Instruction Sheet

CAT 3600 Cylinder Head Tensioner - LVDT

Enerpac Part No: 3600CHT900-1

L4293 Rev. A 05/18

1.0 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.

2.0 SAFETY

2.1 General Hydraulic Safety Precautions

Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury
or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting
from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact
Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on high-pressure hydraulic
safety, consult your distribution or service centre for a free Enerpac Hydraulic safety course.

Failure to comply with the following cautions and warnings could cause equipment damage and personal injury.

Is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or
destruction of equipment or other property.

Indicates a potential danger that requires correct procedures or practices to avoid personal injury.

Is only used when your action or lack of action may cause serious injury or even death.

Is used to indicate information considered important, but not hazard related (e.g. messages relation to
property damage).

Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If
oil is injected under the skin, see a doctor immediately.

Wear proper personal protective gear when operating hydraulic equipment.

Never set the relief valve to a higher pressure than the maximum rated pressure of the tensioner. Higher
settings may result in equipment damage and/or personal injury.
The system operating pressure must not exceed the pressure rating of the lowest rated component in the
system. Install pressure gauges in the system to monitor operating pressure. It is your window to what is
happening in the system.

Do not drop heavy objects on hose. A sharp impact may cause internal damage to hose wire strands. Applying
pressure to a damaged hose may cause it to rupture.

Immediately replace worn or damaged parts with genuine ENERPAC parts. Non ENERPAC parts may break
causing personal injury and property damage. ENERPAC parts are designed to fit properly and withstand high
loads.

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Avoid damaging hydraulic hose. Avoid sharp bends and kinks when routing hydraulic hoses. Using a bent or
kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose leading to
premature hose failure.

Do not lift hydraulic equipment by the hoses or swivel couplers. Use the carrying handle or other means of
safe transport.

Keep hydraulic equipment away from flames and heat. Excessive heat will soften packings and seals,
resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 150°F [65°C] or higher. Protect hoses and cylinders from weld spatter.

Hydraulic equipment must only be serviced by a qualified hydraulic technician. For repair service, contact the
Authorized ENERPAC Service Centre in your area.

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2.2 Hydraulic Tensioner Safety Precautions

Failure to observe the following precautions may result in serious personal injury or death.

Hydraulic tensioners must be installed, operated and maintained only by trained and skilled
personnel familiar with the safe operation of high pressure tensioning devices and related
equipment. All calculations must be performed by a qualified engineer with appropriate training and bolting
experience.
• Always wear eye protection, gloves and boots when working near a pressurized hydraulic system

• When working on site, the work area should be roped-off and all non-essential personnel not
involved with the site operation should be kept clear of the working area.

• Before starting tensioning procedures, be sure that all personnel are aware that pressurization of
high pressure hydraulic equipment is about to occur.

• Never exceed the maximum working pressure of the hydraulic tensioner. Maximum working
pressure is stamped on the tensioner body.

• Do not exceed the maximum allowable piston movement (stroke) of the

hydraulic tensioner. An indicator will appear when the tensioner is near
maximum extension. Refer to the maximum stroke dimension stamped on the
tensioner body.

• Never stand in-line with the bolt axis while tensioning or de-tensioning is in
progress. If the bolt should fail, serious personal injury or death could result if
loose or broken parts become projectiles. All personnel must be aware of this
potential hazard at all times.

• Allow personnel to be near pressurized hydraulic tensioners only when absolutely necessary and only when the pressure is
steady. Continually observe the pump pressure gauge.

• Check that the threaded puller portion of the tensioner is fully screwed onto the stud, and that the thread engagement is
sufficient. Refer to the Stud Protrusion Requirements diagram (Figure 6) later in this document.

• High pressure hydraulic equipment can be very dangerous if misused. Keep away from oil leakages at high pressure. Liquid
escaping from highly pressurized equipment has sufficient power to penetrate the skin, which can cause blood poisoning. In the
case of such an accident, seek IMMEDIATE medical attention.

• Never attempt to repair leaks while the system is pressurized. Be sure system pressure gauge indicates
zero (0) psi/bar before making repairs.

• Never attempt to disconnect a hydraulic coupler while it is under pressure.

• Do not move or lift the hydraulic tensioners using the hydraulic hoses and fittings.

• Hoses should not be twisted or bent too sharply. The bend radius should not be less than the
manufacturer’s specified minimum bend radius for your hose type.

• Before pressurizing the system, carefully inspect all hydraulic hose assemblies. Replace any damaged,
crushed or kinked hoses immediately.

• Before pressurizing the system, be sure that all hydraulic hoses are connected. Each male coupler
must be connected to a corresponding female coupler. Verify that each coupler is fully engaged and
securely locked into position by physically pulling on the connection.

• Never pressurize the back of a disconnected male coupler. Male couplers cannot withstand high pressures when disconnected.
Serious personal injury could result if the coupler fails while it is disconnected and under pressure.

• Check that the bolt material is capable of taking the initial load to be applied. Hydraulic tensioners are powerful tools and are
capable of yielding or breaking studs/bolts if tensile/yield properties are not sufficient to support the load applied.

• Use caution when pressurizing a system. Pressure can rise faster than anticipated. Continuously monitor the pressure gauge
during pressurization. Be prepared to stop the pump immediately at any time.

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• Be sure that the pump relief valve is adjusted to the appropriate setting, so the hydraulic tensioners do not apply excessive
force for the application.

• Never leave a pressurized system unattended. If you must leave the area, stop the pump, fully open
the pressure release valve and ensure that hydraulic pressure gauge indicates zero (0) psi/bar.

• Any maintenance or repairs to the hydraulic tensioners, the pump or related components must be
performed with the equipment in the unpressurized state (0 psi/bar).

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3.0 SPECIFICATIONS

Refer to Table 1 for technical data. Selected tensioner specifications, such as maximum working pressure, maximum load and
maximum stroke are also stamped into the side of the tensioner body. See Figure 1 for location. Note these specifications during
installation and set-up.

A General Assembly drawing for the tensioner is included at the end of this document. Dimensional and technical data can also
be found in this drawing.

The required working pressure for the CAT 3600 Cylinder Head tensioning procedure will be less than the
maximum working pressure stamped on the tensioner body.

Figure 1, Tensioner Specifications (stamped on unit)

Table 1 – Technical Data: CAT 3600 Cylinder Head Tensioner - LVDT (Enerpac Part No. 3600CHT900-1)
Maximum Working Maximum Load
Hydraulic Area Maximum Stroke Weight
Pressure (at 1350 bar)
psi bar kN klbf inch² mm² inch mm lbs. Kg
19,580 1350 946.8 212.85 10.87 7013 0.32 8 32.61 14.791

Note: This tensioner includes stroke measurement electronics in the form of an LVDTs mounted onto the
Piston. This will be used in conjunction with the Smart pump to provide detailed data tracking of Pressure and
Stroke measurements. A Fischer Series 102 connection is used to connect the LVDTs back to the pump.

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4.0 ADDITIONAL PRODUCT INFORMATION

4.1 Tensioner Features and Components

Refer to Figure 2 for a diagram of the tensioner’s major features and components.

Key: 11 1 2
1- Puller Sleeve
2- Top Cap
3- Body
4- Drive Gear
5- Gearbox
6- Bridge
7- Nut Rotating
Socket
8- Swivel Manifold
9- Male Coupler
10 - Cycle Counter
11 - LVDT* 3

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5

7 6 * Linear Variable Differential Transformer

Figure 2, Tensioner Major Features and Components

Note: The Puller Sleeve and Drive Gear have 3/8” female squares. Refer to the General Assembly drawing
included at the end of this document for further details.
Note: This tensioner includes a ‘Cycle Counter’. This tracks the life of the tool and can be used to determine
regular service intervals, as well as indicating when specified parts must be replaced.

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4.2 Maximum Stroke Indicator

Maximum allowable tensioner stroke is visually indicated by a yellow painted groove located on the Puller Sleeve’s
circumference. See Figure 3.

YELLOW GROOVE = MAXIMUM STROKE

Figure 3, Tensioner Maximum Stroke Indicator

Continually watch for the maximum stroke indicator during tensioning procedures. Stop pressurizing the system immediately if
the indicator becomes visible.

If during any tensioning procedure the maximum stroke indicator appears before the desired hydraulic pressure is reached,
immediately STOP the pump. Reaching maximum stroke is a likely indication of a problem with the Cylinder Head Assembly. The
Tensioners should be removed and the Cylinder Head Assembly inspected to ensure correct fitment of components. Tensioning
procedures should be started again.

Note: The tensioner is capable of withstanding full pressure at full stroke, but if the maximum stroke has been reached
before the desired hydraulic pressure is reached, then no additional load will be transferred to the stud and the
application will not be correctly tightened.

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5.0 SETTING UP

5.1 Hydraulic Oil

Use of the correct hydraulic oil is important to successfully completely a tensioned joint. Failure to use the proper oil may result
in damage to tool or pump. It can also lead to pump faults during the smart tensioning process. The recommended oil is CAT's
ADV Hydo 10 (SAE 10W).

Be sure that the oil is clean. The oil cleanliness should be maintained to a maximum level of 18/16/13 per the
ISO4406 standard. If the oil has a milky, cloudy or dark appearance, it should be changed immediately as described in the pump
manufacturer’s instructions.

5.2 Hoses, Fittings and Pump

All hydraulic hoses, fittings and other components used in the circuit must be rated at or above the maximum working pressure
of the tensioner, i.e., 19,580 psi [1350 bar].

A suitable Smart Tensioning Pump (498-6540 or 498-6541) is required for use with the tensioners. If one of these pumps is not
being used, it’s critical that the pump in use be equipped with a pressure gauge and adjustable pressure relief valve. The pump
maximum relief valve setting must not exceed 19,580 psi [1350 bar].

The pump must also contain a pressure release valve that, when opened, directs hydraulic oil back to the reservoir.

Be absolutely certain that any pressure is completely relieved before connecting or disconnecting hoses. Before making any
connections, be sure that the pressure release valve is fully open, and that pressure gauge indicates zero (0) psi/bar.

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5.3 Hydraulic Couplers

Each tensioner includes a male quick-disconnect style hydraulic coupler. The compatible pump, hydraulic hoses and manifolds
should include the same style male and female couplers.

To Connect Couplers:

See Figure 4.

1. Be sure that all couplers are free of dirt and debris.

2. Before making any connections, be sure that pump is OFF, and that pressure gauge indicates zero (0) psi/bar. Verify that the
pump pressure release valve is fully open.

3. Be sure that the locking collar is completely backed-off (unscrewed). Then, hold back the main collar on the female coupler
and push the male coupler into the female coupler.

4. Release the main collar on the female coupler and push the male coupler further into the female coupler until a “click” is
heard and engagement is felt.

5. Thread down the locking collar so it makes contact with the main collar and locks the couplers together. There should be NO
GAP where the collars meet. Tighten by hand only. Do not use tools.

6. At each coupler connection, firmly tug the hose to verify that the couplers are securely connected. Verify the couplers are
locked by attempting to pull back the main collar on the female coupler.

Figure 4, Hydraulic Couplers - Connect and Lock

Do not pressurize disconnected couplers. All couplers must be correctly and completely fastened
together (or have blanking plugs installed in unused couplers) before applying pressure.

Never disconnect or connect any hydraulic hoses or fittings without first unloading the
tensioner(s) and releasing hydraulic pressure. Check the pressure gauge to ensure that pressure
has been completely released [0 psi/bar] before disconnecting or connecting any hoses.

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To Disconnect Couplers:

See Figure 5.

1. Be sure that pump is OFF, and that pressure gauge indicates zero (0) psi/bar. Verify that pump pressure release valve is fully
open.

2. On the female coupler, fully back-off (unscrew) the locking collar to unlock the connection.

3. Pull back the main collar on the female coupler to disconnect the couplers.

Figure 5, Hydraulic Couplers - Unlock and Disconnect

All system pressure must be released prior to making connections. If there is any pressure trapped in the hydraulic
components, it will be not possible to connect or disconnect hoses.

Never attempt to relieve pressure by loosening a fitting or by unseating a coupler check ball or
seat.

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6.0 INSTALLATION

6.1 Before You Begin

1. Be sure all personnel involved in this procedure are trained in tensioning procedures and the tensioning equipment being
used. Ensure that all personnel read and understand the safety information contained in Sections 2 of this document.

2. Be sure all personnel are familiar with the use of the Smart Pump and its interface. Refer to the Smart Pump Instruction
Manual, document number 466-1811_IS for further details.

3. Be sure that the pump reservoir is filled with oil. Refer to Section 5.1 for tensioner oil specification requirements.

Note: Oil volume at maximum stroke is approximately 1.97 fluid ounces [56cm³]. Four Tensioners are used together on
the Cylinder Head application, so the total oil volume required is approximately 7.89 fluid ounces [224cm³]. Additional oil
will be contained inside hoses and fittings.

4. Be sure all personnel are aware of the maximum working pressure and maximum stroke applicable to the tensioners being
used. This information is stamped on the tensioner body. See Section 3.0 for additional information.

5. Inspect the studs to verify that they contain no obvious damage or defects, and that they appear capable of withstanding the
force that will be applied by the tensioners.

6. Ensure the Cylinder Head is correctly and firmly seated. Ensure washers are fitted. Ensure the nuts are fully threaded onto the
studs until they firmly contact the washer surface. There should be a total of 68mm of bolt protrusion above the nut. See Figure
6.

7. Before installing each tensioner, be sure that the threaded portions of the bolts and Puller Sleeves are clean and free of
damage.

6.2 Tensioner Installation and Hook-up. CAT 3600 Cylinder Head Studs

The Cylinder Head has four studs that will always be tensioned or de-tensioned together. Four tensioners will be
mounted to a lifting plate to be used together as a set.
1. Lower the lifting plate with four tensioners onto the four Cylinder Head Studs. The Puller Sleeves will retract freely by
approximately 2.2" [56mm] to clear the studs allowing the tensioners to sit on the washers.

Note: Ensure the couplers and gearboxes are in a suitable orientation to allow connection of the hoses and to allow
access to the Drive Gear of the tensioner gearbox.

2. Locate the ends of the studs with the Puller Sleeves by rotating the Puller Sleeves. A 3/8" drive can be used. Thread the Puller
Sleeves onto the studs until they become tight and cannot rotate any further.

Note: Do not over-tighten the Puller Sleeves. They do not need to be tight; they just need to be threaded in till they
bottom out.

3. Insert a 3/8" drive into the Extension connected to the Drive Gear of a tensioner Gearbox. Rotate the Drive Gear until the Nut
Rotating Socket is aligned with and located around the nut. Do this for all four tensioners

Note: The Nut Rotating Socket is spring-loaded, and an audible “click” can be heard when the socket moves into place
around the nut. Turning the Drive Gear further will begin to turn the nut. A proper connection is confirmed by an increase
in the amount of effort required as turning progresses. If the Nut Rotating Sockets do not seem to engage with the Nuts,
it may be necessary to back-off the Puller Sleeves by a fraction of a turn to allow some movement of the tensioner. Then
engage the Nut Rotating Sockets before re-threading the Puller Sleeves back in.

4. Connect hydraulic hoses and electrical connections from the pump to the manifold and electrical junction box on the lifting
plate.

5. Before pressurizing the system, be sure that all hydraulic hoses are connected. Verify that each coupler is fully engaged and
securely locked into position by physically pulling on the connection. Ensure that the Puller Sleeves and Nut Rotating Sockets are
fully engaged on all bolts and nuts, as described in steps 2 & 3.

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 Figure 6, Stud Protrusion Requirements

7.0 TENSIONING AND DE-TENSIONING

Never stand in-line with the bolt axis while the system is pressurized. If the bolt should fail,
serious personal injury or death could result if loose or broken parts become projectiles. All
personnel must be aware of this potential hazard at all times.

Ensure that the maximum working pressure and maximum stroke are not exceeded. Refer to the
specifications stamped on the tensioner body. Also refer to Table 1, Technical Data, in Section 3.0
(page 5).

If the maximum stroke indicator (yellow line) appears at any time during the following procedures, immediately
STOP the pump. Reaching maximum stroke is an indication of a problem with the Cylinder Head Assembly. The Tensioners
should be removed and the Cylinder Head Assembly inspected to ensure correct fitment of components. Refer to Section 4.2
(page 7) for additional information.

If any leaks occur, immediately stop the pump and open the pressure release (return-to-tank) valve. Be sure that
the hydraulic pressure gauge indicates zero (0) psi/bar. Make repairs as required before continuing with tensioning procedures.

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7.1 Tensioning Instructions - CAT 3600 Cylinder Head Studs

Read precautions and instructions at beginning of Section 7.0 before beginning the following steps. Also refer to
safety information contained in Section 2 (pages 1 – 4).
1. Assemble the Lifting Plate with Tensioners onto the studs and connect hydraulic hoses and electrical connections. Refer to
Sections 5 and 6 (pages 8 – 11) for additional tensioner installation and hose connection instructions.

2. Begin the Tensioning Programme on the Smart Pump. (Refer to Smart Pump Instruction Sheet 466-1811_IS for further
details).

3. The Smart Pump will automatically run through a series of pressurisations, pausing to allow the operator to tighten the nuts
on the application. Follow the instructions on the Pump Screen.

4. When prompted, use a 3/8" drive to tighten the nuts by turning the Drive Gears of the tensioner Gearboxes. Tighten only until
resistance is felt, and ensure that no more than 22.1 lbf.ft [30 Nm] is applied. If a Torque Wrench is available, 15 lbf.ft [20 Nm] is
the ideal recommended Torque and should be applied across the board to ensure consistent bolt loads. When all nuts have been
tightened, press the “Continue” button to proceed.

5. The Smart Pump will ask for nuts to be tightened a second time as a check. Repeat step 4.

6. When the Smart Pump has finished the tensioning procedure, it will indicate whether the joint has been correctly tightened or
not. If the joint has not been correctly tightened, then it will need to be de-tensioned and the tensioning procedure will need to
be re-started.

7. The pistons should automatically retract due to the built in spring return feature, but before removing the tensioners, the
Puller Sleeves should be threaded in to ensure that the pistons are fully retracted. Use a 3/8” drive to turn in the Puller Sleeves
until they are flush with the Top-Cap.

Note: The tensioners must still be connected to the pump to allow the oil to vent out of the tensioners and back into the
pump reservoir.

8. Verify that the hydraulic pressure gauge indicates zero (0) psi/bar.

9. Disconnect the main hydraulic hose and electrical connections from the Lifting Plate.

10. Remove the Tensioners from the studs by threading out the Puller Sleeves until the threads have disengaged. The Lifting
Plate with Tensioners can then be lifted off the studs.

Note: Double check the puller sleeves are free from the studs before lifting the tooling off the engine.

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7.2 De-tensioning Instructions - CAT 3600 Cylinder Head Studs

Read precautions and instructions at beginning of Section 7.0 before beginning the following steps. Also refer to
safety information contained in Section 2 (pages 1 – 4).
1. Assemble the Lifting Plate with Tensioners onto the studs and connect hydraulic hoses and electrical connections. Refer to
Sections 5 and 6 (pages 8 – 11) for additional tensioner installation and hose connection instructions.

2. BEFORE applying any hydraulic pressure, turn out the Puller Sleeve at each stud by approximately 1.5 turns. The tensioners
should have approximately 0.12” [3 mm] of axial free-play on the application.

Note: The number of rotations to turn the Puller Sleeves is approximate and does not need to be exact. The 0.12” [3 mm]
of vertical free-play is there to account for the relaxation in the bolts and joint after de-tensioning, which should be less
than 0.08” [2mm].

3. Begin the De-tensioning Programme on the Smart Pump. (Refer to Smart Pump Instruction Sheet 466-1811_IS for further
details).

4. The Smart Pump will automatically take the tensioners up to the de-tensioning pressure, pausing to allow the operator to
undo the nuts on the application. Follow the instructions on the Pump Screen.

5. When prompted, use a 3/8" drive to undo the nuts by turning the Extensions connected to the Drive Gears of the tensioner
Gearboxes. Turn the Drive Gears anti-clockwise approximately 5 turns (1 rotation of the Drive Gear = 0.3077 rotations of the nut
so the nut would be backed off by approximately 1.5 turns or 0.12” [3mm]).

Note: The number of rotations to turn the Drive Gear is approximate and does not need to be exact. The nut should be
backed off by at least the same amount as the Puller Sleeve (0.12” [3 mm], or 5 turns of the Drive Gears).

If the nuts are backed off too far, there is a possibility for them to become jammed against the
Puller Sleeve after de-tensioning. This can be noticed if the Drive Gears become tight again during
backing off (though this would only happen after a total of approximately 9 - 10 turns). If this does happen, wind the
Drive Gears back in by approximately 1 whole turn.
6. The pump can now be stopped. Verify that the hydraulic pressure gauge indicates zero (0) psi/bar. The bolts should now be
fully de-tensioned.

7. The pistons should automatically retract due to the built in spring return feature, but before removing the tensioners, the
Puller Sleeves should be threaded in to ensure that the pistons are fully retracted. Use a 3/8” drive to turn in the Puller Sleeves
until they are flush with the Top-Cap.

Note: The tensioners must still be connected to the pump to allow the oil to vent out of the tensioners and back into the
pump reservoir.

8. Insert a 3/8" drive into the Extension connected to the Drive Gears of the tensioner Gearbox and verify that the nuts are loose
before removing the tensioners. If the Nut Rotating Socket is loose and the nut is loose, go to Step 9. If the Nut Rotating Socket
is tight, then repeat the de-tensioning procedure from step 1.

9. Verify that the hydraulic pressure gauge indicates zero (0) psi/bar.

10. Disconnect hydraulic hoses and electrical connections, and install a dust cap over each disconnected coupler.

11. Remove the Tensioners from the studs by threading out the Puller Sleeves until the threads have disengaged. The Lifting
Plate with Tensioners can then be lifted off the studs.

Note: Double check the puller sleeves are free from the studs before lifting the tooling off the engine.

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8.0 STORAGE

• The tensioner’s black oxide finish will help protect it from rust and corrosion. However, for added protection, a light coating of
oil or rust inhibitor should be applied to all metal surfaces.
• Cover the internal threads of the threaded Puller Sleeves with oil or a suitable rust inhibitor.
• Store the tensioner(s) upright, with the Puller Sleeves and Pistons fully retracted inside the body.
• Always keep dust caps installed on couplers when the tensioner is not being used.
• Wipe all hoses clean and apply a light coating of oil or suitable rust inhibitor to all couplers.

9.0 TROUBLE-SHOOTING

Symptom Cause Remedy

Puller sleeves not moving when
they should be moving.
Nut rotating socket will not
spin.
Transducers not providing
feedback.
Puller sleeves not returning to
flush with the top cap.
Puller sleeve not returning to
flush with the top cap.
Bad hydraulic connections.
Pump not building pressure.
Over torqued gearbox bolts.
Loose cable connection.
Bad hydraulic connections.
Weak return spring force.
Check ALL hydraulic couplers for
debris and proper engagement.
Check if pressure is increasing, using:
1) mechanical pressure gauge,
2) touchscreen HMI readout,
3) amber LED on proportional relief
valve driver.
Loosen gearbox bolts until nut
rotating socket spins.
Check ALL electrical cable connections
for debris, bent pins, and proper
engagement.
Check ALL hydraulic couplers for
debris and proper engagement.
With hose assembly connected, use
ratchet to manually bring puller
sleeve to flush. Replace broken or
weak return springs.

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