Hydraulic Jack BV 159

Pressure 0 bar · LOCKED

Cylinder Cover Loosening
Hydraulic Tools — Dismantling

Work Card 2265-0301-0026 · Hydraulic Tools 7665-0101-0006

Dismantling sequence

HELP OFF — no next-step guidance and no highlighting of completed targets.

HELP: before pressurising, unscrew the hydraulic jack 6–8 holes (3/4 to 4/4 turn) to create clearance. Increase the oil pressure above 2250 bar. Unscrew the nut 5–7 holes with the tommy bar. Hold the pressure buttons for pressure change.

100%

TEAM LEADER · 8 HYDRAULIC JACKS

Pressing either procedure button immediately restarts that complete procedure.

0 bar

COMMAND 1Place the hydraulic jack on the stud and screw it down until it bears on the cylinder cover.

Waiting for the operator at Hydraulic Jack No. 1.

Hydraulic_Jack_128_Training

V92 English · MAN B&W manual terminology. A Restart control reloads the simulator from its initial condition, and the digital pressure readout is positioned 100 px lower than its original position. Step 7 uses press-and-hold pressure reduction. When Step 7 is completed at 0 bar, the nut remains FREE unless a mechanical contact or jam condition exists. With HELP OFF, completion of sequence targets is not highlighted. During automatic hydraulic-jack removal, the nut remains fixed in its existing axial and angular position. In Team Leader mode, the eight nuts do not release at exactly the same pressure. Each jack has a small hidden deviation around the nominal working pressure. During pressure increase, every operator repeatedly tests the nut with the tommy bar and confirms only after free movement is physically detected. The Team Leader continues increasing the common pressure until all eight operators have confirmed; only then is the pressure rise stopped and the next command issued. During pressure reduction, the trainee can continuously test the nut and signal immediately if it tightens.

1. Pressure / release

Hydraulic jack pressure

The on-screen controls are arranged in two left columns. Hydraulic-jack removal must precede nut removal. Each component is first fully disengaged from the stud thread and is then removed vertically.

Pressure0 bar

Hydraulic lift0.00 mm

Stud load carried by nut100%

Stud load carried by hydraulic jack0%

Actual Stud Tension594 tf

LOCKED: rotation is not permitted.

2. Tommy bar / 100° slot

Manual nut operation: select a visible tommy-bar hole and drag along the slot. Only the active hole is shown; no tommy-bar extension is drawn.

DirectionLoosening

Tommy-bar stroke0° / 100°

Active hole#1 / 8

Travel per 100°2.00 mm

Initial condition: 0 bar. The nut alone bears against the cylinder-cover contact face and the hydraulic jack is not fitted. Pressure may be applied only after the jack is screwed fully onto the stud, the high-pressure hoses are connected, the system is bled / piston zero is established, and the jack is unscrewed within the accepted 3/4 to 4/4 turn range to create clearance.

3. Clearances

Thread travel T0.00 mm

Clearance under pressure0.00 mm

Free clearance at 0 bar0.00 mm

Current visual clearance0.00 mm

Gap nut–cover0.00 mm

Gap nut–support-ring top20.00 mm

Permitted movement—

Nut position within free clearance

Nut axial play0.00 mm

No free clearance is available.

4. H/J assembly on stud

Select one of the visible J-Cylinder holes and drag horizontally. The H/J assembly can be screwed or unscrewed on the stud only at 0 bar.

H/J modeLoosening

Cylinder stroke0° / 100°

Active cylinder hole#1 / 8

H/J axial travel0.00 mm

Support-ring follow0.00 mm

Piston rise in cylinder0.00 mm

5. Complete dismantling sequence

Initial condition: only the nut is visible, bearing against the cylinder-cover contact face and carrying the stud load. The hydraulic jack is not fitted.

Manual hole-count operations and pressure changes are controlled from the main on-screen panel. Full removals are automatic only after separate commands.

High-pressure hosesDisconnected

Piston zeroNo

Back-off hydraulic0.00 / 4.50 mm

Ready for pressureNo

Nut loosen target0.00 / 3.75 mm

Hydraulic-jack removalNot ready

Nut removalNot ready

Dismantling / mounting model: for mounting after removal, fit the nut to 6 mm above the cylinder-cover contact face → manually tighten the nut → fit the hydraulic jack to 5 mm → manually seat the H/J assembly and K-Support ring → connect high-pressure hoses → bleed/reset → increase oil pressure → tighten the nut with the tommy bar → relieve pressure → remove the hydraulic jack.

6. Parameters

M130×P thread pitch

Pitch6 mm

Nut Ø225×130Stud Ø130H-Piston ID M130×6 H=130J-Cylinder OD=K-Support ringSlot 100°Lift 1.5 mmV83 fixed nut during hydraulic removal

Calculation: accepted initial H/J back-off = 6–8 holes = 270°–360° = 3/4–4/4 turn, corresponding to 4.50–6.00 mm on the M130×6 thread. For the nut, 5 holes × 45° = 225° = 5/8 turn, corresponding to 3.75 mm. After the system pressure is relieved and the stud elastically contracts, the nut remains loose and does not bear against the cylinder-cover contact face. Pressure profile: pump delivery progressively decreases as back pressure rises. The rise curve is calibrated so 0 → 2200 bar takes 60 s; the theoretical 0 → 2500 bar time is approximately 71.7 s. Pressure reduction is linear from 2500 → 0 bar in 10 s, only while the relevant button is held.