model gt800pss user manual pneumatic torque wrench
Contents
1. 15 10 IMPACHI uuu umi qy l xe E IM EET 16 Figure SO CET INSTALLATION agri ne ne h n r Men eadera ten diera dpt canes 16 Figure 12 SAMPLE TORQUE eke keke keke kek keke re K K k KAK KK AKA KHK KAKO 17 Figure 13 CHART FOR INTERPOLATION EXAMPLE 18 Figure PRESSURE SETIING 19 Figure 15 SOCKET OVER FASTENER Figure 16 REACTION ARM AGAINST 20 Figure 17 SOCKET OVER FASTENER Figure 18 REACTION ARM AGAINST 21 Figure 19 SAMPLE TORQUE CHAKRT 25 Figure 20 CGIo00PSS DIMENSIONS 28 Figure A FR DIMENSIONS T 29 WWW TORQFUSION COM 30 OF 32 REV 1308 USER MANUAL GT800PSS TOOL INFORMATION DATE PURCHASED SERIAL NUMBER INITIAL CALIBRATION NEXT CALIBRATION NEXT CALIBRATION NEXT CALIBRATION NEXT CALIBRATION NEXT CALIBRATION NEXT CALIBRATION ASSET NUMBER OTHER NOTES WWW TORQFUSION COM 31 OF 32 7 TURUS Fusion REV 1308 n TURUS USER MANUAL GT800PSS Fusion User Manual p n 001 F 0194 Patents Pending Copyright 2011 2013 TORQ Fusion LLC WWW TORQFUSION COM 32 OF 32 REV 13082. 27 PAR LS ORE 28 DIMENSIONS cop 28 eins e no 28 Qj 29 Io PRO MIC iz TRU A 30 WWW TORQFUSION COM 4 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion SAFETY Safety is our primary concern and we want to ensure that our customers enjoy the benefits of our tools while observing all appropriate safety measures Our tools are designed to be operated by trained skilled personnel Never disassemble or modify any portions of the tool or the FRL supplied by Fusion doing so may result in personal injury and the product warranty to become void Never strike or force any portion of the torque wrench or the FRL as this may cause damage to the equipment create an unsafe situation and void the warranty Reading this manual in its entirety is mandatory prior operating the equipment described in it Additional training may be required by your company s training or safety advisor PPE Personal Protective Equipment Always wear protective eyewear when operating power tools or entering an industrial environment Always wear hearing protection when operating power tools or environmental conditions may exceed 85 dB A of noise AN place your hands or other body parts near the reaction arm or any moving component avoid pinch points
3. USER MANUAL GT800PSS 7 TURN TOOL SPECIFICATION Output Drive SQ W pin retainer Max Torque 0 RPM 800 ft lbs Max Speed no load 12 RPM Max Air Pressure 115 PSP Max Air Consumption 20 CFM Air Connection FRL FNPT Max Noise Level 86 dB A 4 Tool Weight w o reaction arm amp output drive 6 4 lbs Reaction Arm Weight 2 9 Ibs Output Drive Weight 0 4 Ibs Optional 6 Tool Extension Weight 4 6 lbs Optional 12 Tool Extension Weight 6 9 Ibs Optional 18 Tool Extension Weight 9 1 Ibs FRL Weight 13 Ibs FRL Battery 9V PP3 Tool Oil Marvel Air Tool Oil MMO80 or MMOO085 5 Tool may also be supplied with a 1 square drive with pin retainer Never set FRL to a pressure higher than indicated on the torque chart 3 To achieve maximum operating range of the tool air supply must be at least 20 CFM Q 115 psi Maximum noise level at 100 PSI without a load noise levels under load are lower 5 May be purchased from TORQ Fusion or directly from a distributor WWW TORQFUSION COM 2 OF 32 REV 1308 7 TORO Fusion PARTS amp ACCESSORIES Standard 34 Square Drive Standard 1 Square Drive 6 Extension 12 Extension 18 Extension Standard Reaction Arm Reaction Arm Weld Blank Accessory Mounting Kit Pneumatic Tool Oil DIMENSIONS GT800PSS All dimensions in inches USER MANUAL GT800PSS Visit WWW TORQFUSION COM for more info P N 001 A 0053 P N 001 0054 P N 001 0044 P N 001 0043 P N 00
4. It is a good practice to also wear work gloves a hard hat steel toe shoes and any other protective equipment suitable for the task being performed Please consult with your company s safety advisor for more information WWW TORQFUSION COM 5 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion WARRANTY TORQ Fusion LLC is proud to offer a one year limited warranty for your torque wrench and FRL assembly We are confident in and stand behind all of the products we manufacture and sell TORQ Fusion LLC warrants this product against all material and workmanship defects for the duration specified above from the date of initial purchase In the event that this product is found be defective after being examined by TORQ Fusion LLC and in accordance with the terms specified in this section the defective product will be repaired or replaced at the discretion of TORQ Fusion LLC without cost to the end user The following list of reasons investigated and assessed by TORQ Fusion LLC will cause this warranty to become void and null in its entirety l Any modifications previous repairs or attempted repairs performed by parties other than TORQ Fusion LLC or factory authorized repair facilities 2 Any visible marks or signs indicating The equipment has been abused or mishandled other than normal wear of the equipment 3 Improper maintenance of the equipment according to the instructions in This manual This warranty covers all
5. A Always make sure that the units displayed on the digital pressure gauge match the units on the torque chart A The motor must not be running while setting The pressure The tool may or may not be engaged with the fastener to be tightened while adjusting the set pressure Pressure gauge Torque chart Air pressure adjustment Figure 14 PRESSURE SETTING WWW TORQFUSION COM 19 OF 32 REV 1308 7 TORCE USER MANUAL GT800PSS9 Fusion TIGHTENING Once the reaction arm and appropriate size impact socket have been installed and the correct pressure for your application has been set you are ready to tighten your fastener Depending on your application you may be required to use lubrication on the nut being tightened and a backup wrench on the nut on the opposite end of the stud please consult the instructions supplied by the fastener manufacturer or the engineering instructions supplied for the project AN Be sure to wear appropriate PPE Personal Protective Equipment please see the sections on SAFETY and PPE the beginning of this manual Never place your hands or other body parts near the reaction arm or any moving component Set the direction lever of the tool R Place the impact socket over the fastener see Figure 15 Slowly depress the tool trigger until the reaction arm touches a robust stationary object like a nearby fastener or other similar metal feature see Figure 16 Remember that the
6. Fusion Tool Swivel fitting storage Air Hose Hose storage Rubber feet Figure 4 BACK VIEW OF FRL Filter Lubricator Regulator Figure 5 BOTTOM VIEW OF FRL WWW TORQFUSION COM 10 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion INSTALLATION A Installation of this tool must be performed by personnel skilled and trained in the installation of pneumatic fittings The air supply will be connected fo the FRL air inlet connection see Figure 3 via a pneumatic hook up hose not supplied with a minimum inside diameter of 2 or larger depending on the distance from the compressor to the FRL It is the responsibility of the end user to ensure that a minimum air supply of 20 CFM 115 PSI is delivered to the inlet connection of the FRL Regardless of hook up hose size used it must have a 2 MNPT fitting entering the FRL The installation of a shut off valve is also recommended Upstream of the FRL Teflon tape must be used on the 2 MNPT fitting prior to installing it to the FRL TORQ Fusion does not recommend the use of any other type of thread sealer Proper torque for that size fitting must be applied 50 60 ft lbs 68 81 N m is common practice No backup wrench is required for installation as the FRL housing will perform that function Un coil the hose supplied with the FRL and connect the free end to the swivel air connection at the base of the tool handle see Figure 1 To engage the fitt
7. below above 75 650 oo TT 76 9 psi T 673 636 elow above Where FOR USE ONLY WITH P set pressure for FRL GT800PSS S N 1101005 IMPERIAL METRIC torque to achieve psi ft lbs Bar EOS 3 1 226 2i3 324 3 3 422 471 920 969 618 667 716 N N on wich io NI Go O NO Co Go Be AIO ek Sj 3 34 2 9 52 WwW 00 I Q2 C9 N DN O O an 2 348 2 420 3 456 3 492 3 1 8 0 6 2 8 PC ly J O 528 64 765 600 4 8 814 Tos 75 2 GIO 5 17 863 _ 650 would fall ere between these lines 90 745 6 21 1010 LAST CALIBRATED MAR 20 2011 Co PSI 60 BS I T above re Fi Figure 13 CHART FOR INTERPOLATION EXAMPLE A simpler but less accurate formula may also be used n 922 75 76 7 psi above 6 WWW TORQFUSION COM 18 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion ADJUSTING THE SET PRESSURE Once the appropriate set pressure has been determined from the torque chart and or by using the information in the previous sections power on the pressure gauge and turn the air pressure adjustment knob see Figure 12 until the set pressure is achieved Always turn the knob clockwise the set pressure If the pressure is too great turn the knob counter clockwise until below set pressure and then clockwise back up set pressure
8. the equipment supplied except l Packaging materials 2 The output drive 3 The reaction arm 4 Consumables batteries lubricating oil etc TORQ Fusion LLC shall in no event be found liable for any damages including personal or material including loss of profits of any parties involved Please contact your sales representative or the factory directly with any questions you may have regarding this warranty WWW TORQFUSION COM 6 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion ABOUT THE TOOL The GT800PSS is a single speed pneumatic torque wrench designed to output a maximum of 800 ft lbs 1 085 of continuous torque The tool is based on a multi vane pneumatic motor driving a high reduction multi stage planetary gearbox When tightening or loosening fasteners requiring torque in the range offered by this tool there are many other methods available large breaker bars manual torque multipliers impact wrenches or hydraulic wrenches Breaker bars and manual torque multipliers are the lowest cost option but are labor intensive and some have questionable torque accuracy Impact wrenches are relatively low cost but have very poor torque accuracy and generate a large amount of vibration and noise these factors may present serious health risks Hydraulic wrenches are very expensive move relatively slow and require heavy hydraulic pumps Continuous torque pneumatic wrenches like this one offer a good balance of po
9. 1 A 0038 P N 001 0217 P N 001 0205 P N 001 A 0068 P N 001 0120 Figure 20 GI800PSS DIMENSIONS WWW TORQFUSION COM 28 OF 32 TD 1 LJ X REV 1308 USER MANUAL GT800PSS9 7 TORQ Fusion FRL All dimensions in inches p i f N 13 6 4 D 11 0 j N m Figure 21 FRL DIMENSIONS WWW TORQFUSION COM 29 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion TABLE OF FIGURES Figure 1 FRONT VIEW OF TOOL illo 7 Figure 2 BACK VIEW OF Mee MEE 8 Figure dem OF FR E 9 Figure 4 BACK VIEW OF FRL M E ekere yekeke ke kek k keke kek kk kek KAKA HERK KA HEAR AK AHA 10 Figure 5 BOTTOM VIEW OF ieri kek k KEK KK KK ERU HAA 10 Fig r NEC PSO CRED 12 Figure 7 TOOL EXTENSION INSTALLATION 13 Figure 8 REACTION ARM INSTALLATION 14 Figure 9 OUTPUT DRIVE INSTALLATION
10. MODEL GT800PSS USER MANUAL PNEUMATIC TORQUE WRENCH TORQ Fusion 7 n TURUS USER MANUAL GT800PSS Fusion WWW TORQFUSION COM 20F32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion INTRODUCTION Thank you for choosing TORQ Fusion as your torque tool manufacturer We understand that our customers have many options when selecting their equipment and we truly appreciate the opportunity to serve your bolting needs Our company firmly believes that the development of any product starts with first understanding the needs of our customers and apprehending the challenges they encounter with the equipment they currently use The TORQ Fusion design Team then tackles these challenges and implements innovative resolutions in the design it develops Next we prototype and evaluate our designs gauging not only performance but also robustness Every one of our designs goes through an exhaustive life test taking into account every possible situation that might occur during normal operation As our tools enter the production phase each unit is calibrated throughout its operating range and our technical staff reviews each calibration certificate before signing off and releasing it Please take the time to review the rest of this manual paying special attention to the safety instructions associated with your equipment If you have additional questions please feel free to contact your sales representative or the factory by
11. d grease engage output drive to gearbox and replace reaction arm see REMOVING AND INSTALLING THE REACTION ARM in the previous pages WWW TORQFUSION COM 15 OF 52 REV 1308 n TURUS USER MANUAL GT800PSS Fusion INSTALLING THE IMPACT SOCKET Only impact sockets must be used with your torque tool They must be properly installed with locking pins and retainer ring The output drive of your tool may be either 34 or 1 depending how the tool was ordered or what additional accessories were purchased with if First slide the retainer ring o ring over the socket as shown in Figure 10 Locking pin hole n Figure 10 IMPACT SOCKET Retainer ring Place the socket over the torque tool output drive square drive aligning the locking pin hole with the hole in the output drive Slide in the locking pin see Figure 11 Socket groove Locking pin Figure 11 SOCKET INSTALLATION Finish the socket installation by rolling the retainer ring into the socket groove to keep the locking pin in place WWW TORQFUSION COM 16 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion DETERMINING THE SET PRESSURE The GT800PSS is capable of operating under a wide range of pressures not exceeding 100 PSI The toque output of the tool will increase as the pressure on the FRL is set to higher values Based on the size and application of the fastener being tightened determine the appropriate torque required Corre
12. e used at a higher duty cycle might require calibration every 6 months or at a different interval Please consult with your sales representative or the factory for the appropriate interval The torque chart below is used to illustrate the information that is normally generated at the time of calibration FOR USE ONLY WITH GI800PSS S N 1101005 PSI ft lbs Bar N m E EU M m 120 07 422 40 384 2 76 220 60 528 4 14 716 70 600 483 814 180 673 552 912 90 745 6 21 1010 LAST CALIBRATED MAR 20 2011 Figure 19 SAMPLE TORQUE CHART Please note that all Torque charts will include the following information e ool model number e Tool serial number e Pressure Torque correlation values e Calibration date Calibration services are available by contacting your sales reoresentative or the factory directly and should never be performed elsewhere WWW TORQFUSION COM 25 OF 32 REV 1308 USER MANUAL GT800PSS 7 TORO Fusion TROUBLESHOOTING If you experience problems while operating the torque tool please use the chart below prior to contacting your sales representative or the factory PROBLEM POSSIBLE CAUSE ACTION The tool doesn t run when trigger is pressed the motor doesn t make any noise he tool doesn t run when trigger is pressed the motor makes a hissing noise but the output drive doesn t turn The tool makes an abnormal or irregular sound w
13. e we recommend disconnecting the FRL unit from the air supply at least once a day depending on the amount of moisture found in the air line Occasionally there might be some debris trapped by the filter which should be cleaned out every months To do so disconnect the air supply and eliminate any air left in the FRL by connecting the torque tool and pressing the trigger until the motor stops turning plus an additional 10 seconds to allow all the air to escape Turn the FRL unit on its side revealing the pneumatics inside see Figure 5 Remove the filter bowl by unscrewing it Empty out the contents of the bowl and wipe off any debris left on the white filter element inside the FRL housing before re installing the filter bowl FRL ADDING TOOL OIL The lubricator mounted in the FRL unit ensures that the air supplied to the torque tool contains a fine mist of oil which lubricates the vanes of the air motor to prevent premature wear AS you can imagine running the torque tool while the lubricator bowl is empty will cause permanent damage to the motor and void the warranty To prevent that from happening please check the oil level in the lubricator bowl by inspecting it thru one of the two large cutouts in the FRL housing see Figure 3 The lubricator oil should be checked at least once a day more often for high duty cycles Under normal conditions a full bowl should last for a minimum of 1 000 cycles Use only the recommended tool oil sp
14. ecified in the TOOL SPECIFICATION section of this manual To add oil first disconnect the air supply and eliminate any air left in the FRL by connecting the torque tool and pressing the trigger WWW TORQFUSION COM 23 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion until the motor stops turning plus an additional 10 seconds to allow all the air fo escape Unscrew the lubricator bowl fill to the MAX mark on the bowl and screw the bowl back into the unit FRL REPLACING THE BATTERY The digital pressure gauge uses a standard 9V battery which will need to be replaced periodically The battery drawer is located on the left side of the FRL housing next to the air inlet connection see Figure 3 To access the drawer a small screw driver will be required Insert the tio of the screw driver in the notch of the battery drawer and push down fo pry if open Slide out the rawer and remove the old battery by pulling if out vertically Insert the new battery the battery can only fit one way to maintain correct polarity Push in the battery drawer into the FRL housing until it clicks WWW TORQFUSION COM 24 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion TOOL CALIBRATION The torque tool is factory calibrated when initially sold but in order to ensure accurate delivery of torque a periodic re calibration is required TORQ Fusion recommends that the Torque tool be calibrated at least once a year Tools that ar
15. ed with 34 square output drive unless a 1 square output drive was specified when purchased or purchased separately To change the size of the square drive see REMOVING AND INSTALLING THE OUTPUT DRIVE section later in this manual Figure 6 IMPACT SOCKET A reaction arm is necessary for the operation of the tool in order to keep the gearbox housing from turning under extreme torque output conditions While operating The reaction arm must be resting against a robust stationary object usually a nearby fastener capable of withstanding a reaction force equal to the torque being generated by the tool During operation the tool handle may be rotated with respect to the gearbox housing as not to transmit a reaction torque greater than a few foot pounds to the operator of the tool WWW TORQFUSION COM 120F 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion REMOVING AND INSTALLING THE TOOL EXTENSION Your tool may be equipped with an optional extension depending on your application The tool extension may be easily removed and re installed for increased tool versatility can be installed in one of 8 positions on the spline of the gearbox housing see Figure 7 To install remove the set screw located on the tool extension using a 1 8 hex wrench Slide out the tool extension retaining pin if the retaining pin does not slide out easily if may be pushed out with the 1 8 hex wrench Ensure that the inside of the gearbox rec
16. email at infoetorqfusion com Thank you again for choosing TORQ Fusion WWW TORQFUSION COM 3 OF 32 REV 1308 T TURUS USER MANUAL GT800PSS Fusion TABLE OF CONTENTS pie e l SAFC s re M M PPE Personal Protective Equipmentl 9 NARRANTE e 6 esM Be rrr rrr r r E ABOUT IRE E 9 STALLA NO 1 i MM epica iaia piano 11 OPERATING INSTRUC HONS m 12 REMOVING AND INSTALLING THE TOOL EXTENSION 13 REMOVING AND INSTALLING THE REACTION ARM 14 REMOVING AND INSTALLING THE OUTPUT DRIVE 15 INSTALLING THE IMPACT SOCITI 16 DEIESMIBINS TIBESEPERESSURSE near E ae 17 CINFARINIERPOLANON 18 ADJUSIINS THI SEW PIE SURE siii EE 19 Ueulzt a0 20 OS ENN ee oommlmlm 2 I T h C uuu m s ekere 22 CARE AND MAINTENANCE 22 Ies U apri 22 l sebr Al Tig Ge 23 OLO Lean 23 FRE RKEPDACINO IHEDBAIJ EKYuu u nw 24 TOO 8 25 Ue CTI O 26 TO OLSPECIHEAMNON
17. eptacle is well lubricated as shown using lithium or petroleum based grease If is also a good practice to check the lubrication on the extension journal by sliding out the inner shaft of the extension lubricate using lithium or petroleum based grease and re insert the inner shaft into the extension housing Fully engage the spline of the tool extension with the spline of the gearbox housing and insert the tool extension retaining pin Replace the setscrew in the tool extension and re tighten Gearbox housing spline Lubricate well Setscrew Reaction arm retaining pin Extension journal Figure 7 TOOL EXTENSION INSTALLATION To remove the tool extension remove the set screw and tool extension retaining pin then slide the extension off the gearbox Be careful not to drop the inner shaft out of the assembly WWW TORQFUSION COM 13 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion REMOVING AND INSTALLING THE REACTION ARM The reaction arm may be installed in one of 8 positions on the spline of the gearbox housing see Figure 8 To install remove the set screw located on the reaction arm using a 1 8 hex wrench Slide out the reaction arm retaining pin if the retaining pin does not slide out easily it may be pushed out with the 1 8 hex wrench Ensure that the output drive journal is well lubricated as shown using lithium or petroleum based grease Fully engage the spline of the reaction arm with t
18. gearbox and reaction arm assemblies can rotate with respect to the tool handle to accommodate the most favorable work angle for the tool NEU Figure 15 SOCKET OVER FASTENER Figure 16 REACTION ARM AGAINST NEARBY FASTENER Fully depress trigger until socket stops turning Once the socket stops do not depress the trigger again doing so may increase the torque applied to the fastener by an undesirable amount If necessary set the direction lever of the tool to L and depress the trigger slightly to ease in disengagement of socket WWW TORQFUSION COM 20 OF 32 REV 1308 TORO USER MANUAL GT800PSS T Fusion LOOSENING When loosening a fastener it is generaly safe to use the maximum available torque To do so power on the pressure gauge and turn the air pressure adjustment knob until the digital pressure gauge reads just under 100 PSI do not exceed 100 PSI or the tool may be damaged and operator injury may occur Be sure wear appropriate Personal Protective Equipment please see the sections on SAFETY and PPE at the beginning of this manual Never place your hands or other body parts near the reaction arm or any moving component Set the direction lever of the tool to L Place the impact socket over the fastener see Figure 17 Slowly depress the tool trigger until the reaction arm touches a robust stationary object like a nearby fastener or other similar metal feature see Fi
19. gure 18 Remember that the gearbox and reaction arm assemblies can rotate with respect to the tool handle to accommodate the most favorable work angle for the tool Figure 17 SOCKET OVER FASTENER Figure 18 REACTION ARM AGAINST NEARBY FASTENER Fully depress trigger until the fastener is removed WWW TORQFUSION COM 21 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion BEST PRACTICES Several steps should be taken when using the torque tool to maintain maximum torque accuracy 1 If tool has not been used for a period of time disconnect the FRI hose from the tool add a few drops of tool oil see the TOOL SPECIFICATION section of this manual down the swivel air connection see Figure 1 re connect the hose and run it in either direction for a few seconds prior to engaging It to the application 2 Neverre torque a fastener to the same setting it will result in a higher than desired torque value The tool is designed to achieve proper torque only in dynamic situations CARE AND MAINTENANCE There is minimal maintenance required for your torque wrench RI Before performing maintenance please be sure to read and understand this manual in its entirety If you still have questions please contact your sales representative or the factory directly TORQUE TOOL The torque wrench is designed to generally be maintenance free for the duration of its life however depending on the duty cycle and t
20. he environment in which it s used in there may be a few parts requiring replacement The output drive has a limited life and after several thousand cycles at full load may require replacement please see the section entitled REMOVING AND INSTALLING THE OUTPUT DRIVE for further instructions Lubricate periodically see Figure 9 With severe duty cycles the air motor may require its vanes replaced We do not recommend this task be performed in the field as it requires a high level of experience with air motors and a re calibration of the tool Replacement vanes are available by contacting your sales representative or the factory Improper installation of the motor vanes will void the warranty and may cause an incorrect torque output or the tool to malfunction WWW TORQFUSION COM 22 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion The gearbox is lubricated for life and will not require additional grease to be added by the operator After intensive use it may need to be rebuilt but this can only be performed by the factory please contact your sales representative or the factory for additional information including cost FRL CLEANING THE FILTER The FRL unit contains a filter see Figure 5 designed to protect the air motor from exposure to water particles or debris from the air line The filter automatically drains the water collected in the bowl onto the floor every time the air supply is cycled on or off therefor
21. he spline of the gearbox housing and insert the reaction arm retaining pin Replace the setscrew in the reaction arm and re tighten Gearbox housing spline Lubricate Reaction arm spline Setscrew Reaction arm retaining pin Figure 8 REACTION ARM INSTALLATION To remove the reaction arm remove the set screw and reaction arm retaining pin then slide The reaction arm off the gearbox WWW TORQFUSION COM 14 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion REMOVING AND INSTALLING THE OUTPUT DRIVE The output drive square drive of the torque wrench is designed to be field replaceable by the operator Some of the reasons for changing the output drive could be replacing the standard 94 square drive with the optional 1 square drive replacing a broken output drive or replacing the standard output drive with a custom output drive Regardless of the reason for replacing the output drive it s as easy as removing one set screw Start by removing the reaction arm see REMOVING AND INSTALLING THE REACTION ARM in the previous pages Continue by simply pulling the square drive out Lubricate well Figure 9 OUTPUT DRIVE INSTALLATION If removing a broken output drive the part should just slide out if it doesn t a pair of pliers or screw driver may be used To re install an output drive first lubricate the output drive journal and quadrilobe areas as shown using a lithium or petroleum base
22. hile running The pressure gauge does not power on The motor sounds normal but the socket doesn t turn The tool is not delivering desired torque WWW TORQFUSION COM 1 o l 2 o l Air supply connected Air supply hose has a kink or heavy object on it Regulator is set on the minimum setting The tool is engaged with a fastener and has reached the max torque The gearbox or motor are defective The direction lever is incorrectly set The motor is not lubricated The gearbox or motor are defective 1 The battery is dead 2 The gauge 15 defective l The output drive is 2 3 4 broken FRL air pressure may be adjusted incorrectly There is insufficient air flow delivered to the FRL Calibration not up to date The gearbox or motor are defective 26 OF 32 Connect air supply Remove kink heavy object and replace hose if necessary Check pressure by turning on the pressure gage Remove tool from fastener and press trigger to ensure proper operation Contact factory for repair Move lever to either R or L positions Check lubricator level Contact factory for repair l Replace battery 2 Contact factory for repair l Replace contact factory for spare Read TORQUE SETTING section of this manual See INSTALLATION section of this manual Contact factory for calibration Contact factory for repair REV 1308
23. ings simply push the female fitting into the male fitting while sliding back the knurled sleeve on the female fitting this is performed easier with the system de pressurized but it may also be done under pressure To ensure sufficient air flow is being supplied to the tool set the FRL to the maximum pressure expected to be used do not set FRL a pressure higher than indicated on the torque chart Install a socket onto the tool and use the tool to tighten a fastener until the tool stops turning while still depressing the tool trigger check the digital pressure gauge on the FRL and ensure the pressure displayed is within 1 psi of the pressure set at the beginning of this paragraph If the pressure drops more than 1 psi a larger pneumatic hook up hose and or compressor is needed The torque tool is now installed WWW TORQFUSION COM 11 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion OPERATING INSTRUCTIONS Before starting completely read this manual and ensuring all steps are understood Any additional questions may be answered by contacting your sales representative or the factory by email at info torqfusion com Ensure that the serial number on the back of the tool see Figure 2 matches the serial number on torque chart located on the FRL see Figure 3 Only 94 or 1 impact sockets may be used with your torque tool properly installed with locking pins and retainer ring see Figure 9 The tool is normally suppli
24. late the required torque to the operating pressure by looking at the torque chart located on the FRL see Figure 3 The torque chart lists pressure values in increments of 5 PSI For most applications if you cannot find the exact torque value on your chart the closest value will do if more precise values are needed use one of the formulas on the next page to calculate the set pressure The chart below is a sample of what the torque chart on your FRL might look like DO NOT use these values to set the pressure for your tool instead use the values on the chart provided with your FRL FOR USE ONLY WITH GT800PSS S N 1101005 IMPERIAL METRIC PSI ft lbs Bar N m 100 817 6 89 1108 LAST CALIBRATED MAR 20 2011 indie che ak NI Go Q N CO Be o WIN N O O PO ly po BS O 00 O1 O1 O1 Qo O1 DINI PSI ft lbs 60 528 70 600 80 673 90 745 100 817 O O VIN Figure 12 SAMPLE TORQUE CHART WWW TORQFUSION COM 17 OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion LINEAR INTERPOLATION Intermediate interpolated values may be calculated using linear interpolation in order to maintain a high level of accuracy for your tool Example To set the tool at 650 ft lbs when that value is not listed on your chart use the following formula to determine the set pressure for the FRL P P
25. wer speed ergonomics and cost Gearbox Replaceable output drive Reaction arm Trigger Air flow adjustment disabled Air exhaust ED E 18 ba 6 w d 4 Swivel air Figure 1 FRONT VIEW OF TOOL connection WWW TORQFUSION COM OF 32 REV 1308 n TURUS USER MANUAL GT800PSS Fusion j Serial number NIS label Direction lever Cushioned grip Figure 2 BACK VIEW OF TOOL WWW TORQFUSION COM 8 OF 32 REV 1308 TURUS USER MANUAL GT800PSS 7 Fusion ABOUT THE FRL The rotary vane motor of the tool produces a torque output proportional to the air pressure it is supplied In order to facilitate adjustment of the torque output of the tool we supply a designated FRL Filter Regulator Lubricator with each one To ensure that the torque output of this tool is as accurate as possible our FRL features a precision grade regulator and digital pressure gauge It is imperative that our tools only be operated with the FRL units supplied by TORQ Fusion and the serial number printed on the torque chart of the FRL matches the serial number printed on the back of the tool Carry Tool storage handle 2 compartment Air pressure Torque d adiustment Pressure Quick start gauge instructions Battery drawer N Swivel fitting Air hose Air inlet Lubricator Figure 3 FRONT VIEW OF FRL WWW TORQFUSION COM 9 OF 32 REV 1308 7 TURUS USER MANUAL GT800PSS
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