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Figure 1, Major Features and Components
Key:
1. Coupler, Male
2. Electrical Connector
3. Puller Sleeves *
4. Thumb Wheel, 3/8 in.**
5. Top Cap
6. Tensioner Body
3.0 PRODUCT DESCRIPTION
3.1 Overview
The Enerpac Model 498-6547 hydraulic tensioner is designed to
precisely tension the connecting rod studs used on CAT 3600
Series engines. It includes the following features:
• Application specific design - custom engineered to precisely
fit CAT 3600 connecting rods.
• Overstroke protection.
• Twin stud tensioning
• Fast castle nut spin down using standard 3/8" square drive.
The tensioner is part of a complete tensioning system that
includes a specially programmed Smart Tensioning Pump. This
pump oers the following advanced features:
• Convenient touchscreen HMI (human-machine interface).
• Automated GO/NO-GO operation with transducer feedback.
• Quality record (Includes: system pressure, tensioner piston
travel, operator ID, serial number and time stamp).
7. Drive Gears *
8. Gearbox
9. Nut Rotating Sockets
10. Tensioner Bridge
11. Cycle Counter
12. Swivel Manifold
* 3/8 inch drive. ** Item included in tensioning kit.
3.2 Additional Tensioner Features
• The tensioner mounts and operates quickly, since it is
especially designed for the CAT 3600 tensioning application.
• The puller sleeves and drive gears contain standard 3/8
inch female square drives. This allows the technician to easily
complete various operations that are part of the tensioning
process.
• Built-in electrical transducers help ensure that proper
tensioning procedures are followed.
• Cycle counter indicates tool cycles, and can be used to
determine when routine inspection and maintenance activities
are required.
• Durable black oxide finish helps protect the tensioner from rust
and corrosion, prolonging its life.
See Figure 1 for a diagram of the tensioner's major features and
components.
3.3 Maximum Working Pressure -
CAT 3600 Tensioning Application
The maximum working pressure for the CAT 3600 tensioning
application is regulated by the Smart Tensioning Pump, when the
pump is operated in the automatic program (P) mode. Note that
this pressure can be less than the maximum working pressure
(“WP”) stamped on the side of the hydraulic tensioners. This
pressure can also be less than the maximum pressure shown on
the pump data plate.
Program (P) mode limits the pump's maximum working
pressure to a setting determined by the Caterpillar Engine
Products Group. The pressure is automatically optimized for the
selected application, to help prevent bolt failure due to over-
pressurization.
The pump also contains a manual (M) mode. The manual mode
should be used only for troubleshooting or diagnostic purposes
while the tensioner is not mounted on the connecting rod, and
with use of appropriate fixturing to prevent over-stroke of the
tensioners.
CAUTION
Use of the pump in manual mode with the
model 498-6547 Smart Tensioners may result in incorrect
clamp load and/or failure of the connecting rod studs.
Tensioner could drop if studs break, possibly injuring
persons in the work area. Property damage could also result.
3.4 Conformance to National & International Standards
Enerpac declares that the Enerpac Smart Tensioner
has been tested and conforms to applicable standards
and is approved to carry the CE certification mark. An
EU Declaration of Conformity is enclosed separately.
4.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping
damage is not covered by warranty. If shipping damage is found,
notify carrier at once. The carrier is responsible for all repair and
replacement costs resulting from damage in shipment.
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General