Product Information

• General Information
  • Safety Signal Words
  • Warranty
  • Website
  • ServAid
  • Safety Data Sheets MSDS/SDS
  • Country of Origin
  • Dimensional Drawings
• Overview
  • Unpacking and Storage
  • Technical Product Data
  • Product Identification

General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

• Read all Safety Information delivered together with the different parts of the system.

• Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

• Read all locally legislated safety regulations regarding the system and parts thereof.

• Save all Safety Information and instructions for future reference.

Safety Signal Words

Warranty

• Product warranty will expire 12+1 months after dispatch from Atlas Copco's Distribution Center.

• Normal wear and tear on parts is not included within the warranty.

  • Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

  • Puller bars have its fatigue life and warrantied for 5000 cycles.

• The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

• Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

• To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

• Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

• Regulatory and Safety Information

• Technical Data

• Installation, Operation and Service Instructions

• Spare Parts Lists

• Accessories

• Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

• Unpacking and Storage
• Technical Product Data
• Product Identification

Unpacking and Storage

Open the package carefully to avoid damaging fixed accessories. Check the contents of the package for obvious damage upon receiving. Check the contents against the delivery note.

• Storage for less than two months:

  Preferably in its original packaging, protected from the elements.

• Storage for longer than two months:

  Preferably in its original packaging, protected from direct sunlight, placed vertically in a dry place.

A frame with a certified lifting point is not included in tensioners alone. It is included in tensioner kits. Tensioner kit also includes a case (box).

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Product Identification

Markings containing basic product related identification can be found on 2 places on the tensioner. One marking is on the back of the tensioner and one on the top of the endcap.

These markings contain, for example:

• Serial number

• Model

• Maximum pressure

• Maximum load

• Certification

Installation

• Installation Instructions
  • Pre-Checks
  • Installing the STT Tensioner

Installation Instructions

• Pre-Checks
• Installing the STT Tensioner

Pre-Checks

• Check the working load of the lifting equipment and weight of the tool.

• Make sure that the lifting device is attached to the tensioner frame.

  

• Make sure that all hydraulic and electric connections are connected properly.

Installing the STT Tensioner

Battery Nutrunner and Wrench Disengagement

For more information about BCV, please visit https://servaid.atlascopco.com/AssertWeb/en-US/AtlasCopco/Catalogue/2247

Fore more information about CWR-85, please visit https://servaid.atlascopco.com/AssertWeb/en-US/AtlasCopco/Catalogue/8658

Operation

• Ergonomic guidelines
• Operating Instructions
  • Preparation
  • Mounting the Tensioner
  • Connecting the Tensioner
  • Status Indicator - LED Lights

Ergonomic guidelines

Consider your workstation as you read through this list of general ergonomic guidelines and see if you can identify areas for improvement in posture, component placement, or work environment.

• Take frequent breaks and change work positions frequently.

• Adapt the workstation area to your needs and the work task.

  • Adjust for convenient reach range by determining where parts or tools should be located to avoid static load.

  • Use workstation equipment such as tables and chairs appropriate for the work task.

• Avoid work positions above shoulder level or with static holding during assembly operations.

  • When working above shoulder level, reduce the load on the static muscles by reducing the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  • Make sure to take frequent breaks.

  • Avoid extreme arm or wrist postures, particularly for operations requiring a degree of force.

• Adjust for convenient field of vision by minimizing movement of the eyes and head during the work task.

• Use the appropriate lighting for the work task.

• Select the appropriate tool for the work task.

• Use ear protection equipment in noisy environments.

• Use high-quality inserted tools or consumables to minimize exposure to excessive levels of vibration.

• Minimize exposure to reaction forces.

Operating Instructions

• Preparation
• Mounting the Tensioner
• Connecting the Tensioner
• Status Indicator - LED Lights

Preparation

WARNING

Burning Hazard

Protect your hands to avoid injury. The unit could get to high temperatures both during and after use.

• Always use protective gloves.

WARNING

Crushing Hazard

Keep hands away from the reaction areas of the tensioner during operation! The tensioner moves with a downward movement and could crush hands or other body parts if not kept away.

WARNING

Risk of Severe Injury

Always protect the face when working with high-pressure equipment. High-pressure equipment could cause severe bodily injury.

• Always wear goggles and/or face shield.

• Monitor the pressurized equipment and pay attention to the pressure gauge, because the pressure can increase quite rapidly in case of low volume circuits.

WARNING

Risk of Damage and Injury

Unexpected bolt failure can result in serious personal injury or death. Premature bolt failure can lead to parts of the tensioner or bolt becoming high velocity projectiles.

• Never stand in-line with the bolt axis during the tensioning or de-tensioning procedure.

• Alert all personnel to the consequences of premature bolt failure and clear the area of non-essential personnel before the procedure starts.

WARNING

High-Pressure Fluids Hazard

Never grab, touch, or in any way come in contact with a hydraulic pressure leak. When the hydraulic circuit is pressurized, the hydraulic fluid can escape at high speed. Escaping fluid under pressure can penetrate the skin causing serious injury. If an accident occurs, contact the nearest health service immediately! Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

• Always relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

• Always wear safety approved eye wear when checking for leaks. Do not use your hands to check for leaks in the hydraulic circuit.

• Always keep away from leaking elements during the tightening process.

• Always wear impact-resistant eye and face protection when involved with or near the operation, repair or maintenance of the unit.

• Be sure all others in the area are wearing impact-resistant eye and face protection.

• Even small projectiles can injure eyes and cause blindness.

WARNING

Risk of Severe Injury

Always use personal protective equipment when operating the unit. Below are possible hazardous situations:

• Impact blows to the head

• Foot injuries

• Exposure to high noise levels

• Heat, splashes from liquids, impacts, cuts, air contaminated with harmful dusts, fumes, mists, sprays, and vapors.

If not avoided, the above hazardous situations could result in severe bodily injury or death.

• Always use the adequate personal protective equipment on your job site.

WARNING

Risk of Severe Injury

Never pressurise an unconnected male coupler. Male couplers are not designed to withstand high pressure while disconnected. Pressurising an unconnected male coupler can lead to serious personal injury or death. It is safe to pressurise the unconnected female coupler fitted to the last tensioner in the circuit.

Mounting the Tensioner

Connecting the Tensioner

Status Indicator - LED Lights

LED on the top left appears in different colors to show the status while the tool is connecting:

• Lighter green light appears when the tool is trying to connect.

  

• Blue light appears when the connection process is in progress.

  

• Darker green light appears when the connection process is completed.

  

LEDs for pressure, torque and angle can appear in sequences shifting from left to right, or from right to left:

• When LED lights illuminate in sequence from left to right, start increasing the pressure, torque, or angle, depending on which row is illuminated.

  

• When LED lights illuminate in sequence from right to left, start decreasing the pressure, torque, or angle, depending on which row is illuminated.

  

• When the pressure reaches the target pressure, all 3 LEDs in the first row (pressure) will turn green which means that the pressure is OK. The same is valid for torque and angle.

Generally, LEDs indicate the following:

• Red light means error.

• White light - check the instruction on the hand controller.

• Green light means OK.

The max stroke indicator on the puller bar should not be visible while pressuring the tensioner. If visible, stop and adjust the position of the puller bar on bolt so that the max position is not reached until the required pressure is achieved. Otherwise, if done repeatedly, it can physically damage the internal components of the tensioner.

Service

• Preventing ESD Problems
• Maintenance Instructions
  • Service Recommendations
  • Overhaul
  • General Service and Maintenance Safety

Preventing ESD Problems

The components inside the product and controller are sensitive to electrostatic discharge. To avoid future malfunction, make sure that service and maintenance is carried out in an ESD approved work environment. The figure below shows an example of an appropriate service work station.

Maintenance Instructions

• Service Recommendations
• Overhaul
• General Service and Maintenance Safety

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

• Clean appropriate parts accurately

• Replace any defective or worn parts

Overhaul

It is important to plan the maintenance of the tool on time, because the tool will stop working after 5000 cycles. The hand controller prevents the tool exceeding 5000 cycles.

The warning will be displayed several times:

• When 250 cycles are left.

• When100 cycles are left.

• When 50 cycles are left.

The last 10 times the warning will be displayed each time. After that, the system will stop the tensioning work.

General Service and Maintenance Safety

Always wear impact-resistant eye and face protection when involved with or near the operation, repair or maintenance of the tool or changing accessories on the tool.

Disconnect the power supply and depressurize the hydraulic system before disconnecting or connecting hoses, fittings, or accessories or adjusting or dismantling the tool.

• All investigation, maintenance or repair work should only be carried out when the tensioner is at zero pressure.

• Always examine the condition of the elements that assemble the hydraulic circuit. If there are any faulty elements, contact the customer center to replace it with another element with the same characteristics in proper condition. Only qualified and trained personnel can do maintenance and improvement services on this device.

Cleaning Instruction

Equipment should be wiped off with a damp/wetted cloth.

Contact your Atlas Copco service technician for cleaning advice as per current recommendations and for your particular tool.

Regular Cable Inspections

Regularly inspect the power cable and the tool cable. If the cables show any sign of damage, replace them.

Recycling

• Environmental Regulations

Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.