WSS-WSL Bolt Tensioner - SPX · PDF fileWSS-WSL Bolt Tensioner Original ... Assembling the...

Operating Instructions for:WSS-WSL Series

WSS-WSL Bolt Tensioner

Original Instructions

Unit 4, Wansbeck Business ParkRotary ParkwayAshingtonNorthumberland NE63 8QW

Tel: +44 (0) 1670 850580Fax: +44 (0) 1670 [email protected]

SPX Bolting Systems

© SPXForm No. 1000587

Rev. 0 February 14, 2012

2© SPXForm No. 1000587


Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Safety Symbols and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33



Description

The WSS/WSL Hydraulic Bolt Tensioner is designed to provide simple but safe tensioning operations with the added benefit of speed and reliability. The WSS/WSL tensioning tool uses a single chamber hydraulic load cell to load standard studbolts. In operation, the tensioning tools are assembled to one or more bolts to be tightened. The tensioner is placed over the nut and a second nut is screwed down onto the tensioner. Multiple tensioners can be assembled to a single joint to create simultaneous and uniform joint compression and bolt loading. In order to apply load to the bolt, the pump is activated and a predetermined pressure is applied to the system. As the tensioners apply load to each bolt, the nuts are lifted from the joint surface as the bolt stretches due to the load. While the tensioner system pressure is maintained, each of the flange nuts are tightened back down against the joint face. Upon release of the system pressure, the load is retained/trapped in each bolt.

Figure 1. Gearbox Drive Type Figure 2. Manual Nut Rotator Type



The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.IMPORTANT: Important is used when action or lack of action can cause equipment failure, either immediate or over a long period of time.

Safety Symbols and Definitions

WARNING: To prevent personal injury,

• The following procedures must be performed by qualified, trained personnel who are familiar with this equipment. Operators must read and understand all safety precautions and operating instructions included with the device. If the operator cannot read these instructions, operating instructions and safety precautions must be read and discussed in the operator's native language.

• These products are designed for general use in normal environments. These products are not designed for use in special work environments such as: explosive, flammable, or corrosive. Only the user can decide the suitability of this product in these conditions or extreme environments. Power Team will supply information necessary to help make these decisions. Consult your nearest Power Team facility.

• Safety glasses must be worn at all time by the operator and anyone within sight of the unit. Additional personal protection equipment may include: face shield, goggles, gloves, apron, hard hat, safety shoes, and hearing protection.

• The owner of this tool must verify that safety-related decals are installed, maintained, and replaced if they become hard to read.

• Shut OFF the motor before opening any connections in the system.

Pump


• Do not exceed the hydraulic pressure rating noted on the pump nameplate or tamper with the internal high pressure relief valve. Creating pressure beyond rated capacities can result in personal injury.

• Retract the system before adding fluid to prevent overfilling the pump reservoir. An overfill can cause personal injury due to excess reservoir pressure created when cylinders are retracted.

Safety Precautions



Electric Motor


• Electrical work must be performed and tested by a qualified electrician per local directives and standards.

• Disconnect the pump from the power supply and relieve pressure before removing the motor case cover or performing maintenance or repair.

• Check the total amperage draw for the electrical circuit you will be using. For example: Do not connect a pump that may draw 25 amps to a 20 amp fused electrical circuit.

• Never use an ungrounded power supply with this unit.• Changing the voltage is an involved and, if incorrectly performed, hazardous procedure.

Consult the manufacturer for specific information before attempting rewiring.• Wire pump motors for counterclockwise rotation when viewed from the shaft end of

the motor.• Do not attempt to increase the power line capacity by replacing a fuse with another

fuse of higher value. Overheating the power line may result in fire.• Exposing electric pumps to rain or water could result in an electrical hazard.• Avoid conditions that can cause damage to the power cord, such as abrasion,

crushing, sharp cutting edges, or corrosive environment. Damage to the power cord can cause an electrical hazard.

Hoses


• Before operating the pump, tighten all hose connections using the correct tools. Do not overtighten. Connections should be only secure and leak-free. Overtightening can cause premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.

• Should a hydraulic hose rupture, burst, or need to be disconnected, immediately shut off the pump and shift the control valve twice to release pressure. Never attempt to grasp a leaking hose under pressure with your hands. The force of escaping hydraulic fluid could cause serious injury.

• Do not subject the hose to potential hazard, such as fire, sharp surfaces, heavy impact, or extreme heat or cold. Do not allow the hose to kink, twist, curl, or bend so tightly that the fluid flow within the hose is blocked or reduced. Periodically inspect the hose for wear, because any of these conditions can damage the hose and possibly result in personal injury.

• Do not use the hose to move attached equipment. Stress can damage the hose and possibly cause personal injury.

Safety Precautions continued



• Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must not come in contact with corrosive material such as creosote-impregnated objects and some paints. Consult the manufacturer before painting a hose. Never paint the couplers. Hose deterioration due to corrosive materials may result in personal injury.

Safety Precautions continued



Initial Setup

Each tensioner is supplied completely assembled and ready for use. A hydraulic pump is required to provide the speed and pressure that makes the tensioner system efficient and accurate.

1. Read and understand all instructions before operating the tensioner. It is the operator's responsibility to read, understand, and follow all safety instructions.

2. Remove the tensioner from the shipping container and visually inspect all components for any shipping damage. If any damage is found, notify the carrier immediately. DO NOT USE TOOL.

Hydraulic Connections• Never connect or disconnect any hydraulic hoses or fittings without first unloading the

tensioner and the pump.• Open all hydraulic controls several times to verify the system has been completely

depressurized.• If the system includes a gauge, double check the gauge to verify pressure has been

released.• When making connections with quick-disconnect coupling, verify the couplings are fully

engaged. Threaded connections such as fittings, gauges, etc., must be securely tightened and leak-free.

SafetyThe tensioner is a high-power hydraulic tool. It is strongly recommended that all users are fully trained and competent in the use of tensioner systems. Incorrect use of the equipment or failure to follow any of the safety precaution included herein could lead to serious injury.

NOTE: The tensioner is designed for the tightening and loosening of bolts and studbolts only. Do not use it for any other purpose.

• Never exceed the tensioning tool maximum working pressure of 1350 bar (19,580 psi)• Verify the studbolt protrusion is set to the specified length.• Verify the threaded Puller Bar is the correct thread form and size, and is correct for the hydraulic cell

to be used.• Verify the hydraulic cell is correctly assembled onto the bridge.• When assembling the tensioning tool to the flanged joint, verify the bridge sits squarely on the flange

face and does not damage the flange hub or adjacent bolting.• Check that hoses are in good condition and undamaged. When assembling the hydraulic hoses do

not kink or bend hoses beyond their safe bend radius limit.• Do not pressurize unconnected quick connect couplings.• Take care when handling equipment. Quick connect couplings are especially susceptible to knocks

and damage. Therefore care must be taken. Damaged couplings are difficult to connect. Do not force couplings.

• Do not tighten any equipment while under pressure.• Stand to the side of the tensioning tools while under pressure. Do not work over the top of the

tensioning tool.• Keep the system under pressure for as short a time as possible. Fully understand operating

procedures before starting to keep operating time to a minimum.



• Keep other personnel clear of the working area and only allow trained personnel to use the equipment. Rope off the working area when possible.

• Only use pumps, hoses, tensioners, etc, which were supplied by the manufacturer or distributor. Verify the equipment is certified for the specific working pressures.

• Only use the manufacturer's genuine parts for repairs and servicing. Repairs should only be carried out by the manufacturer.

• Do not strike, misuse or abuse any of the equipment. If any abuse or misuse of the equipment is evident, the warranty shall be invalid and the manufacturer shall not be responsible for any injuries or failures as a result.

• If not in use, and when practical, disconnect the pump from the power supply to prevent accidental starting. Also verify tensioning tools are not pressurized.

Initial Setup continued



Operating Instructions

Studbolt PreparationIn order to reduce potential problems during the tensioning operation, a few simple checks carried out before the tools are applied can significantly reduce wasted time. It is recommended that the following studbolt preparations and checks be carried out before the tensioning tools are assembled.• In order to accommodate the tensioning system, there must be a thread protrusion above the hex

nut, and it must be within the following limits.• If possible, check that the hex nut on the side of the bolt protrusion is free running over a further

20mm of thread.

Bar

/Stu

d P

rotr

usio

nS

ee T

able

Bel

ow

Figure 3. Studbolt Length

TOOL REF BOLT SIZE STUD PROTRUSION MIN

WSS1 / WSS1-10 #10 – 75 ksi 206 mmWSS1 / WSS1-11 #11 – 75 ksi 219 mmWSL1 / WSL1-10 #10 – 75 ksi 255 mmWSL1 / WSL1-11 #11 – 75 ksi 266 mm

WSS2 / WSS2-125 1-1/4” – 150 ksi 226 mmWSS2 / WSS2-138 1-3/8” – 150 ksi 238 mmWSL2 / WSL2-125 1-1/4” – 150 ksi 269 mmWSL2 / WSL2-138 1-3/8” – 150 ksi 280 mm

Table 1. Studbolt Sizes

Assembling the Tools onto the Bolt/FlangePrior to using the tensioning tool the following checks should be carried out before and during operation:

10© SPXForm No. 1000587


Operating Instructions continued

CAUTION: The handle strap included with the tensioning tool is generally used for transportation purposes, rather than an application aid. If the tool is lowered onto the bolt using the handle strap, hand injury could occur. Use caution to avoid hand injury as the foundation bolt protrudes through the center of the tensioner. The handle strap should be moved out of the way to avoid injury or damage.1. Verify that the tensioning tools (hydraulic cell and bridge) are correct for the bolts to be tensioned.2. Verify that the hydraulic cell pistons are fully retracted3. Place the bridge around the nut ensuring that it sits squarely on the joint surface, with the bridge

positioned such that the access window (or gearbox) can be easily accessed.4. Visually examine the assembly checking that no part of the tensioner fouls the flange hub taper,

welds, etc or the adjacent nuts and bolts. If there is interference between flange and tensioner the tensioner assembly must either be repositioned or an alternative tensioner used.

5. Connect the hose from the pump unit to the hydraulic coupling on the tensioning tool.

NOTE: All hoses are fitted with self-sealing quick connect couplings that prevent hydraulic fluid from flowing through the coupling unless fully connected. Therefore, it is important to verify the female coupling is fully engaged with the male coupling before pressurizing the system.

Piston Overstroke PreventionIn the interest of safety, an overstroke eliminator valve has been included. Should the tensioner be accidentally stroked beyond the specified stroke limit, the valve will be activated and hydraulic fluid safely vented. Not only does this prevent the operator from being exposed to high pressure hydraulic fluid, but it also eliminates seal damage and downtime due to seal replacement.During a tensioning operation, if the yellow piston stroke indicator band becomes visible, stop the pump unit, turn down the flange nuts, and release system pressure. After the tensioner has retracted, reset the reaction nut against the piston surface and continue with the tensioning operation.

Stroke Indicator Band

Figure 4. Indicator Band

The valve will only operate if the maximum piston stroke is exceeded. When the valve operates the pump will suddenly lose pressure (or will not continue to build pressure) and the maximum stroke indicator line on the piston will be fully visible. During operation of the valve, hydraulic fluid will be vented from the underside of the hydraulic cell.

11© SPXForm No. 1000587



Tensioning Operation1. Apply tensioning tool to stud.

Figure 5. Applying Tool

2. Verify the nut rotator is properly engaged around the nut. The tensioner should sit squarely on the joint face without obstruction.

Figure 6. Seating Tool

3. Assemble a hexagon nut onto the threaded protrusion above the tensioner.

Figure 7. Secure Tool

4. Attach the hose (or hoses if multiple tools are used). If fitted, ensure hose coupling locking collars are fully screwed up.

Figure 8. Attaching Hose

12© SPXForm No. 1000587


5. Slowly apply pre-determined pressure to achieve desired bolt load.

Figure 9. Apply Pressure


6. Hold pressure and turn down nuts.

Figure 10. Hold Pressure

7. While the system is under pressure turn down the nut.

Max Torque 30Nm

Figure 11. Gearbox Drive Type Figure 12. Manual Nut Rotator Type

Tap the toggle bar with a hammer to firmly seat the nut against the surface.

13© SPXForm No. 1000587



8. Slowly release system pressure. Repeat steps 5–8 two additional times to generate accurate bolt load

Figure 13. Release Pressure

9. Allow tensioner piston to fully retract.

PistonExtended

FullyRetracted

Figure 14. Piston

10. Unscrew and remove tensioning tool.

Figure 15. Remove Tool

14© SPXForm No. 1000587


Performance Specifications

Technical SpecificationsThe following data is applicable to the WSS-WSL Hydraulic Bolt Tensioner:TENSIONER DESIGN: Single chamber, spring assisted piston retract. MAXIMUM PRESSURE: 1350 bar (19,580 psi) OPERATING TEMPERATURE LIMITS: -20°C to +50°C

LOAD CELL REF

ADAPTOR KIT REF

WILLIAMS® INC REBAR

SIZE

MINIMUM STUD PROT

STROKE MAX LOAD

HYD AREA WEIGHT

WSS1WSS1-10 #10 - 75ksi 206 mm

10 mm470 kN 3481 mm2

5.70 kgWSS1-11 #11 - 75ksi 219 mm 5.90 kg

WSL1WSL1-10 #10 - 75ksi 255 mm

25 mm9.00 kg

WSL1-11 #11 - 75ksi 266 mm 9.20 kg

WSS2WSS2-125 1-1/4” - 150ksi 226 mm

10 mm760 kN 5630 mm2

8.20 kgWSS2-138 1-3/8” - 150ksi 238 mm 8.30 kg

WSL2WSL2-125 1-1/4” - 150ksi 269 mm

25 mm12.30 kg

WSL2-138 1-3/8” - 150ksi 280 mm 12.40 kgTable 2. Maximum Load

The following table indicates the maximum tool working pressure in order to induce a gross load equivalent to 90% yield strength of the rebar. THIS TOOL PRESSURE SHOULD NOT BE EXCEEDED.

LOAD CELL REF

ADAPTOR KIT REF

WILLIAMS® INC REBAR

SIZE

MINIMUM STUD PROT MWP LOAD @

MWP

WSS1WSS1-10 #10 - 75ksi 206 mm 1097 Bar 382 kNWSS1-11 #11 - 75ksi 219 mm 1350 Bar 470 kN

WSL1WSL1-10 #10 - 75ksi 255 mm 1097 Bar 382 kNWSL1-11 #11 - 75ksi 266 mm 1350 Bar 470 kN

WSS2 WSS2-125 1-1/4” - 150ksi 226 mm 1066 Bar 600 kNWSS2-138 1-3/8” - 150ksi 238 mm 1350 Bar 760 kN

WSL2WSL2-125 1-1/4” - 150ksi 269 mm 1066 Bar 600 kNWSL2-138 1-3/8” - 150ksi 280 mm 1350 Bar 760 kN

Table 3. Maximum Working Pressure

15© SPXForm No. 1000587


General Maintenance

Storage and MaintenanceIn order to keep the tensioning system in good working condition, it is recommended that simple post use maintenance be carried following each period of use.

TENSIONING TOOLS - POST USE MAINTENANCEPost use maintenance can be carried out as follows:1. Ensure that all tensioning tool pistons are fully retracted. The pistons may be retracted by simply

connecting to the pump unit and allowing the hydraulic fluid to drain back to tank.2. Clean any debris from the surfaces of tensioning tools and bridges using a clean cloth. Clean

tensioner Puller Bar internal threads.3. Spray all components with a water-repellent spray (such as WD40).

HYDRAULIC HOSES - POST USE MAINTENANCE1. Clean and inspect each hydraulic hose and quick connect coupling. Check the entire length of the

hose for cuts, abrasions and damage. Any evidence of hose damage and the entire hose must be replaced.

2. Coat each quick connect coupling with a water repellent spray (WD40), retracting and releasing the collars several times to ensure correct operation and ingress of repellent spray.

16© SPXForm No. 1000587


Troubleshooting

PROBLEM CAUSE SOLUTIONTensioner will not advance.Tensioner will not retract.

1. Coupling not fully mated.2. Tensioner seal leakage.3. Pump unit.4. Faulty coupling.

1. Check coupling.2. Replace seal.3. Check pump unit.4. Replace coupling.

Pressure will not build. 1. Tensioner seal leakage.2. Defective pump unit.

1. Change seals.2. Check pump unit.

Pressure builds, but tensioner does not move.

1. Hose restriction.2. Coupling not fully

assembled.

1. Change hose.2. Fully tighten coupling.

Slow tensioner operation. 1. Hose restriction.2. Coupling not fully

assembled.3. Pump flow rate too small.

1. Change hose.2. Fully tighten coupling.3. Use higher flow pump.

Difficulty in hose connection. 1. Pressure within hose.2. Damaged coupling.

1. Vent hose.2. Replace coupling.

17© SPXForm No. 1000587


Repair Procedures

GENERAL SERVICINGIt is recommended that servicing is carried out on an annual basis. The Manufacturer or Approved Service Agent should carry out any repairs and annual servicing. All components shall be inspected and critical components subjected to non-destructive testing where appropriate. Hydraulic cells will be pressure tested and issued with Test Certification.Although it is possible to inspect and replace tensioner components on-site, it is recommended that this operation be carried out in a clean workshop environment, as ingress of debris can severely affect the performance of the seal and tensioning tool. Eye protection should be worn at all times during tool dis-assembly.1. Verify that the pistons are fully retracted. If the piston is not fully retracted, re-connect to the pump

unit and allow the hydraulic fluid to drain to tank.

WARNING: If the piston is not fully retracted, stored energy may exist within the hydraulic cell due to spring load. If a hydraulic coupling is removed, pressurised hydraulic fluid may be eject-ed.2. Remove the hydraulic coupling.

1

2

3

Item Description1 Capscrews

2 Reaction Ring

3 Coupling

Figure 16. Reaction Ring

3. Remove the 4 capscrews.4. Detach the reaction ring.5. Remove the central cylinder sleeve by setting up the load cell on spacers.

18© SPXForm No. 1000587


Spacers

Spacer

Figure 17. Sleeve Removal

a. Use a press to push down the cylinder, thus compressing the springs and pulling the central sleeve through the cylinder, exposing the retaining clip. Only compress the springs enough to gain sufficient access to remove the clip. Remove the retaining clip and release the press.

b. Withdraw the sleeve and remove the springs and spring pins. Do not remove the overstroke eliminator valve.

1

2

Item Description1 Springs

2 Spring Pins

Figure 18. Springs and Spring Pins

c. Turn over the load cell, and assemble M5 capscrews into the piston surface threaded holes and use the capscrews to pull the piston out of the cylinder bore.

6. Withdraw the sleeve and remove the springs and spring pins.7. Thread the M5 capscrews into the piston holes. Use them to remove the piston from the cylinder

bore.

Repair Procedures continued

19© SPXForm No. 1000587


1

2

3

Item Description1 Clip

2 Piston

3 Seal

Figure 19. Piston Removal

NOTE: If the piston is tight, it can be removed by applying a low hydraulic pressure to the load cell in a controlled manner, however, precautions must be taken to prevent the piston from tilt-ing which could cause seizure and damage. The following procedure should be adopted;

a. Temporarily assemble the hydraulic coupling into the load cell. Assemble the load cell, complete with bridge, onto a bolt (chosen within the range covered by the load cell).

b. Screw the appropriate hex nut onto the bolt until it contacts the piston. Back off the nut approx 2 full turns, leaving a gap between the piston and nut.

c. Apply pressure to the load cell (ideally using a hand pump) until the piston comes into contact with the nut.

d. Repeat Steps b and c above until the piston stroke indicator line appears. At this point the piston should be free enough to remove by hand. If the piston is still tight, continue to repeat Steps 2 and 3 until the piston is free.

8. With the piston removed from the cylinder, clean away any debris, but do not remove the seal. Inspect the inner and outer seal lips for cuts, abrasion and damage, and check the backup rings for excessive feathering and extrusion.

9. Inspect the cylinder bore, looking for signs of wear and scoring. If wear, scoring or damage is evident the cylinder must be replaced. Verify the cylinder is clean and free from debris. If the seals and cylinder appear in good condition proceed to Step 15.

10. If the seal and/or backup rings are not serviceable, the seal can be removed and replaced as follows:• Single-seal type—Using a pair of pliers, grip the outer sealing lip and pull the seal downward and

away from the piston. Remove the backup rings.• Dual-seal type—Using a pair of pliers, grip the lip of the outer seal and pull the seal downward and

out of its recess. Remove the backup rings. Repeat for the inner seal.11. Discard the seals and backup rings.


20© SPXForm No. 1000587


12. Inspect the seal grooves in the piston, verifying they are free from damage and debris. Inspect the cylinder bore for signs of wear and scoring.

13. Locate the correct seal for the piston and fit the backup ring onto the seal, positioning the tapering surface of the backup ring onto the tapering surface of the seal. On single-seal types, verify both inner and outer backup rings are fitted.

14. Install the seal and backup ring assembly into the piston recess, pushing the seal down firmly. The seal should click into place when fully engaged. Visually inspect the seal and piston assembly, looking for ripples and ridges that indicate that the seal is not fully engaged.

15. Remove the capscrews from the piston (if still fitted).16. Lubricate the seal lips and cylinder bores using clean hydraulic fluid or silicone o-ring assembly

paste.17. Taking care not to nip the seals, push the piston into the cylinder bore. The outer seal will enter first

followed by the inner seal. A gentle rocking of the piston may help during installation. Push the piston into the cylinder until the top face of the piston is flush with the top of the cylinder.

18. Working from the underside of the hydraulic cell, insert the compression springs and spring pins.19. Insert the bottom plate/sleeve into the hydraulic cell verifying the 'key' protruding from the bottom

plate aligns with the cut out in the hydraulic cell.20. Compress the springs to re-fit the retaining clip in a similar manner.21. Assemble the retaining clip and verify it enters the recess in the top of the piston.22. Replace the hydraulic quick-connect coupling.23. Attach the reaction ring.24. Assemble the tensioning tool to an appropriate bolt and test to the maximum working pressure of

1350 bar (19,580 psi). Verify the test bolt is capable of withstanding the maximum tool pressure.

WARRANTYAll bolt tensioners are supplied under the manufacturers’ standard terms and conditions.All components shall be guaranteed for a period of twelve months from the date of purchase against material defects and workmanship. All components shall be guaranteed for a period of twelve months from the date of purchase against defects arising from normal use with the following exclusions:• Hydraulic seals and back-up rings• O-ring seals• Quick-disconnect couplings• Labels and decals• Tommy bars• Paints and coatings• Plastic screws• Springs

END OF LIFE AND DISPOSALIn accordance with our End of Life Policy, should the product be no longer required for use, it should be returned to SPX Bolting Systems where it shall be disposed of in a safe and environmentally friendly manner.


21© SPXForm No. 1000587


Parts Lists

Figure 20. WSS Exploded View

11

2

6

13

12

8

7

3

10

9

1

4

5

14

15

16

22© SPXForm No. 1000587


Parts Lists continued

LOAD CELL REF: WSS1 Parts ListItem No. Description Qty Part No.

WSS1 LOAD CELL ASSEMBLY 1 WSS11 CYLINDER, WSS1 1 WSSCY0100012 PISTON, WSS1 1 WSSPI0100013 SLEEVE, WSS1 1 WSSSL0100014 SRT RELIEF VALVE 1 SRTRV0000015 SEAL 1 STDSE0000016 SEAL, WSS1 1 WSSSE0100017 SPRING PIN 8 SRTSP0000018 SPRING 8 STDST0000019 MALE COUPLING 1 STDHC000001

10 ADAPTOR 1 STDHC00001411 CLIP 1 STDRC00005912 SCREW 3 STDFA00006413 ANTI-SLIP TAPE 1 SRTAT01000114 HANDLE STRAP 1 WTCHS00000115 WASHER 2 WTCHW00000116 SCREW 2 STDFA000125

LOAD CELL REF: WSS2 Parts ListItem No. Description Qty Part No.

WSS2 LOAD CELL ASSEMBLY 1 WSS21 CYLINDER, WSS2 1 WSSCY0200012 PISTON, WSS2 1 WSSPI0200013 SLEEVE, WSS2 1 WSSSL0200024 SRT RELIEF VALVE 1 SRTRV0000015 SEAL 1 STDSE0000016 SEAL, WSS2 1 WSSSE0200017 SPRING PIN 8 SRTSP0000028 SPRING 8 STDST0000029 MALE COUPLING 1 STDHC000001


24© SPXForm No. 1000587



LOAD CELL REF: WSL1 Parts ListItem No. Description Qty Part No.

WSL1 LOAD CELL ASSEMBLY 1 WSL11 CYLINDER, WSL1 1 WSLCY0100012 PISTON, WSL1 1 WSLPI0100013 SLEEVE, WSL1 1 WSLSL0100014 SRT RELIEF VALVE 1 SRTRV0000015 SEAL 1 STDSE0000016 SEAL, WSL1 1 WSLSE0100017 SPRING PIN, WSL 12 WSLSP0000018 SPRING 12 STDST0000929 MALE COUPLING 1 STDHC000001


LOAD CELL REF: WSL2 Parts ListItem No. Description Qty Part No.

WSL2 LOAD CELL ASSEMBLY 1 WSL21 CYLINDER, WSL2 1 WSLCY0200012 PISTON, WSL2 1 WSLPI0200013 SLEEVE, WSL2 1 WSLSL0200024 SRT RELIEF VALVE 1 SRTRV0000015 SEAL 1 STDSE0000016 SEAL, WSL2 1 WSLSE0200017 SPRING PIN, WSL 13 WSLSP0000018 SPRING 13 STDST0000929 MALE COUPLING 1 STDHC000001


25© SPXForm No. 1000587



WSS1 ADAPTOR KIT REF: WSS1 -10M Parts ListItem No. Description Qty Part No.

WSS1 ADAPTOR KIT, #10 REBAR 1 WSS1-10MBRIDGE ASSEMBLY, #10 REBAR 1 WSSAS010001

1 BRIDGE, #10/11 REBAR 1 WSSBR0100022 HEX ROT DISC, #10 REBAR 1 WSSNR0100013 CLIP 1 STDRC0000134 REACTION RING, WSS1 #10 REBAR 1 WSSRR0100015 SCREW 4 STDFA000026

2

5

1

3

4

Figure 22. WS Exploded Adapter 1

26© SPXForm No. 1000587



WSS1 ADAPTOR KIT, #11 REBAR 1 WSS1-11MBRIDGE ASSEMBLY, #11 REBAR 1 WSSAS010002

1 BRIDGE, #10/11 REBAR 1 WSSBR0100022 HEX ROT DISC, #11 REBAR 1 WSSNR0100023 CLIP 1 STDRC0000134 REACTION RING, WSS1 #11 REBAR 1 WSSRR0100025 SCREW 4 STDFA000026

WSL1 ADAPTOR KIT REF: WSL1 -10M Parts ListItem No. Description Qty Part No.

WSL1 ADAPTOR KIT, #10 REBAR 1 WSL1-10MBRIDGE ASSEMBLY, #10 REBAR 1 WSSAS010001

1 BRIDGE, #10/11 REBAR 1 WSSBR0100022 HEX ROT DISC, #10 REBAR 1 WSSNR0100013 CLIP 1 STDRC0000134 REACTION RING, WSL1 #10 REBAR 1 WSLRR0100015 SCREW 4 STDFA000026


WSL1 ADAPTOR KIT, #11 REBAR 1 WSL1-11MBRIDGE ASSEMBLY, #11 REBAR 1 WSSAS010002

1 BRIDGE, #10/11 REBAR 1 WSSBR0100022 HEX ROT DISC, #11 REBAR 1 WSSNR0100023 CLIP 1 STDRC0000134 REACTION RING, WSL1 #11 REBAR 1 WSLRR0100025 SCREW 4 STDFA000026


27© SPXForm No. 1000587




WSS2 ADAPTOR KIT, 1-1/4” BAR 1 WSS2-125MBRIDGE ASSEMBLY, 1-1/4” BAR 1 WSSAS020001

1 BRIDGE, 1-1/4”/1-3/8" BAR 1 WSSBR0200022 HEX ROT DISC, 1-1/4” BAR 1 WSSNR0200013 CLIP 1 STDRC0000604 REACTION RING, WSS2 1-1/4” BAR 1 WSSRR0200015 SCREW 4 STDFA000026


WSS2 ADAPTOR KIT, 1-3/8” BAR 1 WSS2-138MBRIDGE ASSEMBLY, 1-3/8” BAR 1 WSSAS020002

1 BRIDGE, 1-1/4”/1-3/8" BAR 1 WSSBR0200022 HEX ROT DISC, 1-3/8” BAR 1 WSSNR0200023 CLIP 1 STDRC0000604 REACTION RING, WSS2 1-3/8” BAR 1 WSSRR0200025 SCREW 4 STDFA000026


WSL2 ADAPTOR KIT, 1-1/4” BAR 1 WSL2-125MBRIDGE ASSEMBLY, 1-1/4” BAR 1 WSSAS020001

1 BRIDGE, 1-1/4”/1-3/8" BAR 1 WSSBR0200022 HEX ROT DISC, 1-1/4” BAR 1 WSSNR0200013 CLIP 1 STDRC0000604 REACTION RING, WSL2 1-1/4” BAR 1 WSLRR0200015 SCREW 4 STDFA000026


WSL2 ADAPTOR KIT, 1-3/8” BAR 1 WSL2-138MBRIDGE ASSEMBLY, 1-3/8” BAR 1 WSSAS020002

1 BRIDGE, 1-1/4”/1-3/8" BAR 1 WSSBR0200022 HEX ROT DISC, 1-3/8” BAR 1 WSSNR0200023 CLIP 1 STDRC0000604 REACTION RING, WSL2 1-3/8” BAR 1 WSLRR0200025 SCREW 4 STDFA000026

28© SPXForm No. 1000587


WSS1 ADAPTOR KIT REF : WSS1 -10GB Parts ListItem No. Description Qty Part No.

WSS1 ADAPTOR KIT, GEARED #10 REBAR 1 WSS1-10GBBRIDGE ASSY, GEARED #10 REBAR 1 WSSAS010003

1 BRIDGE, GEARED #10/11 REBAR 1 WSSBR0100042 HEX ROT DISC, GEARED #10 REBAR 1 WSSNR0100033 CLIP 1 STDRC0000134 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSS1 #10 REBAR 1 WSSRR0100016 SCREW 4 STDFA000026


2

5

6

1

3

4

Figure 23. WS Exploded Adapter 2

29© SPXForm No. 1000587




WSS1 ADAPTOR KIT, GEARED #11 REBAR 1 WSS1-11GBBRIDGE ASSY, GEARED #11 REBAR 1 WSSAS010004

1 BRIDGE, GEARED #10/11 REBAR 1 WSSBR0100042 HEX ROT DISC, GEARED #11 REBAR 1 WSSNR0100043 CLIP 1 STDRC0000134 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSS1 #11 REBAR 1 WSSRR0100026 SCREW 4 STDFA000026

WSL1 ADAPTOR KIT REF : WSL1 -10GB Parts ListItem No. Description Qty Part No.

WSL1 ADAPTOR KIT, GEARED #10 REBAR 1 WSL1-10GBBRIDGE ASSY, GEARED #10 REBAR 1 WSSAS010003

1 BRIDGE, GEARED #10/11 REBAR 1 WSSBR0100042 HEX ROT DISC, GEARED #10 REBAR 1 WSSNR0100033 CLIP 1 STDRC0000134 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSL1 #10 REBAR 1 WSLRR0100016 SCREW 4 STDFA000026


WSL1 ADAPTOR KIT, GEARED #11 REBAR 1 WSL1-11GBBRIDGE ASSY, GEARED #11 REBAR 1 WSSAS010004

1 BRIDGE, GEARED #10/11 REBAR 1 WSSBR0100042 HEX ROT DISC, GEARED #11 REBAR 1 WSSNR0100043 CLIP 1 STDRC0000134 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSL1 #11 REBAR 1 WSLRR0100026 SCREW 4 STDFA000026


WSS2 ADAPTOR KIT, GEARED 1-1/4” BAR 1 WSS2-125GBBRIDGE ASSY, GEARED 1-1/4” BAR 1 WSSAS020003

1 BRIDGE, GEARED 1-1/4"/1-3/8 BAR 1 WSSBR020004

30© SPXForm No. 1000587


Item No. Description Qty Part No.2 HEX ROT DISC, GEARED 1-1/4” BAR 1 WSSNR0200033 CLIP 1 STDRC0000604 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSS2 1-1/4” BAR 1 WSSRR0200016 SCREW 4 STDFA000026


WSS2 ADAPTOR KIT, GEARED 1-3/8” BAR 1 WSS2-138GBBRIDGE ASSY, GEARED 1-3/8” BAR 1 WSSAS020004

1 BRIDGE, GEARED 1-1/4"/1-3/8 BAR 1 WSSBR0200042 HEX ROT DISC, GEARED 1-3/8” BAR 1 WSSNR0200043 CLIP 1 STDRC0000604 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSS2 1-3/8” BAR 1 WSSRR0200026 SCREW 4 STDFA000026


WSL2 ADAPTOR KIT, GEARED 1-1/4” BAR 1 WSL2-125GBBRIDGE ASSY, GEARED 1-1/4” BAR 1 WSSAS020003

1 BRIDGE, GEARED 1-1/4"/1-3/8 BAR 1 WSSBR0200042 HEX ROT DISC, GEARED 1-1/4” BAR 1 WSSNR0200033 CLIP 1 STDRC0000604 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSL2 1-1/4” BAR 1 WSLRR0200016 SCREW 4 STDFA000026


WSL2 ADAPTOR KIT, GEARED 1-3/8” BAR 1 WSL2-125GBBRIDGE ASSY, GEARED 1-3/8” BAR 1 WSSAS020004

1 BRIDGE, GEARED 1-1/4"/1-3/8 BAR 1 WSSBR0200042 HEX ROT DISC, GEARED 1-3/8” BAR 1 WSSNR0200043 CLIP 1 STDRC0000604 GEARBOX ASSEMBLY 1 WTGAS0000015 REACTION RING, WSL2 1-3/8” BAR 1 WSLRR0200026 SCREW 4 STDFA000026


31© SPXForm No. 1000587



Tensioner Gearbox Assembly (WTGAS000001) Parts ListItem No. Description Qty Part No.

1 HOUSING, TENSIONER GEARBOX 1 WTGHG0000012 TOP PLATE, TENSIONER G’BOX 1 WTGTP0000013 DRIVE GEAR, TENSIONER G’BOX 1 WTGDG0000014 IDLER GEAR, TENSIONER G’BOX 1 WTGIG0000015 BEARING, TENSIONER G’BOX IDLER 1 WTGIB0000016 BEARING, TENSIONER G’BOX TOP 1 WTGTB0000017 BEARING, TENSIONER G’BOX

HOUSING1 WTGHB000001

8 SCREW 1 MODFA0001199 SCREW 2 STDFA000120

10 SCREW 2 STDFA00003011 SCREW 2 STDFA00002612 DOWEL PIN 3 STDST000108

11

10

2

6

3

7

9

12

4

5

1

8

Figure 24. Gearbox Exploded View

32© SPXForm No. 1000587


SPX Bolting SystemsUnit 4, Wansbeck Business ParkRotary ParkwayAshingtonNorthumberland NE63 8QWTel: +44 (0) 1670 850580Fax: +44 (0) 1670 850655spxboltingsystems.com

We declare that this product complies with the appropriate ESR’s of the following directives,• 2006/42/EC

Where appropriate the requirements of the following standards have been invoked,• EN 292/2/91

Product description: HYDRAULIC BOLT TENSIONER.

Model type: WSS1, WSS2, WSL1, WSL2 HYDRAULIC BOLT TENSIONERS

In addition, the goods supplied have been classified as Category 1 (Mod A) according to the EC Pressure Equipment Directive (PED) 97/23/EC.

SPX Bolting Systems is the person authorised to compile the technical file.

SPX Bolting Systems, the manufacturer / supplier, undertake to transmit and / or make available in response to reasoned request, technical file details and other relative information to EEC National Authorities, in electronic or hard copy format

Installation and operation of this equipment must be in accordance with the installation and operating instructions provided. This product must not be put into service until the machinery into which it is incorporated has been declared in conformity with the provisions of the above directives.

The Company Directors are the equally responsible persons. The person named below is empowered to act as signatory on behalf of the Company Directors

Signed:

Printed: DAVID CAMPBELL Date: 24th November 2011

Declaration of Incorporation

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