Final Drawings/Manual S: Pitgrim

I PITGRIM
Final Drawings/Manual
s
For
Shipyard: DaewooShipbuilding& MarineEng.Co.Ltd.

Hull No: 4163
P.O.No: 4000508393
Vendor: Pilgrim International

Ltd.
Enclosed:
Product Documents
Description Ouantitv
Drg No.
Enc Total Sent
RadialFit Bolt Assemblv- CouolinsI t2 K482s 0 5
RadialFit Bolt Assembly- Coupling2 t2 K4825 0 5
RadialFit Bolt Assembly - Coupling3 t2 K4825 0 5
RadialFit Bolt Assembly- Coupline4 20 K4826 0 5
ClampBolt Assemblv- Coupline4 4 K4827 0 5
Bolt Tensionns Kit - CouplingI,2 & 3 (2 sheets) I K7247 0 5

Bolt Tensionng Kit - Coupling4 (2 sheets) I K7248 0 5
BS970817M40'T'
MaterialSpecification 0 5
Instruction Manuals Enc Total Sent
RadialFit Bolt inc. Tool List / Mandreldetails/ Handpumpdetails I 5

PILGRIM RADIAL FIT BOLTS
WITH EXTERNAL THREAD
OUR ORDER REF: 4605 PILGRIM

INTERNATIONAL LTD
CUSTOMER : D.S.M.E – Hull Nos. 4163
Southlink
Oldham, U.K.
OL4 1DE
Telephone : +44 161 785 7700

Facsimile : +44 161 785 7777
DATA SHEET FOR

OPERATORS INSTRUCTION
AND SAFETY MANUAL
This Data is supplied for use with:-

Serial No’s K4825/22/1-12 NO.1 INT/PROP
K4825/23/1-12 NO.1 INT/NO.2 INT
K4825/24/1-12 NO.2 INT/NO.3 INT
K4826/18/1-20 NO.3 INT/THRUST
PILGRIM CLAMP BOLTS

Serial No’s K4827/18/1-4 NO.3 INT/THRUST
BOLT TENSIONING KIT

Serial No’s K7247/18/1 NO.1 INT/PROP, NO.1 INT/NO.2 INT &
NO.2 INT/NO.3 INT
K7248/19/1 NO.3 INT/THRUST
WARNING:
THIS DATA SHEET IS TO BE USED IN CONJUNCTION WITH THE
APPROPRIATE RADIAL FIT BOLT INSTRUCTION MANUAL
1. HIGH PRESSURE HYDRAULIC EQUIPMENT CAN BE DANGEROUS IF MISUSED - KEEP AWAY

FROM OIL LEAKAGES AT HIGH PRESSURE.
Jets of liquid escaping from High Pressure Equipment have sufficient power to penetrate the skin which will
often cause blood poisoning. In the case of such an accident occurring, HOWEVER SUPERFICIAL,
IMMEDIATE medical attention MUST be sought.
2. THIS MANUAL GIVES INSTRUCTIONS FOR OPERATING PILGRIM RADIAL FIT BOLTS.
OBSERVANCE OF THE PROCEDURES COVERED IN THIS PUBLICATION IS ESSENTIAL FOR THE
SAFETY OF PERSONS WHO USE AND MAINTAIN THE EQUIPMENT AND WORKING AREAS
WHERE THE EQUIPMENT IS LIKELY TO BE USED OR MAINTAINED.
IT IS ESSENTIAL THAT ALL PERSONS INVOLVED WITH EQUIPMENT COVERED BY THIS

MANUAL SHOULD READ THE SAFETY NOTES IN SECTION 7.
IF IN DOUBT, CONSULT: Pilgrim International Ltd.
MANUAL REF: RFBDTA/MNW/05
1
WITH EXTERNAL THREAD PTLGRIM
DATA SHEET
INSTALLATION OF PILGRIM RADIAL FIT BOLTS

DATA SHEET (FOR EXTERNAL THREAD TENSIONING)
COUPLING/ FLANGE
Datachecked
by Engr: NO.I INT/PROP
q[t NO.I INTNO.2INT NO.3INT/THRUST
NO.2INT/NO.3INT
BOLTTENSIONING KIT
AssemblyDrawingNo. K7247 K7248
SheetI & 2 SheetI & 2
Max.WorkingPressure Bar I 500 l 500
(DesignPressure) psi 2t750 21750
Load at Max.Working KN 4230 2076

Pressure lbs.f 951032 466592
Max. Load Ring Extension mm l0 8

inch 0.394" 0.315"
PLEASENOTE - THE ABOVE ARE NOT OPERATINGPRESSURES

AssemblyDrawingNo. K482s K4826
SleeveClearance
Allowance 0.13/0.16 0.09/0.r2
IT
lnch 0.0051/0.0063" 0.0035/0.0047"
OPERATING PRESSURES
SleeveSettingPressure Bar 390 440
psi 5655 6380
Bolt TensioningPressure Bar 1300 1300
psi I 8850 I 8850
SleeveRelease Pressure Bar I 500 I 500

(oil injection)maximum psi 21750 2r750
SleeveReleasePressure Bar 390 440

(hydraulichead) psi 5655 6380
PILGRIM CLAMP BOLTS

AssemblyDrawingNo. K4827
Bolt TensioningPressure Bar I 300
psi I 8850
MANUAL REF: RFBDTANV{NWOS

OPERATORS INSTRUCTION AND SAFETY MANUAL

PILGRIM
INTERNATIONAL LTD
Southlink
Oldham, U.K.
OL4 1DE
Telephone : +44 161 785 7700

Facsimile : +44 161 785 7777
OPERATORS INSTRUCTION
AND SAFETY MANUAL
WARNING:
THIS MANUAL IS TO BE USED IN CONJUNCTION WITH THE
APPROPRIATE RADIAL FIT BOLT DATA SHEET.
1. HIGH PRESSURE HYDRAULIC EQUIPMENT CAN BE DANGEROUS IF MISUSED - KEEP

AWAY FROM OIL LEAKAGES AT HIGH PRESSURE.
Jets of liquid escaping from High Pressure Equipment have sufficient power to penetrate the skin
which will often cause blood poisoning. In the case of such an accident occurring, HOWEVER
SUPERFICIAL, IMMEDIATE medical attention MUST be sought.
2. THIS MANUAL GIVES INSTRUCTIONS FOR OPERATING PILGRIM RADIAL FIT

BOLTS. OBSERVANCE OF THE PROCEDURES COVERED IN THIS PUBLICATION IS
ESSENTIAL FOR THE SAFETY OF PERSONS WHO USE AND MAINTAIN THE
EQUIPMENT AND WORKING AREAS WHERE THE EQUIPMENT IS LIKELY TO BE
USED OR MAINTAINED.
IT IS ESSENTIAL THAT ALL PERSONS INVOLVED WITH EQUIPMENT COVERED BY

THIS MANUAL SHOULD READ THE SAFETY NOTES IN SECTION 7.
IF IN DOUBT, CONSULT: Pilgrim International Ltd.
MANUAL REF: RFBEXT/MNW/05 1


CONTENTS
SECTION 1 INTRODUCTION
SECTION 2 HOLE PREPARATION
SECTION 3 INSTALLATION PROCEDURE
SECTION 4 DISMANTLING PROCEDURE
SECTION 5 HYDRAULIC PUMP AND HARNESS
SECTION 6 RECOGNISING FAULTS AND

PARTS REPLACEMENT
SECTION 7 SAFETY NOTES


SECTION 1
1.1. INTRODUCTION
This manual is intended to give a step-by-step guide to the installation and

removal of PILGRIM Radial Fit Bolts, PILGRIM Clamp Bolts and also covers the
safe use of all associated hydraulic equipment during these operations.
A data sheet is provided to accompany this manual with specific details of your
application.
This manual should be read in conjunction with the Arrangement Drawings stated
on the Data Sheet. The Arrangement Drawings have been prepared to cover the
exact details of the particular application, unlike the diagrams within this Manual
which illustrate a typical application only.
1.2 CONSTRUCTION AND USE
The PILGRIM Radial Fit Bolt is a cost effective fitted bolting system designed to
simplify installation and removal. It works on the principle of pulling a taper
shank bolt into a matching taper bored sleeve expanding its outside diameter to
exert a radial force in the hole, creating a controlled interference fit.
The Bolt is installed and removed in the clearance condition, which overcomes
problems such as bolt seizure and hole damage which are common-place with
conventional fitted bolts and ensures that the Bolts are re-usable. The Bolts have
been designed to give easy and accurate alignment and, combined with the
simplified fitting and removal procedures, offer benefits in time and cost savings.
In a typical example, in order to produce a cost effective solution to propulsion

shaft flange bolting problems, the PILGRIM Radial Fit Bolt can be used in
combination with PILGRIM Clamp Bolts which are fitted in a clearance condition
and provide an axial clamping force only on the shaft flanges. The full diameter
of the PILGRIM Radial Fit Bolt (Sleeve plus Bolt) is effective in transmitting
torque by shear force in the bolts. The total axial clamping force on the flange,
which is effective in transmitting thrust and bending loads and also in maintaining
the flange alignment, is the addition of the clamping force in the Radial Fit Bolts
and the Clamp Bolts.
The constructional details together with brief details of the Installation and
Removal procedure are illustrated overleaf.


SECTION 2HOLE PREPARATION
KEY ANCILLARY EQUIPMENT (not shown)

1. Radial Fit Bolt with tapered shank Hydraulic Head
2. Taper bored sleeve Tensioning Bridge
3. Extra long external thread Setting bridge
4. External thread Puller
5. Internal thread for oil injection adapter Oil Injection Adapter
6. Internal oilway Hydraulic Pump
7. Oil distribution grooves Hydraulic Link Pipe
8. Round nut with tommy bar holes
INSTALLATION PROCEDURE
Assemble the taper bored sleeve onto the tapered shank bolt and insert the assembly into the coupling
flange hole in the clearance condition. Using a hydraulic head to locate and position the tapered
sleeve, the bolt is pulled through the sleeve which expands to achieve a radial fit in the hole. The nuts
are then hand tightened and the same equipment is used to develop a clamping force on the flanges.
REMOVAL PROCEDURE
The bolt is initially detensioned and the nuts loosened but not removed. Oil is then injected between
the mating surfaces of the bolt and the sleeve via the internal oilway and distribution grooves to eject
the bolt from the sleeve. The nuts are removed and the assembly withdrawn from the coupling hole in
the clearance condition.


SECTION 2HOLE PREPARATION
2.1 INTRODUCTION
2.1.1 The Sleeves for Radial Fit Bolts are normally supplied 2.5mm (0.1") oversize
on nominal diameter to allow for their machining by customer to suit final,
measured, bored hole sizes.
At special request sleeves can be supplied finish machined to size with the correct
fitting allowance to suit:-
a) hole sizes supplied by customer
or b) holes bored by customer to H7 tolerances shown in the following table:-
Nominal Hole/ 30 - 50mm 50 - 80mm 80 - 120mm 120 – 180mm
Sleeve dia. (1.2-2.0") (2.0-3.15") (3.15-4.75") (4.75-7.09”)
Tolerance (H7) 0.025mm 0.03mm 0.035mm 0.04mm
(0.001") (0.0012") (0.0014") (0.0016”)
2.1.2 Where PILGRIM Radial Fit Bolts are to be fitted as a replacement for
conventional fitted bolts, removal of the fitted bolt may result in damage to the
machined surface of the hole or the bolt having to be bored out where it has
become seized during withdrawal. In either case, where the PILGRIM Radial
Fit Bolt is to be installed, the bolt holes have to be line bored and/or honed in
exactly the same way as for conventional bolts. Steps in the bore at the
interface between coupling halves must be avoided.
2.2. MACHINING SPECIFICATION FOR

BOLT HOLES AND SLEEVES
2.2.1 The surface of the holes must be smooth and free from score marks. Surface
finish must not exceed 1.6 micrometers (63 microinches). The diameter must be
circular, straight and parallel within the Form Tolerance stated in the table
below:-
Nominal Hole/ 30 - 50mm 50 - 80mm 80 - 120mm 120 – 180mm
Sleeve dia. (1.2-2.0") (2.0-3.15") (3.15-4.75") (4.75-7.09”)
Form 0.013mm 0.015mm 0.018mm 0.02mm
Tolerance (0.0005") (0.0006") (0.0007") (0.0008)
The hole diameter should be measured at 4 or 5 positions along the fitted length.
Measure two diameters 90 deg. apart at each position. All measurements should
be recorded and the minimum diameter taken as final hole diameter.
After boring, the holes must be identified, measured and the sizes recorded in
accordance with machine manufacturer's recommendations.


SECTION 2HOLE PREPARATION (cont'd)
2.2.2 Where the sleeves are supplied finished machined, the sleeves will have been
machined to give the correct clearance for fitting into the hole sizes given by the
customer or to suit H7 Tolerance holes. The clearance allowance is stated in the
Data Sheet.
2.2.3 Where the sleeves are supplied oversize for machining by customer to suit
measured hole sizes recorded in 2.2.1, the outside diameter has to be machined
by grinding or fine turning to the measured hole size minus the clearance
allowance stated in on the Data Sheet. The sleeve should be circular, straight and
parallel within the tolerance stated in the Table in Section 2.2.1. The surface
finish must not exceed 1.6 micrometers (63 microinches). To prevent
distortion of the sleeve during machining due to its thin wall, the sleeve should be
mounted on the mandrel, having a matching taper, supplied with the sleeves.
(See FIG 2.2.3)
It is recommended to aim for the maximum clearance stated when machining the sleeve.
2.3. BORING PROCEDURE:

2.3.1 The in-situ boring of flange holes is normally carried out after the shafts have
been lined up and flanges pulled together by slave or temporary bolts. A
minimum of four temporary bolts are recommended. The lining up, parallelism
and concentricity checks should be carried out in accordance with machine
or shaft manufacturer's instructions.
2.3.2 Two holes above the shaft centre line and approximately 90 deg. apart should be
bored through, measured and the Radial Fit Bolts installed using the procedure
detailed in Section 3 of this Manual. The shaft should be turned through 180
deg. and two further bolt holes bored, measured and Bolts installed. The shaft
should be turned through 90 deg. and the process of boring and installing the
Radial Fit Bolts repeated until all Bolts are fitted. The temporary bolts should
be removed one by one during this process.
2.3.3 Where PILGRIM Clamp (Clearance) Bolts are fitted the body of the Bolt should
have a small clearance in the hole in accordance with machine manufacturer's
recommendations in order to centralise the Bolt. It is important in high speed
applications to maintain coupling balance.
2.3.4 The end faces of the flanges under the Nuts should have a surface finish not
exceeding 3.2 micrometers (125 microinches) and be square to bore within
0.2mm (.008") Total Indicator Reading.
NOTE: The flange hole diameters must never be smaller than the machine manufacturer's
original nominal diameter. This situation may occur after the flange holes have
been bushed.


FIG. 2.2.3


SECTION 3 INSTALLATION PROCEDURE
3.1. PREPARATION
3.1.2. BOLT TENSIONING KIT
3.1.2.a A Storage Box is provided for all parts of the Bolt Tensioning Kit.
3.1.2.b Check that all parts of the Bolt Tensioning Kit are available. See copy of
Assembly Drawing included with this Manual for list of parts required and
identification - see Data Sheet for drawing number.
- Spare seals should always be available for the Hydraulic Heads prior to use
of the Bolt Tensioning kit.
3.1.2.c Clean all parts and examine for any apparent defects or damage which may have
occurred since last used. If any serious defects are present refer to Pilgrim
International Ltd for advice before attempting use.
3.1.2.d TECHNICAL DATA - BOLT TENSIONING KIT
Maximum Working Pressure (Design Pressure) given in Data Sheet is the

maximum system pressure and not necessarily the Operating Pressure.
Use the OPERATING PRESSURES stated in Data Sheet for setting of Sleeves
and tensioning the Bolts.
NOTE:
After use, all parts of the Bolt Tensioning Kit should be coated with rust
preventative and returned to the Storage Box. Stow the Storage Box in a secure,
dry location for future use.


SECTION 3INSTALLATION PROCEDURE (cont'd)
3.1. PREPARATION (cont'd)
3.1.3. RADIAL FIT BOLTS AND NUTS
3.1.3.a Clean off protective coating from Bolts, Taper Sleeves and Nuts. (See
Assembly Drawing included with this Manual for identification - the drawing
number is quoted on the Data Sheet ).
PLEASE NOTE: Bolts, Sleeves and Nuts are shipped assembled as a unit and marked with
corresponding numbers. Although components are interchangeable it is recommended this
grouping should be maintained after cleaning and installation. This may be important to
maintain weight tolerance of Bolts for balance purposes or where sleeves have been finished
machined prior to delivery.
3.1.3.b The tapered surfaces of the Bolts and the bore of the Sleeves should be cleaned
and degreased with Silkolene or similar evaporating solvent.
NOTE: Radial Fit Bolt Sleeves are designed to be assembled DRY - DO NOT lubricate
the tapered surfaces on the bolt or sleeve in any way.
3.1.3.c Assemble the Sleeve onto the Bolt by holding the Bolt vertically with the small
end of the taper uppermost. Hold the Sleeve with its end face level with the top
of the tapered section of the Bolt and allow the Sleeve to fall, under its own
weight, onto the Bolt. Check that the Sleeve is locked onto the Bolt by applying
hand force only to the Sleeve.
DO NOT APPLY ADDITIONAL FORCE TO THE SLEEVE SUCH AS

TAPPING WITH A HAMMER OR MALLET.
3.1.4 CLAMP BOLTS AND NUTS (IF SUPPLIED)
3.1.4.a Clean off protective coating from Bolts and Nuts. (See Assembly Drawing
included with this Manual for identification - the drawing number is quoted on
the Data Sheet ).
NOTE: Maintain grouping of coupling of Bolts and Nuts as stated in Section 3.1.3.a.


3.2 INSTALLATION OF PILGRIM RADIAL FIT BOLTS (cont'd)
IMPORTANT NOTES
A) LOAD RING RETRACTION
When fitting or removing the Hydraulic Head during the Installation and Dismantling
Procedures that follow, it is IMPORTANT that the Load Ring in the Hydraulic head is
fully retracted.
To retract the Load Ring, the Hydraulic Head should be screwed onto the Bolt with the
Hydraulic Hose connected and the pressure release valve on the pump ‘open’. The Load
Ring should be in contact with the Setting or Tensioning Bridge.
Turn the Hydraulic Head clockwise using the tommy bar supplied until the Load Ring is
fully retracted. This cannot be done with the Hydraulic Hose disconnected as the non-
return valve in the Quick Connect nipple will be closed. The Load Ring should always
be retracted before removing the Hydraulic Head at any stage during the following
procedures.
B) PUMP OPERATION
When releasing hydraulic pressure, always open the Release Valve on the Pump slowly
to avoid damage to the system.


RADIAL LOADING
3.2.1 Insert the Radial Fit Bolt, with Tapered Sleeve fitted, into the pre-bored hole in
the flange. The Sleeve diameter is smaller than the hole so that the Bolt can be
easily slid into position by hand. (See FIG. 3.2.1)
TINSTALLATION OF BOLT FIG. 3.2.1
To ensure that the Taper Sleeve is correctly positioned with respect to the split
line of the coupling - it is IMPORTANT to insert the Radial Fit Bolt in the
correct direction.


3.2.2 Position the Bolt assembly and insert the Setting Bridge into the hole, at the long
thread end of the Bolt, to locate against the Sleeve.
- Ensure that faces 'A' and 'B' are in contact
(See FIG. 3.2.2)
SETTING OF SLEEVE FIG. 3.2.2


3.2.3 Screw the Hydraulic Head onto the Bolt until it is nipped tight against the
Setting Bridge.
3.2.4 Apply the Sleeve Setting Pressure (see Data Sheet) to the Hydraulic
Head to pull the Bolt into the Tapered Sleeve. This expands the sleeve to
take up clearance and creates a controlled interference fit.
- See FIG. 3.2.2 and Data Sheet. For location and identification of parts see
Bolt Tensioning Kit Assembly drawing, Section A, Sheet 1. (See Data
Sheet).
3.2.5 Release the hydraulic pressure.

- Because the tapers in the Sleeve and on the Bolt are self-locking, the
interference fit will be maintained when the hydraulic pressure is released.
3.2.6 Remove the Hydraulic Head and Setting Bridge.
AXIAL LOADING
3.2.7 Fit the Round Nuts to each end of the Bolt and hand-tighten.
- Maintain grouping of Bolts with individual nuts
Fit the Tensioning Bridge, followed by the Hydraulic Head, at the long thread end
of the Bolt.
IMPORTANT
WHERE THE TENSIONING BRIDGE HAS MACHINED SURFACE TO AVOID

CONTACT WITH THE SHAFT RADIUS ENSURE THAT THE BRIDGE IS
CORRECTLY POSITIONED TO LINE UP THE CHAMFER & RADIUS. See fig 3.2.3


3.2.8 Apply the Bolt Tensioning Pressure (see Data Sheet) to the Hydraulic
Head. This stretches the Bolt allowing the Round Nut to be tightened against the
flange face by turning the Nut itself using the tommy bar supplied.
3.2.9 Release the hydraulic pressure; the Bolt will retain the axial clamp load.
- See Data Sheet - For location and identification of parts see Bolt Tensioning
Kit Assembly Drawing, Section B, Sheet 1. (See Data Sheet).
TENSIONING OF BOLT FIG. 3.2.3
3.2.10 Re-apply the Bolt Tensioning Pressure as in 3.2.8 and re-tighten the Nut
against the flange face.
- This is important as it will ensure that the maximum load is retained in the
Bolt.
3.2.11 Release the hydraulic pressure.


3.2.12 Remove the Hydraulic Head, Tensioning Bridge. Fit the thread protectors
(when supplied) over the extended threads at each end of the Bolt.
The Radial Fit bolt is now installed and tensioned.
PROCEDURE STEPS 3.2.1 to 3.2.12 ARE REPEATED FOR EACH RADIAL

FIT BOLT IN THE FLANGE.
It is a good idea to mark the Bolt or Coupling after each Bolt Sleeve is expanded and each Bolt is
tensioned. This will help to avoid any stage of the installation being missed.
3.2.13 IMPORTANT NOTE

It is well recognised that when loading a series of bolts individually or in pairs
the bolts which are loaded earlier in the series can lose some of their original load
as the subsequent bolts are loaded. This loss is caused by movement and
compression in the whole assembly as the combined bolt load increases. It is
therefore necessary to repeat the tensioning operation for all the bolts for a
second time to guarantee a maximum and uniform load throughout all the bolts.


3.3 INSTALLATION OF PILGRIM CLAMP BOLTS (IF SUPPLIED)
3.3.1 Insert the Clamp Bolt into the hole in the flange and fit Round Nuts at each end.
Ensure that the Bolt is inserted in the correct direction as shown on Assembly
Drawing (see Data Sheet for Assembly Drawing Number).
- Maintain grouping of Nuts with individual bolts.
3.3.2 Adjust the position of the Round Nuts so that the Bolt projects the correct
amount at on each side of the coupling, as shown on Assembly drawing referred
to in the Data Sheet. See also FIG. 3.3.1
3.3.3 Fit the Tensioning Bridge, followed by the Hydraulic Head, at the long thread
end of the Bolt. Apply the Bolt Tensioning Pressure (see Data Sheet).
This stretches the Bolt allowing the Round Nut to be tightened against the flange
face by turning the Nut using the tommy bar supplied.
3.3.4 Release the hydraulic pressure, retaining an axial clamp load in the Bolt. (See
FIG. 3.3.1. For location and identification of parts see Bolt Tensioning Kit
Assembly Drawing Section B, Sheet 1. See Data Sheet, - for Drawing
Number).



3.3 INSTALLATION OF PILGRIM CLAMP BOLTS (IF SUPPLIED)
(cont'd)
TENSIONING OF CLAMP BOLT FIG. 3.3.1
3.3.5 Re-apply the Bolt Tensioning Pressure as in 3.3.4 and re-tighten the Nut against
the flange face. This is important as it will ensure that the maximum load is
retained in the Bolt. Release the hydraulic pressure.
3.3.6 Remove the Hydraulic Head and Tensioning Bridge, and fit thread protectors
(when supplied) over the extended thread. The Clamp Bolt is now installed and
tensioned.
PROCEDURE STEPS 3.3.1 to 3.3.6 ARE REPEATED FOR EACH CLAMP
BOLT IN THE FLANGE.
It is a good idea to mark the Bolt or Coupling after each Bolt Sleeve is expanded and each Bolt is
tensioned. This will help to avoid any stage of the installation being missed.
3.3.7 IMPORTANT NOTE
It is well recognised that when loading a series of bolts individually or in pairs

the bolts which are loaded earlier in the series can lose some of their original load
as the subsequent bolts are loaded. This loss is caused by movement and
compression in the whole assembly as the combined bolt load increases. It is
therefore necessary to repeat the tensioning operation for all the bolts for a
second time to guarantee a maximum and uniform load throughout all the bolts.


SECTION 4DISMANTLING PROCEDURE
4.1 REMOVAL OF PILGRIM RADIAL FIT BOLTS
4.1.1 Remove the Thread Protectors from each end of the Bolt. Fit the Tensioning
Bridge and Hydraulic Head at the long thread end of the Bolt. A pressure
similar to the Tensioning Pressure (see Data Sheet ) is applied until the Round
Nut becomes loose - back-off the Round Nut two turns.
DO NOT REMOVE NUT FROM BOLT.
See FIG. 4.1.1
During the de-tensioning stage the Hydraulic Head should be backed off from the Tensioning
Bridge by quarter of a turn before pressurisation to avoid locking up as the bolt retracts to its
original length.
WARNING:
IF THE NUTS ARE REMOVED DURING THE OIL INJECTION PROCESS,
THE BOLT CAN BE EJECTED FROM THE HOLE WITH ENOUGH
VELOCITY TO CAUSE INJURY OR DAMAGE.
DE-TENSIONING OF BOLT FIG. 4.1.1
4.1.2 Remove Hydraulic Head and Tensioning Bridge. See FIG. 4.1.1 and Data
Sheet. For location and identification of parts see Bolt Tensioning Kit
Assembly Drawing - Section B.


4.1 REMOVAL OF PILGRIM RADIAL FIT BOLTS (cont'd)
4.1.3 The oil injection adapter is connected to the small internal thread in the Bolt and
pressure applied via internal oil ports to the interface between the Bolt and
Tapered Sleeve. As the pressure increases the sleeve releases from the taper on
the Bolt and reduces in diameter, thus relieving the interference fit. The
pressure required to release the Sleeve is stated on the Data Sheet. DO NOT
exceed the maximum pressure stated.
NOTE: It is important that the correct grade of oil is used for this operation to
avoid leakage - see Section 5.1.1.
See FIG. 4.1.3 and Data Sheet. For location and identification of parts see
Bolt Tensioning Kit Assembly Drawing - Section C.
RELEASING OF BOLT USING OIL INJECTION METHOD FIG. 4.1.3


4.1 REMOVAL OF PILGRIM RADIAL FIT BOLTS (cont'd)
4.1.4 If the Sleeve will not release at the maximum Sleeve Release Pressure stated in
the data Sheet, the following alternative procedure should be used.
4.1.5 Remove the Nut at the short thread end of the Bolt using procedure in Section
4.1.1. Only apply pressure to the Hydraulic Head until the Nut becomes loose.
- the pressure required should not be more than 350 bar (5075 psi).
4.1.6 Fit the Removal Bridge and Hydraulic Head at the end opposite to oil injection
adapter. Apply pressure to the Hydraulic Head to pull the Bolt out of Sleeve
which will reduce in diameter allowing the Bolt and Sleeve to be removed from
the hole. A pressure approximately equal to the Sleeve Setting Pressure will be
required. SEE FIG. 4.1.6
RELEASING OF BOLT USING HYDRAULIC HEAD METHOD FIG. 4.1.6
4.1.7 The Round Nut at the oil injection end can now be removed and the Radial Fit
Bolt and Sleeve withdrawn from the flange.
NOTE: To preserve coupling balance, when dismantling be sure to re-assemble the Bolt,
Sleeve and Nuts associated with each bolt hole as a group.
PROCEDURE STEPS 4.1.1 to 4.1.7 ARE REPEATED FOR EACH BOLT IN THE FLANGE


SECTION 4DISMANTLING PROCEDURE (cont'd)
4.2 DISMANTLING OF PILGRIM CLAMP BOLTS
4.2.1 Remove the Thread Protectors from each end of the Bolt. Fit the Tensioning
Bridge and the Hydraulic Head at the long thread end of the Bolt. A pressure
similar to the Tensioning Pressure - (see Data Sheet) is applied. The nut
inside the Tensioning Bridge is backed-off two turns and the Bolt
Tensioning Kit removed.
See FIG. 3.3.1
During the de-tensioning stage the Hydraulic Head should be backed off from the Tensioning
Bridge by quarter of a turn before pressurisation to avoid locking up as the bolt retracts to its
original length.
4.2.2 Remove the Nuts from the Bolt and remove the Bolt from the flange.
NOTE: To preserve coupling balance, when dismantling be sure to re-assemble the Bolt,
Sleeve and Nuts associated with each bolt hole as a group.
PROCEDURE STEPS 4.2.1 to 4.2.2 ARE REPEATED FOR EACH BOLT IN THE FLANGE


SECTION 5HYDRAULIC PUMP AND HARNESS
5.1 INTRODUCTION
5.1.1 The Hydraulic Pump and Harness assemblies, when supplied, are complete and
ready for use. Final connections between Pump and Hydraulic Head are made
by simple quick release nipples and couplings.
Maximum Safe Working Pressure of flexible hose (4-ply -Blue - Type 5/4),
quick release nipples and couplings is 1500 Bar (21,750 psi).
NOTE: It is important for efficient operation of the PILGRIM Radial Fit Bolts
that the correct grade of hydraulic oil is used.
The Hydraulic Pump should be filled with a premium grade hydraulic oil having
an ISO Viscosity grade number ISO VG 32 having Kinematic Viscosity limits at
40 deg.C of 28.8 cSt minimum to 35.2 cSt maximum.
Typical grades are: Shell Tellus V25
Esso Nuto HP32
5.2 SETTING AND TENSIONING BOLTS
5.2.1 The pressurisation of the Hydraulic Heads can be achieved in two alternative
ways:-
1) Shown in FIG. 5.1.2. This illustrates the pump and harness set-up for the
setting and tensioning of a single Radial Fit Bolt.
2) Shown in FIG. 5.1.3. This illustrates the pump and harness set-up for the
setting and tensioning of two Radial Fit Bolts simultaneously.
NOTE: (2) can only be used when 2 Hydraulic Heads and a connector hose is supplied.
5.3 RELEASING BOLTS

5.3.1 During the dismantling of the Bolts, each bolt is released individually. This is
illustrated in FIG. 5.3.1 and FIG. 5.3.2 for both oil injection releasing and for
Hydraulic Head releasing.
DO NOT ATTEMPT TO RELEASE TWO BOLTS SIMULTANEOUSLY
5.4. SAFETY NOTES

5.4.1 It is important that all personnel working with the hydraulic equipment should
adhere to the Safety Notes covered in Section 7.
Under no circumstances must a quick release nipple be pressurised when it is
disconnected.


SECTION 5HYDRAULIC PUMP AND HARNESS (cont'd)
FIG. 5.1.2
FIG. 5.1.3


SECTION 5HYDRAULIC PUMP AND HARNESS (cont'd)
FIG. 5.3.1
FIG. 5.3.2


SECTION 6RECOGNISING FAULTS AND PARTS REPLACEMENT
6.1 FAULT: Failure to build-up pressure required

6.1.1. Check that pump oil reservoir is full.
6.1.2 Check air supply if air operated pump is being used.
6.1.3 Check all connections visually for leaking oil. Tighten any joint thought to be
suspect.
6.1.4 Weeping at the conical joints (used on the Air Operated Pumps) evidenced by
visual presence of oil, are sealed by increasing slightly the tightness of the
adaptors..
CAUTION:
Do not overtighten the adaptors. It is sufficient to tighten a little at a time
until the joint no longer leaks. If the leak persists, the adaptor should be
replaced.
6.1.5 If oil emerges from around the Load Ring in the Hydraulic Head, the nitrile seal
requires attention (See 6.6).
6.1.6 If oil leaks from around the quick release nipples on the Hydraulic Head or
Hydraulic Hoses, the bonded (Dowty) seals should be replaced.
DO NOT RE-USE THESE SEALS.
6.2 FAULT: Failure of gauge to register pressure

6.2.1 When the pump initially begins to deliver oil to the Hydraulic Head, it does so
against no resistance, other than a very small amount due to the friction of the
circuit, pipes, etc. The pump will therefore reciprocate rapidly until the
pressure build-up is sufficient to slow down the pumping action, at which point
the pressure should begin to register on the gauge and increase steadily until the
operating pressure is reached.
6.2.2 If the pumping action slows down, with no pressure showing on the gauge, the
pump must be stopped immediately and the release valve opened to vent any
pressure back to the oil supply tank.
6.2.3 Close the release valve and remove the gauge.
6.2.4 Start the pump, if oil exudes from the top of the gauge connection pipe, the
gauge is faulty and must be renewed.
IT IS IMPORTANT TO DO THIS. THE WHOLE OPERATION OF INSTALLING A

RADIAL FIT BOLT DEPENDS UPON THE CORRECT STRETCHING FORCE
BEING APPLIED AND THE PRESSURE GAUGE IS THE ONLY MEANS OF
MEASURING THIS FORCE.



(cont'd)
6.3 FAULT: Pump Failure
6.3.1 Should the pump fail to operate it should not be tampered with; it must be
returned to store for replacement/refurbishment.
6.4 FAULT: Difficulty with Bolt Assembly

WARNING:
UNDER NO CIRCUMSTANCES MUST THE BOLTS BE FORCED INTO HOLES BY
USING HAMMER BLOWS. THIS PRACTICE WILL RESULT IN DAMAGE TO THE
BOLT AND THE FLANGE HOLE SURFACE.
6.4.1 Ensure that the machined parts (e.g. coupling flanges) are correctly aligned and
that the bore is a continuous parallel diameter throughout the flanges.
6.4.2 If the Bolt will not enter the flange hole:-
6.4.3 Check that the Bolt and the hole markings are the same, to ensure that the
correct Bolt is being fitted in its hole.
6.4.4 Re-check the flange holes and compare with the previously recorded values.
Ensure that the edges of the holes are free from burrs.
6.4.5 Check the flange hole diameter and the sleeve diameter as follows:-
i) Carefully measure the hole diameter along its full length. Measure two
diameters at 90 deg. apart at each position, check for any out of roundness or
parallelism.
If the hole is smaller than that measured and recorded in Section 2.2, the
records should be revised with the new measurement. The sleeve must then
be re-machined to the new hole measurement minus the clearance allowance
stated in the Data Sheet.
It is important that the flange hole diameters must never be smaller than the
machine manufacturer's original nominal diameter.
ii) If, when measured, the hole diameter is correct with that recorded in Section
2.2 carry onto (iii) below.
iii) Remove sleeve from Bolt and carefully measure the outside diameter along its
full length. Measure two diameters at 90 deg. apart at each position. Check
for any out of roundness.
If the sleeve is larger than the measured hole minus the clearance allowance
specified in Data Sheet, re-machine the sleeve outside diameter using taper
mandrel (see 6.6).



(cont'd)
6.4 (cont'd)
6.4.6 If the Bolt enters the flange hole but has excessive clearance then:-
6.4.7 Check that the Bolt and hole markings are the same, to ensure that the correct
Bolt is being fitted in its hole.
6.4.8 Check the flange bolt hole diameter and sleeve diameter as in 6.4.5 (i) and (ii).
Check that the hole diameters are as previously recorded in Section 2.2. If the
sleeve outside diameter is less than required, new sleeves of the correct diameter
must be fitted.
DO NOT fit undersize Sleeves.
6.5 FAULT: Difficulty with Bolt Removal using Oil Injection Method
6.5.1 If oil leaks from either end of Sleeve when attempting to release Sleeve as stated
in Section 4.1.5, check that correct grade of hydraulic oil is being used - See
Section 5.1.1.
If the correct grade of oil is being used and oil leaks occur or Sleeves fail to
release at specified pressures, the alternative method recommended in Section
4.1.4 to 4.1.7 should be used.
6.6 PARTS REPLACEMENT

6.6.1 Hydraulic Head Seal replacement - proceed as follows:-
6.6.2 NOTE: It is important that spare nitrile seals are not removed from their
packing until required. They should be stored at a temperature between 10
deg.C and 40 deg. C in an ozone free environment. Spare seals, when unpacked,
must not be exposed for long periods to fluorescent light. In the event of seal failure the
following procedure should be observed.
6.6.3 With the Hydraulic Head removed from the Bolt, apply low hydraulic pressure
to expel Load Ring and Seal from the body. See Bolt Tensioning Kit Assembly
Drawing in Data Sheet for identification of parts.
6.6.5 Remove old seal and discard. Thoroughly clean the annular chamber in the
Body and the Load Ring.


(cont'd)
6.6 PARTS REPLACEMENT - Hydraulic Head Seal (cont'd)
6.6.5 In general there are two types of seals used in the Hydraulic Head.
1) A loose low profile seal which sits on top of the Load Ring.
2) A captive inner and outer seal which fit into grooves in the side of the Load
Ring
6.6.6 Re-assembly of Hydraulic Head and Seal. Apply a thin coating of grease to new
seals and the chamber during re-assembly.
1) With low profile seal. Carefully insert the Seal with its lips pointing into the
chamber. Insert the Load Ring, with recessed face towards Seal and carefully
push into Body chamber
2) With Inner and Outer Seal. Mount the inner and outer seals onto the Load
Ring. Insert the Load Ring with the seals facing the body chamber
Apply even pressure all round to ensure that Load Ring enters squarely to avoid
jamming. Press the Load Ring in until fully engaged. (This is applicable to 1 & 2
above).
6.7 MACHINING TAPERED SLEEVE
6.7.1 If it is found necessary to re-machine the Sleeve outside diameter or if the

Sleeves have been supplied oversize for finishing to suit individual hole sizes,
the Sleeves must be fitted onto a mandrel which has a taper corresponding to
Bolt taper to avoid permanent distortion of the Sleeve during this operation.
6.7.2 A tapered mandrel supplied by Pilgrim International Ltd should be used to

ensure that the necessary accuracy is achieved.
6.7.3 Full details of hole preparation and Tapered Sleeve machining are given in
Section 1.
6.8 ORDERING SPARE PARTS
When ordering any spare parts for Radial Fit Bolts, Clamp Bolts or for the
Hydraulic Tensioning Equipment, quote the identification numbers etched on the
parts. Also quote the Serial numbers and our company's Order reference which
appear on the Data Sheet provided with the Manual.


SECTION 7SAFETY NOTES
7.1 High pressure hydraulic equipment can be dangerous if misused. Keep away
from oil leakages at high pressure. Jets of liquid escaping from high pressure
equipment have sufficient power to penetrate the skin, which will often cause
blood poisoning. In the case of such an accident, HOWEVER
SUPERFICIAL, IMMEDIATE medical attention MUST be sought.
7.2 Operation of this equipment must not be undertaken by lone workers. There
must be no lone workers operating outside normal working hours.
7.3 Eye goggles must be worn when operating this equipment.
7.4 Gloves and suitable footwear must be worn when operating this equipment.
7.5 Hydraulic oils can produce skin complaints, therefore the following precautions
must be taken:-
7.5.1 Many mineral oils are carcinogenic on prolonged contact with skin. They
should therefore be washed off the skin as soon as possible after contamination.
Barrier creams are some help in reducing skin contamination, but do not place
undue reliance on them.
7.5.2 Change out of protective clothing or items of normal clothing that have become
contaminated with oil. NEVER keep oily rags in overall pockets.
7.5.3 Avoid inhaling oil mist into the lungs.
7.6 EATING, DRINKING AND SMOKING are forbidden in the working area.


SECTION 7SAFETY NOTES (cont'd)
7.7 Certain basic rules for lifting and handling apply which are well known but
which will be reiterated.
7.7.1 NEVER stand or put fingers under a slung load
7.7.2 ALWAYS use properly rated lifting equipment, slings, shackles, etc.
7.7.3 NEVER exceed ratings of slings, hoists or other lifting gear.
7.7.4 ALWAYS STOP, look and listen if anything strikes you as unusual.
7.8. WASTE DISPOSAL:

7.8.1 The legal regulations covering the disposal of liquid and solid waste must be
adhered to by all personnel.
7.8.2 Liquid spillages must be collected immediately in an absorbent material held

ready for the purpose. Provision must be made for the safe disposal of used
absorbent.
7.8.3 Contaminated absorbent, particularly that with oil, must be stored only in metal
bins with lids whilst awaiting collection.
7.9 Under NO circumstances must oxygen be used in the equipment covered by this
Manual. Air at a pressure of 120 lbs. per sq. inch (8.2 Bar) maximum is the
usual method of operating the MORPRESS Pack; however Nitrogen, Carbon
Dioxide, Helium or any other inert gas may be utilised if air is not available.
7.10 HIGH PRESSURE PIPEWORK:

7.10.1 Steel piping should not be bent to less than six times the pipe outside diameter.
No kinked bends must ever be used.
7.10.2 Flexible hoses, other than those supplied by Pilgrim International Ltd must never
be utilised without the prior approval of Pilgrim International Ltd..
DO NOT bend Type 5/4 Blue flexible hoses to less than 150mm (6") radius.
7.10.3 Tubing should be checked periodically for accidental (external) damage.


SECTION 7SAFETY NOTES (cont'd)
7.10.4 No heating of the tubing must be allowed, e.g. for the attachment of clamps or
shields by brazing, or to facilitate bending.
7.11 Modification of the equipment covered by this Manual should never be carried
out by the customer, without consultation with the supplier, and without
written approval of the modification(s) proposed.
7.12 FIRE PROCEDURE:
7.12.1 Fire may lead to leakage from or failure of, equipment such as that covered by
this Manual. Whilst the hydraulic mineral oils used in this product are not
inflammable under normal conditions: when leakage occurs it can atomise, or
when heated it can vaporise, and in both circumstances become highly
inflammable.
7.12.2 In these forms, therefore, a fire can be fed and may lead to it becoming of much
greater intensity; in these circumstances therefore the following precautions
should be taken:-
a) If possible the hydraulic pressure should be relieved back to tank
b) The air pressure should be turned off and vented
c) Further, after the fire, any equipment that has been involved must be replaced,
since invisible damage may have been caused to the metallurgical structure of
the components.
7.13 Use only new or clean hydraulic oils, when replenishing the MORPRESS Pack
tank.

OUR ORDER REF: 4605 PILGRIM
INTERNATIONAL LTD
CUSTOMER : D.S.M.E – Hull Nos. 4163 Southlink

Oldham, U.K.
OL4 1DE
Telephone : +44 161 785 7700

Facsimile : +44 161 785 7777
SERVICE MANUAL
This manual is supplied for use with:-
HIGH PRESSURE HAND PUMP
MODEL
1600 BAR
Serial No. 4605/01
CONTENTS: Section 1 OPERATION

Section 2 BLEEDING
Section 3 DIS-ASSEMBLY AND ASSEMBLY
Section 4 TROUBLE SHOOTING & REMEDIES ON
DEFECTIVE PUMPS
Section 5 SPARES LIST
MANUAL REF: PIL/HP16&24/NIK2172/MNW/04

SERVICE MANUAL

MODEL 1600 BAR & 2400 BAR
SECTION 1 OPERATION
When the pump handle is raised, the low pressure piston is withdrawn. The
stationary high pressure piston, mounted in the valve body, is simultaneously
withdrawn from the hollow low pressure piston. The vacuum that is then
created both in the low pressure piston's pump bore and inside the piston,
causes oil to be sucked from the oil container via a passage, past the two intake
balls and into the void created.
When the pump handle is lowered, the pump pistons are pushed into each
other, the intake balls close and the oil from both the high and the low pressure
piston is forced past the discharge ball and out through the discharge
connection.
When the load on the pump increases, a valve opens a passage between the low
pressure pump piston's pump bore and the oil container. The low pressure
function is disengaged. Only the high pressure piston now operates.
The safety valve opens a passage between the high pressure piston and the oil
container when the load becomes excessive.
When the release screw is turned anti-clockwise, a passage is opened between

the discharge connection and the oil container.
2
SERVICE MANUAL

SECTION 2 BLEEDING
After dis-assembly, hose replacement or filling with oil, the pump sometimes
needs to be bled in order to function satisfactorily.
If the pump is equipped with a quick disconnect coupling in the discharge

connection, loosen it while pumping slowly. Allow the oil to run out. Tighten
the quick disconnect coupling before the pump handle reaches the bottom.
3
SERVICE MANUAL

SECTION 3 DIS-ASSEMBLY AND ASSEMBLY
PILGRIM hand pumps are easy to dis-assemble and require no special tools,
but the following sequence is recommended:-
IMPORTANT:
Make sure that all parts are well cleaned and be careful not to damage
the seals.
Oil the moving parts and seals for easier assembly.

Always use genuine PILGRIM Spare Parts.
TO ASSEMBLE THE PUMP:-

Assemble the components in the reverse order to the dis- assembly as described
below.
TO DIS-ASSEMBLE THE PUMP:-

Drain the oil. Remove the pump handle and the lifting arm. Remove the front
housing and then remove the pump cylinder with the pump pistons. Unscrew
the high pressure piston from the back of the low pressure piston.
Unscrew the bolt in the endplate. Remove the oil container tube.
NOTE:
The high pressure pump piston is retained with locking fluid so that it
will not come loose. On assembly, new locking fluid must be applied to
the threads before the piston is screwed in. Use LOCTITE No.542 or
its equivalent.
4
SERVICE MANUAL

SECTION 4 TROUBLE SHOOTING & REMEDIES

ON DEFECTIVE PUMPS
4.1. FAULT: NO HEAD or POOR HEAD
4.1.1 Discharge or intake balls do not seal tightly:-

Dis-assemble the pump so that the balls are accessible. Minor damage to the
ball seat can be remedied by tapping the ball home with a light hammer blow.
IMPORTANT:
Use a drift made of soft material that will not damage the ball.
4.1.2 Impurities in the oil:-

Dis-assemble and clean the pump - See Section 3.
4.1.3 Safety valve incorrectly adjusted:-

Adjust the safety valve (see care and maintenance instructions)
4.1.4 Release screw damaged or not tightened:-

Check that the release screw is tight. If the release screw is damaged,
replace it.
4.1.5 Too little oil in the pump:-

Add oil through filler plug on top of the oil cylinder.
4.1.6 Air in the pump:-

Bleed the pump - See Section 2.
5
SERVICE MANUAL

SECTION 4 TROUBLE SHOOTING & REMEDIES

ON DEFECTIVE PUMPS (cont'd)
4.1. FAULT: NO HEAD or POOR HEAD (cont'd)
4.1.7 Damaged packing:-

Check for visible oil leakage during pumping. If no leakage can be seen,
remove and check the packings in the valve body and on the pump pistons.
4.2. PUMP LEAKING OIL
Clean the pump. Locate any visible leakage.
Check the following:-
- that all screws are securely tightened
- that the seals are intact
- that the sealing surfaces on the seals are undamaged
- for any damage, such as cracks, deformation or dirt
6
SERVICE MANUAL

SECTION 5 SPARES LIST
SPARE PARTS LIST FOR DRAWING K8700

REF. 1600 BAR 2400 BAR
NO. DESCRIPTION PART NO. QTY. PART NO. QTY.
1 Handle 602113 1 602113 1

2 Grip 602114 1 602114 1
3 Track ring 601648 4 601648 4
4 Axle 602075 2 602075 2
5 Gauge 602174 1 602137 1
6 Screw 602072 3 602072 3
7 O-ring * 1 * 1
8 Spring * 1 * 1
9 Ball * 1 * 1
11 Ball * 1 * 1
13 Ball * 1 * 1
14 Plug 602077 2 602077 2
15 Packing * 3 * 3
16 Washer * 1 * 1
17 Piston 602079 1 602126 1
18 O-ring * 1 * 1
19 Support ring * 1 * 1
20 Wiper * 1 * 1
21 O-ring * 1 * 1
22 Piston 602080 1 602127 1
23 Housing 602081 1 602128 1
24 O-ring * 1 * 1
25 Piston 602082 1 602129 1
26 Spring * 1 * 1
27 Packing * 1 * 1
28 Plug 602083 1 602130 1
29 Screw 602084 1 602084 1
30 O-ring * 1 * 1
31 Release screw 602085 1 602131 1
32 Hand wheel 602102 1 602102 1
33 Screw 602103 1 602103 1
34 Ball * 1 * 1
35 Plug 602086 1 602132 1
36 Relief valve 602090 1 602133 1
37 Suction pipe 602091 1 602091 1
38 Filter 602092 1 602092 1
39 O-ring * 1 * 1
40 Mesh 602073 1 602151 1
41 Coupling 601020 1 601021 1
• indicates Overhaul Kit Parts
7
SERVICE MANUAL

SECTION 5 SPARES LIST (cont’d)
SPARE PARTS LIST FOR DRAWING K8700
REF. 1600 BAR 2400 BAR

NO. DESCRIPTION PART NO. QTY. PART NO. QTY.
42 Ball * 1 * 1
43 Rod 602094 1 602094 1
44 Oil tank 602134 1 602134 1
45 Plug 601341 1 601341 1
46 Packing 16621 1 16621 1
47 Adapter 601583 1 602135 1
48 Packing * 1
49 Yoke 602107 1 602107 1
50 Packing * 1 * 1
51 Nut 602096 1 602096 1
52 Bolt 601004 2 601004 2
53 Foot 602153 1 602153 1
Overhaul kit 602097 1 602138 1
* indicates Overhaul Kit Parts
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Material Specification 817M40
Pilgrim Radial Fit Bolts
The standard material used to manufacture all components of the Radial Fit Bolt is to a British
Standard BS970. The specification used is 817M40. The raw material is purchased in black
bar form in the hardened and tempered condition. Unless there is a specific design or
application requirement the material is used in the ‘T’ condition.
Chemical Composition %
Specification C Si Mn P
817M40 0.36 to 0.44 0.10 to 0.40 0.45 to 0.70 0.035 max
S Cr Mo Ni
0.040 max 1.00 to 1.40 0.20 to 0.35 1.30 to 1.70
Mechanical Properties
Specification Ruling Section UTS Rm Yield Re Elongation A
817M40 ‘T’ mm N/mm² N/mm² % (5.65 S o )
> 63 ≤ 150 850 to 1000 680 min 13 min
Impact/Izod Impact/Charpy Proof R p 0.2 Hardness

J J N/mm² HB
54 min 50 min 665 min 248 to 302
The above data has been extracted from BS970 : Part 3 : 1991.
Although the minimum yield strength listed in the above Mechanical Properties table is 680
N/mm² it is often the case that the figure is much higher. When a greater value is required for
a design or application then a specific cast of material can be identified with the necessary
properties.
International Comparisons:
W.-Nr: 1.6582 DIN: 34CrNiMo6 AISI/SAE/ASTM: 4340 JIS: SNCM 447
Pilgrim Radial Fit Bolts can also be manufactured from other materials if specific
requirements dictate that the above material is not suitable. Eg. Higher strength alloy steels,
Stainless steel, Nickel Aluminium Bronze etc.
26/01/06

Final Drawings/Manual S: Pitgrim

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I PITGRIM

Shipyard: DaewooShipbuilding& MarineEng.Co.Ltd.

Vendor: Pilgrim International

Bolt Tensionns Kit - CouplingI,2 & 3 (2 sheets) I K7247 0 5

Instruction Manuals Enc Total Sent

RadialFit Bolt inc. Tool List / Mandreldetails/ Handpumpdetails I 5

OUR ORDER REF: 4605 PILGRIM

Telephone : +44 161 785 7700

DATA SHEET FOR

PILGRIM RADIAL FIT BOLTS

PILGRIM CLAMP BOLTS

BOLT TENSIONING KIT

1. HIGH PRESSURE HYDRAULIC EQUIPMENT CAN BE DANGEROUS IF MISUSED - KEEP AWAY

IT IS ESSENTIAL THAT ALL PERSONS INVOLVED WITH EQUIPMENT COVERED BY THIS

IF IN DOUBT, CONSULT: Pilgrim International Ltd.

MANUAL REF: RFBDTA/MNW/05

INSTALLATION OF PILGRIM RADIAL FIT BOLTS

Load at Max.Working KN 4230 2076

Max. Load Ring Extension mm l0 8

PLEASENOTE - THE ABOVE ARE NOT OPERATINGPRESSURES

SleeveRelease Pressure Bar I 500 I 500

SleeveReleasePressure Bar 390 440

PILGRIM CLAMP BOLTS

MANUAL REF: RFBDTANV{NWOS

PILGRIM RADIAL FIT BOLTS

Telephone : +44 161 785 7700

1. HIGH PRESSURE HYDRAULIC EQUIPMENT CAN BE DANGEROUS IF MISUSED - KEEP

2. THIS MANUAL GIVES INSTRUCTIONS FOR OPERATING PILGRIM RADIAL FIT

IT IS ESSENTIAL THAT ALL PERSONS INVOLVED WITH EQUIPMENT COVERED BY

IF IN DOUBT, CONSULT: Pilgrim International Ltd.

MANUAL REF: RFBEXT/MNW/05 1

PILGRIM RADIAL FIT BOLTS

SECTION 2 HOLE PREPARATION

SECTION 3 INSTALLATION PROCEDURE

SECTION 4 DISMANTLING PROCEDURE

SECTION 5 HYDRAULIC PUMP AND HARNESS

SECTION 6 RECOGNISING FAULTS AND

SECTION 7 SAFETY NOTES

MANUAL REF: RFBEXT/MNW/05 2

PILGRIM RADIAL FIT BOLTS

This manual is intended to give a step-by-step guide to the installation and

1.2 CONSTRUCTION AND USE

In a typical example, in order to produce a cost effective solution to propulsion

MANUAL REF: RFBEXT/MNW/05 3

PILGRIM RADIAL FIT BOLTS

SECTION 2HOLE PREPARATION

KEY ANCILLARY EQUIPMENT (not shown)

MANUAL REF: RFBEXT/MNW/05 4

PILGRIM RADIAL FIT BOLTS

SECTION 2HOLE PREPARATION

2.2. MACHINING SPECIFICATION FOR

MANUAL REF: RFBEXT/MNW/05 5

PILGRIM RADIAL FIT BOLTS

2.3. BORING PROCEDURE:

MANUAL REF: RFBEXT/MNW/05 6

PILGRIM RADIAL FIT BOLTS

MANUAL REF: RFBEXT/MNW/05 7

PILGRIM RADIAL FIT BOLTS

SECTION 3 INSTALLATION PROCEDURE

3.1.2. BOLT TENSIONING KIT

3.1.2.d TECHNICAL DATA - BOLT TENSIONING KIT

Maximum Working Pressure (Design Pressure) given in Data Sheet is the

MANUAL REF: RFBEXT/MNW/05 8