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...

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John Woiwode Fernando C. Parra
Senior Marketing Consultant Senior Marketing Consultant
[email protected] [email protected]
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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