HD23

High Strength Bolts Tightening

Operating Procedure
HD23 high strength bolt tightening_007_e
 WARNINGS

Do not operate the top climbing unit if the instructions and procedures outlined in the manual are
not clearly understood. Should there be any doubt, ask for the intervention of Comedil’s technical
service.
Comedil reserves the right to make changes to specifications or to modify the equipment at any
time without prior notice.

SYMBOLS

Very important sections in this manual are highlighted by the following symbols:

F INDICATION: Indications regarding the proper use of the top climbing

unit and the responsabilities of the persons in charge of
safety.

ATTENTION: section in which a note of particular importance is stated.

DANGER: important notes to prevent accidents or heavy material

damages.

F MANDATORY AND ADVISORY RULES

Mandatory rules of this volume are characterized by use of the word shall. If a provision is of an
advisory nature, it is indicated by use of the word should and is a recommendation to be considered,
the advisability of which depends on the facts in each situation.

Page 3/15 HD23 high strength bolt tightening_007_e

 INDEX

1 HD23 HIGH STRENGTH BOLTS WITH “ROTABOLT” CONTROL

1.1 GENERAL
1.2 TIGHTENING PROCEDURE
1.3 TENSIONING SEQUENCE
1.4 TIGHTENING CONTROL
1.5 MAINTENANCE
2 HD23 HIGH STRENGTH BOLTS WITHOUT “ROTABOLT” CONTROL
2.1 GENERAL
2.2 TIGHTENING PROCEDURE
2.3 TENSIONING SEQUENCE
2.4 TIGHTENING CONTROL
2.5 MAINTENANCE

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1 HD23 HIGH STRENGTH BOLTS WITH “ROTABOLT” CONTROL

1.1 GENERAL
“Rotabolt” control consists of a tension readout trimmer applied to one end of the high strength
bolts (M36 - M39 - M45 - M52) studied for Comedil “HD23” crane tower and for other connecting
systems of similar design.
The device indicates when tensioning of the high strength bolt by hydraulic torque wrench is achieved
with an approximation of ±5%, thus granting a correct and uniform tightening of high strength bolts
with friction factors even much different one from the other.

F Any uncertainty about the proper tensioning of the high strength bolt is then removed, contrary to
what happens when relying on the pure value shown by the pressure gauge on the hydraulic power
pack energizing the torque wrench, so studs and bolts can be re-used more and more times.

1.2 TIGHTENING PROCEDURE

Clean and visually inspect the threads of both the nuts and high strength bolts for signs of wear or
damage. Replace as needed.
Then lubricate them with care, using one of the following recommended products (picture 1.2.1):
- Molypaul Easyrun 100 (KS Paul Ltd.)
- Molycote G-Rapid (Dow Corning)
Brush application of lubricant should be on both the mating threads of the nut and bolt, as well as
the nut and flange contact faces.

Picture 1.2.1

Connect HYPUR-MATE HL-CT torque wrenches from HEDLEY PURVIS Limited (HPL) to
SST SE-10 (110V - 50/60 Hz) power pack.

Page 7/15 HD23 high strength bolt tightening_007_e

 Table 1.2.1 shows the HYPUR-MATE HL-CT torque wrench models to be used according to the
high strength bolts involved. It indicates also the maximum pressure value for the proper setting of
the hydraulic power pack.

7RUTXH9DOXHV

+LJK 3RZHU3DFN
%ROWWLJKWQHVV 7RUTXH:UHQFK
6WUHQJWK%ROW 0D[3UHVVXUH
0RGHO
6L]H >N1@ >OEV@ >EDU@ >SVL@

0
  +/&7  
VHFRQGKDQG

0
  +/&7  
QHZ

0   +/&7  

0   +/&7  

0   +/&7  

Table 1.2.1

F The values read on the pressure gauge of the hydraulic power pack, when tensioning the high
strength bolts with “Rotabolt” controls, are purely indicative. In fact, the “Rotabolt” control itself
shows the attainment of the designed tightening torque to the operator.

As a rule, position the high strength bolt with the “Rotabolt” control placed downwards (picture
1.2.2).

Picture 1.2.2

HD23 high strength bolt tightening_007_e Page 8/15

 Screw the hexagon nut on the upper part and the square nut on lower part down to their joint plates
( picture 1.2.3).

Picture 1.2.3

Joint plate

F Using a square nut on the lower part of the high strength bolt is not crucial. Hexagon nuts (like those
in picture 1.2.4) will also serve the purpose.
Square nuts are recommended, since they facilitate the tensioning operations, avoiding undesired
rotation of the high strength bolt.

Joint plate

Picture 1.2.4

Attention to “x” protrusion of the high strength bolt (picture 1.2.5), which should not exceed 5 mm
(high strength bolts M36/M39) or 10 mm (high strength bolts M45/M52).
“X” values exceeding the recommended limits would seriously compromise the correct operation
of the “Rotabolt” control.

x
Picture 1.2.5

Page 9/15 HD23 high strength bolt tightening_007_e

 Carry out tensioning by hydraulic torque wrench on the upper nut, thus allowing the operator an
easy access to the “Rotabolt” control.
Manually check the “Rotabolt” control for free rotation (picture 1.2.4). When the motion stops, the
high strenght bolt is properly tensioned.

First tighten the left nut by HEDLEY PURVIS torque wrench (picture 1.2.6).

Picture 1.2.6

The tightening of the left hand nut doesn’t need the application of the special reaction arm.

F Prior to tightening the right hand nut, position the special reaction bracket on the tightened left hand
nut to achieve a full-face contact with the mast section stanchion (picture 1.2.7).

Reaction arm

Picture 1.2.7

HD23 high strength bolt tightening_007_e Page 10/15

1.3 TENSIONING SEQUENCE
Tightening shall observe the following order:

1 £ £ 2 6 £ £ 5 Following the tensioning order in picture 2.3.1

avoids the user from having to tension high
1 £ £ 2 6 £ £ 5 strength bolts again after the crane erection is
finished.

The non-observance of this recommended

7 £ £ 8 4 £ £ 3 procedure might result in an irregular
tensioning of the 16 high strength bolts:
7 £ £ 8 4 £ £ 3 Dangerous!

Picture 1.3.1

F The tensioning order of picture 1.3.1 is valid not only for HD23 mast sections, but for lower slewing
ring supports, undercarriages and expendable foundation anchors of any HD23 type.

1.4 TIGHTENING CONTROL

During the high stsrength bolts tightening, HD23 mast sections respond with elasticity. Then, it
may happen that, on completing the tensioning sequence of picture 1.3.1, some “Rotabolt” controls
proved still free to rotate.
Further loosening can be detected within the first 2/3 working days of the crane, with a 6 to 7%
deviation from the rated torque values.
Check again, therefore, the high strength bolts for proper tightening, adjusting them as necessary,
regardless of the time required to complete the operation.

PRELOADING

You can reduce the time needed for retorquing of the studs or bolts by applying additional torque
(i.e. 6-7%) at initial installation.

Page 11/15 HD23 high strength bolt tightening_007_e

 PERIODIC CHECKS

Whatever torquing procedure is used (standard procedure or preloading procedure), random check
25% of the bolts for proper tension within two (2) working weeks from the crane erection.
Following carefully the torque values in table 1.2.1, eliminates further checking of the bolts.
If the crane is working for an extended period, random check 25% of the bolts every six (6) months.

F The high strength bolts with “Rotabolt” control and their nuts cannot be reused unlimitedly, but
restricted to 6 installations.

High strength bolts placed on the lower slewing ring support, instead, can be reused up to a peak
of 8 installations. This is because they are subject to less wear.
The crane User is then recommended to note down how many times each set of high strength
bolts with “Rotabolt” control and their nuts have been used.

F1.5
For further information, refer to the operation manual delivered with the crane.

MAINTENANCE
High strength bolts with “Rotabolt” control and their nuts (hexagon or square nuts apart) don’t need
any special maintenance.
Just check them for impurity and grease them as necessary prior to storing them in a proper place,
which is protected against rain and humidity.
“Rotabolt” control doesn’t need, instead, any maintenance.
Just protect it against impacts, which could remove it or compromise its proper functioning
(picture 1.5.1).

Picture 1.5.1

HD23 high strength bolt tightening_007_e Page 12/15

2 HD23 HIGH STRENGTH BOLTS WITHOUT “ROTABOLT”
CONTROL

2.1 GENERAL

F GRU COMEDIL authorizes also the use of M36 - M39 - M45 - M52 threaded studs or bolts not
equipped with ROTABOLT, if the threaded studs or bolts are of a type and grade approved by Gru
Comedil and supplied by them exclusively.

2.2 TIGHTENING PROCEDURE

A) Clean and visually inspect the threads of both the nuts and high strength bolts for signs of
wear or damage. Replace as needed.
Then lubricate them with care, using the following recommended product, or equivalent, with
a friction factor not exceeding 0.11:
- DOW CORNING ® G-N METAL ASSEMBLY PASTE
Brush application of lubricant should be on the mating threads of the nut and bolt, as well as
the nut and flange contact faces.
B) Screw the hexagon nut on the upper part and the square nut on lower part down to their joint
plates (picture 2.2.1).

Joint plate

Picture 2.2.1

F Using a square nut on the lower part of the high strength bolt is not crucial. Hexagon nuts will
also serve the purpose.
Square nuts are recommended, since they facilitate the tensioning operations, avoiding
undesired rotation of the high strength bolt.

Page 13/15 HD23 high strength bolt tightening_007_e

 C) Tighten nuts using a knocker wrench. Be sure to tighten all nuts to a similar amount of torque,
i.e. six impacts with the hammer per hexagonal nut.
The number of impacts is not critical (e.g. it may take five or eight impacts). What is critical is
that the bolts have the same approximate amount of torque.

F This is to be done for the tower erection, prior to installing the slewing upper part of the crane.
After the tower erection is completed, torque the bolts as indicated below.
- Connect LONE STAR HYTORC, INC. torque wrenches HY-XLT type to an adequate power
pack powered at 110V - 50/60 Hz.
Table 2.2.1 shows the HY-XLT torque wrench models to be used according to the high strength
bolts involved. It indicates also the maximum pressure value for the proper setting of the
hydraulic power pack.

7RUTXH9DOXHV

+LJK 3RZHU3DFN
%ROWWLJKWQHVV 7RUTXH:UHQFK
6WUHQJWK 0D[3UHVVXUH
0RGHO
%ROW6L]H >N1@ >OEV@ >EDU@ >SVL@

0   +<;/7  

0   +<;/7  

0   +<;/7  

0   +<;/7  

Table 2.2.1

F Now you can go on erecting the slewing upper part of the crane.

2.3 TENSIONING SEQUENCE

Tightening shall observe the following order:

1 £ £ 2 6 £ £ 5 Following the tensioning order in picture 2.3.1

avoids the user from having to tension high
1 £ £ 2 6 £ £ 5 strength bolts again after the crane erection is
finished.

The non-observance of this recommended

7 £ £ 8 4 £ £ 3 procedure might result in an irregular
tensioning of the 16 high strength bolts:
7 £ £ 8 4 £ £ 3 Dangerous!

Picture 2.3.1

F The tensioning order of picture 2.3.1 is valid not only for HD23 mast sections, but for lower slewing
ring supports, undercarriages and expendable foundation anchors of any HD23 type.

HD23 high strength bolt tightening_007_e Page 14/15

2.4 TIGHTENING CONTROL
During the high strength bolts tightening, HD23 mast sections respond with elasticity. Then, it may
happen that, on completing the tensioning sequence of figure 2.3.1, some threaded studs may be
below the recommended torque value.
Further loosening can be detected within the first 2/3 working days of the crane, with a 6 to 7%
deviation from the rated torque values.
Check again, therefore, the high strength bolts for proper tightening, adjusting them as necessary,
regardless of the time required to complete the operation.

PRELOADING

You can reduce the time needed for returquing of the studs or bolts by applying additional torque
(i.e. 6-7%) at initial installation.

PERIODIC CHECKS

Whatever torquing procedure is used (standard procedure or preloading procedure), random check
25% of the bolts for proper tension within two (2) working weeks from the crane erection.
Following carefully the torque values in table 2.2.1, eliminates further checking of the bolts.
If the crane is working for an extended period, random check 25% of the bolts every six (6) months.

F The high strength bolts without “Rotabolt” control and their nuts cannot be reused unlimitedly, but
restricted to 4 installations.

High strength bolts placed on the lower slewing ring support, instead, can be reused up to a peak
of 6 installations. This is because they are subject to less wear, but to many more torquing
procedures when top climbing.
The crane User is then recommended to note down how many times each set of high strength
bolts and their nuts have been used.

F
2.5
For further information, refer to the operation manual delivered with the crane.

MAINTENANCE
High strength bolts without “Rotabolt” control and their nuts (hexagon or square nuts apart) don’t
need any special maintenance.
Just check them for impurity and grease them as necessary prior to storing them in a proper place,
which is protected against rain and humidity.

Page 15/15 HD23 high strength bolt tightening_007_e