Operating manual

Bolt Tensioning Device

PG 4

SSV : M72x6 A67420000

order number : 24390
customer : Gebr. Pfeiffer AG
Work Order No : 107810065
Foreword

With the SCHAAF bolt tensioning device SSV you took a decision for a hydraulic tool
which does justice to highest demands by its sophisticated technology, easy handling
and low maintenance.

In addition, with the SCHAAF company you have found the competent partner for all
questions and problems that may arise in the fields of high-pressure hydraulic and
tensioning technology. Our experts will gladly advise you in this respect with the
planning and execution of your projects and orders. More than 40 years of experience
in these sectors are a guarantee for an optimal execution adjusted to today's standard
of technology. Even for very special problems we offer you the right solution.

Name us your problem - we will reply immediately.

In General

In this manual, we would like to inform you about the operation and the safe handling
of the SCHAAF bolt tensioning device (referred to hereafter as SSV).

Please read this manual thoroughly and take care that every user receives it.

Guarantee
The period of guarantee is six months from the day of delivery to the first buyer.
Please always bear in mind that any insurance claim or right of recourse is only valid
when the general accident-prevention rules as well as the regulations mentioned in
this manual are strictly observed.

Damages caused by inexpert handling and maintenance as well as by wear and tear
or the use of an unsuitable hydraulic liquid will not be recognized. Further claims, es-
pecially those regarding substitution of damages not having occured at the SSV itself,
are excluded. Transport damages are not subject to guarantee as well.

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1. Table of Contents

Foreword ........................................................................... 2
In General .......................................................................... 2
1. Table of Contents ........................................................... 3
2. Function of the Bolt Tensioning Device (SSV) .................... 4
3. Safety Hints................................................................... 5
4. Working Hints ................................................................ 7
5. Explanation and Determination of Losses of Setting Force ... 8
6. Stroke Indication ...........................................................10
7. Turnable Connection Unit ...............................................11
8. Coupling of the High-Pressure Hoses ...............................13
9. Tensioning Procedure of the SSV-4 .................................14
10. Loosening Procedure of the SSV-4 ..............................16
11. Adjustment and Turn Back of the Main Nut..................21
12. Piston Return Stroke .................................................22
13. Exchange of the Seals ...............................................23
14. Breather Screw .........................................................25
15. Maintenance and Storage...........................................26
High-Pressure Hose A-652 ..................................................27

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2. Function of the Bolt Tensioning Device (SSV)

Tensioning bolts with the SCHAAF SSV is one of the most exact procedures to bring
defined tensioning forces into a bolt connection. In opposition to the turning proce-
dures, the hydraulic bolt tensioning makes generating a torsion-free tensioning force
possible by a strictly axial input of force. Thus, a much better use of the bolt material
is feasible which can be used to increase the safety of the bolt connections or de-
crease the dimensions of the connection since frictional influences are completely ex-
cluded. In addition, several bolts can be tensioned or loosened in one operation with
definitely equal forces when several SSVs are connected to one pressure generator,
which is not possible in any other procedure either.

Beside the versions shown below, we offer a variety of different types being, cor-
responding to our customers' wishes and to the way of assembly, the most cost-ef-
fective and most practical solution.

In order to achieve an optimal result with one or several SSVs, some rules have to be
considered. We expressly point out that a conscientious handling of the SSV as well
as the accessories is of highest importance. To ignore these rules or separate hints
means danger to life or danger of injuries! See "Safety Hints"

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3. Safety Hints

Beside regarding the general accident-prevention rules, the safe handling of the SSV
and the hydraulic accessories demand especially the consideration of the following
hints. When disregarding even single items, you can cause danger to life and/or
danger of injuries!

1. When leakages occur during the pressurization, bleed pressure immediately and
seal the leakage or replace defect parts.

2. In case of repair, use exclusively original spare parts. Inexpert substitution of

damaged parts by non-original spare parts is prohibited.

3. All assembly parts are to be handled in correspondence to the manual and the
assembly drawing only. A change in the procedure or another operation of the
SSV is not allowed.

4. Make sure that the components to be tensioned do not exceed the admissible
strain.

5. In order to use the SSV, the thread has to be sufficiently exceeding in order to
avoid that the turn of a thread cracks (see item 4).

6. During the pressurization the people involved have to remain in an appropriate

distance. Staying in direction towards the bolt axis is forbidden.

7. Tensioning pressures or tensioning forces are to be given or changed by

authorized personnel only while considering the admissible component loads (see
item 4).

8. The operation and handling of the SSV are to be carried out by expert staff only.

9. The given max. operation pressure is not to be exceeded in any case and is to be
watched at the manometer of the pressure generator during the complete
tensioning or loosening procedure. When having achieved the given pressure,
stop the pressurization immediately.

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10. During the pressurization when tensioning or loosening the bolt connection,
always watch the admissible stroke of the SSV. Exceeding this stroke is
connected with damaging the SSV as well as with danger of accidents or insuf-
ficient generating of tensioning force.

11. On principle, when connecting high-pressure hoses it has to be taken care that
the connections are correct (see also separate hints).

12. The hydraulic hoses have to be installed in a way that they are not run over by
vehicles or unnecessarily walked over by people. Never lay hoses across sharp
objects (danger of cuts) and never bend or jam them in (see also separate
manual "High-Pressure Hoses").

13. When transporting the device by help of hoisting gears, staying below a sus-
pended load is not allowed.

14. Only use hoisting gears corresponding to the needed transport load. Only use
them at the assigned handling means of the SSV.

15. Never hold or transport the device by using the high-pressure hoses.

16. An incorrect working manometer that doesn´t show the right pressure leads to
overstressing of the parts and to an incorrect bolt connection. Apart from
damaged parts an incorrect bolt connection can also cause conditions that are
danger to life. Therefore take care that the manometer shows the right value or
the tensioning force is checked in an other way (for example by using a master
manometer). Tensioning forces can be checked for example by measuring the
linear deformation. Damaged manometers have to be exchanged immediately.

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4. Working Hints

In order to achieve a bolt connection of high precision, it is vital to consider the fol-
lowing working hints:

- Prior to setting the device, clean all threads and remove possible damages in
order to avoid a "freeze on".

- The base plate for the SSV must be plain and free of dirt. Further check the
squareness towards the bolt axis in order to avoid that the bolt has a bending
stress during the pressurization (tensioning).

- The main nut has to be made with a sufficient axial flank clearance. This is
necessary because due to the input of force at the upper bolt end the thread in
the area of the main nut expands proportional to the force. A "lead fault" of the
bolt is created being compensated by the axial flank clearance of the main nut. If
this flank clearance misses, turning the main nut during the input of force
through the SSV is rendered more difficult if not even impossible. The exactitude
of the tensioning force will be strongly affected.

The flank clearance is calculated as follows:

X min = min. axial flank clearance

F = max. tensioningforce

Xmin = F x m x fs m = nut height

Ak x E
Ak = core diameter of the bolt
E = elasticity module
fs = 1,3 safety factor

- The stroke of the SSV may not at any point be exceeded (watch optical stroke
indication).

- For transporting the SSV it is necessary to uncouple all high-pressure hoses.

- After each pressurization, bring the SSV back to zero (see also "Piston Return
Stroke").

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5. Explanation and Determination of Losses of Setting Force

A vital aspect for the use of the SSV is the loss of tensioning force after the pressuri-
zation.

Having tensioned the bolt with the SSV, tighten the main nut until it fits to the flange
again. When bleeding the hydraulic pressure, the flow of force is no longer ducted
through the SSV but directly via the nut into the flange (see schematic drawing).

Due to the changed flow of force there are additional elastic and plastic deformations
of the components to be tensioned (e.g. because of smoothening the harshness
peaks).

The value of the loss of setting force depends on the surface finish, the length of
grip, the thread pitch, the tensioning force etc. and reduces the tensioning force to a
lower value.

Determination and Compensation of Losses of Setting Force

A loss of setting force can very easily be determined by means of the SSV itself.

Immediately after the tensioning procedure (see "Tensioning Procedure") another

pressurization takes place. During the pressurization, a slight loosening momentum is
applied to the main nut. Exactly at the moment, when the main nut can be loosened,
check the pressure at the manometer of the hydraulic pump and interrupt the pres-
surization. The actual tensioning force (FVR) ensues from multiplying the checked
pressure (p) with the piston surface (A K) of the SSV.

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The efficiency results from the relation between the remaining tensioning force (FVR)
and the original tensioning force (Fv).

FVR
( 1) η =
FV

Experiences have shown that by repeated pressurization up to the first tensioning

force followed by tightening of the main nut, the loss of stressing force is consid-
erably reduced since the deformations of the surfaces (harshness peaks) and the
components are mostly compensated.

Another way to eliminate the losses of setting force is to increase pressure during the
first pressurization in correspondence to the given or determined grade of efficiency.
The tensioning force is increased so that after the setting the wanted force is
achieved.

Attention! Here, too, the admissible component strains have to be considered (see
"Safety Hints").

η =
FV =
PV η = grade of efficiency (determini ed from (1))
FV 2 PV 2

FV = set tensioning force

FV
FV = PV = pressure at FV
η
2

FV2 = increased tensioning force

PV
PV 2 = PV 2 = pressure at FV 2
η

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6. Stroke Indication

The SSV is equipped with a stroke indication showing when the piston reached its
max. admissible stroke. The stroke indication is realized by a red signal ring that is
applied to the piston, the immersion nut and/or to the tension nut showing "max.
stroke". If the piston is at its zero position, the ring is hidden by the cylinder or the
cover of the SSV (see picture).

The max. admissible stroke of the SSV is reached when the signal ring is completely
visible. Stop pressurization immediately (see "Tensioning Procedure" and "Loosening
Procedure").

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7. Turnable Connection Unit

In order to simplify the connection of the hydraulic hose, a turnable connection unit is
supplied as well.

According to the version, one or two hydraulic hoses can be coupled or screwed to it.

The turnable connection unit consists of the following components:

- bolt nipple - disc
- seal - nut

Furthermore, an entry guide is available or contained in the scope of supply (see

picture).

Exchange of the Seals

Should leakages show up at the connection unit, it might be necessary to exchange
the seals.

For doing so, loosen the nut and take the disc off the bolt nipple. Having removed the
seals, clean the components with fluff-free cleaning material. You can also apply
compressed air. Having checked the components for damages and oiled them slightly,

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apply new seals by help of the entry guide and reassemble the turnable connection
unit.

Hint: For the cleaning, never use aggressive cleaning liquids.

For oiling the parts, use exclusively hydraulic oil.

For replacements, use exclusively new seals.

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8. Coupling of the High-Pressure Hoses

- Only couple when the hydraulic system is in a pressureless condition.

- To produce a high-pressure connection, put one coupling and one nipple into
each other while the coupling socket is pulled back. When letting the coupling
socket go, there is a form fit barring the connection.

- By drawing the hose with a manual force of about 100 N make sure that the
connection is correctly barred.

- For decoupling the high-pressure hose in a pressureless condition, first pull back
the coupling socket and then take off the hose.

Hoses with fast-lock coupling sockets or fast-lock coupling nipples avoid, also when
uncoupled, that oil runs out. When the hoses get heated, there can be an inside pres-
sure in the uncoupled condition making a coupling impossible. By loosening one screw
connection (see picture) the pressure can be bleeded (see also separate manual "High-
Pressure Hose").

- To avoid a contamination use protecting caps for the sockets and nipples.

- Should the high-pressure hoses be assembled without fast-lock coupling nipples

or sockets, i.e. mounted rigidly, check the screw connections.

For further information see operating manual "High-Pressure Hose".

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9. Tensioning Procedure of the SSV-4

Prior to the tensioning procedure make sure that the components to be tensioned are
correctly positioned towards each other. Then screw the SSV onto the bolt.

When having a version with a separate support sleeve, first put this on the bolt and
align it centrically to the bolt axis. When screwing on the device take care that the
support sleeve at the cylinder is correctly centered (consider centering shoulder).

There might be an order given according to which the bolts are to be tensioned (ask
authorized personnel, if necessary). Screw the device until the support sleeve or the
support cylinder fits exactly to the flange. The piston of the SSV must be at its zero
position. Furthermore, take care that the hydraulic connector and the window for the
adjusting rod or the pinion are well accessible. If necessary, turn back the SSV or the
piston with the cylinder, but make sure that the max. admissible stroke of the SSV is
not exceeded. Beside that, it has to be ensured at versions with a separate support
sleeve that the cylinder and the support sleeve remain centrically towards each other
(consider centering shoulder). Should the SSV be equipped with a support sleeve, it is
advisable to adjust between the window for the adjusting rod or pinion and the hy-
draulic connector a side-offset in order to avoid the hydraulic hoses hindering turning
the main nut.

Having made all hydraulic connections correctly (see "Coupling of the High-Pressure
Hoses"), vent devices equipped with breather screw, if necessary (see "Breather
Screw").

Attention: With SSV with hydraulic piston return stroke, it is vital to connect the con-
nector for the return stroke cylinder or the return stroke side with the tank of the
pressure generator so that the piston is not prevented from extending (see "Piston
Return Stroke"). Then start the pressurization for the tensioning procedure. If the
necessary pressure is achieved (see also "Explanation and Determination of Losses of
Setting Force"), stop pressurization. The inducted force causes the bolt to extend or
an edging of the components to be tensioned so that the main nut is lifted from the
flange. Screw it back to the flange (see "Adjustment and Turn-Back of the Main

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Nut"). Depending on the version of the SSV, the support sleeve or the support cylin-
der are equipped with a little window at the bottom side. This enables you to check
by help of a feeler gauge leaf whether the main nut really fits tight to the flange.
After that, bleed hydraulic pressure. Now the connection is tensioned.

Having brought the piston to its zero position (see "Piston Return Stroke"), the hy-
draulic hoses can be decoupled. In order to prevent impurities, it is advisable to close
coupling sockets and coupling nipples or loosened screw connections at once by pro-
tecting caps. The SSV can be unscrewed from the bolt.

⇒ Always consider the safety and working hints!

Hint: If several bolts with the same SSV (e.g. on a pitch circle) are to be tensioned, it
is advisable that one person tightens the main nuts in order to minimize different
losses of setting force.

Tensioning Procedure in Several Steps

Depending on each single case it might be necessary that the tensioning procedure is
done step by step since e.g. quite long stressing ways are to be taken. The procedure
is equal to the one described above, but the main nut is tightened when the max.
stroke of the SSV is achieved. After the depressurization, bring the piston back to its
zero position (see "Piston Return Stroke").

Now do it a second time. The necessary tensioning pressure is achieved only during
the second or even another turn.

Especially with highly sensible flange connections can a tensioning procedure in sev-
eral tensioning steps be given in order to minimize deformations in the components.
Here, the components, for instance, are tensioned only to 50 % of the tensioning
force. After this the force is to increase step by step. (⇒ It is vital to consider the
necessary information here. Accept the values from authorized staff only!)

Attention: Here, too, the regulations given in "Tensioning Procedure" are to be fol-
lowed! This also applies to each single step during the tensioning.

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10. Loosening Procedure of the SSV-4

In order to loosen an existing bolt connection, screw the SSV onto the bolt, according
to the drawing. When having a version with a separate support sleeve, first put this
on the bolt and align it centrically to the bolt axis. When screwing on the device take
care that the support sleeve at the cylinder is correctly centered (consider centering
shoulder).

The piston of the SSV must be at its zero position. Having screwed the SSV down
until the support sleeve or the support cylinder fits tight to the flange, turn back the
SSV or the piston with the cylinder by at least the value (slit measure) which the bolt
and the components spring back elastically during the loosening procedure.

(⇒ In most cases, about one turn of the nut is sufficient.)

Hint: The adjusted slit measure may never exceed the admissible stroke of the SSV!
Furthermore, take care that the hydraulic connections and the window for the ad-
justing rod or the pinion are well accessible. Should the SSV be equipped with a sup-
port sleeve, it is advisable to adjust between the window for the adjusting rod or pin-
ion and the hydraulic connector a side -offset in order to avoid the hydraulic hoses
hindering turning the main nut.

Having made all hydraulic connections correctly (see "Coupling of the High-Pressure
Hoses"), vent devices equipped with breather screw, if necessary (see "Breather
Screw").

Attention: With SSV with hydraulic piston return stroke, it is vital to connect the con-
nector for the return stroke cylinder or the return stroke side with the tank of the
pressure generator so that the piston is not prevented from extending (see "Piston
Return Stroke"). Then start the pressurization.

During the pressurization, a slight turn-back momentum is applied to the main nut
with the adjusting rod or the pinion. At the moment, when the main nut can be loos-
ened, interrupt the pressurization. ⇒ This pressure is always less than the tensioning
pressure by help of which the connection was tensioned! Should it not be possible to

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loosen the main nut when achieving the original tensioning pressure, interrupt the
pressurization immediately. Find the cause with expert staff.

Depending on the version of the SSV, the support sleeve or the support cylinder are
equipped with a little window at the bottom side. This enables you e.g. to check by
help of a feeler gauge leaf whether the main nut still fits tight to the flange.

Hint: The pressure at which the main nut can be loosened, can also help determine
the actual tensioning force (see "Explanation and Determination of Losses of Setting
Force").

Having achieved the loosening pressure, turn back the main nut by the value that the
bolt and the components spring back during the loosening procedure. The slit meas-
ure, however, must be lower than the slit measure adjusted at the SSV before (see
also hint b).

The main nut may never be turned back until it fits to the piston or the cylinder since
then the SSV can be tensioned in itself.

Having turned back the main nut, the pressure can be bled. The bolt connection is
loosened. Before unscrewing the SSV, bring the piston back to its zero position (see
"Piston Return Stroke"). After that, the hydraulic hoses can be decoupled. In order to
prevent impurities, it is advisable to close coupling sockets and coupling nipples or
loosened screw connections at once by protecting caps. The SSV can be unscrewed
from the bolt.

⇒ Make sure that no operational forces (e.g. inner pressure of a vessel) affect the
components to be loosened since only part of the bolts take over these forces
and thus the bolts, which are not yet loosened, might be overburdened.
⇒ The pressure when the main nut can be loosened may never exceed the ten-
sioning pressure by help of which the connection was tensioned! Should it not
be possible to loosen the main nut when reaching the original tensioning pres-
sure interrupt the pressurization immediately. Find the cause with expert staff.
⇒ Always consider the safety and working hints!

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Hint:
a) Should it be impossible to unscrew the SSV after the depressurization, it has
been turned back by a too low measure prior to the pressurization. Pressurize
again until the original tensioning pressure is reached, turn the main nut and
bleed the pressure again (tensioning procedure). Now you can turn back the SSV
further. (Attention: consider the admissible stroke of the SSV!) Now repeat the
loosening procedure explained above. If the slit measure has already been ad-
justed to the max. admissible stroke of the SSV, do the loosening procedure in
several steps (see following pages).

b) Should it be impossible to loosen the main nut after the depressurization, it has
been turned back by a too low measure prior to the pressurization. Pressurize
again and turn the main nut further back. Bleed the pressure again.

Hint: Never screw the main nut back until it fits to the piston since the SSV can be
tensioned in itself. If the slit measure has already been adjusted to the max. admis-
sible stroke of the SSV, do the loosening procedure in several steps.

Loosening Procedure in Several Steps

As during the tensioning procedure, during the loosening procedure it might also be
necessary to take several steps in case big tensioning ways are to be overcome or
flexible components are to be disassembled.

Loosening Procedure with Big Loosening Ways in Several Steps

Having put on and connected the SSV in accordance with the above description, turn
back the SSV by a measure (slit measure) which is about 2 mm smaller than the max.
admissible stroke of the SSV.

During the pressurization, a slight turn-back momentum is applied to the main nut
with the adjusting rod or the pinion. Turn back the main nut and bleed the hydraulic
pressure.

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Attention: Never turn back the main nut until it fits to the piston or the cylinder since
the SSV can be tensioned in itself.

Due to the fact that the loosening way exceeds the max. admissible stroke of the
SSV, it will not be possible to unscrew the SSV from the bolt. Should this be the
case, tighten the main nut again until it fits tight to the flange, then pressurize. As
soon as the main nut can be turned by about 1/4, stop the pressurization. The hy-
draulic pressure can be bled. After that, bring the piston back to its zero position (see
"Piston Return Stroke"). The second step can be started. Only if the SSV is no longer
tight after the depressurization the SSV can be taken off.

Loosening Procedure of Flexible Components in Several Steps

With flexible components it might be necessary to loosen bolt connections step-by-
step since otherwise the components could be damaged.

Screw the SSV to a bolt and pressurize it as described in "Loosening Procedure".

Turn back the main nut and bleed the pressure by for instance 50 % of the loosening
pressure. If the given part hydraulic pressure is achieved, turn the main nut until it fits
tight again to the flange. After that, depressurize completely.

Hint:
- Should it not be possible to unscrew the SSV from the bolt after having bled the
hydraulic pressure, it has not been sufficiently turned back prior to the pressuri-
zation (proceed as described in hint (a) of "Loosening Procedure") or the main
nut has been turned back too far.

- Should it not be possible to unscrew the SSV from the bolt after the depressuri-
zation although the adjusted slit measure at the SSV corresponds almost to the
max. admissible stroke of the SSV, do not bleed the pressure by, for instance,
more than 50 % but only by, say, 25 % (ask authorized staff).

The first step is finished and the SSV can be put onto the next bolt. ⇒ Consider the
hints of "Loosening Procedure" here, too.

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The order to loosen the bolts and the steps to take off the tensioning force of the
connections, are to be given by expert staff.

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11. Adjustment and Turn Back of the Main Nut

During the pressurization of the SSV, the bolt is being extended by the tensioning
force and the components are being edged. The result is that the main nut does no
longer fit to the flange.

Having achieved the necessary pr essure, adjust the main nut - when tensioning - until
it fits to the flange again before bleeding the pressure (see "Tensioning Procedure").
When loosening the bolts, turn back the main nut after the pressurization according to
the bolt and component deformations (see "Loosening Procedure").

Hint: During the loosening procedure, never turn back the main nut until it fits to the
piston or the cylinder since the main nut sticks after the depressurization.

The main nut is embraced by a hexagon nut having radial bores it its outer diameter.

Throught the window in the support sleeve or the support cylinder of the SSV, the
adjusting rod (supplied as well) can be put into the radial bores and thus the main nut
can be adjusted or turned back.

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12. Piston Return Stroke

After each pressurization it must be ensured that the piston of the SSV is brought
back to its zero position. On principle, it has to be considered that hydraulic oil is
being displaced from the piston area. In order to enable the oil to flow back to the
tank of the pressure generator, the corresponding hydraulic connections must be
done.

The piston return stroke is done by a screw-down at the bolt itself before the SSV is
taken off. The piston has to be brought back by screwing down the piston itself (see
picture).

Hint: When using fast lock coupling elements, the oil's running out and thus a piston
return stroke in an uncoupled condition is impossible!

During the piston return stroke, considerable back-pressures can occur in the piston
area of the SSV since quite large quantities of oil have to flow back through the small
cross sections of the high-pressure connections.

In order not to unnecessarily increase the force for the piston return stroke turn the
piston slowly. On principle the piston of the SSV has to be pushed back until it fits to
the cylinder again.

⇒ Consider the stroke indication!

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13. Exchange of the Seals

Should leakages occur at the piston of the SSV, an exchange of the seals might be
necessary.

Drive out the piston by carefully beating with a hammer while using a plastic spacer
in order to protect the SSV from unnecessary damages. For driving out the piston
most easily, remove the hydraulic connector and loosen the breather screw, if there is
one. After removing the hydraulic connector, you can also carefully lead compressed
air into the piston area while the possibly existing breather screw remains closed.

Attention: Sudden input of compressed air can lead to the piston's uncontrolled
outlet.

The disassembly of big pistons is facilitated by help of a crane or of jack screws.

After removal of the piston, the seals and the backup rings can be removed from the
piston and the cylinder.

Carefully clean the components with fluff-free material and check them for damages.
If necessary, use compressed air for the cleaning, but never aggressive cleaning
liquids. After that, slightly oil these components with hydraulic oil and assemble new
backup rings as well as new seals to the piston and the cylinder according to the
drawing.

As shown in the picture, first assemble the

backup ring, then put the seal with the flat
side onto the backup ring.

Piston and cylinder can now be assembled again by putting the components together.

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By slightly hammering on the piston (with plastic spacer), it can be driven in until it
fits tightly to the cylinder (piston in its zero position). It is essential that the piston
does not tilt during being driven in since this might damage the seals as well as the
components. When assembling the piston it has to be taken care that the air can
come out of the piston area.

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14. Breather Screw

The SSV is equipped with a breather screw making it possible to vent the device and
the complete hydraulic system. In the factory, the SSV has already been vented. It
just has to be vented again if the seals have been exchanged, the high-pressure con-
nection has been removed or the max. stroke of the SSV has been exceeded. Fur-
thermore, a venting can be necessary, if the remaining hydraulic components show
trapped air.

Venting Procedure
First, loosen the breather screw by about one turn. Then operate the pressure genera-
tor until the hydraulic oil leaves the breather screw bladder-free. Please take care that
the breather screw is placed at the highest position of the SSV in order to let the air
escape. If necessary, tilt the SSV. As soon as bladder-free oil comes out, the venting
procedure is finished and the breather screw can be tightened again.

Hint: The assembly and disassembly of the piston of the SSV during the exchange of
the seals is made much easier by loosening the breather screw since an excess pres-
sure or a vacuum in the piston area is being avoided (see "Exchange of the Seals").

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15. Maintenance and Storage

Regular maintenance of the SSV is not necessary, but you should consider the
following points:

a) Storage
After each operation, repair possible damages and clean the SSV in order for it to be
ready for the next operation immediately. In order to avoid a corrosion it is advisable
to oil the SSV and especially its thread. All coupling nipples, coupling sockets and
also loosened screw connections are to be closed by protecting caps.

In addition, check the components of the SSV and its accessories (including the
operating manual) for completion.

Keep the SSV in a dry place also offering protection from mechanical damages.

The temperature must be between -20 C and +70 C in order to exclude a damage of
the seals.

Keeping the SSV vertical (thread axis vertical), increases the lifetime of the seals.

b) Start-up of the SSV

Prior to the SSV's operation, repair possible damages and clean the SSV.

Check the components of the device and its accessories, according to the drawings
and the list of parts, for completion.

The operating manual has to be read by all users.

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High-Pressure Hose A-652

Pos. Name
1 High Pressure hose A-578 .... metres
2 Adaptor M16x1,5 AG / 58°DK / G1/4" AG
3 Fast-lock coupling socket CVK30 M16x1,5 IG

Max. operation pressure for pos. 1: 3000 bar

Test pressure for pos. 1: 4650 bar
Burst pressure for pos 1: 6200 bar

Lengths on stock for pos. 1 are:

1 m; 2 m; 3 m; 4 m; 5 m; 6m
All other lengths can be delivered upon request.

All hoses are equipped with a protection hose. The specifications printed on the high pressure
hose are: -SCHAAF-D-41812-ERKELENZ/EN/A578/5/XQJJ/PN3000
They are exclusively related to the high-pressure hose pos. 1
The minimal bending radius of the high pressure hose is 175 mm

ATTENTION: Prior to any pressurization, the high-pressure hose and all pressure-
conducting
parts connected with it have to be checked regarding damages. Damaged
parts have to be replaced by new ones immediately.

ATTENTION !!! High-pressure hydraulic

Fundametal: Should leakages occur while under pressure,
bleed hydraulic pressure immediately and seal leakages
and/or replace faulty parts

For pressure transfer, only hydraulic oils are admissible. Any other liquids
may only be used with the expressed permission of SCHAAF company.

Never expose the hose to mechanical load and never bend it sharply. The
min. admissible bending radius is 175 mm. The admissible temperature of the
environment and contact surface is between - 10° and + 70° C.

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High-Pressure Hose A0652 (3000 bar)

Lengths available from stock

for pre-assembled and pressure-tested high-pressure hose
Art. No. Designation Art. No. Designation
A065200.22 High-pressure hose 0.220 m long A06520002 High-pressure hose 2.0 m long
A065200.27 High-pressure hose 0.270 m long A06520003 High-pressure hose 3.0 m long
A065200.34 High-pressure hose 0.340 m long A06520004 High-pressure hose 4.0 m long
A065200.5 High-pressure hose 0.5 m long A06520005 High-pressure hose 5.0 m long
A065200.55 High-pressure hose 0.550 m long A06520006 High-pressure hose 6.0 m long
A065200.557 High-pressure hose 0.557 m long A06520007 High-pressure hose 7.0 m long
A065200.6 High-pressure hose 0.6 m long A06520008 High-pressure hose 8.0 m long
A06520001 High-pressure hose 1.0 m long A06520009 High-pressure hose 9.0 m long
A06520001.5 High-pressure hose 1.5 m long A06520010 High-pressure hose 10.0 m long
A06520001.7 High-pressure hose 1.7 m long A06520015 High-pressure hose 15.0 m long
A06520001.8 High-pressure hose 1.8 m long A06520020 High-pressure hose 20.0 m long
A06520002.1 High-pressure hose 2.1 m long
Other lengths are available at short notice upon request,
as these are assembled by SCHAAF.

All items are available individually.

Item Designation Article No.
1 High-pressure hose A0578 ... m long A0578....
2 Adapter M16x1.5 AG 58° DK / G¼“ AG 60° A28222900
3 Quick-release coupling sleeve SVK30 M16x1.5 IG A60000001

Hose specifications
All high-pressure hoses are fitted with an additional
protective hose. The data printed on the high-pressure hose
(applies only to Item 1 above):

-SCHAAF- 41812-ERKELENZ-GERMANY/EN/HDS3000/5/XQJJ/PN3000
EN Standard Quality Assurance max. operating pressure in bar
All high-pressure hoses are checked for material quality,
dimensional accuracy, correct functioning and load-
resistance. During order execution, they are subject to e.g. 4Q05 (4th quarter 2005)
continuous quality assurance measures and are supplied
together with detailed technical information.
Hose type

Nominal diameter
High-Pressure Hose A0652 (3000 bar)

Caution!! High-Pressure Hydraulics

If leaks occur when pressure is being applied, always relieve the hydraulic pressure immediately and either seal
the leak or replace the defective part.
Max. operating pressure for item 1: 3000 bar
Test pressure for item 1: 4650 bar
Bursting pressure for item 1: 6200 bar
Inner tube: POM

PG20.a0652.e_0407_indd_online · Errors excepted. Data will change as developments occur. Only the latest state of the art design is decisive. Copyright as per standard ISO 16016.
Pressure jacket: 6 spiralled layers of corrosion-proof high tensile steel
Outer sheath: PA, Nylon
Protective hose: PVC
Inside diameter: 5.0 mm
Outside diameter: 13.0 mm
Outside diameter incl. protective hose: 22.0 mm
Weight: 0.43 kg/m

Caution!! The high-pressure hose and all pressure-carrying parts associated with it, must always be inspected for
damage before pressure is applied. Damaged parts must immediately be replaced by new parts.

It is only permitted to use hydraulic oils for transferring pressure. Other fluids may only be used with the express approval
of SCHAAF. The high-pressure hose must never be subjected to mechanical stress or kinking. The minimum bending
radius is 175 mm. The permissible ambient and contact temperature is between –40 °C and +100 °C. It is recommended
to replace the high-pressure hose with a new hose, at the latest, every 5 years. Earlier replacement is recommended
if the hose is subject to extreme conditions. The maximum cycles-to-failure count can be assumed to be 20,000.
Dirt, contamination, mechanical damage and very high or low temperatures can reduce the cycles-to-failure count
considerably. Contact us if you have any questions in this respect.

Fitting information: If the high-pressure hose is fitted with quick-release coupling sleeves or nipples, a pressure
build-up can occur as a result of the oil in the high-pressure hose heating up to a high temperature, making connection
impossible.
If this is the case, a connection point must be loosened so that the pressure inside the high-pressure hose can decrease.
When the pressure has decreased, the loosened connection must be properly tightened.

Other products manufactured by SCHAAF Complete solution from SCHAAF

Bolt tensioners The high-pressure hydraulic hoses, connection couplings
Hydraulic nuts and adapters are all aligned to function with SCHAAF
High-pressure hydraulic pumps: high-pressure hydraulic tools and high-pressure hydraulic
manually operated, electrically or pneumatically driven generators = 100% system solution.
Couplings, nipples, adapters, distributors up to 4000 bar
ExpaTen, EcoRolls and many more