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    Special Edition Tensioner June

    Uploaded by

    Djebali Mourad
    This document provides information on the Smart Hydraulic Tensioning Pump and Group. It details the technical specifications of the pump and group, their applications, warranty information, and service repair items. Pictures and dimensions of the pump are also included. Subscription and contact information for dealer support is listed at the bottom.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Special Edition Tensioner June

    Uploaded by

    Djebali Mourad
    289 views3 pages
    This document provides information on the Smart Hydraulic Tensioning Pump and Group. It details the technical specifications of the pump and group, their applications, warranty information, and service repair items. Pictures and dimensions of the pump are also included. Subscription and contact information for dealer support is listed at the bottom.

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    Special-Edition-Tensioner-June

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    This document provides information on the Smart Hydraulic Tensioning Pump and Group. It details the technical specifications of the pump and group, their applications, warranty information, and service repair items. Pictures and dimensions of the pump are also included. Subscription and contact information for dealer support is listed at the bottom.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    289 views3 pages

    Special Edition Tensioner June

    Uploaded by

    Djebali Mourad
    This document provides information on the Smart Hydraulic Tensioning Pump and Group. It details the technical specifications of the pump and group, their applications, warranty information, and service repair items. Pictures and dimensions of the pump are also included. Subscription and contact information for dealer support is listed at the bottom.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    Tool News

    Special Edition
    June 16, 2016

    THE SMART HYDRAULIC TENSIONING PUMP & SMART HYDRAULIC


    TENSIONING GROUP

    See following pages for technical details and in-depth specifications...

    To Subscribe or Unsubscribe to this DEALER SUPPORT COVERAGE


    publication, visit the Tool News Page.
    John Woiwode Fernando C. Parra
    Senior Marketing Consultant Senior Marketing Consultant
    [email protected] [email protected]
    309-636-1673 305-476-6834
    • USA Western Region • USA Eastern Region
    • Canada, Europe • Latin America
    • Africa • Caribbean
    • Middle East • Australia
    • C.I.S • New Zealand
    • Russia • Asia Pacific
    • China
    • India

    Dealer Service Tools • USA: 1-800-542-8665, option 1 • International: 1-309-578-7372 • dealer.cat.com/dealer-service-tools


    Smart Hydraulic Tensioning Pump: 498-6540, 498-6541
    Model Usage: G3600 / 3600 / C280
    Warranty: Manufacturer’s  Smart Hydraulic Tensioning Pumps (498-6540 and 498-6541) require
    use of 498-6542 Smart Tensioning Group.
     Electronically controlled hydraulic pump for bolt tensioning
     Touchscreen user interface (HMI) with pre-loaded programs for spe-
    cific tensioning jobs
     Independent hydraulic control interface for safety
     Quality Record creation for job traceability
     Go/No-Go feedback in Program mode to ensure joint quality
     Automatic execution helps ensure joint quality while significantly de-
    creasing time needed to create the bolted joint
     Manual mode allows for the use of non-smart tensioners with the
    pump

    Certified

    Part # Voltage Freq. Plug Max Pressure Oil Cap. Weight

    498-6540 115v 60 Hz NEMA 5-15P 1500 BAR 7.5 L 55 kg


    (USA Style)

    498-6541 230v 50/60 Hz Schuko 1500 BAR 7.5 L 55 kg


    (Euro Style)
    NOTE: The pump includes; touchscreen (HMI), HMI case, HMI cable, and HMI mounting group

    Operating Temperatures: Service Repair Items:


    Temperature Range Hydraulic Oil Part # Description
    Required
    °C °F 466-1821 HMI Mounting Group
    TDTO Arctic 466-1822 HMI Travel Case
    0 to 60 32 to 140
    332-8851 (4.0 L)*
    498-6561 Pump Pressure Relief Valve
    ADV Hydo 10
    15 to 60 60 to 140 498-6562 Hydraulic Pendant Kit
    309-6932 (3.8 L)*
    498-6563 HMI (touchscreen)
    * Qty. 2 required to fill pump
    498-6564 Manifold Valve Filter Kit

    498-6565 Mechanical Pressure Gauge Kit (0-200bar)

    498-6566 Valve Seal Kit

    498-6567 HMI Cable


    Product Dimensions:
    Item MM IN
    D
    A 520 20.50

    B 317 12.50
    A
    C 654 25.75 E

    D 246 9.69
    F
    E 270 10.63

    F 109 4.29 B C
    Smart Hydraulic Tensioning Group: 498-6542
    Model Usage: G3600 / 3600 / C280
    Warranty: Manufacturer’s  498-6542 Smart Tensioning Group requires use of either 498-6580 Pump
    Group (115v) or 498-6541 Pump Group (230v).
     Twin stud design allows tensioning two bolts at one time
     Tensioner design features for improved technician efficiency include nut
    rotating gearbox, puller sleeve free float and spring loaded nut rotating
    sockets for inverted operation
     Tool group includes everything except for smart pump
     Tensioners feature a hydraulic cycle counter to help ensure proper
    maintenance is followed to maintain safe operation of the tools
     Integrated hose assembly features the necessary electrical cables for
    communication from the tensioner to the pump
     All hydraulic components rated for 1500 bar max pressure
     Travel case includes pockets for rod guides for both the Inline and Vee
    engines

    Certified
    Service Repair Items:
    Part # Description
    466-1812 Hose - Pump - 3M Length
    Part # Engine Application Weight 498-6546 Cable Junction Box
    498-6542 3600 Series Connecting Rods 41 kg 498-6550 Flow Divider
    498-6552 Tensioner Return Spring Kit
    498-6553 Tensioner Cover Kit

    Tool Group Contents: 498-6554 Tensioner Fasteners Kit


    498-6555 Tensioner Socket Spring Kit
    Part # Description Qty.
    498-6556 Tensioner Seal Kit
    466-1810 Tool Group Travel Case 1
    498-6557 Tensioner Relief Valve Kit
    498-6545 3600 ConRod Hose Group 1
    498-6558 Tensioner Transducer Kit
    498-6547 3600 ConRod Smart Tensioner 2
    498-6559 Tensioner Puller Sleeve Assm Kit
    498-6551 High Force Socket Group 1
    498-6560 Swivel Manifold Assm Kit
    498-6572 Thumbwheel Assm 2
    498-6568 Transducer Cable - Pump
    498-6573 Rod Guide Retaining Nut 4
    498-6569 Transducer Cable - Tensioner
    498-6570 Chafe Gear - 3M Section
    498-6571 Hose - Tensioner - 3M Length
    498-6574 Quick Disconnect Group - 90°

    Smart Hydraulic Tensioner: 498-6547


    Part # Max Pressure Max Load Max Stroke Weight
    498-6547 1500 BAR 264 kN 8 mm 7.9 kg

     Integrated electronics provide automatic feedback to ensure joint quality


     Robust top cap design for puller sleeve retention
     Over stroke protection includes a visual indicator and internal relief valve
     360° rotation of quick disconnect allows for convenient hose installation
     High pressure design allows for compact tool reducing technician fatigue

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