# Troubleshooting Guide

## At Start of Shift

Procedure | Acceptance Criteria | Alternative Action
--- | --- | ---
Check that internal and external screw threads of the thread insert are clean and free from burring and notching. | There is no excessive amount of minute solid particles within the lubricating grease residue. The screw threads are complete with no jagged edges or parts of teeth missing. | Clean the screw threads with a suitable solvent to remove the grease residue and any particles contained within. Replace any components where the screw threads are damaged. If in doubt, return to Atlas Copco for assessment.
Check for cracking on the thread insert. | There are no minute but visible cracks around the radius corners between the shank and flanged head. Neither are there any cracks on the external surface of the shank, in the area where the thread undercut meets the shank. | Replace any components where evidence of cracking is visible. If in doubt, return to Atlas Copco for assessment.
Check functionality of hydraulic seals. | The load cell assembly may be hydraulically pressurised to maximum working pressure and that pressure maintained for 2-3 minutes. | Remove affected tensioners and contact Atlas Copco for seal replacement.
Check condition of all hydraulic connectors. | The male and female fittings can be mated and screwed together with ease. There are no pressure leaks between male and female fittings. | The fittings may wear periodically. Replace any fittings that are difficult to mate and screw together. In the event of leakage, check torque values for the fittings in the first instance. If the torque values are satisfactory, return the tensioners to Atlas Copco for replacement of the fittings.
Check that the hydraulic hoses are free from indentation and bulging. | The polymer coating on the hydraulic hose is not indented in any way. There is no swelling or bulging in the hose. | Replace any damaged hoses immediately. It is not safe to pressurize a damaged hose.
Check cleanliness and volume of hydraulic fluid. | Fluid should not be excessively discoloured. There should be no particle sediment in the fluid. Volume of fluid in pump reservoir should be to maximum level indicator on sight glass. | Return the pump unit to Atlas Copco for draining, flushing, and re-filling with clean fluid. Top up fluid as required. Use ISO Grade 10, 32 and 68; Shell Morlina oil 10.
Check functionality of pump on/off valve. | Pump should cycle when valve is in ‘on’ position. Pump cycle should stop immediately without over-run, when valve is switched to ‘off’ position. | Remove pump from process and return to Atlas Copco for repair.
Check functionality of clutch mechanism on pump pressure release valve. | Valve should allow system to be pressurised when clutch mechanism clicks out. | Remove pump from process and return to Atlas Copco for repair.
Observe pump workings for signs of fluid leakage. | There should be no wet areas within the pump frame or on any pipework, which may signify leakage through a loose connection. Operate the pump, unconnected, up to 100 bar and hold for 1 minute. There should be no pressure drop on the pressure gauge. | If any fluid leaks are found, remove pump from process and return to Atlas Copco for repair.
Hydraulic Pressure Gauge should be functional and glass not cracked. | Gauge needle should advance steadily without jumping, and return fully to zero when pressure released. | Remove pump from process and return to Atlas Copco for repair.

## On arrival at new location

Procedure | Acceptance Criteria | Alternative Action
--- | --- | ---
Check that the load cell and thread insert are free of surface rust. | There is no surface rust on all external surfaces of the load cell assembly including the central bore. There is no surface rust on the external surfaces of the thread insert including the internal screw thread. | Lightly brush the affected area with a wire brush. Do not apply excessive force on the load cell assembly to prevent damage to the plating. Apply rust inhibitor to the brushed area of the load cell assembly only, e.g. Ambersil.
Check torque values for hydraulic connectors. | ¼ x ¼ in BSP adaptor to tensioner and pump hydraulic outlet. Torque: 35Nm Male hydraulic connection to ¼ x ¼ in BSP adaptor. Setting Torque 45Nm. Check Torque 40Nm. Female hydraulic connection to ¼ x ¼ in BSP adaptor to tensioner and pump hydraulic outlet. Setting Torque 45Nm. Check Torque 40Nm. | Use a 17mm AF open-ended wrench fitting to check ¼ x ¼ in BSP adaptor to torque 35Nm. Use a 22mm AF open-ended wrench fitting to check torque on male hydraulic connection. Setting Torque 45Nm. Check Torque 40Nm. Use a 24mm AF open-ended wrench fitting to check torque on female hydraulic connection. Setting Torque 45Nm. Check Torque 40Nm.
Check hydraulic hoses are free from indentation and bulging. | The polymer coating on the hydraulic hose is not indented in any way. There is no swelling or bulging in the hose. | Replace any damaged hoses immediately. It is not safe to pressurize a damaged hose.
Check torque values for pump hydraulic outlet female connector. | ¼ x ¼ in BSP adaptor to pump hydraulic outlet. Torque: 35Nm Female hydraulic connection to ¼ x ¼ in BSP adaptor to tensioner and pump hydraulic outlet. Torque 45Nm | Use a 17mm AF open-ended wrench check ¼ x ¼ in BSP adaptor to torque 35Nm. Use a 24mm AF open-ended wrench fitting to check torque on female hydraulic connection. Setting Torque 45Nm. Check Torque 40Nm.

## Applies to: