 Piston 3 Stroke
signal band
Pre-tension force can be measured, for example, from the change in length of the
bolt being tensioned.
If you have any questions, please contact our Service Department.
Under no circumstances is the SSV to be secured or transported when the hose is

connected.
Bolt tensioners must be replaced at the end of the load cycle, which is specified in
the technical data.

4. Abbreviations
DBV - Pressure limiting valve
DM - Pressure transducer
DT / S - Pushbutton switch
DÜ - Pressure intensifier
ES - Limit switch
FM - Temperature switch
FSE - Mobile Control Unit
H - Pilot light
HDE - Electrohydraulic High-pressure Unit
HDL - Air-Hydraulic Pump
HDS - High-pressure hose
HM - Hydraulic Nut
HP - Hand Lever Pump
HS - Main switch
KM - Force measuring transducer
NA - Emergency shut off
SPS - Stored programme control
SS - Float switch
SSV - Bolt tensioner
TS - Temperature switch
WS - Selector switch
Y - Hydraulic-valve

5. Operation
1 Support sleeve 5 Bearing ring 9 Adapter 13 Retaining ring

2 Cylinder 6 Seal 10 Stroke signal band 14 Set screw
3 Piston 7 Bearing ring 11 Adjustable rod 15 Hex nut
4 Seal 8 Quick-release coupling nipple 12 Socket
5.1 Screwing on the SSV before the Tensioning Procedure

Clean all threads and supporting surfaces
Turn the nut on the threaded bolt until it touches the flange.
Slide the SSV over the nut.
Tighten the SSV (a guide value of 2-5 turns applies to thread diameters
>Ø140 mm.
Centre the socket over the nut.
Note! When setting down the SSV a sudden load on the thread sides must be
avoided. Support for the thread sides must be used when screwing on heavy SSVs
(refer to section “Wear”).
5.2 Tensioning Procedure

Before applying any pressure, undo the hex-head nut (15) completely to prevent
it tearing off.
Remove the dust cap from the nipple.

Connect the SSV to the pump (see “Attaching the pressure connector”).
Bring the piston to the zero position (see “Piston return stroke”).
Generate the tensioning pressure with the pump (see “Technical data”).
Do not exceed the stroke (watch for signal band).
Turn the nut until it touches the flange (see “Positioning and reversing the nut”).
Release the hydraulic pressure.
Bring the piston to the zero position (see “Piston return stroke”).
Note: In the case of longer elongation, the tensioning procedure must be repeated
until the required force is achieved ( see “Technical data, Tensioning process in multiple steps”).

Disconnect the SSV from the hose connector.
Close off the nipple with a dust cap.
Unscrew the SSV from the threaded bolt (a guide value of 2-5 turns applies to
thread diameters >Ø140 mm).
Note! When joining special parts separate instructions may exist. These must
always be adhered to.
5.3 Screwing on the SSV before the Loosening Procedure

Clean all threads and supporting surfaces
Slide the SSV over the nut.
Tighten the SSV (a guide value of 2-5 turns applies to thread diameters >Ø140
mm.
Centre the socket over the nut.
Note! When setting down the SSV a sudden load on the thread sides must be
avoided. Support for the thread sides must be used when screwing on heavy SSVs
(refer to section “Wear”).
5.4 Loosening Procedure

Before applying any pressure, undo the hex-head nut (15) completely to prevent
it tearing off.
Remove the dust cap from the nipple.

Connect the SSV to the pump (see “Attaching the pressure connector“).
Bring the piston to the zero position (see “Piston return stroke“).
Undo the SSV by about one turn (clearance).
Generate the tensioning pressure with the pump (see “Technical data“).
Do not exceed the stroke (watch for signal band).
Turn the nut back about 1 mm from the locating face of the cylinder or piston
(see “Positioning and reversing the nut“).
Release the hydraulic pressure.
If the travel is long, the release process must be repeated (see “Release process in multiple
steps“).
Disconnect the SSV from the hose connector.
Close off the nipple with a dust cap.
Unscrew the SSV from the threaded bolt
(a guide value of 2-5 turns applies to thread diameters >Ø140 mm).

5.5 Tensioning Procedure in Several Steps
Depending on the individual situation it may be necessary to carry out the tensioning
procedure in several steps because e.g. large tensioning distances must be
covered.
With highly sensitive flange connections or resilient elastic parts a tensioning
procedure can be necessary in several steps in order to minimize deformation of the
parts.
5.6 Loosening Procedure in Several Steps with Large Loosening Distances

Depending on the individual situation it may be necessary to carry out the loosening
procedure in several steps because e.g. large tensioning distances must be
covered.
With highly sensitive flange connections or resilient elastic parts a loosening
procedure can be necessary in several steps in order to minimize deformation of the
parts.

6. Piston return stroke
6.1 Piston return stroke by reset elements

Note: Make the connection to the pressure generator.
The oil must flow back into the tank without obstruction.
Turn the hex-head nuts back ¾ of a turn.

Screw the piston slowly onto the threaded bolt until it 1 Piston
2 Cylinder
touches the cylinder (a guide value of 2-5 turns applies to 3 Set screw
4 Hex nut
thread diameters >Ø140 mm). 5 Adjusting rod
Note: Back-pressure (oil block) can occur when the piston is turned back because
the oil is flowing through very small openings back into the tank).
7. Positioning and reversing the nut

7.1 Positioning with socket (tightening)
Insert the control rod into the bore of the socket.
Turn the socket until the nut touches the flange.
Use a feeler gauge to check that the nut is touching the
flange.
Attention! For heavy workpieces work should be done using

weight supports.
1 piston
2 cylinder
3 hex nut
7.2 Reversing with socket (releasing) 4 socket
5 flange
Insert the control rod into the bore of the socket. 6 control rod
7 checking tap for feeler
Turn the socket in the release direction until the nut is about 1 mm
from the locating face of the cylinder or piston.
Note: When the nut is being released, the nut or socket must never be reversed
up to the locating face of the piston or cylinder as they may jam when the
pressure is released.

8. Attaching the pressure connector
Check all parts for damage before pressurisation. Damaged parts must be
replaced by new ones immediately.
Make sure the system is depressurised before making any connections.
Couplings and nipples must be clean before connection.
8.1 Coupling the Quick-Release Coupling Sleeve and Nipple

(SVN30 with SVK30)
Note: Operating pressure max. 3,000 bar
Remove dust protection cover.

Pull back coupling sleeve.
Connect the quick-locking coupling
nipple onto quick-locking coupling 1 Quick-locking coupling socket
1.1 Slot
socket. The nose of the nipple must slide fully into 1.2 Nose
1.3 Coupling sleeve
the recess in the coupling. 2 Quick-locking coupling nipple
2.1 Nose
Release the coupling sleeve.
Note: The sleeve will spring back into position under its own force.
Turn the sleeve 30° to lock the connection.
Note: The nose of the coupling socket is no longer above its corresponding slot.
Use approx.100 N to make sure the connector is properly seated (100 N = approx.
10 kg).
The connection is now in place and secured.
8.2 Uncoupling the Quick-Release Coupling Sleeve and Nipple

(SVN30 with SVK30)
Before uncoupling the hydraulic elements, check using a manometer whether

the hydraulic pressure is fully released.
Twist the coupling sleeve until the noses of the coupling sockets are above the
associated slots.
Separate the socket and nipple.
Replace the dust protetion cover.

9. Bolt tensioner wear
If the bolt tensioner is used frequently, the thread on the SSV can become worn and
damaged by being tightened and loosened so many times. The thread can no longer
support the tensile loads. This leads to overload breakage in the thread. If there is a
break, the SSV or parts of it may explode. Thread wear is accelerated by damaged
bolts and/or bolts of inferior quality.
Note: The sides of the thread should not be put under load when the SSV is
fitted/bolted on. Avoid putting stress on the thread during installation. Disregard can
lead to increased wear on the thread. The guide value of 2-5 turns applies when
bolting on or removing threads with diameters >Ø140 mm.
We recommend checking the SSV thread after 100 torquings/removals. The entire
SSV should be sent for servicing if the NO-GO gauge screws in more than 2-3 turns.
Serious danger!
Damaged and/or worn threads.

10. Maintenance, storage and transport
Depressurise the equipment before carrying out any maintenance work!
10.1 General
Do not use aggressive cleaning materials. Use lint-free cloths and make sure parts
are clean before installation. Aggressive media (acids, caustic solutions, solvents,
steam) can damage components.
Tighten all bolts and threaded connections after installation.
10.2 Changing seal (above 1,600 bar)

Note: Only use new seals and support rings.
It is easier to insert and remove the piston if the bleed screw is undone. (optional)
Remove the high-pressure connector/angled connector from the SSV.

Use a plastic hammer to tap the piston carefully out of the cylinder.
Remove the seals and support rings.
Clean all parts.
Check the parts for damage.
Lubricate the parts.
Insert the new support rings.
Note: The edge of the support ring always faces away from the seal.
Insert the new support seals.
1 Cylinder 3 Seal 5 Seal

2 Piston 4 Bearing ring 6 Bearing ring
Carefully tap the piston back into the cylinder using a plastic hammer (Warning:
Do not tip the piston during assembly).
Refit the high-pressure connector/angled connector on the SSV.
Note: Make sure no dirt gets into the SSV. It could damage the seals, support rings
and mating faces.

10.3 Changing seal – angle connector
Note: Only use new replacement seals.
1 Housing 3 Spring clip/nut 5 Quick-locking coupling nipple 7 Insertion guide

2 Bolt nipple 4 Seals 6 Adapter
Remove the angle connector from the SSV.

Remove the nut and/or spring clip.
Pull the bolt nipple out of the housing.
Remove the seal from the bolt nipple.
Clean all parts.
Check the parts for damage.
Lubricate the parts.
Using the insertion guide, slide the new seals onto the bolt nipple.
Slide the bolt nipple back into the housing.
Secure the bolt nipple with the nut and/or spring clip.
Fit the high-pressure connector to the SSV (see table).
pressure connection torque
G1/4“ SK 90 Nm
G1/4“ 60° DK 40 Nm
G1/4“ BSP 120° DK 50 Nm
M16x1,5 AG 58° DK 50 Nm
M14x1,5 60° DK 40 Nm
10.4 Bleeding
Undo the bleed screw on the SSV by turning it one turn using
a hexagonal offset screwdriver.
Connect the SSV to the pump (see “Attaching the pressure connectors“).
Operate the pump until bubble-free oil emerges from the
bleed screw.
Close the bleed screw.
1 Bleed screw
Release the hydraulic pressure. 2 Ball
Disconnect the SSV from the pump.
Note: The SSV should be bled in its highest position. If necessary, tip the SSV.

10.5 Troubleshooting
Problem Solution
SSV cannot be The SSV was not turned back far enough before being
switched off pressurised.
The nut was turned back too far before the hydraulic
pressure was relieved.
This despite the fact that the pre-set clearance
corresponded to the maximum permissible stroke on the
SSV. Do not bleed off 50% of the pressure for example, just
25%.
The SSV cannot be Care with resilient-elastic parts and loosening procedure in
turned even though
the previously set several steps:
clearance corresponds Release the pressure not by e.g. 50% but only by circa 25%
to the max. and tighten the main nut. Begin a new loosening procedure.
permissible stroke of
the SSV.
Insufficient Check visually for leaks; replace faulty parts if necessary.
pressure Bleed SSV (see “Maintenance, storage and transport“).
Pressure drop Check visually for leaks; replace faulty parts if necessary.
Nut cannot be The nut must have sufficient axial clearance. This is needed
turned because the thread in the area of the nut expands in
proportion to the force when this is applied to the upper end
of the bolt. The bolt undergoes a “change of pitch” which is
compensated for by the axial clearance of the nut. If this
clearance is not there, it becomes more difficult, if not
impossible, to turn the nut when the force is applied. The
pretension accuracy is greatly affected.
The side clearance is calculated as follows:
Damages to the thread in the nut and bolt area will reduce
the side clearance.
Maintenance must be carried out with the system unpressurised.
If you have any questions, please contact our Service Department

10.6 Storage
Clean items before putting them in storage.
Always store and transport products horizontally.
Lubricate all threads and moving parts before storage and at regular intervals.
Close all coupling nipples and boxes.
Protect products from corrosion and dirt.
10.7 Transport
The eyebolts and clamping devices provided or other suitable transport equipment
must be used.
Disconnect all hoses before transport.
11. Guarantee
This product is guaranteed for a period of 6 months from the date of delivery to the
first owner.
Be sure to follow the maintenance and operating instructions in this manual.
SCHAAF GmbH & Co KG is not liable for damage or injuries arising from improper
transport or installation, inadequate maintenance, incorrect operation, wear or
unsuitable hydraulic fluid.
12. Disposal
Older equipment contains valuable recyclable materials which should be reused. All
materials and oils should be disposed of correctly.
Follow the disposal regulations for your country.
13. Technical data Item no. A67420000

Pressure connector Angle connector M16x1.5 AG 58° DK with SVN30
quick-locking coupling nipple
Hydraulic oil HLP ISO VG 15
Weight 17.2 kg
Diameter 158
Height 208
Ambient temperature -10°C to +50°C
Max. load change 2500
Clamping pressure 2944 bar
Clamping force 1,600 kN

14. Drawing SSV M72x6 A6742

15. Parts list
SSV M72x6 / Date 12/2008 / Item no. A67420000
Wear classes:
A normal wear sufficient stock required urgently
B minor wear no stock recommended
individual parts should be stocked
C normally no wear
for emergencies
Item Name Qty Item no./dwg no. Wear class
01 Support sleeve 1 A67420100 C

02 Cylinder 1 A67420200 C
03 Piston 1 A67420300 B
04 SW105 hex-head nut 1 A70000200 C
05 Seal 1 124-109-10PUSN A
06 Backup ring 1 Z6-124-109-3P A
07 Seal 1 107-092-10PUSN A
08 Backup ring 1 K6-107-092-3P A
09 O-ring 1 25070NBR C
0.3
10 Stroke signal band m HSB-12 C
11 Set screw 1 09131001045H C
12 Ball bearing 1 Ku-07.5 C
13 Set screw 2 09131006045H C
14 Hex nut 2 0934010 C
15 Angle connector 1 A28191800 B
16 Adjuster rod 1 ZU0050205 C
17 Eye bolt 2 0580010 C

Operating manual
Hand-lever pump
02/2009
01.04.2009 P:\2-Konstruktion\Dokumentation\Betriebsanleitung\Artikelnummer\A43000033-ENG.doc Seite 1 von 19

Inhaltsverzeichnis:
1. Foreword .........................................................................................................4

3. Safety instructions for hand-lever pump......................................................7
4. Abbreviations ..................................................................................................8
5. Operation .........................................................................................................9
5.1 Pressure build-up .......................................................................................................9
5.2 Pressure reduction ...................................................................................................10
6. Attaching the pressure connector ..............................................................10

6.1 Connecting the M16 x1.5 AG 58º DK /G1/4" AG 60º adapter ..................................10
6.2 Undoing the M16 x1.5 AG 58° / G1/4“ AG 60° adapter ............................................11

7.1 General ....................................................................................................................11
7.2 Checking oil level – adding oil ..................................................................................11
7.3 Bleeding ...................................................................................................................11
7.4 Troubleshooting .......................................................................................................12
7.5 Storage ....................................................................................................................12
7.6 Transport..................................................................................................................12
8. Guarantee ......................................................................................................13
9. Disposal .........................................................................................................13

10. HP 3000-HT A4300 model coding................................................................14
10.1 Your model code ......................................................................................................14
11. Technical data HP 3000-HT A4300 0-3,000 bar ..........................................15
12. HP 3000-HT A4300 drawing .........................................................................16
13. Parts list.........................................................................................................17

1. Foreword
problems.

Bruesseler Allee 22
Phone: +49 - 2431 - 97770-0

Fax: +49 - 2431 - 97770-77
Service:
Phone: +49 - 2431 - 97770-0
Fax: +49 - 2431 - 97770-77

Danger



operating manual.


data).

work process.

connected.

Technical data).



equipment.


Incorrect operation
Product breakdown
3. Safety instructions for hand-lever pump

Make all connections only when the system is unpressurised.
Under no circumstances is the hand pump to be secured or transported when the

hose is connected.
Hydraulic cylinders running on the HP may not be upheld by the pump valves alone.
Use additional non-return valves and support the weight by using appropriate
mechanical supports.

4. Abbreviations
ES - Limit switch
H - Pilot light
HM - Hydraulic Nut
HS - Main switch
SS - Float switch
Y - Hydraulic-valve

5. Operation
1 Pump body 4 Handle 7 Bleeder 10 Pressure gauge

2 Tank 5 Arm 8 Pressure relief valve 11 Pressure connector
3 Lever 6 Oil filler neck 9 Distributor
Note: Raise the handle (to the left) out of its mounting, then turn it hard against the
stop in the lever on the HP 3000-HT. Use the complete handle travel when pumping.
Slowly raise (to suck in oil) – quickly lower (to compress oil).
5.1 Pressure build-up

Remove the dust cap from the pressure connector.
Connect the pump to the user (see “Attaching the pressure connector”).
Open the bleeder in the oil filler neck by one turn (to the left) using the SW5
socket wrench provided.
Note: The HP 3000-HT only increases the pressure if the tank has been bled.
Close the pressure relief valve on the pump body

(turns to the right, max. 10 Nm).
Use the handle to pump until the desired pressure is reached.
Note: The HP 3000-HT is a two-stage pump that switches automatically from the 1st
to the 2nd stage at approx. 30 bar. The effort used on the hand lever in the 1st stage
is reduced significantly and immediately in the 2nd.

5.2 Pressure reduction
Slowly open the pressure relief valve (turns to the left) until the pressure is zero.
Note: The more oil flowing back into the tank, the slower the pressure relief valve
should be opened. Releasing the pressure quickly with a large quantity of oil present
will increase wear and tear on the components.
Pressure release at tensioning process Pressure release at dismounting process
12
10
0
0 50 100 150 200 250 300 350 400
Pressure release in s ec
Use pressure gauge to check that the hydraulic pressure has been released fully.
Disconnect the pump from the user (see “Attaching the pressure connector”).
Note: Close the bleeder in the oil filler neck for transport and storage.

6.1 Connecting the M16 x1.5 AG 58º DK /G1/4" AG 60º adapter

Undo the union nut.

Remove the balls.
Screw the adapter tightly to the HDS using
40 Nm. 1 Adapter
2 Ball
2 Union nut
The connection is in place.

6.2 Undoing the M16 x1.5 AG 58° / G1/4“ AG 60° adapter
Use a pressure gauge to check that the hydraulic pressure is zero before
releasing the hydraulic parts.
Undo the connection to the HDS.

Insert the balls and tighten the union nut.
7.1 General
7.2 Checking oil level – adding oil

Unscrew the oil filler neck.
Check the oil level (approx. 2.0 cm from top of tank).
If level too low, add hydraulic oil (approx. 2.0 cm from top of tank).
Retighten the oil filler neck.
Bleed the pump.
Make sure no dirt gets into the tank or pump as it could cause damage
or breakdowns.
7.3 Bleeding
Open the bleeder in the oil filler neck by one turn (to the left) using the SW5
socket wrench provided.
Undo the bleed screw on the pump body by one turn using an SW2.5 hexagonal
offset screwdriver.
Close the pressure relief valve on the pump body (turns clockwise).
Operate the lever several times until oil without bubbles emerges from the bleed
screw.
Close the bleed screw.

7.4 Troubleshooting
Problem Solution
No pressure Check oil level and top up if necessary (see “Maintenance,
build-up storage and transport”).
Close pressure relief valve (see “Maintenance, storage and
transport”).
Check visually for any points of leakage; replace faulty
parts if necessary.
Bleed pump (see “Maintenance, storage and transport”).
Insufficient Check oil level and top up if necessary (see “Maintenance,
pressure storage and transport”).
Close pressure relief valve (see “Maintenance, storage and
transport”).
Check visually for leaks; replace faulty parts if
necessary.
Bleed pump (see “Maintenance, storage and transport”).
Pressure drop Close pressure relief valve (see “Maintenance, storage and
transport”).
Check visually for leaks; replace faulty parts if
necessary.
Maintenance works must be carried out when the system is unpressurised.
If you have any questions, please contact our Service Department.
7.5 Storage
7.6 Transport
must be used.

8. Guarantee
first owner.
9. Disposal

10. HP 3000-HT A4300 model coding
10.1 Your model code
0 2 2 A 4 3 0 0 3 0 0 / 0 9 X / M A / 1 / X X / X X X
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

11. Technical data HP 3000-HT A4300 0-3,000 bar
Geometric swept volumes: Stage 1: 32 cm² / stroke up to approx.30 bar
Stage 2: 0.9cm² / stroke up to 3,000 bar
Max. hydraulic pressure: 3,000 bar
Pressure connection: M22x2
Tank contents: 1.9 litres
Usable volume: 1.7 litres
Hydraulic oil: ISO VG 15
Pump body: High-strength tempered steel
Tank: Aluminium
Oil-level indicator: fitted
Weight (filled with oil, without 20 kg
distributor disk and pressure gauge):
Length: 830 mm
Width: 200 mm
Height with pressure gauge (Ø100): 292 mm
Height with pressure gauge (Ø160): 300 mm
Distributor disk: Depends on design (see Annex)
Pressure gauge: Ø100 mm, class 1.0 glycerine-filled
Ambient temperature: -10°C to 50°C

12. HP 3000-HT A4300 drawing

13. Parts list
HP 3000-HT / Date 11/2008 / Dwg no. A43000033
Wear classes:
A normal wear sufficient stock required urgently
B minor wear no stock recommended
individual parts should be stocked
C normally no wear
for emergencies
01 Cavity plate 1 A43000100 C

02 Plate 1 A43000200 C
03 Plunger guide 1 A43000300 B
04 Plunger guide 1 A43000400 B
05 Plunger 1 A43000500 B
06 Fork 1 A43000600 B
07 Link 1 A43000700 B
08 DU bronze bush 1 DU020-023-11 B
09 Tank plate 1 A43000900 C
10 Tank pipe 1 A43001000 C
11 Foot 1 A43001100 C
12 Threaded rod M12 1 A43001200 C
13 Cylinder bolt 2 0912060148.8 C
14 Tank stop-cock flange 1 A43001400 C
15 Tank stop-cock spindle 1 A43001500 B
16 Set screw 1 A43001600 C
17 Dowel pin 1 797910040m6 C
18 Dowel pin 1 797910080m6 C
19 Dowel pin 1 A43001900 C
20 Seal 2 A43002000 A
21 Set screw 1 A43002100 C
22 Sealing plug 2 A43002200 C
23 Ferrule 1 A43002300 B

Parts list
HP 3000-HT / Date 11/2008 / Dwg no. A43000033

24 Ferrule 1 A43002400 B
25 Ferrule 1 A43002500 A
26 Ferrule 1 A43002500 C
27 Stop-cock flange 1 A43002700 C
28 Stop-cock spindle 1 A43002800 B
29 Set screw 1 A43002900 B
30 Special spring 1 RF16x32-VE C
31 Grooved ring Ø12/Ø6x6 3 012-006-06PUZN A
32 Bearing ring 4 A43003200 A
33 Set screw 1 09130802045H C
34 Cylinder bolt 4 0912080168.8 C
35 Seal 1 036-028-06,5PUSN A
36 Dowel pin 1 797912040m6 A
37 Pressure valve 2 DV161S2Z A
38 Nylon ring 8 DR018-012_Ny A
39 Valve 1 A43003900 B
40 Pressure spring 1 DF0,8x6x10 A
41 Grooved ring 1 020-010-08PUKN A
42 Set screw 8 09131201245H A
43 Ball bearing Ø9 8 Ku-09 A
44 Ball bearing Ø7.5 4 Ku-07.5 A
47 Pressure spring 1 DF0.5x7,1x16 A
48 Dowel pin 1 797905028m6 C
49 Star grip 1 StG-B12x63 C
50 Spring dowel pin 1 148104020 C
51 Hex-head bolt 2 933080258.8 C
52 Spring dowel pin 1 148104036 C
53 Hex-head bolt 2 0933060208.8 C

Parts list
HP 3000-HT / Date 11/2008 / Dwg no. A43000033
54 Cylinder bolt 5 0912060148.8 C

55 Lever 1 A43005601 C
56 Lever 1 A43005602 C
57 Handle 1 HandNr410 C
58 Set screw 1 09131604045H C
59 Hex-head bolt 1 0933120208.8 C
60 Hex nut 1 04398012 C
61 Nipple 1 A43006100 C
62 Flat-rolled steel 1 A43005800 C
63 Hex-head bolt 1 0933080208.8 C
64 Bleed screw 1 Entl-St-1/2“ C
65 Hex-head dome nut 1 091712STBL C
66 Copper seal 1 01801201CUDR B
67 Hex nut 1 0934016 C
68 Screw piece for pressure gauge 1 A39705200 C
69 O-ring 1 10990NBR A
70 0-3,000 bar pressure gauge 1 ZU0080040 B
71 1-way distributor disk 1 A43006001 B
72 Pressure connector 1 A28222900 B

Operating manual
High-pressure hose
02/2009

Inhaltsverzeichnis:
1. Foreword .........................................................................................................3

3. Safety instructions for high-pressure hose .................................................7
4. Abbreviations ..................................................................................................7
5. Operation .........................................................................................................8
6. Attaching the pressure connector ................................................................8

6.1 Attaching the quick-locking coupling socket and nipple .............................................8
6.2 Detaching the quick-locking coupling socket and nipple ............................................9

7.1 General ....................................................................................................................10
7.2 Storage ....................................................................................................................10
7.3 Transport..................................................................................................................10
8. Guarantee ......................................................................................................10
9. Disposal .........................................................................................................10
10. Technical data for A0652 (3,000 bar) ..........................................................11

10.1 Hose Information / Coding .......................................................................................11

1. Foreword
problems.

Bruesseler Allee 22
Phone: +49 - 2431 - 97770-0

Fax: +49 - 2431 - 97770-77
Service:
Phone: +49 - 2431 - 97770-0
Fax: +49 - 2431 - 97770-77

Danger



operating manual.


data).

work process.

connected.

Technical data).



equipment.


Incorrect operation
Product breakdown

3. Safety instructions for high-pressure hose
The nipple on the quick-locking coupling must never be disconnected while under
pressure!
Make all connections only with the system unpressurised.
Never place mechanical loads on the high-pressure hose and never kink hose. The
minimum bending radius is 130 mm. The permitted ambient and contact
temperature is between –40°C and +100°C.
4. Abbreviations
ES - Limit switch
H - Pilot light
HM - Hydraulic Nut
HS - Main switch
SS - Float switch
Y - Hydraulic-valve

5. Operation
Note: Hoses with quick-locking coupling sleeves or nipples prevent oil leakage, even
when disconnected. Pressure build-up can occur when hose is disconnected
because of intense temperature rise of oil in the high-pressure hose. This then
makes connection impossible. The pressure can be released by undoing the
threaded connectors (see illustration).
The loosened connectors should then be retightened to 40 Nm.
Connect the high-pressure hose to the pump and the tool (see “Connecting high-pressure
hose”).

6.1 Attaching the quick-locking coupling socket and nipple

(SVN30 with SVK30)
Remove dust caps.

Connect the quick-locking coupling
nipple onto quick-locking coupling 1 Quick-locking coupling socket
1.1 Slot
socket. The nose of the nipple must slide fully into 1.2 Nose
1.3 Coupling sleeve
the recess in the coupling. 2 Quick-locking coupling nipple
2.1 Nose
Release the sleeve.
Note: The sleeve will spring back into position under its own force.
Turn the sleeve 30° to lock the connection.
Note: The nose of the coupling socket is no longer above its corresponding slot.

Use approx.100 Nm to make sure the connector is properly seated (100 N =
approx. 10 kg).
The connection is now in place and secured.
6.2 Detaching the quick-locking coupling socket and nipple

(SVN30 with SVK30)
Use a pressure gauge to check that the hydraulic pressure is zero before
detaching the hydraulic elements.
Twist the coupling sleeve until the noses of the coupling sockets are above the
associated slots.
Separate the socket and nipple.
Replace the dust caps.

7.1 General
7.2 Storage
7.3 Transport
must be used.
8. Guarantee
first owner.
9. Disposal

10. Technical data for A0652 (3,000 bar)
1 High-pressure hose 3 Quick locking coupling socket SVK30

2 Adapter M16 x 1.5 AG 58° DK/G1/4“ 60° DK
Max. operating pressure for Item 1: 3,000 bar

Test pressure for Item 1: 4,650 bar
Seating pressure for Item 1: 6,200 bar
Hose lining: POM
Load bearer: 6 coiled layers of corrosion-resistant
spring steel wire
Top cover: PA, Nylon
Protective sleeve: PVC
ID: 5.0 mm
OD: 13.0 mm
OD with protective sleeve: 22.0 mm
Weight: 0.43 kg/m
10.1 Hose Information / Coding

All high-pressure hoses are provided with an additional protective sleeve. The
details marked on the hose: (refer exclusively to item 1)
EN quality-assurance standard Max. operating pressure in bar

All high-pressure hoses are tested on their material quality,
size retention, operation and safety under pressure. Quality
checks are applied continuously during production and e.g. 4Q05 (4th quarter 2005)
products are supplied with comprehensive documentation.
Hose type
Nominal width

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What safety instructions are mentioned?

What safety instructions are mentioned?

What are the steps for coupling and uncoupling the quick-locking coupling socket and nipple?

What are the steps for coupling and uncoupling the quick-locking coupling socket and nipple?

Operating manual

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2. General safety instructions ...........................................................................5

3. Safety instructions for bolt tensioner...........................................................8

6. Piston return stroke......................................................................................13

7. Positioning and reversing the nut...............................................................13

8. Attaching the pressure connector ..............................................................14

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10. Maintenance, storage and transport...........................................................16

11. Guarantee ......................................................................................................19

12. Disposal .........................................................................................................19

13. Technical data Item no. A67420000 ............................................................19

14. Drawing SSV M72x6 A6742..........................................................................20

15. Parts list.........................................................................................................21

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SCHAAF GmbH & Co. KG

Phone: +49 - 2431 - 97770-0

You’ll find your closest national or regional representative on the Internet.

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Dangerous electrical voltage

Environmental hazard warning

2.2 Caution: high-pressure hydraulics

2.3 Employee qualifications and training

Areas of responsibility, competences and the supervision of personnel must be

2.4 Safety instructions for operators/users

Danger! Do not exceed the maximum permitted pressure (see Technical

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A faulty pressure gauge is a risk to life!

Pressure must never be applied to the quick-release coupling nipple if it is not

Faultless operation is only guaranteed at the prescribed ambient temperature (see

Check all components for damage before pressurisation. Damaged components

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2.5 Safety instructions for maintenance, inspection and installation work

Depressurise the equipment before carrying out maintenance work..

2.6 Dangers of not following safety instructions

Improper use of the product

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Exposed length of bolt must be at least 1.0 x the thread diameter

Zero stroke Maximum stroke 1 Cylinder

Under no circumstances is the SSV to be secured or transported when the hose is

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1 Support sleeve 5 Bearing ring 9 Adapter 13 Retaining ring

5.1 Screwing on the SSV before the Tensioning Procedure

5.2 Tensioning Procedure

Remove the dust cap from the nipple.

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5.3 Screwing on the SSV before the Loosening Procedure

5.4 Loosening Procedure

Remove the dust cap from the nipple.

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5.6 Loosening Procedure in Several Steps with Large Loosening Distances

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6.1 Piston return stroke by reset elements

Turn the hex-head nuts back ¾ of a turn.