SQUARE DRIVE HYDRAULIC WRENCH - Gee
Contents
1. cause equipment dam age or Operator injury Long reach or deep sockets are not recommended for use with hydraulic torque tools as they tend to make the wrench and socket unstable However some applications demand the use of long reach sockets therefore it is imperative that support is provided for both the socket and reaction facility The same applies to socket accessories such as extension bars knuckle joints not recommended etc Setting Torque Setting Up Prior to Operation Setting up the equipment only takes a few minutes and some simple checks during set up will aid in the success of the torquing operation Obtain the torque value that is to be used for the tightening operation Ensure that the bolt threads nut threads and nut to flange contact faces are liberally coated with anti seize lubri cant of known friction co efficient Ensure that the lubricant friction co efficient matches that which has been used to derive the torque value Make sure that the torque wrench is suitable to deliver the required torque Should the torque value exceed 80 of the torque wrench output consider using a higher capacity torque wrench Use the Pressure Torque Conversion Chart for the particular torque wrench to be used supplied with the torque wrench to obtain the required pump pressure Make sure that the socket to be used is of the correct type and size A poor fitting or oversize socket will damage nuts induce inaccurate bolt2. loads and possible cause operator injury Place the proper size impact socket on the square drive and secure it properly with the locking ring and pin Make sure the square drive is fully engaged into the socket Place the wrench and socket on the nut Make sure the socket is fully engaged on the nut Make sure the reaction arm is placed firmly against a stationary object such as an adjacent nut flange equip ment housing etc NOTE When positioning the wrench make sure the hose connection will not hit any stationary object This may result in snapping a hose connection or breaking the coupler connection Apply momentary pressure to the system to ensure proper wrench placement Setting Torque Electric and Air Pumps 1 Make sure the system is fully connected and the proper power supply is available 2 Use the Pressure Torque conversion chart supplied with the wrench to find the required pressure setting NOTE On electric or air pumps this pressure is set on the pump 3 Turn on the pump 4 Press and hold the remote control button Sheet No 6 of 12 5 Check the pressure on the gauge a ee 6 Increase or decrease pressure as required by loosening the locking ringon Rev Date 16 July 2007 Operating Instructions the pressure regulator valve and turning the thumb screw NOTE Turn the thumb screw clockwise to increase pressure and counterclockwise to decrease pressure When decreasing pressure it is necessary to turn the thumb sc
3. will not build Reversed couplings Cylinder Seal leakage Swivel Seal leakage Defective pump unit Check pump hose and torque wrench for cross connection Change seals Change seals Check pump unitPa Pressure builds but wrench does not move Hose restriction Coupling not fully assembled Change hose 2 Fully tighten coupling Slow torque wrench operation Hose restriction Coupling not fully assembled Pump flow rate too small Change hose Fully tighten coupling Use higher flow pump Erratic or slow retraction speed Hose restriction Coupling not fully assembled Change hose 2 Fully tighten coupling Torque wrench does not ratchet Ratchet jumps whilst driving Broken drive shoe Jammed drive shoe Damaged ratchet Worn damaged ratchet Worn damaged drive shoe Wrench incorrectly retracted Weak snapped drive shoe spring Replace drive shoe Check drive shoe and spring Check replace ratchet Replace ratchet and drive shoe Replace ratchet and drive shoe Allow time to fully retract Replace springs Difficulty in hose connection Pressure within hose Damaged coupling Vent hose 2 Replace coupling Sheet No 12 of 12 Rev Date 16 July 2007
4. July 2007 Operating Instructions TWSD SERIES HYDRAULIC TORQUE WRENCH PRESSURE TORQUE CONVERSION CHART PUMP PRESSURE TORQUE OUTPUT Ibf ft Nm PSI Bar TWSD1 TWSD11 TWSD25 1200 83 156 211 1400 97 182 247 1600 110 208 282 1800 124 234 317 2000 138 260 352 2200 152 286 388 2400 165 312 423 2600 179 338 458 2800 193 364 493 3000 207 390 528 3200 221 416 564 3400 234 442 599 3600 248 468 634 3800 262 494 669 4000 276 520 705 4200 290 546 740 4400 303 572 775 4600 317 598 810 4800 331 624 846 5000 345 650 881 5200 359 676 916 5400 372 702 951 5600 386 728 986 5800 400 754 1022 6000 414 780 1057 6200 427 806 1092 6400 441 832 1127 6600 455 858 1163 6800 469 884 1198 7000 483 910 1233 7200 496 936 1268 7400 510 962 1304 7600 524 988 1339 7800 538 1014 1374 8000 552 1040 1409 8200 565 1066 1444 8400 579 1092 1480 8600 593 1118 1515 8800 607 1144 1550 9000 621 1170 1585 9200 634 1196 1621 9400 648 1222 1656 9600 662 1248 1691 9800 676 1274 1726 10000 689 1300 1762 Sheet No Rev 11 of 12 Date 16 July 2007 Operating Instructions Cylinder will not advance Cylinder will not retract Coupling not fully mated Cylinder seal leakage Pump unit Faulty coupling Check coupling Replace seal Check pump unit Replace coupling Torque wrench operates backwards Pressure
5. POWER TEAM Operating Instructions and SPX Fluid Power Tech Services 800 477 8326 5885 11th Street Fax 800 765 8326 Parts List for Order Entry 800 541 1418 Rockford IL 61109 3699 USA Fax 800 288 7031 TWSD Series www powerteam com SQUARE DRIVE HYDRAULIC WRENCH OPERATING MANUAL Instructions Before Use 1 Read and understand all instructions before operating the hydraulic wrench Most malfunctions in new equip ment are the result of improper operation and or setup It is the operators responsibility to read understand and follow all safety instructions 2 Remove the hydraulic wrench from the shipping container and visually inspect all components for any shipping damage If any damage is found notify the carrier immediately DO NOT USE TOOL 3 Locate a solid secure reaction point to absorb and counteract the forces created as the hydraulic wrench is operated 4 Make sure the hydraulic hoses are free of the reaction point 5 Momentarily pressurize the system If the wrench tends to ride up or creep stop and readjust the reaction arm to a more solid and secure reaction point 6 Cycle the hydraulic cylinder inside the wrench to ensure proper function Note Each time the hydraulic cylinder inside the wrench is extended and retracted it is called a cycle Working Pressure The maximum working pressure for this hydraulic wrench is 10 000 psi 68 900 kPa Make sure all hydraulic equipment used with this wr
6. at nut rotation will always cease at the end of the wrench stroke and must not be confused with the wrench stalling WHEN THE WRENCH STALLS APPLY ANOTHER FORWARD STROKE AND OBSERVE THE PUMP PRESSURE GAUGE WHICH SHOULD READ THE DESIRED PRE SET PRESSURE Retract the torque wrench stop the pump unit and remove from the nut Sheet No 7 of 12 Rev Date 16 July 2007 Operating Instructions Loosening Bolts 1 Connect the torque wrench to the pump unit Ensure that the couplings are fully screwed together as they are self sealing and will restrict oil flow if not fully connected 2 Prior to applying the torque wrench and socket to the application the pump output pressure must be pre set to deliver the maximum pressure of 690 Bar 10 000psi This can be done with the torque wrench connected to the pump and resting on the floor or bench Applying advance pressure to the torque wrench will extend the pis ton until it reaches the end of its stroke whereby the pump pressure will build Holding the wrench at the end of its stroke will allow the pump pressure to be adjusted Retract the torque wrench piston and advance again making sure that the pump delivers full pressure Blanking the pump outlets using blank couplings can also be done to carry out the pump pressure setting 3 Apply the torque wrench and socket to the nut to be loosened ensuring that the reaction arm butts firmly and squarely against the selected reaction point 4 Start th
7. d the following must be borne in mind at all times SOCKET REACTION ARM PARALLEL TO SOCKET AND BUTTED FIRMLY AGAINST FLANGE lt 7 SS lt E Oo O Fig 2 CORRECT POSITIONING OF REACTION ARM The reaction structure must be rigid enough to accommodate the reaction forces from the torque wrench which can be extreme at times Carefully assess the reaction points for suitability before applying the torque tool If in doubt contact the torque wrench supplier for advice Ensure that the reaction structure is suitably shaped to accommodate the reaction arm Tapered surfaces are generally unsuitable as the torque wrench tends to ride up the taper causing adverse tool loads Flat surfaces are most preferred If in any doubt over the suitability of the reaction point contact your torque wrench Supplier as various reaction accessories are available which may prove more suitable Don t improvise Packing pieces spacers etc are dangerous and must never be used as a makeshift reaction point Sheet No 5 of 12 Rev Date 16 July 2007 Operating Instructions Use of Sockets Use high quality industrial impact sockets at all times Ensure that sockets are rated to accept the full torque output of the torque wrench that they are to be used with Regularly check the socket for cracks and flaws if any sign of damage is evident discard it immediately as a damaged socket breaking under load could
8. e pump and advance the torque wrench As the wrench strokes forward the reaction arm will press against the reaction point As the pump pressure builds and thus torque applied to the nut the nut will break free Once the nut has been released remove the nut by hand if loose enough or alternatively use an impact wrench it is not recommended to use the torque wrench NOTE Should maximum pump pressure be reached and the nut has still not broken free use a higher capacity torque tool providing that the nut bolt material will accept the higher torques without damage Do not under any circumstances strike the socket or torque wrench in an attempt to shock the nut free 5 Retract the torque wrench stop the pump unit and remove from the nut Notes on Loosening Bolts Loosening of bolts using torque tools can be unpredictable and often unsuccessful especially if the nuts and bolts are severely corroded However some measures can be carried out to increase the success rate of nut breakout e In general loosening mildly rusted bolts requires up to twice the make up torque to release the nut Heavily cor roded bolts may take up to three times the make up torque Ensure that the bolt and nut material is strong enough to accept these higher torques e Remove surface rust and scale using a wire brush Apply releasing oil to the nut bolt and bearing face and allow time for the release oil to soak in and penetrate Only use the torque
9. e wrench maximum working pressure Advance 689 Bar 10 000 psi Retract 69 Bar 1000 psi lt Keep hands and fingers clear of the torque wrench head and reaction arm area before and during operation Fingers could be inadvertently trapped if care is not taken C Keep other personnel clear of the working area and only allow trained personnel to use the equipment Ideally rope off the working area D Prior to operation ensure that all hoses sockets and ancillary equipment is undamaged and fit for purpose H lt Ensure that all torque wrench components i e square drive reaction arm etc are properly attached and secure Ensure that the square drive retainer button is properly located Do not strike any of the components including the socket with a hammer in order to shock the nut free Check that reaction structures are strong and rigid enough to accept the torque tool reaction forces Do not use wedges packing pieces etc as a temporary reaction lt Take care when handling equipment Quick connect couplings are especially susceptible to knocks and damage and therefore care must be taken Note that damaged couplings are difficult to connect Do not force couplings Do not retighten any equipment whilst under pressure Some torque wrenches and sockets weigh in excess of 20Kg therefore Sheet No 3 of 12 ensure that lifting equipment is available and used Rev Date 16 July 2007 Operat
10. ench are rated for 10 000 psi 68 900 kPa operating pressure Hydraulic Connections e Never connect or disconnect any hydraulic hoses or fittings without first unloading the wrench and the pump A WARNING Open all hydraulic controls several times to make sure the system has been completely depressurized e If the system includes a gauge double check the gauge to make sure pressure has been released e When making connections with quick disconnect coupling make sure the coupling are fully engaged Threaded connections such as fittings gauges etc must be securely tightened and leak free IMPORTANT _ Loose or improperly threaded fittings can be potentially dangerous if pressurized however over tightening can cause premature thread failure Fittings should only be tightened until they are secure and leak free Sheet No 1 of 12 Rev Date 16 July 2007 Operating Instructions A This is the safety alert symbol A WARNING To help prevent personal injury It is used to alert you to potential personal injury haz ae aod ria prorechon whenever eperating ards Obey all safety messages that follow this sym ydraulic equipment bol to avoid possible injury or death e Always wear hearing protection as required DANGER Operation repair or maintenance of hydraulic equipment should be performed by a qualified Denotes an imminently hazardous situation which if person who understands the proper function of not avoided will
11. flanged joint STAGE 3 Working in a diametrical sequence tightening opposite bolts apply the minimum torque available i e set pump to lowest possible output 1000psi Note the sequence used STAGE 4 Repeating the above noted tightening sequence apply approximately 25 of the torque value specified in the torque data STAGE 5 Using the same noted tightening sequence apply approximately 50 Sheet No 9 of 12 of the torque value specified in the torque data q j a Rev Date 16 July 2007 Operating Instructions STAGE 6 Using the same noted tightening sequence apply the full torque value specified in the torque data STAGE 7 Working in a clockwise or anti clockwise direction make a final pass around the flange tightening each bolt to the full torque value specified in the torque data STAGE 8 Following completion of Stage 7 using a hammer ring each nut to ensure that each bolt has been cor rectly loaded and that no slack bolts remain Maintenance and Preventative Maintenance Inspect hoses and fittings before every use Connections must be clean and properly connected before each use Replace worn or damaged fittings Keep tools clean and protected from damage Post Use Maintenance In order to keep the TWSD torque wrench in good working condition it is recommended that simple post use main tenance be carried following each period of use TWSD Torque wrench 1 Wipe away any debris that may have accumulated particu
12. ing Instructions J Do not strike misuse or abuse any of the equipment If any abuse or misuse of the equipment is evident the warranty shall be invalid and the Manufacturer shall not be responsible for any injuries or failures as a result K In some instances it may be necessary for the Operator to support the torque wrench whilst it is tightening i e upside down applications If the torque tool cannot be strapped into position using ropes etc then the operator must take the utmost care to avoid pinch points L Never use the torque wrench with just one hose connected to the Advance port port A This will cause a pres sure intensification within the retract chamber possibly leading to tool damage Always ensure that both hoses are connected OPERATION For top performance frequently inspect wrench pump and accessories for visual damage CAUTION Always follow instructions for proper wrench and pump maintenance Do not use other equipment to increase the capability for example hammering on socket wrench General Each hydraulic wrench is supplied completely assembled and ready for use A hydraulic pump is required to pro vide the speed and pressure that makes the hydraulic wrench system efficient and accurate Connecting the System The hydraulic wrench head and power pack are connected by a 10 000 psi 68 900 kPa single line hose assembly Each end of the hose will have one female connector NOTE DO NOT switch the ho
13. larly around the square drive area reaction arm splines and hydraulic couplings 2 Check the following areas Hydraulic Couplings for signs of damage replace if evident Swivel Manifold Ensure the spiral retaining ring is present and fitted correctly Ensure the Guard is present and securely attached Replace re attach as necessary Remove the square drive from the torque wrench and inspect for damage cracks etc Re lubricate the bearing journals using Lithium Complex EP Grease and replace the square drive Note that that the torque tool drive components must be lubricated using the specified product only Using alternative lubri cants will affect the torque tool output and possibly lead to premature component failures 3 Itis preferable to lightly spray the torque wrench with water repellent spray WD40 prior to placing back into storage Hoses and Ancillaries 1 Clean and inspect each hydraulic hose and quick connect coupling Check the entire length of the hose for cuts abrasions and damage Any evidence of hose damage and the entire hose must be replaced 2 Coat each quick connect coupling with a water repellent spray WD40 Maintenance Servicing and Warranty In addition to post use maintenance and to ensure that the Product Warranty remains valid it is recommended that routine maintenance and servicing be carried out by the Manufacturer or authorized Service Centre Sheet No 10 of 12 Rev Date 16
14. lic hoses pump power or remote control cords as means of moving the equipment sgh Read and understand this material before Y operating or servicing this equipment Failure to understand how to safely operate this tool could result in a accident causing serious injury ordeal e Remain clear of the reaction arm during operation Never put body parts between the reaction arm and the reaction point e Make sure all hydraulic connections are securely attached Verify that the hydraulic hoses are not kinked e Only qualified operators should install operate adjust maintain clean repair or transport this machinery e Always use top quality impact sockets in good condi tion and remain clear of sockets during operation e Inspect tool before use Replace any worn or because hidden flaws could cause breakage damaged parts Failure to observe these warnings can result in severe injury or death To prevent wrench damage e Keep work area clean and well lit CAUTION always use the properly sized tool and accessories Do not use a e When not in use wrenches and accessories wrench for anything other than the should be properly stored to avoid deterioration intended purpose Operating Instructions 2 MULTI AXIS SWIVEL SQUARE DRIVE MANIFOLD RELEASE BUTTON HYDRAULIC COUPLINGS REACTION ARM RELEASE BUTTON SQUARE DRIVE REACTION ARM REACTION ARM PROTECTION PAD Safety Never exceed the torqu
15. orque wrench will extend the piston until it reaches the end of its stroke whereby the pump pressure will build Holding the wrench at the end of its stroke will allow the pump pressure to be adjusted Retract the torque wrench piston and advance again making sure that the pump relieves at the desired pressure setting Blanking the pump outlets using blank couplings can also be done to carry out the pump pressure setting NOTE Allow time for the wrench to retract If another advance stroke is made before the torque wrench has fully retracted the ratchet mechanism may not engage correctly causing it to jump a ratchet tooth probably damaging the ratchet Before applying another advance stroke make sure that the pump is idling at 69 Bar 1000psi which indicates full retraction 3 Apply the torque wrench and socket to the nut to be tightened ensuring that the reaction arm butts firmly and squarely against the selected reaction point Start the pump and advance the torque wrench As the wrench strokes forward the reaction arm will press against the reaction point and the nut socket will rotate When the torque wrench reaches the end of its stroke the pump pressure will build rapidly Retract the torque wrench the wrench ratchet mechanism will be heard clicking as it retracts and apply another forward stroke Several forward strokes are made until the nut ceases to rotate during the stroke known as stalling but bear in mind th
16. p pressure The hydraulic cylinder inside the wrench will automatically retract and an audible click will be heard This completes one cycle 5 Continue to loosen the nut with successive cycles until the nut can be removed by hand 6 Proceed to the next nut 7 General Torquing Procedure General Torquing Procedure The following procedure is for use with TWSD torque wrenches and outlines the basic steps in order to carry out the torque tightening of a flanged joint It is important that personal protective clothing gloves footwear safety hel met eye protection is worn at all times not only by the Operator but also by any personnel within the work area The torquing procedure is compiled around using a single torque wrench the object of the procedure being to accurately achieve a pre determined residual bolt stress SAFETY Prior to commencement of bolt torquing ensure that All necessary safety precautions have been carried out Personnel involved in torquing are competent and fully trained in the use of hydraulic torque tools and tightening techniques The procedure and data to be used is authorized by a responsible Engineer The joints pipework to be worked on are not live Joints must be at zero pressure and free from hazardous substances Torque value selected must be based upon the lubricant applied STAGE 1 Number each bolt consecutively 1 2 3 etc STAGE 2 Using torque wrenches if necessary square up the
17. result in death or serious injury hydraulic equipment per local directives and standards A WARNING e To prevent personal injury use common sense Do not use any power equipment under the influence of any mood altering substances e Never place your hands or other body parts near a hydraulic fluid leak Denotes a potentially hazardous situation which if not avoided could result in death or serious injury A caution Denotes a potentially hazardous situation which if not for a possible leak avoided may result in minor or moderate injury Never use your hands or other body parts to check High pressure fluid can be injected under your skin CAUTION causing serious injury and or infection ee e Electric motors may spark causing an explosion Caution used without the safety alert symbol indicates when flammable materials are present Do not a potentially hazardous situation which if not avoided operate in an explosive atmosphere or in the pres may result in property damage ence of conductive liquids Use an air motor or uly hand pump instead IMPORTANT Y To prevent electrical shock make sure the pump is properly grounded and the proper voltage Denotes an operating or service procedure or condi is being used tion considered essential for expedient and efficient operation and service e To prevent personal injury the WARNING remote control must only be used by the wrench operator A WARNING e Do not use hydrau
18. rew to a pressure setting below what is desired and gradually increase pressure to the desired level 7 Once the desired pressure is stabilized release the remote control button and tighten the locking ring 8 Prior to tightening a nut press the remote control button and confirm the correct pressure has been set Manual Pumps Find the required torque in the Pressure Torque conversion chart and read across the chart to the corresponding pressure Operating the Wrench Electric or Air Pump Tightening 1 Connect the torque wrench to the pump unit Ensure that the couplings are fully screwed together as they are self sealing and will restrict oil flow if not fully connected NOTE TWSD torque wrenches are equipped with a pressure release valve built into the Multi Axis Swivel Manifold to protect against retract pressure intensification should the retract port hydraulic coupling not be fully con nected or become loose during use If an intensification occurs the valve will bleed hydraulic oil externally from the manifold yoke Note that oil bleeding from the swivel manifold is not a sign of seal leakage 2 Prior to applying the torque wrench and socket to the application the pump output pressure must be pre set to relieve at the pressure obtained from the Pressure Torque Conversion Chart This can be done with the torque wrench connected to the pump and resting on the floor or bench Applying advance pressure to the t
19. se connector from female to male It is necessary for the hose to have a female connector to engage the male connecter on the hydraulic wrench Electrical Connections Make sure the power supply is compatible with the requirements of the electric pump motor Minimize the length of extension cords and be sure they are of adequate gauge and grounded Air Connections Make sure the air flow rating is adequate and compatible prior to pressuring the pump Make sure all connections are tight and leak free Changing the Drive Direction In order to change drive direction press and hold the drive release button then pull out the square drive The square drive retainer cap and button assembly are now free from the torque wrench take care not to lose them To re install insert the square drive into the tool head the square drive won t enter until the splines are aligned and replace the retainer cap assembly As a check pull the square drive to ensure that it is locked in position Using the Reaction Arm The TWSD torque wrench features a 360 adjustable reaction arm Although the reaction arm can be placed in a multitude of positions always try to use the torque tool with the reaction arm positioned parallel to the socket i e 90 to the torque tool body See Fig 2 below Sheet No 4 of 12 Rev Date 16 July 2007 Operating Instructions Reaction Point Safety Extreme care must be taken when selecting appropriate reaction points an
20. wrench to break the nut free Using the torque tool to wind the nut from the bolt can induce high torsion and reaction forces therefore it is better to use and impact wrench to completely remove the nut Never strike the socket or torque wrench in an attempt to shock the nut free This will cause damage to the socket and torque wrench and could result in operator injury Evidence of torque wrench abuse will invalidate the Manufacturer s Warranty Manual Pumps _ TO operate the hydraulic wrench with a hand pump make sure the pump is rated at 10 000 psi 68 900 kPa maximum pressure Connect the hand pump to the hydraulic wrench with a single line hose assembly N Sheet No 8 of 12 Rev Date 16 July 2007 Operating Instructions Tightening Determine the required pressure Make sure the hydraulic wrench and the reaction arm are in the tightening mode Pump the hand pump to advance the hydraulic cylinder inside the wrench until the socket stops turning Release the pump pressure The hydraulic cylinder inside the wrench will automatically retract and an audible click will be heard This completes one cycle RON Loosening 1 Make sure the hydraulic wrench and the reaction arm are on the loosening mode 2 Pump the hand pump to advance the hydraulic cylinder inside the wrench As pressure builds the bolt will begin to loosen 3 Stop pumping when the socket stops turning 4 Release the pum
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