GT SERIES USER MANUAL GT200PSS GT500PSS
Contents
1. 22 intelTORQ FRL ADJUSTING THE SET PRESSURE 23 inteliTORQ M FRL CHANGING THE ACTIVE IOOL 24 intelTORQ FRL ADDING A NEW IOQOL 24 inteliTORQTM FRL REMOVING TOQOL 24 II H oommn xyy 25 Esecidicem 26 LT E ak N N DM DMDMDMNMNNnNHNHNnunHnEnNnEEnRnnEnozP JJ RR NE 27 CARE AND MAINTENANCE 27 191469 ot 27 Fre TA i GIHTE rC uu om _w 28 FRE ADDING a 28 dud ING IHE BATERY nn a bera b a seen k M 29 916 AR RON dd a ed a gt s 30 TROUBLES OO NS 31 WWW TORQFUSION COM 4 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion RO CIC IN um Mann 32 Ea dE M ES d ee 32 p P 33 DIMENS Lr 33 cuin 33 34 34 es r rJ 35 12 02 8 C e 35 FRL TTS O RQ c2. TORDE USER MANUAL GT SERIES User Manual p n 001 F 0325 Patents Pending Copyright 2011 2014 TORQ Fusion LLC WWW TORQFUSION COM 40 OF 40 REV 1411
3. 4 The gearbox or Contact factory for motor are defective repair WWW TORQFUSION COM 31 OF 40 REV 1411 USER MANUAL GT SERIES mes TOOL SPECIFICATION PARAMETER Output Drive Max Torque Min Torque Noise system Accuracy Tool Weight Total Weight FRL Weight Air Pressure Air Consumption Air Connection FRL Accuracy Warranty Tool Oil GT200PSS IMPERIAL METRIC 200 ft lbs 500 55 IMPERIAL 3 4 or 1 SQ 271 N m 500 ft lbs 35 ft Ibs RPM 100 ft lbs 2 4 165 8 7 165 GT800PSS GTI 300PSS IMPERIAL METRIC IMPERIAL 3 4 or 1750 1 300 ft lbs 120 ft Ibs 12 RPM 86 200 ft lbs 7 2 RPM 4 4 lbs 13 lbs 5 9 110 psi 7 58 Bar 20 566 l min 1 2 standard PPS inteliTORG FRE 1 5 cell ER20 1 year limited Marvel Air Tool Oil MMOB MMO085 gt c GT2600PSS IMPERIAL METRIC 1 1 2 56 2 600 550 ft lbs C lt f 16 4 ls LL 16 4 ls gt 2 O t 2 USER MANUAL GT SERIES PARTS amp ACCESSORIES Standard 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 GT200PSS All dimensions in inches T TURLUS Fusion Visit W
4. Fusion FRL Standard and inteliTORQ All dimensions in inches N m m Figure 28 FRL DIMENSIONS WWW TORQFUSION COM 36 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion TABLE OF FIGURES Figur FRONT VIEW OF OO E vena e denke EE RA 9 Figur 2 REAR VIEW OF TOOL 10 Figure s FRONT VIEW OF FR E et ec te nn ne 1 Figure d BACK VIEW OF FRL Asyaya herk n n hn hebe nek ake e Mn kek eci nA RUE 12 Figure 35 BOTIO N VIEW OF ER 12 Figure 6 intelllORQTM FRL 13 Hove 7 IMPACT SCORE ___ 14 Figure 8 TOOL EXTENSION INSTALLATION 15 Figure 9 REACTION ARM INSTALLATION 16 Figure 10 OUTPUT DRIVE INSTALLATION eke keke rek ke kek kek KA HA 17 Figure 11 2600 REACTION FIXTURE REMOVAIL INSTALLATION 18 Figure 12 ANM a ene ONU 19 Figure 13 SOCKET TALONS 19 Figure 14 SAMPLE TORQUE CHART eee eee eke kek keke keke
5. KERA KA KAK KAKA 20 Figure 15 CHART FOR INTERPOLATION EXAMPLE 21 Figure 22 PLE ST RQ IM CONSOLE 23 Figure 18 SOCKET OVER FASTENER Figure 19 REACTION ARM AGAINST 25 Figure 20 SOCKET OVER FASTENER Figure 21 REACTION ARM AGAINST 26 Figure 22 SAMPLE TORQUE CHART 428 30 Figure 23 GT200PSS DIMENSIONS 33 Figure 24 2 1500855 1 si uUo dken la kerey a e keka 34 Figure 25 GT800PSS DIMENSIONS Ke KK KAKA KRA KA 34 10016 26 02211 0 02 DIMENSION a k n key ask W nn 35 Figure 27 12600 55 DIMENSIONS uetus n k da i w d la 35 Figure 28 FRE DIMENSIONS a shun l n k n n ean 36 WWW TORQFUSION COM 37 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES Fusion 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 38 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion WWW TORQFUSION COM 39 OF 40 REV 1411 Fusion
6. 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 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES 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 to the FRL air inlet connection see Figure 3 via a pneumatic hook up hose not supplied with a minimum inside diameter of gt 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 if 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 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 ba
7. bowl by pulling the release lever and turning the bowl in either direction 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 several hundred cycles Use only the recommended fool oil listed 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 until the motor stops turning plus an additional 5 seconds to allow all the air to escape Remove the lubricator bowl by pulling the release lever and turning the bowl in either direction fill to the MAX mark on the bowl and re install the bowl back into the unit WWW TORQFUSION COM 28 OF 40 REV 1411 USER MANUAL G
8. hole Retainer ring Figure 12 IMPACT SOCKET 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 13 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 19 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES Fusion STANDARD FRL DETERMINING THE SET PRESSURE The GT series tool is capable of operating under a wide range of pressures not exceeding the maximum pressure listed on the torque chart 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 Correlate 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 in the next section 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 cha
9. is capable of working with up to 4 different tools and the LINE PRESSURE mode which simply displays the set pressure If you just purchased a new GT series tool and intend to use it with the inteliTORQ you must first add it the FRL The GT series tools contain a RFID chip in the serial number label with the tool s torque chart that torque chart can be uploaded in the inteliTORQTM FRL in a few seconds To add a new tool first set the FRL to LINE PRESSURE mode see CHANGING THE ACTIVE TOOL Place the back of the tool you wish to add in the RFID tool reader receptacle see Figure 6 Press and hold the ADD DEL left button for 30 seconds the torque chart of that tool will be added to the FRL inteliTORQ REMOVING TOOL If a tool will no longer be used with the intiTORQ FRL it should be removed from the FRL s memory to avoid confusion Similarly if a tool that was previously used with the intiTORQ FRL but was recently calibrated it must first be removed from the FRL memory and then added back see the ADDING A NEW TOOL section To remove a particular tool from the FRL memory first set the FRL to that fool see CHANGING THE ACTIVE TOOL Press and hold the ADD DEL left button for 30 seconds then confirm the removal of that tool WWW TORQFUSION COM 24 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion TIGHTENING Once the reaction arm and appropriate size impact socket ha
10. it is set at into the corresponding torque displaying it dynamically This eliminates the possible errors associated with reading torque charts interpolating exact values for in between pressures and reading analog pressure gauges The inteliTORQ FRL can store digital calibration charts and be used with up to 4 TOR Fusion pneumatic torque wrenches can also display pressure values like a conventional FRL RFID tool reader 2 line multi function display Function buttons Figure 6 inteliTORQTM FRL WWW TORQFUSION COM 13 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES 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 the factory 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 Standard FRL see Figure 3 or on the display of the intelTORQ FRL see Figure 6 Only impact sockets may be used with your torque tool properly installed with locking pins and retainer ring see Figure 12 The GT series tool is normally supplied with a standard square drive unless a different size was specified or purchased separately To change the size of the square drive see REMOVING AND INSTALLING THE OUTPUT DRIVE section later in this manual Figure 7 IMPACT SOCKET A r
11. GT SERIES USER MANUAL GT200PSS GTSOOPSS GT800PSS 1300 55 GT2600PSS PNEUMATIC TORQUE WRENCH TOROQ Fusion 7 USER MANUAL SERIES Fusion WWW TORQFUSION COM 2 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 fr
12. OF 40 REV 1411 J USER MANUAL GT SERIES Fusion STANDARD FRL 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 A Always make sure that the units disolayed 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 while adjusting the set pressure as the tool should not be turning Pressure gauge Torque chart Air pressure adjustment Figure 16 PRESSURE SETTING WWW TORQFUSION COM 22 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion inteliTORQ FRL ADJUSTING THE SET PRESSURE Power on the FRL by pressing either of the two buttons Check the model number and serial number on the back of the tool you are using and ensure it is disolayed on the lower row of the FRL display inteli URU FRL QUICK START INSTRUCTIONS RAS NO TI TEN Ji PED ri BE SI E THE TEFKAN AT j AI Tik c UTI WI i D mur LITE En Fusion Figure 17 inteliTORQTM CONSOLE A Always make sure that the model number and se
13. T SERIES TORJE Fusion FRL REPLACING THE BATTERY Standard FRL The digital pressure gauge uses a 9V battery which wil 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 tip of the screw driver in the notch of the battery drawer and push down to pry it open Slide out the rawer and remove the old battery by pulling it 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 inteliTORQ FRL The digital disolay uses 1 5V D size battery which will need to be replaced periodically The battery compartment is located underneath the FRL on the left side Tilt the FRL housing back unscrew the battery compartment cover replace the battery and re install the battery compartment cover WWW TORQFUSION COM 29 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES 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 are used at a higher duty cycle might require calibration every months or at a different interval Please consult with your sales rep
14. WW TORQFUSION COM for more info P N 001 A 0053 P N 001 0054 P N 001 0044 P N 001 A 0043 P N 001 A 0038 P N 001 0072 P N 001 0205 P N 001 A 0068 P N 001 0120 Figure 23 GT200PSS DIMENSIONS WWW TORQFUSION COM 33 OF 40 REV l411 J USER MANUAL GT SERIES Fusion GTSOOPSS All dimensions in inches Figure 24 GT500PSS DIMENSIONS 800 55 All dimensions in inches 5 WWW TORQFUSION COM 34 OF 40 REV 1411 Figure 25 GI800PSS DIMENSIONS USER MANUAL GT SERIES TORJE Fusion GT1300PSS All dimensions in inches Figure 26 GT1300PSS DIMENSIONS GT2600PSS All dimensions in inches Figure 27 GI2600PSS DIMENSIONS WWW TORQFUSION COM 35 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES
15. eaction 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 usualy a nearby fastener capable of withstanding a reaction force equal to the torgue 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 several foot pounds to the operator of the tool WWW TORQFUSION COM 14 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 It can be installed in one of 8 positions on the spline of the gearbox housing 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 receptacle is well lubricated as shown using a 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 in
16. ee to contact your sales representative or the factory at info torqfusion com Thank you again for choosing TORQ Fusion WWW TORQFUSION COM 3 OF 40 REV 1411 7 USER MANUAL SERIES Fusion TABLE OF CONTENTS ae er db ee 3 17 1 8 40 zQ H 4 sy DEM 6 PPE Personal Protective Equipmenl 6 VV Pus IS A L Tr Tm TO PP HH 8 ABOUTTRE TIDE aa aa ERRE E E EESE EEE E 9 ABOUT TAE T Dol 11 HANDARD MODE a E 1 li OS ODE 13 ids seii ene m 14 REMOVING AND INSTALLING THE TOOL k r 15 REMOVING AND INSTALLING THE REACTION AFM 15 REMOVING AND INSTALLING THE OUTPUT DRFIVE 17 REMOVING AND INSTALLING THE 2600 REACTION ATTACHMENT 18 INSTALLING THE IMPACT SOCKEL I 19 STANDARD FRL DETERMINING THE SET PRESSURE 20 STANDARD FRL LINEAR INTERPOLATION 2 STANDARD FRL ADJUSTING THE SET PRESSURE
17. ement 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 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 WWW TORQFUSION COM 27 OF 40 REV 1411 7 USER MANUAL GT SERIES Fusion 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 therefore 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 6 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 5 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
18. est cost option but are labor intensive and some have questionable torque accuracy Impact wrenches are relatively low cost but have poor torque accuracy and generate large amount of vibration and noise these factors may present serious health risks Hydraulic wrenches are more expensive move relatively slow and require heavy hydraulic pumps Continuous torque pneumatic wrenches like the GT series offer a good balance of power speed ergonomics and cost Gearbox Replaceable output drive Reaction arm Le Trigger Air flow adjustment disabled Air exhaust Swivel qir Figure 1 FRONT VIEW OF TOOL connection WWW TORQFUSION COM 9 OF 40 REV 1411 7 USER MANUAL SERIES Fusion ara Serial number ee label Direction lever Cushioned grip Figure 2 REAR VIEW OF TOOL WWW TORQFUSION COM 10 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion ABOUT THE FRL STANDARD MODEL 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 Before shipping a tool and regulator package they calibrated together as a set to eliminate a possible er
19. it salla y k nd ae 36 5 CIT hI 37 WWW TORQFUSION COM 5 OF 40 REV 1411 7 USER MANUAL SERIES 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 LL 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 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 place your hands or other body parts near the reaction arm or any moving component avoid pinch points If is 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 compan
20. k heavy 2 Air supply hose has a object and replace kink or heavy object hose if necessary on it 3 Check pressure by 3 Regulator is set on turning on the the minimum setting pressure gage 1 The tool is engaged Remove tool from The tool doesn t run with a fastener and fastener and press when trigger is pressed has reached the trigger to ensure the motor makes a mox torque proper operation hissing noise but the 2 The gearbox or 2 Contact factory for output drive doesn t motor are defective repair turn 3 The direction lever is 3 lever to either incorrectly set R or L positions l The motor is not l Check lubricator lubricated level 2 The gearbox or 2 Contact factory for motor are defective repair The tool doesn t run when trigger is pressed the motor doesn t make any noise The tool makes an abnormal or irregular sound while running 1 The battery is dead l Replace battery The pressure gauge 2 The gquge is 2 Contact factory for does not power on I defective repair The motor sounds 1 The output drive is 1 Replace contact normal but the socket broken factory for spare doesn t turn FRL air pressure may Read TORQUE be adjusted SETTING section of incorrectly this manual 2 There is insufficient See INSTALLATION The tool is not air flow delivered to section of this delivering desired the FRL manual torque 3 Calibration not up to Contact factory for date calibration
21. me 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 Never re 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 torgue wrench L 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 the 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 10 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 Replac
22. ngagement of socket WWW TORQFUSION COM 25 OF 40 REV 1411 7 TORO USER MANUAL GT SERIES Fusion LOOSENING When loosening a fastener it is generally safe to use the maximum available torque To do so power on the FRL and adjust it the maximum allowed setting see ADJUSTING THE SET PRESSURE sections do not exceed this setting or the tool may be damaged and or operator injury may occur A Be sure tO wear appropriate PPE 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 20 Slowly depress the tool trigger until the reaction arm touches a robust stationary object like a nearby fastener or other similar rigid feature see Figure 21 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 20 SOCKET OVER FASTENER Figure 21 REACTION ARM AGAINST NEARBY FASTENER Fully depress trigger until the fastener is removed WWW TORQFUSION COM 26 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 ti
23. resentative 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 POR USE ONLY WITH GTB00PSS S N 1101005 IMPERIAL METRIC PSI ft lbs Bar Nem 10 187 069 226 15 208 103 275 20 239 1 38 324 275 172 373 40 311 207 422 35 348 241 471 30 384 2 8 520 45 420 310 9 90 458 345 618 55 492 379 667 780 528 414 716 63 564 448 785 600 483 814 15 638 5 17 863 80 673 5 52 912 85 119 585 981 90 45 821 1010 95 781 655 1059 100 817 5 83 1108 LAST CALIBRATED MAR 20 2011 Figure 22 SAMPLE TORQUE CHART Please note that all torque charts will include the following Information e Tool model number e Tool serial number Pressure Torque correlation values e Calibration date Calibration services are available by contacting your sales representative or the factory directly and should never be performed elsewhere WWW TORQFUSION COM 30 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 1 Air supply not 1 Connect air supply connected 2 Remove kin
24. rial number on the back of the tool you are using matches the ones displayed on the lower row of the FRL display A The motor must not be running while setting the pressure If the model number and serial number on the back of the tool do not match the ones on the display follow the steps in the CHANGING THE ACTIVE TOOL section Once the model number and serial numbers on the FRL display match the ones on tool label turn the TORQUE knob until the desired torque is displayed If you exceed the maximum allowable pressure OvrPress will be displayed instead of the set value If the pressure is set too low LowPress will be displayed To change the units of the FRL press and hold the UNIT right button for 5 seconds Repeat until the desired units are displayed To turn on the display backlighting press the right button once WWW TORQFUSION COM 23 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES Fusion inteliTORQ FRL CHANGING THE ACTIVE TOOL The intiTORQ M FRL is capable of electronically storing torque charts for up to 4 different fools and the LINE PRESSURE mode which simply displays the set pressure To change between the different tools stored and the LINE PRESSURE mode press and hold the TOOL SEL left button for 5 seconds the display backlight will flash once and the button can be released Repeat until the desired tool mode is displayed inteliTORQ FRL ADDING A NEW TOOL The intiTORQ FRL
25. ror accumulation It is recommended 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 This will yield the maximum precision possible Our FRLs may be set without the tool running as the regulators will automatically adjust the pressure to compensate for any flow rate required by our tools Carry Tool storage handle compartment Air pressure Torque 2 adjustment Pressure Quick start gauge instructions Battery drawer Swivel fitting Air inlet Air hose Lubricator Figure 3 FRONT VIEW OF FRL WWW TORQFUSION COM 11 OF 40 REV 1411 J TORDE USER MANUAL GT SERIES 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 12 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion inteliTORQ MODEL Fusion also offers a more technologically advanced FRL designed to significantly reduce uncertainty and the possibility of human error This model has all the features of our standard FRL plus the ability of converting pressure into torque for your specific tool and displaying the torque values directly This FRL uses RFID to read the torque chart digitally stored inside a tool and converts the pressure
26. rt provided with your FRL FOR USE ONLY WITH GT800PSS SIN 1101005 PSI ft lbs Bar N m 10 167 0 69 26 15 203 103 25 25 30 422 35 471 520 569 150 456 345 618 55 492 3 79 667 LAST CALIBRATED MAR 20 2011 Figure 14 SAMPLE TORQUE CHART WWW TORQFUSION COM 20 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion STANDARD FRL LINEAR INTERPOLATION Intermediate interpolated values may be calculated using linear interpolation in order to maintain a high level of accuracy for your tool Example set the tool to 650 ft lbs when that value is not listed on your chart use the following formula to determine the set pressure for the FRL PP 90 75 PP x telew above 75 650 218 z 76 9 psi Dos above 673 63 6 Where FOR USE ONLY WITH P set pressure for FRL GT800PSS SIN 1101005 IMPERIAL METRIC PSI ft lbs Bar N m 10 167 0 69 226 _ 15 203 103 275 20 239 1 38 324 45 420 310 569 50 456 345 618 55 492 379 667 T 00 CIS SIT 863 _ rem C80 C 6724 5 52 912 these lines P 5 86 961 T u 100 817 6 89 1108 LAST CALIBRATED MAR 20 2011 desired torque Figure 15 CHART FOR INTERPOLATION EXAMPLE A simpler but slightly less accurate formula may also be used j NUT 36 above 6 WWW TORQFUSION COM 21
27. se of the tool handle see Figure 1 To engage the fittings 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 if 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 to 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 psi a larger pneumatic hook up hose and or compressor is needed The torque tool is now installed WWW TORQFUSION COM 8 OF 40 REV 1411 USER MANUAL GT SERIES TORJE Fusion ABOUT THE TOOL The GT series tool is a single speed pneumatic torque wrench designed to output 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 low
28. slide the reaction arm off the gearbox WWW TORQFUSION COM 16 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 changing the square drive size 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 10 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 based grease engage output drive to gearbox and replace reaction arm see REMOVING AND INSTALLING THE REACTION ARM in the previous pages WWW TORQFUSION COM 17 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES Fusion REMOVING AND INSTALLING THE 2600 REACTION ATTACHMENT If you have purchased GT2600PSS you will be happy to know that if can be used as both a 2600 ft lb and 800 ft lb tool To switch bet
29. to the extension housing Fully engage the spline of the tool extension with the spline of the gearbox housing and insert the retaining pin Replace the setscrew in the tool extension and re tighten Gearbox housing spline Lubricate well Setscrew i Retaining pin 2 Figure 8 TOOL EXTENSION INSTALLATION Extension journal To remove the tool extension remove the set screw and retaining pin then slide the extension off the gearbox Be careful not to drop the inner shaft out of the assembly REMOVING AND INSTALLING THE REACTION ARM WWW TORQFUSION COM 15 OF 40 REV 1411 7 TORDE USER MANUAL GT SERIES Fusion The reaction arm may be installed in one of 8 positions on the spline of the gearbox housing To install remove the set screw located on the reaction arm using a 1 8 hex wrench Slide out the 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 a lithium or petroleum based grease Fuly engage the spline of the reaction arm with the spline of the gearbox housing and insert the retaining pin Replace the setscrew in the reaction arm and tighten Gearbox housing spline Lubricate e Setscrew Retaining pin Reaction arm spline Figure 9 REACTION ARM INSTALLATION To remove the reaction arm remove the set screw and reaction arm retaining pin then
30. ve been installed and the correct pressure torque 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 A Be sure tO wear appropriate PPE 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 R Place the impact socket over the fastener see Figure 18 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 19 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 18 SOCKET OVER FASTENER Figure 19 REACTION ARM AGAINST NEARBY FASTENER Fuly 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 ease in dise
31. ween modes the 2600 reaction attachment will need to be removed or installed To detach the 2600 reaction fixture use a 1 8 hex wrench to remove the 2 setscrews and pins shown Slide off the reaction fixture and replace with an output drive and reaction arm now the tool will operate as a 1800 55 Remove setscrews and pins Tool serial number label 2600 reaction fixture serial number label Figure 11 2600 REACTION FIXTURE REMOVAL INSTALLATION To change back to 2600 mode remove the reaction arm and output drive and reinstall the 2600 reaction fixture securing it with the 2 sefscrews and pins previously removed It may be necessary to slightly rotate the 1 1 2 square drive of the reaction fixture to be able to re install Use a 1 8 hex wrench to secure the set screws A Always make sure that the serial number on the label of the 2600 reaction fixture matches the serial number on the back of the tool otherwise the toque output will be incorrect WWW TORQFUSION COM 18 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 34 1 or 1 1 2 depending on how the tool was ordered or what additional accessories were purchaseq with it First slide the retainer ring o ring over the socket as shown in Figure 10 Locking pin
32. y s safety advisor for more information WWW TORQFUSION COM 6 OF 40 REV 1411 USER MANUAL GT SERIES TORJE 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 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 to 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 the equipment supplied except l Packaging materials 2 he output drive 3 The reaction arm 4 Consumables batteries lubricating oil etc TORQ Fusion LLC shall in no event
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