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Technical Requirements for the use
of Bolt Tensioning Cylinders
Technical introduction
Industrial bolting tools can be divided by their fundamental affect the bolt itself. When using the ITH Stretch Method
bolting method: there is the rotation method (torqueing) there are no effects of friction, bending or torsion (“Hydraulic,
and tensioning method. Rotation methods (torqueing) work friction-free and torsion-free tightening”) affecting the bolting
according to the torque or the rotation angle principle. When procedure. The initial assembly preload FVM are applied with a
torqueing the accuracy of the preload force is influenced very high precision of +/- 2.0% and with a high repeatability.
negatively by friction and by torsion and bending loads which

Functional principle

The change bushing (light green) of The required pressure p is generated When the pressure has been
the Bolt Tensioning Cylinder (BTC) by an ITH high pressure pump. This achieved, the nut is threaded onto
is threaded onto the projecting creates an elongation in the bolt the support surface without friction
thread of the bolt. The turning sleeve (Δl). The initial assembly preload FVM by turning the turning sleeve. The
encloses the nut. is applied free of friction and free of Bolt Tensioning Cylinder can be
torsion. removed once the pressure is
released.

See the explanation video on www.ITH.com

The 3D animation video explains the ITH stretch method in
40 seconds. Our responsive design website automatically
adapts its size to smart phones, tablet computers or desktop
computers.

To see the video scan the QR code with your

smart phone or visit www.ITH.com

Advantages of the ITH stretch method 3 High utilization of the proof stress
3 No friction effects between the nut / supporting surface (up to > 90% RP0.2 possible).
or between nut thread / bolt thread. 3 Bolted joints subject to high temperatures (e.g. on
3 High precision and high repeatability of the target gas turbines) can be disassembled easily and
value assembly preload FM because of no friction effects. damage-free even after long periods of time.
3 Linear relation between pressure p and initial 3 Perfect for use with stainless steels as there is no risk of
assembly preload FVM ensures a high system accuracy cold soldering (seizing) on the thread.
and a high reproducibility. 3 Well suited for on-site assembly.
3 No bending stresses in the bolt, no torsion effects in 3 Simultaneous pre-tensioning of several bolts at the
the bolt because the force is applied in an only axial same time possible (ITH Multi Tensioning System,
direction. see page 19).
3 High preload forces even in small tool dimensions
* clamping length ratio must be lK/d ≥ 5, fasteners must be
(e.g. thread W 510 or M340; 45,000 kN).
machine processed.
3 Small αA-factors up to 1.05* when designing bolted joints.

2  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Bolt Tensioning Cylinder (BTC) designs

The design of Bolt Tensioning Cylinders (BTC) can be divided two or more piston areas. For this reason the multi-stage
into single-stage and multi-stage types. Single-stage BTCs Bolt Tensioning Cylinders usually have a reduced outside
have one effective piston area while multi-stage BTCs have diameter.

Standard Bolt Tensioning Cylinders

Type ES - Single-stage BTC Type MS - Multi-stage BTC
3 One effective piston surface 3 Parallel design of the piston surface
3 Short design for application with axially limited and 3 Slim design for application with radially limited and
radially free spaces. axially free spaces.

FVM
FVM

p
p

Special design Bolt Tensioning Cylinders

Type TWIN Type Segment
3 Two change bushings in one cylinder. 3 Several change bushings in one cylinder
3 For the simultaneous tightening and loosening of 3 For the simultaneous tightening and loosening of
multiple bolt connections. multiple bolt connections.
3 Field of application: Engine and turbine construction. 3 Field of application: Turbine construction, heavy
machinery and flange connections.

FVM FVM FVM FVM FVM FVM

p
p

Explanation:

Piston Return Change Bushing Piston Cylinder Lock Nut

ITH Bolting Technology · www.ITH.com · [email protected]3

Features of ITH Bolt Tensioning Cylinder

1
10
2

3
4

5
8

Safety Features Accelerating Features

1. Carrying strap: Strong and flexible for an easy handling. 7. Heavy Duty direct gear drive ( ¼“ - ½“).
Steel bar version optionally. Bigger BTCs can be equipped 8. Spring loaded turning sleeve: Speed up the assembling
with balancers or other custom lifting devices (ring loops of the Bolt Tensioning Cylinder. The spring system pushes
and more). the turning sleeve over the nut when the nut aligns.
2. Patented cycle counter: Counts and displays pressure 9. Automatic piston return: return of the piston to the
cycles and offers easy information regarding tool starting position after pre-tensioning.
maintenance.
3. NIOX coating: Extra Nickel-Chromium coating offers extra
protection from corrosion. Standard BTCs are protected by Precision Features
burnishing. 10. Direct pressure stretch documentation system
4. Patented protection cap with handle: Increasing work (PD / PSD-System): Digital documentation of all bolting
safety and ergonomic handling. applications by operation with Bolt Tensioning Cylinders.
Safety measurement pin (PD-System only): Measuring
5.  11. ITH Multi Tensioning: 4 or more BTCs can be used
bolt elongation after applying pressure. simultaneously
6. Patented safety fracture device: Increasing safety by 12. Reproducible pre-tensioning force with a tight tolerance
keeping the energy inside of the tool in case of wrong use. of ± 2.0%

4  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Modular design of Bolt Tensioning Cylinders
Change bushings Change bushings
… 3 O
 ne BTC can be equipped with several change
and more bushings to adapt different thread profiles or bolt
diameters.

Cylinder unit Supports

3 O ne BTC can be equipped with several supports to
match the nut and washer design.
3 ITH BTCs cover all nut / washer set ups like:
1. DIN ISO standards,
2. heavy hex nuts,
3. HV-standard,
4. ITH round nuts RMS/RMZ and IHF Roundnuts
… 5. any hexagonal nut designs, any radial hole nut
Supports and more designs and any customized nut designs.

Turnings sleeves
3 T he turning sleeve is the part of the support which
… contacts the nut radially.
Turnings sleeves and more 3 T he turning sleeve can be exchanged to fit any nut
and washer set-ups (hexagonal nut designs or radial
nut designs).

Recommendations for designing bolted joints

To use the benefits of the ITH stretch method most efficiently certain design
parameters can be recommended: T
A
3 R  atio between thread projection above the nut (h2) should be bigger than
1.0 times the bolt diameter (d) (h2 ≥ 1.0 x d). Depending on the required d
preload force also h2 ≥ 0.8 x d possible.
3 A  certain thread flank of the bolts should be considered (ITH recommends
the design according to DIN 2510, part 2). h2 ≥ 1.0 x d
3 T he ratio between clamping length lK to outer thread diameter d should be A
bigger than 2.0 (lKmin ≥ 2.0 x d).
3 T he initial assembly preload FVM may not extend the bolt load at the 0,2 %
proof stress F0.2. dS
3 P  erpendicularity between bolt and supporting surface (tolerance is 1°).
T
Alternatively the use of cardanic washers is recommended. lKmin ≥ 2.0 x d
3 T he number of split joints should be kept as low as possible (avoid using
washers). If washers are necessary their outer diameter should be big
enough for the Bolt Tensioning Cylinder to stand on.
3 C  onsider the form tolerances and positional tolerances of the fasteners and
further components.
3 T he limiting surface pressure pG at the supporting area should be checked.
3 P  lease consider that surface quality or coatings can affect the bolting result.

ITH Bolting Technology · www.ITH.com · [email protected]5

Technical Requirements for the use
of Bolt Tensioning Cylinders

To choose the right BTC the

following issues should be clarified:
3 Bolt diameter d, thread pitch P, bolt quality
3 The required assembly preload FM
3 Fastener dimensions (hS, h1, h2) and clamping length lK
3 The surrounding dimensions of the bolted joint (le, t, dt, he)

he
d

h2
le
h1 dt
hS

t SW/AF
lK

Pos. Bolt-Ø d Bolt Required Width Nut height Thread Washer Clearance Clamping Radial Bolt Pitch Number
x quality assembly across Projection thickness Height Length Distance Spacing Diameter of bolts
pitch P preload flat
FM SW | AF h1 h2 hS he lK le t dt nS

Fill in the columns and send it to us, preferably via email to [email protected]. We would be happy to help you choosing the right ITH Bolt
Tensioning Cylinder for your application.

Indexes:
FM (Residual) assembly preload t Bolt spacing in a multi-bolted joint
FVM (Initial) assembly preload = bolt load created by BTC dt Pitch diameter
F0.2 Bolt load at the 0,2% proof stress ns Number of bolts in a multi-bolted joint
d Bolt diameter = outside diameter of thread (nominal diameter) ds Diameter at stress cross section AS
P Pitch of the thread pG Limiting surface pressure
SW | A/F Width across flats of the nut
H1 Tool height of the BTC
D3 Tool diameter of the BTC
h1 Nut height
h2 Thread projection above the nut
hS Washer thickness
he Clearance height
le Radial distance
lK Clamping length

6  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Preload forces
Design parameters Defining the preload force
For the use of Bolt Tensioning Cylinders ITH recommends The required preload force is usually determined in the bol-
a thread projection above the nut of 1.0 x bolt diameter d, ted joint design. For a bolted joint design ITH recommends
depending on the required preload force (h2 ≥ 1.0 x d). The to use the fundamental German bolting guideline VDI 2230.
ratio between clamping length lK to bolt diameter d should The following preload forces are an ITH recommendation for
be bigger than 2.0 (lKmin ≥ 2.0 x d). shank bolts and reduced shank bolts based on a 90% utiliza-
tion of the stress at 0,2% non-proportional elongation (Rp0,2).

Property class acc. to

6.8 8.8 10.9 12.9
DIN EN ISO 898-1
Lower yield stress ReL
480
[N/mm2]
Stress at 0,2% non-proportional
660 940 1100
elongation Rp0,2 min [N/mm2]
Thread size A/F width* FVS [kN] FVD [kN] FVS [kN] FVD [kN] FVS [kN] FVD [kN] FVS [kN] FVD [kN]
acc. to DIN 2510
M 16x2 24 64 49 88 67 125 96 146 112
M 20x2,5 30 100 76 138 105 196 150 230 175
M 22x2,5 34 125 92 172 127 245 181 286 212
M 24x3 36 145 110 199 151 284 215 332 252
M 27x3 41 190 143 261 196 372 279 435 327
M 30x3,5 46 232 179 319 247 454 351 532 411
M 33x3,5 50 288 221 397 303 565 432 661 506
M 36x4 55 340 257 467 353 665 502 779 588
M 39x4 60 407 316 560 434 797 618 933 723
M 42x4,5 65 468 358 643 493 916 702 1072 821
M 45x4,5 70 546 428 751 588 1070 837 1252 980
M 48x5 75 616 477 847 656 1207 934 1412 1093
M 52x5 80 737 570 1014 784 1444 1117 1689 1307
M 56x5,5 85 852 657 1171 903 1668 1286 1951 1505
M 60x5,5 90 993 766 1365 1053 1944 1499 2275 1754
M 64x6 95 1123 882 1544 1213 2198 1728 2573 2022
M 68x6 100 1284 1008 1766 1386 2515 1974 2943 2310
M 72x6 105 1457 1161 2003 1597 2852 2274 3338 2661
M 76x6 110 1640 1304 2255 1793 3211 2554 3758 2989
M 80x6 115 1834 1478 2522 2032 3592 2894 4203 3387
M 85x6 120 2092 1710 2876 2352 4097 3349 4794 3920
M 90x6 130 2367 1909 3254 2624 4635 3738 5424 4374
M 95x6 135 2659 2171 3656 2986 5207 4252 6093 4976
M 100x6 145 2965 2394 4077 3292 5806 4688 6795 5486
M 110x6 155 3631 2903 4992 3992 7110 5685 8320 6653
M 120x6 170 4366 3530 6004 4854 8551 6913 10006 8090
M 125x8 180 4590 3812 6311 5242 8989 7466 10519 8736
M 130x8 185 4993 4218 6866 5800 9778 8261 11443 9667
M 140x8 200 5850 4724 8044 6496 11457 9252 13407 10827
M 150x8 210 6775 5472 9316 7525 13268 10717 15527 12541
M 160x8 220 7761 6276 10671 8629 15199 12290 17786 14381
M 170x8 230 8819 7134 12126 9809 17271 13970 20210 16348
M 180x8 255 9947 8047 13677 11064 19479 15758 22795 18440

*SW/AF width from M16 to M 68 according to ISO 4032. SW/AF width > M68 according to DIN 2510

Preload forces for shaft bolts and reduced shaft bolts with a 90% utilization of the stress at 0,2% non-
proportional elongation Rp0,2:
Preload forces for shank bolts FVS Preload forces for reduced shank bolts FVD

ITH Bolting Technology · www.ITH.com · [email protected]7

Bolt Tensioning Cylinder Type ES - Single-stage
3 Short design for application with axially limited and 3 Use for hexagon nut, heavy hex nuts, ISO 4032, DIN
radially free spaces. 2510, EN 14399, Roundnuts, ITH Roundnuts RMS/RMZ,
3 Minimum thread projection (h2) above the nut ≥ 1.0 x d and IHF Roundnuts.
(depending on the initial assembly preload FVM).

D3 Features
1. Patented safety fracture device
2. Automatic piston return
3. Interchangeable parts for different
thread and nut profiles
4. Pre-configured for optional bolt
d elongation measurement
5. Direct gear drive with internal gear
6. Spring loaded turning sleeve
H1
7. Stroke limitation
h2 (Over-stroke limiter)
8. Control notch
9. Patented safety carrying handle
10. Patented cycle counter
SW
/AF

Optional
1. Chrome-nickel surface coating NIOX
Fig. with optional features 2. Safety measurement pin for
thread projection
3. Swivel connection for high pressure
couplings and nipples
Modular design 4. Multi Tensioning high pressure
3 O
 ne Cylinder
… can be equipped coupling
and more with several 5. Patented protection cap with handle
change bushings,
… supports & tur-
and more ning sleeves
3 See page 5
… for details
and more

Assembling of BTC type ES on an ANSI flange. Foundation bolt connection.

8  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Type ES for Bolt Quality 10.9 – Standard 150
Type Order no. Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]* [mm] ["] [mm] ["] [mm] ["]
ES 16 - 10.9
ES 20 - 10.9 Contact us for technical specifications with an email to: [email protected]
ES 22 - 10.9
ES 24 - 10.9 33.05441 306.2 68837 M 24 x 3 1 36 1 4/9 77.5 3,05 116.5 4.59
ES 27 - 10.9 33.05442 399.6 89834 M 27 x 3 - 41 1 5/8 87.5 3.44 116.5 4.59
ES 30 - 10.9 33.05443 486.1 109280 M 30 x 3,5 1 1/8 46 1 4/5 96.0 3.78 121.0 4.76
ES 33 - 10.9 33.05444 604.4 135875 M 33 x 3,5 1 1/4 50 2 105.0 4.13 137.3 5.41
ES 36 - 10.9 33.05445 712.0 160053 M 36 x 4 1 3/8 55 2 1/5 115.0 4.53 132.4 5.21
ES 39 - 10.9 33.05446 848.7 190787 M 39 x 4 1 1/2 60 2 3/8 124.5 4.90 139.2 5.48
ES 42 - 10.9 33.05447 980.9 220516 M 42 x 4,5 1 5/8 65 2 4/7 134.0 5.28 156.7 6.17
ES 45 - 10.9 33.05448 1145.9 257599 M 45 x 4,5 1 3/4 70 2 3/4 144.0 5.67 153.0 6.02
ES 48 - 10.9 33.05449 1290.0 290005 M 48 x 5 1 7/8 75 3 154.0 6.06 157.2 6.19
ES 52 - 10.9 33.05450 1540.0 346207 M 52 x 5 2 80 3 1/8 167.0 6.57 176.3 6.94
ES 56 - 10.9 33.05451 1775.0 399038 M 56 x 5,5 2 1/4 85 3 1/2 177.7 7.00 179.0 7.05
ES 60 - 10.9 33.05452 2075.6 466618 M 60 x 5,5 2 3/8 90 3 3/4 193.0 7.60 190,5 7.50
ES 64 - 10.9 33.05453 2325.2 522728 M 64 x 6 2 1/2 95 3 7/8 204.0 8.03 239.4 9.43
ES 68 - 10.9 33.05454 2685.4 603700 M 68 x 6 - 100 4 1/4 219.5 8.64 193.3 7.61
ES 72 - 10.9 33.05455 3010.1 676694 M 72 x 6 2 3/4 105 4 5/8 231.5 9.11 221.4 8.72
ES 80 - 10.9
Up to Contact us for technical specifications with an email to: [email protected]
ES 110 - 10.9

Technical enhancements and modifications reserved. *Inch dimensions for a pitch of 8 UN, any further pitches available.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

Foundation bolt connection. Cylinder head assembly.

ITH Bolting Technology · www.ITH.com · [email protected]9

Type ES for Bolt Quality 10.9 – Slim Line 225*
Type Order no. Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]** [mm] ["] [mm] ["] [mm] ["]
ES 16 - 10.9
ES 20 - 10.9 Contact us for technical specifications with an email to: [email protected]
ES 22 - 10.9
ES 24 - 10.9 33.05541 307.6 69152 M 24 x 3 1 36 1 4/9 73.0 2.87 114.2 4.49
ES 27 - 10.9 33.05542 400.5 90036 M 27 x 3 - 41 1 5/8 81.0 3.19 121.8 4.80
ES 30 - 10.9 33.05543 489.6 110067 M 30 x 3,5 1 1/8 46 1 4/5 88.5 3.48 122.8 4.83
ES 33 - 10.9 33.05544 604.4 135873 M 33 x 3,5 1 1/4 50 2 97.0 3.82 134.7 5.30
ES 36 - 10.9 33.05545 713.7 160449 M 36 x 4 1 3/8 55 2 1/5 106.5 4.19 135.1 5.32
ES 39 - 10.9 33.05546 850.9 191300 M 39 x 4 1 1/2 60 2 3/8 115.0 4.53 137.2 5.40
ES 42 - 10.9 33.05547 979.2 220138 M 42 x 4,5 1 5/8 65 2 4/7 124.0 4.88 145.9 5.74
ES 45 - 10.9 33.05548 1146.3 257697 M 45 x 4,5 1 3/4 70 2 3/4 132.0 5.20 155.5 6.12
ES 48 - 10.9 33.05549 1291.4 290324 M 48 x 5 1 7/8 75 3 142.0 5.59 151.5 5.96
ES 52 - 10.9 33.05550 1540.8 346396 M 52 x 5 2 80 3 1/8 153.0 6.02 173.1 6.81
ES 56 - 10.9 33.05551 1781.2 400420 M 56 x 5,5 2 1/4 85 3 1/2 165.0 6.50 181.7 7.15
ES 60 - 10.9 33.05552 2121.5 476925 M 60 x 5,5 2 3/8 90 3 3/4 178.0 7.01 189.5 7.46
ES 64 - 10.9 33.05553 2350.7 528454 M 64 x 6 2 1/2 95 3 7/8 189.0 7.44 198.9 7.83
ES 68 - 10.9 33.05554 2684.5 603498 M 68 x 6 - 100 4 1/4 201.0 7.91 202.0 7.95
ES 72 - 10.9 5533.055 3011.4 676995 M 72 x 6 2 3/4 105 4 5/8 214.0 8.43 216.7 8.53
ES 80 - 10.9
Up to Contact us for technical specifications with an email to: [email protected]
ES 150 - 10.9

*Slim Line: Reduced dimensions of BTC type ES. **Inch dimensions for a pitch of 8 UN, any further pitches available. Technical enhancements and
modifications reserved.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

Casing bolt connection. Multi-Tensioning at gearbox housing.

10  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
 Type ES for Bolt Quality 8.8 – Standard 150
Type Order no. Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]* [mm] ["] [mm] ["] [mm] ["]
ES 16 - 8.8 33.05638 88.0 19783 M 16 x 2 5/8 24 1 1/16 50.0 1.97 115.8 4.56
ES 20 - 8.8 33.05639 138.0 31024 M 20 x 2,5 3/4 30 1 1/4 58.0 2.28 122.8 4.83
ES 22 - 8.8 33.05640 172.0 38667 M 22 x 2,5 7/8 34 1 7/16 67.0 2.64 122.1 4.81
ES 24 - 8.8 33.05641 200.3 45025 M 24 x 3 1 36 1 4/9 69.0 2.72 114.2 4.49
ES 27 - 8.8 33.05642 260.7 58608 M 27 x 3 - 41 1 5/8 73.6 2.90 127.3 5.01
ES 30 - 8.8 33.05643 320.0 71939 M 30 x 3,5 1 1/8 46 1 4/5 81.7 3.22 122.0 4.80
ES 33 - 8.8 33.05644 400.3 89991 M 33 x 3,5 1 1/4 50 2 92.0 3.62 125.6 4.94
ES 36 - 8.8 33.05645 470.0 105661 M 36 x 4 1 3/8 55 2 1/5 98.6 3.88 131.1 5.16
ES 39 - 8.8 33.05646 560.0 125894 M 39 x 4 1 1/2 60 2 3/8 106.5 4.19 136.2 5.36
ES 42 - 8.8 33.05647 640.0 143878 M 42 x 4,5 1 5/8 65 2 4/7 115.0 4.53 142.7 5.62
ES 45 - 8.8 33.05648 754.0 169507 M 45 x 4,5 1 3/4 70 2 3/4 123.2 4.85 144.7 5.70
ES 48 - 8.8 33.05649 854.0 191988 M 48 x 5 1 7/8 75 3 132.5 5.22 147.9 5.82
ES 52 - 8.8 33.05650 1016.0 228407 M 52 x 5 2 80 3 1/8 142.0 5.59 169.5 6.67
ES 56 - 8.8 33.05651 1176.0 264377 M 56 x 5,5 2 1/4 85 3 1/2 155.0 6.10 179.8 7.08
ES 60 - 8.8 33.05652 1400.0 314734 M 60 x 5,5 2 3/8 90 3 3/4 166.0 6.54 180.8 7.12
ES 64 - 8.8 33.05653 1550.0 348456 M 64 x 6 2 1/2 95 3 7/8 176.0 6.93 211.5 8.32
ES 68 - 8.8 33.05654 1678.0 377231 M 68 x 6 - 100 4 1/4 187.0 7.36 185.8 7.31
ES 72 - 8.8 33.05655 1800.0 404658 M 72 x 6 2 3/4 105 4 5/8 191.0 7.52 214.2 8.43
ES 80 - 8.8 33.05656 2276.8 511843 M 80 x 6 - 115 5 215.0 8.46 221.9 8.73
ES 90 - 8.8 33.05657 2450.0 550785 M 90 x 6 3 1/2 130 5 3/8 225.0 8.86 233.3 9.19
ES 100 - 8.8 33.05658 2750.0 618228 M 100 x 6 4 145 6 1/8 243.0 9.57 271.0 10.67
ES 110 - 8.8 33.05659 3350.0 753114 M 110 x 6 4 1/4 155 6 1/2 268.0 10.55 297.7 11.72

Technical enhancements and modifications reserved. *Inch dimensions for a pitch of 8 UN, any further pitches available.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

Tower bolt connection. Turbine casing bolt connection.

ITH Bolting Technology · www.ITH.com · [email protected]11

Type SES – Single-stage Bolt Tensioning Cylinder simple
3 F or radially open but vertical limited clearance 3 T he SES can be used for the following fastener configu-
applications. rations: Hexagon nuts, Heavy Hex Nuts, ISO 4032, DIN
3 S tandard for bolt quality 8.8, further bolt qualities are 2510, EN 14399, Roundnuts, ITH Roundnuts RMS/RMZ,
available. and IHF Roundnuts.
3 M inimum thread projection (h2) above the nut ≥ 1.0 x d
(depending on the initial assembly preload FVM).

D3 Features
1. Patented safety fracture device inside
2. Exchangeable change bushings
3. Bore hole to use the optional bolt elonga-
tion measurement
4. Deviation distance limitation
d
5. Control notch for the nut
6. Burnished surface treatment (blackening)

h2 H1
Optional
1. Patented cycle counter
2. NIOX coating (Nickel-Chromium) offers
extra protection from corrosion
3. Two direction swivel for the hydraulic
SW

connector
|A/
F

4. Multi Tensioning high pressure

coupling
5. Patented safety cap with handle
Figured with optional features 6. Spring loaded turning sleeve

Modular design
3 O
 ne Cylinder
… can be equipped
and more with several
change bushings,
… supports & tur-
and more
ning sleeves
… 3 See page 5
and more for details

The flexible change bushing gets run down onto the BTC body. Foundation bolt tensioning.

12  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
SES for Bolt Quality 8.8 – Standard 150
Type Order no. Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]* [mm] ["] [mm] ["] [mm] ["]
SES 16 - 8.8 33.10390 125 28101 M 16 x 2 5/8 24 1 1/16 50.9 2.00 75.5 2.97
SES 20 - 8.8 33.10391 150 33722 M 20 x 2.5 3/4 30 1 1/4 56.9 2.24 81.5 3.21
SES 22 - 8.8 33.10389 150.0 33722 M 22 x 2.5 7/8 34 1 7/16 60.0 2.36 81.2 3.20
SES 24 - 8.8 33.10392 200 44962 M 24 x 3 1 36 1 4/9 65.6 2.58 81.2 3.20
SES 27 - 8.8 33.10393 260 58451 M 27 x 3 - 41 1 5/8 73.0 2.87 84.0 3.31
SES 30 - 8.8 33.10394 320 71939 M 30 x 3.5 1 1/8 46 1 4/5 82.0 3.23 90.0 3.54
SES 33 - 8.8 33.10395 400 89924 M 33 x 3.5 1 1/4 50 2 91.5 3.60 100.0 3.94
SES 36 - 8.8 33.10396 470 105661 M 36 x 4 1 3/8 55 2 1/5 98.9 3.89 109.7 4.32
SES 39 - 8.8 33.10397 560 125894 M 39 x 4 1 1/2 60 2 3/8 108.0 4.25 109.0 4.29
SES 42 - 8.8 33.10398 640 143878 M 42 x 4.5 1 5/8 65 2 4/7 116.0 4.57 119.0 4.69
SES 45 - 8.8 33.10399 750 168608 M 45 x 4.5 1 3/4 70 2 3/4 123.0 4.84 119.0 4.69
SES 48 - 8.8 33.10400 854 191988 M 48 x 5 1 7/8 75 3 132.0 5.20 127.0 5.00
SES 52 - 8.8 33.10401 1016 228407 M 52 x 5 2 80 3 1/8 145.0 5.71 135.0 5.31
SES 56 - 8.8 33.10402 1175 264152 M 56 x 5.5 2 1/4 85 3 1/2 155.5 6.12 145.0 5.71
SES 60 - 8.8 33.10403 1400 314734 M 60 x 5.5 2 3/8 90 3 3/4 166.0 6.54 140.0 5.51
SES 64 - 8.8 33.10404 1550 348456 M 64 x 6 2 1/2 95 3 7/8 176.0 6.93 161.0 6.34
SES 68 - 8.8 33.10405 1678 377231 M 68 x 6 - 100 4 1/4 184.5 7.26 169.0 6.65
SES 72 - 8.8 33.10406 1800 404658 M 72 x 6 2 3/4 105 4 5/8 191.0 7.52 181.0 7.13
SES 80 - 8.8 33.10408 2350 528304 M 80 x 6 - 115 5 215.0 8.46 193.0 7.60
SES 90 - 8.8 33.10409 2450 550785 M 90 x 6 3 1/2 130 5 3/8 225.9 8.89 198.0 7.80
SES 100 - 8.8 33.10411 2750 618228 M 100 x 6 4 145 6 1/8 245.0 9.65 242.0 9.53
SES 110 - 8.8 33.10414 2500 562025 M 110 x 6 4 1/4 155 6 1/2 245.0 9.65 216.0 8.50
SES 120 - 8.8
Up to Contact us for technical specifications with an email to: [email protected]
SES 150 - 8.8
Technical enhancements and modifications reserved. *Inch dimensions for a pitch of 8 UN, any further pitches available.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

BTC type SES together with an ITH Eco-MAX 18. Typical ANSI flange application at a heat exchanger.

ITH Bolting Technology · www.ITH.com · [email protected]13

Type MS - Multi-stage Bolt Tensioning Cylinder
3 Slim design for application with radially limited and 3 Use for hexagon nut, heavy hex nuts, ISO 4032, DIN
axially free spaces. 2510, EN 14399, Roundnuts, ITH Roundnuts RMS/RMZ,
3 Minimum thread projection (h2) above the nut ≥ 1.0 x d and IHF Roundnuts.
(depending on the initial assembly preload FVM).

Features
D3 1. Patented safety fracture device
2. Automatic piston return
3. Interchangeable parts for different
thread and nut profiles
4. Pre-configured for optional bolt
elongation measurement
5. Direct gear drive with internal gear
6. Spring loaded turning sleeve
7. Stroke limitation
d (Over-stroke limiter)
8. Control notch
H1
9. Patented safety carrying handle
10. Patented cycle counter
h2

Optional
1. Chrome-nickel surface coating NIOX
2. Safety measurement pin for thread
SW

projection
/AF

3. Swivel connection for high pressure

couplings and nipples

Fig. with optional features 4. Multi Tensioning high pressure

coupling

Modular design 5. Patented protection cap with handle

3 O
 ne Cylinder
… can be equipped
and more with several
change bushings,
… supports & tur-
and more ning sleeves
3 See page 5
… for details
and more

Slewing bearing. Casing bolt connection.

14  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Type MS for Bolt Quality 10.9 – Slim Line 180 / 225
Type Order no. Design Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]* [mm] ["] [mm] ["] [mm] ["]
MS 16 - 10.9
MS 20 - 10.9 Contact us for technical specifications with an email to: [email protected]
MS 22 - 10.9
MS 24 - 10.9 33.02791 322.0 72389 M 24 x 3 1 36 1 4/9 66.0 2.60 172.0 6.77
MS 27 - 10.9 33.02792 379.3 85270 M 27 x 3 - 41 1 5/8 71.5 2.81 166.5 6.56
MS 30 - 10.9 33.02793 457.6 102873 M 30 x 3,5 1 1/8 46 1 4/5 77.0 3.03 192.2 7.57
MS 33 - 10.9 33.02794 567.0 127467 M 33 x 3,5 1 1/4 50 2 84.5 3.33 181.5 7.15
MS 36 - 10.9 33.02795 Slim line 666.0 149723 M 36 x 4 1 3/8 55 2 1/5 93.4 3.68 197.5 7.78
180
MS 39 - 10.9 33.02796 800.0 179848 M 39 x 4 1 1/2 60 2 3/8 99.5 3.92 210.0 8.27
MS 42 - 10.9 33.02797 924.0 207724 M 42 x 4,5 1 5/8 65 2 4/7 107.0 4.21 220.0 8.66
MS 45 - 10.9 33.02798 1080.0 242795 M 45 x 4,5 1 3/4 70 2 3/4 113.0 4.45 226.0 8.90
MS 48 - 10.9 33.02799 1221.4 274583 M 48 x 5 1 7/8 75 3 121.5 4.78 231.0 9.09
MS 52 - 10.9 33.12800 1450.0 325975 M 52 x 5 2 80 3 1/8 127.0 5.00 259.8 10.23
MS 56 - 10.9 33.12801 1682.2 378166 M 56 x 5,5 2 1/4 85 3 1/2 137.8 5.43 287.9 11.33
MS 60 - 10.9 33.12802 Slim line 1966.0 441976 M 60 x 5,5 2 3/8 90 3 3/4 149.5 5.89 274.1 10.79
MS 64 - 10.9 33.12803 225 2213.0 497505 M 64 x 6 2 1/2 95 3 7/8 156.5 6.16 294.6 11.60
MS 68 - 10.9 33.12804 2545.0 572141 M 68 x 6 - 100 4 1/4 169.5 6.60 305.0 11.95
MS 72 - 10.9 33.12805 2882.0 647902 M 72 x 6 2 3/4 105 4 5/8 179.0 7.05 318.9 12.56
MS 80 - 10.9
Up to Contact us for technical specifications with an email to: [email protected]
MS 110 - 10.9
Technical enhancements and modifications reserved. *Inch dimensions for a pitch of 8 UN, any further pitches available.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

Tower segment bolt connection at wind turbine. Tower segment bolt connection at tower crane.

ITH Bolting Technology · www.ITH.com · [email protected]15

Type MSK - Multi-stage Bolt Tensioning Cylinder
with lock nut
3 Slim design for application with radially limited and 3 Use for hexagon nut, heavy hex nuts, ISO 4032, DIN
axially free spaces. 2510, EN 14399, Roundnuts, ITH Roundnuts RMS/RMZ,
3 Minimum thread projection (h2) above the nut ≥ 1.0 x d and IHF Roundnuts.
(depending on the initial assembly preload FVM).

D3 Features
1. Patented safety fracture device
2. Automatic piston return
3. Interchangeable parts for different
thread and nut profiles
4. Pre-configured for optional bolt
elongation measurement
5. Direct gear drive with internal gear
6. Spring loaded turning sleeve

H1 7. Stroke limitation
(Over-stroke limiter)
d 8. Control notch
9. Patented safety carrying handle
h2 10. Patented cycle counter

Optional
1. Chrome-nickel surface coating NIOX
SW
|A/

2. Safety measurement pin for thread

F

projection
Fig. with optional features 3. Swivel connection for high pressure
couplings and nipples
Modular design 4. Multi Tensioning high pressure
3 O
 ne Cylinder
coupling
… can be equipped
and more with several 5. Patented protection cap with handle
change bushings,
supports & tur-
ning sleeves
…
and more 3 See page 5
for details

Rotor blade assembling. Casing bolt connection.

16  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Type MSK for Bolt Quality 10.9 – Compact 150
Type Order no. Preload force Bolt diameter d SW | A/F-width Tool diameter D3 Tool height H1
[kN] [lbs] [mm] ["]* [mm] ["] [mm] ["] [mm] ["]
MSK 16 - 10.9
Up to Contact us for technical specifications with an email to: [email protected]
MSK 22 - 10.9
MSK 24 - 10.9 33.50091 308.5 69354 M 24 x 3 1 36 1 4/9 57.0 2.24 190.5 7.50
MSK 27 - 10.9 33.50092 401.5 90261 M 27 x 3 - 41 1 5/8 63.5 2.50 199.6 7.86
MSK 30 - 10.9 33.50093 485.5 109152 M 30 x 3,5 1 1/8 46 1 4/5 70.0 2.76 202.7 7.98
MSK 33 - 10.9 33.50094 606.3 136302 M 33 x 3,5 1 1/4 50 2 78.3 3.08 224.6 8.84
MSK 36 - 10.9 33.50095 708.3 159233 M 36 x 4 1 3/8 55 2 1/5 82.6 3.25 237.0 9.33
MSK 39 - 10.9 33.50096 842.2 189335 M 39 x 4 1 1/2 60 2 3/8 90.8 3.57 259.4 10.21
MSK 42 - 10.9 33.50097 974.4 219044 M 42 x 4,5 1 5/8 65 2 4/7 98.0 3.86 263.0 10.35
MSK 45 - 10.9 33.50098 1140.5 256396 M 45 x 4,5 1 3/4 70 2 3/4 105.0 4.13 278.9 10.98
MSK 48 - 10.9 33.50099 1288.4 289645 M 48 x 5 1 7/8 75 3 111.5 4.39 293.8 11.57
MSK 52 - 10.9 33.50100 1529.7 343899 M 52 x 5 2 80 3 1/8 122.0 4.80 307.2 12.09
MSK 56 - 10.9 33.50101 1785 401286 M 56 x 5,5 2 1/4 85 3 1/2 130.5 5.14 350.4 13.80
MSK 60 - 10.9 33.50102 2125.8 477892 M 60 x 5,5 2 3/8 90 3 3/4 140.8 5.54 342.0 13.46
MSK 64 - 10.9 33.50103 2336.8 525336 M 64 x 6 2 1/2 95 3 7/8 147.8 5.82 352.4 13.87
MSK 68 - 10.9 33.50104 2745 617103 M 68 x 6 - 100 4 1/4 159.8 6.29 377.4 14.86
MSK 72 - 10.9 33.50105 3041.2 683697 M 72 x 6 2 3/4 105 4 5/8 168.0 6.61 387.0 15.24
MSK 80 - 10.9
Up to Contact us for technical specifications with an email to: [email protected]
MSK 110 - 10.9
Technical enhancements and modifications reserved. *Inch dimensions for a pitch of 8 UN, any further pitches available.

Most of ITH Bolt Tensioning Cylinders are designed due to customer specification

ITH BTCs are designed according to nearly all bolt qualities, any bolt/nut-configurations or customer
specific requirements. Contact us and we would be pleased to help you to find the right ITH Bolt
Tensioning Cylinder or when having technical questions.

Ladle turret bolt connection. Casing bolt connection.

ITH Bolting Technology · www.ITH.com · [email protected]17

Special designs
The Bolt Tensioning Cylinder (BTC) portfolio presented in this The following examples give you a snapshot of the ITH Bolt
brochure is only the standard range. However, ITH has the Tensioning Cylinders (BTC) solutions – and there is even
competence and the know-how to design Bolt Tensioning more. Contact us for a free of charge technical consultation
Cylinders exactly to customer‘s requirements. regarding your bolted joint.

BTC type Segment BTC type TWIN

Several BTC segments are Simultaneous pre-tensio-
combined to a ring which ning of 2 bolted connections
allows simultaneous bolting within a close axial distance.
of several bolts. The even ITH offers a scope from M16
preload distribution leads to M52 (3/8’’ to 2’’).
to a high precision – useful
on ANSI flanges or sensitive
areas like this Nuclear Power
Station.

BTC type Large-Scale Foundation BTC

Based on the single-stage It is commonly recommen-
design ITH delivers Bolt ded to tighten anchor rods
Tensioning Cylinders up to or other foundation bolts
M 800 (31 1/2‘‘). They are with ITH Bolt Tensioning
applied like on this main Cylinders. because no ben-
shaft of a gas turbine. ding effects and no torsion
effects appear during their
use.

BTC type RPVH ITH Multi Tensioning

ITH tightens and loosens Simultaneous tensioning
the bolted joints in Nuclear of several bolts at the
Power Stations safely, same time like these 2.5‘‘ –
precisely and reliably. Next 8 UN turbine rotor bolts.
to other solutions a special
BTC set for the reactor
pressure vessel head (RPVH)
was deigned (M150, 6“).

Pressure-Stretch-Documentation ITH Auto-Stretch

The optional PD / PSD ITH developed a robot sup-
System (see page 19) offers ported automation solution
automatic control and for Bolt Tensioning Cylinders
digital documentation of which can be applied to
the bolting procedure tighten bolts in series
with ITH Bolt Tensioning production.
Cylinders.

18  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Digital Documentation System: PD/PSD System
The ITH PD / PSD System is a digital management
system for nearly all applications with ITH Bolt Tensioning
Cylinders.
Functions:
• Digital management & digital documentation of all
application data via industrial touch panel PC’s (several
designs).
• Automatic control of the hydraulic pump unit by
Automatic Pressure Control (APC).
• Version 1: The PD system measures and records
the hydraulic pressure.
• Version 2: The PSD System measures and records both
the hydraulic pressure and the bolt elongation of the
bolts.
Both systems offer direct feedback about the joint quality.
All bolting procedures can be documented. The ITH soft-
ware can be customized.

ITH Multi Tensioning System

By using the ITH Multi Tensioning method, multiple
Bolt Tensioning Cylinders are used simultaneously by
connecting them to one hydraulic unit (connected in series
or in parallel).

All bolts are tightened simultaneously and the required

assembly preload are generated evenly. This leads to
precise results: Using ITH Multi Tensioning repeatable
assembly preload within a tolerance level of ± 2% can be
reached.

This accurate and simultaneous loading provides a balan-

ced load across the flange and increases its operating life
significantly.

ITH Multi Tensioning reduces the risk of leakages signifi-

cantly (like on ANSI or ASME flanges, pictures on the
right) and decreases down times of machines and plant.

ITH Bolting Technology · www.ITH.com · [email protected] 19

 oster
Hydro Bology
Techbonltinog procedures
st
for faste
Hydro-MAX
Electric High Pressure Pump

The electric high pressure pump Hydro-MAX, developed by designed for high cycles and fast working processes.
ITH, is manufactured in different designs. The Hydro-MAX 18 Additional features include user-friendly operation and
is used for service jobs and the Hydro-MAX 37, 38 and 39 are increased safety because of the positioning of the hydraulic
used for shop applications. ITH Hydro-MAX pumps are couplings.

5 7

4
3
2 Features
1. Oil cooler
2. ITH Hydro Booster
8
1 3. Protective aluminium frame with
lifting point
9 4. Hydraulic shut-off valve
5. High pressure gauge with protective
cover
6. Safety positioning of the two high
pressure couplings (directed away
10 from user, work safe design)
7. Oil level indicator
8. Pressure adjusting valve (PAV),
for variable pressure adjusting
9. Multi ribbed oil tank, made of light-
weight and robust aluminium (high
temperature conductivity),
for optimal cooling
Fig.: Hydro-MAX 18 10. Low voltage indicator light and
electronic cycle counter at the control
box

Performance Remotes
3 Max. operating pressure 2.500 bar.
3 Voltage range from 90 V - 480 V for 50 Hz and/or 60 Hz.
3 NIOX-Coating of all steel components (offshore ready).
3 Safe positioning of the two high pressure couplings.
3 Wear-free single rotor-eccentric shaft.
3 Standard: Remote.
3 Optional: Digital Remote displaying pressures.
3 Optional: Constant digital automatic pressure control
(APC, see page 23).
3 Optional: Direct pressure stretch documentation system
(PSD-System).
3 Optional for Hydro-MAX 18 and 38: Suitable for offshore
applications by NIOX-Coating and aluminium frame with Standard (10m) Optional: Multi-Function
protective cage. Digital (10m) Remote for
Automatic
Pressure Control
function (APC)

20 Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
 Hydro-MAX 18
Field of application: Order no. 34.x1318- Motor-ID
3 For service and assembling jobs Type 1813 1815 1825
3 Optimized weight Pressure max. [bar] 1.350 1.500 2.500
3 Easy transport Dimension (LxWxH) 620 x 360 x 400mm
3 One-man operation with remote Weight 41.6 kg (without oil 37 kg)
Connection 90-110 V 1 50+60 Hz -09174
190-230 V 1 50 Hz -19150
190-230 V 1 60 Hz -19160
200-230 V 3 50+60 Hz -20370
380-420 V 3 50+60 Hz -40370
480 V 3 60 Hz -48360
Capacity Phase Frequency Motor-ID

Hydro-MAX 37
Field of application: Order no. 34.x1337- Motor-ID
3 For shop applications Type 3713 3715 3725
3 Manual shut-off valve Pressure max. [bar] 1.350 1.500 2.500
3 High performance motor Dimension (LxWxH) 640 x 440 x 450mm
3 Designed for high bolt cycles Weight 61.0 kg
and large bolt dimensions Connection 230 V 1 50 Hz -23150
230 V 1 60 Hz -23160
230 V 3 50+60 Hz -23370
380-420 V 3 50+60 Hz -40370
480 V 3 60 Hz -48360
Capacity Phase Frequency Motor-ID

Hydro-MAX 38
Field of application: Order no. 34.x1338- Motor-ID
3 For shop applications Type 3813 3815 3825
3 One-man operation with remote Pressure max. [bar] 1.350 1.500 2.500
3 High performance motor Dimension (LxWxH) 640 x 440 x 450mm
3 Designed for high bolt cycles Weight 66.4 kg
and large bolt dimensions Connection 230 V 1 50 Hz -23150
230 V 1 60 Hz -23160
230 V 3 50+60 Hz -23370
380-420 V 3 50+60 Hz -40370
480 V 3 60 Hz -48360
Capacity Phase Frequency Motor-ID

Hydro-MAX 39
Field of application: Order no. 34.x1339- Motor-ID
3 For shop applications and Type 3913 3915 3925
service jobs Pressure max. [bar] 1.350 1.500 2.500
3 One-man operation with remote Dimension (LxWxH) 640 x 370 x 450mm
3 High performance motor Weight 64.3 kg
3 Optimized weight Connection 230 V 1 50 Hz -23150
3 Designed for high bolt cycles 230 V 1 60 Hz -23160
and large bolt dimensions
230 V 3 50+60 Hz -23370
380-420 V 3 50+60 Hz -40370
480 V 3 60 Hz -48360
Capacity Phase Frequency Motor-ID

ITH Bolting Technology · www.ITH.com · [email protected] 21

Eco-MAX
Electric High Pressure Pump

For standard applications with high cycles ITH developed obtained by aluminium protection and transport frame.
electric high pressure pumps Eco-MAX. A robust design is

3
4

2
1 Features
1. Aluminium Frame
2. High pressure couplings
3. High pressure gauge
4. Oil level sight glass
5
5. 
Pressure adjusting valve (PAV),
6 for variable pressure adjusting
6. Multi ribbed oil tank, made of light-
weight and robust aluminium (high
temperature conductivity),
for optimal cooling

Fig.: Eco-MAX 18
with optional two hydraulic connectors (standard is one)

Performance Remotes for Eco-MAX 18

3 Max. operating pressure 1.500 bar.
3 Voltage range from 90 V - 690 V for 50 Hz and/or 60 Hz.
3 Wear-free single rotor-eccentric shaft.
3 Service-friendly by small number of components
Reduction of Maintenance-costs.
3 Easy transport.
3 Standard for Eco-MAX 18: Remote.
3 Optional for Eco-MAX18: Digital remote with displayed
pressure.
3 Optional for Eco-MAX 18: Constant digital automatic
pressure control (APC, see page 23).

Standard (10m) Optional: Multi-Function

Digital (10m) Remote for
Automatic
Pressure Control
function (APC)

22 Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
 Eco-MAX 17
Field of application: Order no. 34.x1117- Motor-ID
3 For service and assembling jobs Type 1713 1715
3 Optimized weight
Pressure max. [bar] 1.350 1.500
3 Easy transport
3 Manual shut-off valve Dimension (LxWxH) 495 x 350 x 375mm
Weight 30.5 kg
Connection 90-110 V 1 50 Hz -09151-IS19
90-110 V 1 60 Hz -09161-IS19
190-230 V 1 50 Hz -19151-IS19
190-230 V 1 60 Hz -19161-IS19
230 V 3 50+60 Hz -23371
380-420 V 3 50+60 Hz -40371
480 V 3 60 Hz -48361
690 V 3 50+60 Hz -69371
Capacity Phase Frequency Motor-ID

Eco-MAX 18
Field of application: Order no. 34.x1218- Motor-ID
3 For service and assembling jobs Type 1813 1815
3 Optimized weight
Pressure max. [bar] 1.350 1.500
3 Easy transport
3 One-man operation Dimension (LxWxH) 495 x 350 x 375mm
Weight 35.0 kg
Connection 90-110 V 1 50 Hz -09150-IS1
90-110 V 1 60 Hz -09160-IS1
190-230 V 1 50 Hz -19150-IS1
190-230 V 1 60 Hz -19160-IS1
230 V 3 50+60 Hz -2337x
380-420 V 3 50+60 Hz -4037x
480 V 3 60 Hz -4836x
690 V 3 50+60 Hz -6937x
Capacity Phase Frequency Motor-ID

Automatic-Pressure-Control APC
When operating ITH Bolt Tensioning Cylinders, it can happen the bolt connection. The digital automatic pressure control
that the pressure drops by stretching of the hose lines or (APC) readjusts the pre-determined pressure constantly and
settling of the construction. This has effects on the results of ensures a high degree of accuracy at the bolt connection.

Pressure

APC-Pressure

Current-Pressure

Time
Pressure ITH High Pressure Pump with APC control

ITH Bolting Technology · www.ITH.com · [email protected] 23

Compact High Pressure Pumps Type Micro-MAX

ITH Micro-MAX Series were developed for service jobs for In limited spaces or jobs of certain height the ITH Micro-MAX
crane and wind turbine manufacturers. By a compact design, work reliable, quick, safe and comfortable. Battery version
low weight and optimized dimensions the ITH Micro-MAX type Micro-MAX 72 even enables you to work independently
perfectly match the requirements for these applications. from wired power supplies.

4
3 5

2
Features
1. Two high pressure couplings
2. Pressure adjusting valve (PAV),
1
for variable pressure adjusting
7 3. High pressure gauge
with protection cover
4. Protective aluminium frame
5. Automatic Cycle counter integrated
6. Oil Level Sight Glass
7. Hydraulic Shut Off Valve

Dimensioning compared

Fig.: Micro-MAX 70

Easy handling by lightweight and compact

design

Performance Remotes for Micro-MAX 70

3 Easy transport by lightweight design.
3 Maximum pressure: 1.500 bar.
3 Worldwide use: motor works on both 50 Hz and 60 Hz
with voltages from 90 V – 110 V or 190 V – 230 V.
3 NIOX-Coating of all steel components (Offshore ready).
3 Builds up pressure quickly – fast working process.
3 Easy handling even in limited spaces.
3 Standard for Micro-MAX 70: Remote.
3 Optional for Micro-MAX 70: Digital remote with displayed
pressure.
3 Optional for Micro-MAX 70: Suitable for offshore
applications by NIOX-Coating and aluminium frame with
protective cage. Standard (10m) Optional:
Digital (10m)

24  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Micro-MAX 70 - with remote
Field of application: Order no. 34.01070-Motor-ID 34.11070-Motor-ID
3 For service jobs Type 7013 7015
3 Optimized weight
Pressure max. [bar] 1.350 1.500
3 Easy one-man operation with
remote Dimension (LxWxH) 390 x 290 x 450mm
Oil tank volume 3 l / 1.5 l usable
Weight 22.5 kg
Connection 90-110 V 1 50+60 Hz -09174
190-230 V 1 50+60 Hz -19174
Capacity Phase Frequency Motor-ID

Micro-MAX 71 – with manual shut-off valve

Field of application: Order no. 34.01071-Motor-ID 34.11071-Motor-ID
3 For service jobs Type 7113 7115
3 Optimized weight
Pressure max. [bar] 1.350 1.500
3 Manual adjusting of the
pressure by PAV Dimension (LxWxH) 390 x 290 x 450mm
(Pressure Adjusting Valve) Oil tank volume 3 l / 1.5 l usable
Weight 21.5 kg
Connection 90-110 V 1 50+60 Hz -09174
190-230 V 1 50+60 Hz -19174
Capacity Phase Frequency Motor-ID

Micro-MAX 72 – Battery version

Field of application: Order no. 34.00072 34.10072
3 For service jobs Type 7213 7215
3 High performance motor,
Pressure max. [bar] 1.350 1.500
long battery capacity
3 Easy cordless operation Dimension (LxWxH) 340 x 250 x 450mm
3 Long life 28V-Li-Ion battery Oil tank volume 3 l / 1.5 l usable
3 Fast pressure built-up for fast Weight 14.8 kg
assembling jobs
Connection 28 V / Li-Ion

Included with:

Replacement battery Quick-charger battery station

ITH High Pressure Pumps for offshore applications

Features:
3 Suitable to all ITH High Pressure
Pump units
3 Coated components
3 Aluminium frame with protective
cage for protection of all
important components

Fig.: Micro-MAX 70 with protective cage

ITH Bolting Technology · www.ITH.com · [email protected]25

Pneumatic High Pressure Pumps
Aero-MAX & Travel-MAX

For bolting jobs in areas where there is a risk of explosion or and 10 are designed for shop applications while Aero-MAX
where there is no electric power supply ITH offers Pneumatic 89 and 90 are made for service jobs because of their light-
High Pressure Pumps „Aero-MAX“ in several types. Aero-MAX 9 weight design and easy transport.

5 6
2

7 Features
1 1. Two high pressure couplings
2. Pressure adjusting valve (PAV),
for variable pressure adjusting
3. Protective aluminium frame
4. Support Unit with oiler, water filter,
air pressure gauge and air shut off
valve
5. High pressure gauge
6. Oil level sight glass
7. Shut-off valve
Fig.: Aero-MAX 9

Performance Pneumatic Remote

3 Maximum Pressures up to 3.000 bar.
3 No electric power supply required.
3 Easy-to-service-design by optimized number of components,
which leads to a reduction of maintenance costs.
3 Easy transport.
3 Movable and lockable wheels.
3 Optional for Aero-MAX 179: Pneumatic remote.

Only for Aero-MAX 179: Remote (5m) with pneumatic

shut-off valve (No electric power supply required)

26  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Aero-MAX 9 - Shop-Version with PAV and Aero-MAX 10 – Shop version without PAV
Field of application: Order no. 34.x0009 / 34.x0010
3 For shop applications Type 0913 / 1013 0915 / 1015 0925 / 1025 1030 1040
3 Designed for high cycles
Pressure max. [bar] 1.350 1.500 2.500 3.000 4.000
Min. air pressure [bar] 4.5 5.0 6.0 7.0 6.0
Air requirement ca. 1400 l/min
Dimension (LxWxH) 430 x 330 x 660mm
Weight 35.0 kg

Aero-MAX 89 - Mini-Version with PAV and Aero-MAX 90 – mini version without PAV
Field of application: Order no. 34.x0089 / 34.x0090
3 For service and assembling jobs Type 8913 / 9013 8915 / 9015 8925 / 9025 9030
3 Light-weight design
Pressure max. [bar] 1.350 1.500 2.500 3.000
3 Easy transport
Min. air pressure [bar] 5.0 5.5 6.0 7.0
Air requirement ca. 900 l/min
Dimension (LxWxH) 430 x 330 x 660mm
Weight 21.0 kg

Aero-MAX 179 - Shop-Version with pneumatic Remote

Field of application: Order no. 34.x0179
3 For service and assembling jobs Type 7913 7915 7925 7930
3 Light-weight design
Pressure max. [bar] 1.350 1.500 2.500 3.000
3 Easy transport
3 Easy-to-use by pneumatic remote Min. air pressure [bar] 6.0 6.0 6.0 7.0
Air requirement ca. 1400 l/min
Dimension (LxBxH) 430 x 400 x 660mm
Weight 21.0 kg

Travel-MAX 41
Field of application: Order no. 34.x0041
3 For service and assembling jobs Type 4115 4125
3 Compact and light weight design
Pressure max. [bar] 1.350 2.500
3 Easy to maintain
3 Easy transport by case with Min. air pressure [bar] 6.0 6.0
trolley function Air requirement ca. 900 l/min
Dimension (LxWxH) 500 x 305 x 457mm
Weight 27.5 kg

ITH Bolting Technology · www.ITH.com · [email protected]27

Manual High Pressure Pumps Lever-MAX – Single-stage
Lever-MAX 111 and 125
For service and assembling jobs, ITH offers the practical hand transport. For hand lever high pressure pumps no power
lever high pressure pumps. The compact design enables supply is required.
operating in difficult accessible working areas and an easy

4
5

Features
1. Pressure adjusting valve (PAV),
for variable pressure adjusting
2. High pressure gauge
with protection cover
3. Locking mechanism for easy transport
4. Shut-off valve
5. High pressure coupling

Fig.: Lever-MAX 125 - mini

Lever-MAX 111 - Standard and Mini*

Order no. 34.x0111

Type 11113 11115 11125 11130
Pressure max. [bar] 1.350 1.500 2.500 3.000
Dimension (LxWxH) 760 x 180 x 305 mm
Weight 10.0 kg

Lever-MAX 125 - Standard and Mini* with PAV

Order no. 34.x0125

Type 12513 12515 12525
Pressure max. [bar] 1.350 1.500 2.500
Dimension (LxWxH) 760 x 180 x 305 mm
Weight 10.4 kg

*Mini for 1.350 bar and 1.500 bar: The hand lever high pressure pump mini-version has a shorter oil tank and therefor a lower weight.

28  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
 D o u b l e-stage
New ment
Devteblooltinpg procedures
s
for faste

Manual High Pressure Pumps Lever-MAX – Double-stage

Lever-MAX 235 / 240 and Lever-MAX 255
To perform faster bolting procedures ITH offers a double- rate per stroke for more faster and more efficient bolting
stage manual pump series. Lever-MAX 255 with high flow procedures.

1
2

3
4

Features
1. High pressure gauge with protection
cover
2. Locking mechanism for easy transport
3. Shut-off valve
4. One high pressure coupling (standard),
second coupling optional for ITH Multi
Tensioning

Fig.: Lever-MAX 235 – with optional two high pressure couplings

Lever-MAX 235 without PAV and Lever-MAX 240 with PAV

Order no. 34.x0235 / 34.x0240
Type 23515 / 24015 23525 / 24025 23530
Pressure max. [bar] 1.500 2.500 3.000
Oil volume 1.75 l 1.75 l 1.75 l
(usable oil volume) 1.4 l 1.4 l 1.4 l
Oil flow rate / stroke 12.2 cm3
Dimensions (LxWxH) 830 x 220 x 270 mm
Weight 11.0 kg 13.5 kg 13.5 kg

Lever-MAX 255 high oil flow rate pump

Order no. 34.x0255
Type 25515 25525 25530 25540
Pressure max. [bar] 1.500 2.500 3.000 4.000
Oil volume 1.75 l 1.75 l 1.75 l 1.75 l
(usable oil volume) 1.4 l 1.4 l 1.4 l 1.4 l
Oil flow rate / stroke 26 cm3
Dimensions (LxWxH) 1000 x 220 x 300 mm
Weight 12.5 kg 17.5 kg 17.5 kg 17.5 kg

ITH Bolting Technology · www.ITH.com · [email protected]29

Hydraulic equipment
High Pressure Hose Lines
Series 30 - Standard Series 32 - Protection cover

3 Inner: Polyamide 3 Material: PVC

3 Outer: Polyurethane 3 Abrasion resistant
3 Chemical resistant

Series 33 – Safety spring (kink protection) Series 34 - Protection cover + safety spring

3 Hard drawn
3 Galvanized

Fig.: 2.500 bar version

Series 30 high pressure hose line standard • High abrasion resistance

Series 32 high pressure hose line with protection cover • Small bending radius
Series 33 high pressure hose line with safety spring (kink protection) • Pressure cover of steel wire (across)
Series 34 high pressure hose line with protection cover + safety spring • High flexibility

Order no. key: 34.x00xx-xxxx

Length Length-ID Pressure
Colour hose line Pressure-ID
max.
2.0 m 0020 Pressure-ID
1.500 bar Silver 1
3.0 m 0030 Series
Length-ID 2.500 bar Blue with black letters 2
4.0 m 0040
3.000 bar Blue with white letters 3
5.0 m 0050
4.000 bar Red 4
6.0 m 0060
Further lengths available

Nipples and Couplings

Series 50: Series 52: Series 55:

3 Galvanized steel 3 Galvanized steel 3 Galvanized steel

3 With protection cap 3 With protection cap 3 With protection cap
3 Lock ring

Series 50 high pressure coupling with internal thread* • Non-drip coupling

Series 52 high pressure coupling with internal thread* • Patented sealing system
Series 54 high pressure coupling with lock ring 1.500 bar* • One-hand coupling
Series 55 high pressure coupling with lock ring 2.500 bar* • With safety locking. Prevented inadvertently uncoupling.

Order no. key: 34.x00xx

Pressure-
Colour Pressure-ID
max.
Pressure-ID
1.500 bar* Black 1
Series
2.500 bar* Blue 2
3.000 bar** Red 3
4.000 bar* Blue 4

*:With outer and inner thread standard G - ¼“ deliverable.

**: 3.000 bar coupling with safety ring as a standard feature.

30  Find further information on www.ITH.com and contact your local ITH representative. We would be happy to give support.
Hydraulic equipment
Couplings
Coupling elbow Series 120 – Twin thread nipple

67 mm
90 mm

Fig.: 34.20061

Pressure Dimension Pressure Dimension Thread

Colour Order no. Order no.
max. [mm] max. [mm] Version
1.500 bar* Black 67 x 66 x 28.2 34.10061 2.500 bar 19 x 45 G ¼‘‘ 34.20120
2.500 bar* Blue 67 x 79 x 28.2 34.20061 2.500 bar 19 x 45 G ¼‘‘, M16 x 1.5 74.02702
3.000 bar** Red 113 x 95 x 32 34.30060 3.000 bar 25 x 44 M16 x 1.5 74.02800

Order no. key: 34.x00xx

Version Version-ID
Coupling distributor
2-way 75 Pressure-ID
3-way 76 Series
230mm 4-way 77
240mm
5-way 78

Pressure
Colour Pressure-ID
max.
1.500 bar* Black 1
2.500 bar* Blue 2
Fig.: 34.20076 3.000 bar** Red 3

High pressure gauges to test hydraulic pump units

Series 112 – Series 150 – Series 151 – 3U  p to 3.000 bar
Test gauge (end) Test gauge (transition) Digital test gauge max. operating pressure
3 Digital gauge: Accuracy
classes from 0.25 to 1
3 Analog gauges:
Accuracy classes up to 1
3 Series 112 and 150: Glycerin
filling, scaling in 10 bar steps
3 Find more detailed informa-
tion on www.ITH.com

Order no. key: 34.x0xxx-xxxx-xx

Pressure
Pressure-ID Accuracy class Class-ID ø ø-ID
max.
Pressure-ID
1.500 bar 1 1.0 C10 100 mm 11
Series
2.500 bar 2 0.5 C05 160 mm 17
Class-ID
3.000 bar 3 0.25 C025 ø-ID

*:With outer and inner thread standard G - ¼“ deliverable.

**: 3.000 bar coupling with safety ring as a standard feature.

ITH Bolting Technology · www.ITH.com · [email protected]31

 Technical Sales & Service Offices Worldwide
ITH drives innovation in Bolting Technology
With more than 30 years in the bolting industry, ITH ü Individual industry- and customer solutions
continuously invests experience and know-how into new ü Expert advisory service in all questions involving bolts
technical developments. More than 200 national and inter- ü Synergy effects being a whole system supplier
national patents prove the innovative capabilities of ITH. Many ü Since 1995: ITH was the first mover to implement the
of these developments have become standards of bolting international quality guideline DIN ISO 2008-9001
technology. ü Fast and qualified service, worldwide spare part availability

ITH South Europe ITH United Kingdom ITH France ITH GmbH & Co. KG ITH Japan
Bilbao, Spain Liverpool, England Besancon Head Office Meschede, GER Head Office Tokyo
+ Osaka

ITH China
Head Office
Shanghai

ITH Asia Pacific

Kuala Lumpur,
Malaysia

ITH subsidiaries
ITH employees
ITH representatives

ITH Engineering ITH South Africa ITH Middle East ITH India ITH Australia
Head Office Chicago + Johannesburg Dubai, UAE Head Office Kolkata Perth
Atlanta, Houston, Mexico City

ITH offers synergy effects as a system supplier

The quality of a bolted connection depends on several factors: analysing all 4 core components: tools, engineering, fasteners,
design elements, fasteners, bolting method and assembly. As a service. These components are combined to create the best
system supplier only ITH offers complete bolting solutions by technical and cost-effective solutions for customers.

Find further information and your ITH GmbH & Co. KG

local person in charge on our website Steinwiese 8 | Postfach 1365 | 59872 Meschede | Germany
– mobile device optimized. Phone: +49 (0) 291 - 9962 - 0 | Fax: +49 (0) 291 - 9962 - 11
www.ITH.com [email protected] | www.ITH.com

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