LC Operating Instructions - Gee
Contents
1. TWLC SERIES HYDRAULIC TORQUE WRENCH PRESSURE TORQUE CONVERSION CHART TORQUE OUTPUT ibis Ain TER die fitale rir ant TRD E mns me 3076 S ET aa ET 25445447 321012485 Tenai T LU 22 5068 3400 239 536 720 ZPO 3662 9792 13268 EE mO 2562 3878 ji si Tal RT 14925 3800 262 7 d N ti LZ Nm 2008 60 USTJE as TE ES Ts satih skrij SoS EM id ni ji DS 10497 21487 2909 019 10806 as Sab MANE SER HM TE Erre PE 402 aera 9207 12476 17656 24185 R oa BA sili IS EA 572 14483 5 ime fees s0 sor 5907 ee BOO soos sor Sim 300 steno 068 ll 6068 31040 31220 V2 IO 6515 gaa 23616 32000 ACE 13662 1851 EEE EZMECE rran 1 14553 19720 E HH Beats ISS Medi 20122 2 i4 9744 a emer UPE Sheet No 13 of 14 Rev Date 16 July 2007 Operating Instructions Form Noo Sheet No 14 of 14 Rev Date 16 July 2007 Operating Instructions Form Noo Sheet No 15 of 14 Rev Date 16 July 2007 Operating Instructions Form Noo Sheet No 16 of 14 Rev Date 16 July 2007 Operating Instructions Form Noo Sheet No 17 of 14 Rev Date 16 July 20072. 5 5 3 y yJywFomNo o Operating the Torgue Wrench Setting up prior to operation Setting up the eguipment only takes a few minutes and some simple checks during set up will aid in the success of the torguing operation Obtain the torgue 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 torgue value Make sure that the torgue wrench is suitable to deliver the reguired torgue Should the torgue value exceed 80 of the torgue wrench output consider using a higher capacity torgue wrench Use the Pressure Torgue Conversion Chart for the particular torgue wrench to be used supplied with the torgue wrench to obtain the reguired pump pressure Make sure that the drive head to be used is of the correct type and size A poor fitting or oversize drive head will damage nuts induce inaccurate bolt loads and possible cause operator injury Tightening Bolts 1 2 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 Prior to applying the torque wrench to the application the pump output pressure must be pre set to relieve at the pressure obtained from the
3. Apply the torque wrench and socket to the nut to be loosened ensuring that the reaction pad butts firmly and squarely against the selected reaction point 4 Start the 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 torque wrench or nut bolt 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 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 Remove surface r
4. 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 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 5 Check the pressure on the gauge 6 Increase or decrease pressure as required by loosening the locking ring on 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 screw 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 Sheet No 4 of 14 Rev Date 16 July 2007 Operating Instruc
5. 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 of the torque value specified in the torque data STAGE 6 Using the same noted tightening sequence apply the full torque value sheer Nos Sotla specified in the torque data Rev Date 16 July 2007 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 Servicing Post Use Maintenance In order to keep the TWLC torque wrench in good working condition it is recommended that simple post use main tenance be carried following each period of use TWLC Torque wrench 1 Wipe away any debris that may have accumulated particularly around the swivel manifold and hydraulic couplings 2 Remove the drive head from the body Check the following areas see diagram Hydraulic Couplings for signs of damage replace if evident Shuttle pins Ensure they are present and spring freely Head Body Pin retainer Ensure it is undamaged and operates correctly Swivel Manifold Ensure the spiral retaining r
6. proper function of not avoided will result in death or serious injury hydraulic equipment per local directives and standards A WARNING To prevent personal injury use common sense Do not use any power equipment under the influence of any mood altering substances 9 e Never place your hands or other body parts near Denotes a potentially hazardous situation which if not avoided could result in death or serious injury a hydraulic fluid leak A caution Never use your hands or other body parts to check Denotes a potentially hazardous situation which if not for a possible leak avoided may result in minor or moderate injury ae l v ai High pressure fluid can be injected under your skin CAUTION causing serious injury and or infection l l 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 dli 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 To prevent personal injury the WARNING remote control must only be used by t
7. torque wrench locates directly around the nut with it s built in reaction pad designed to react against an adjacent nut Fig 3 below indicates correct positioning of the torque tool shown in tightening mode Always ensure that the reaction pad butts firmly against an adjacent nut or secure reaction structure CORRECT POSITIONING OF TORQUE WRENCH REACTION PAD BUTTED FIRMLY AGAINST AN ADJACENT NUT Reaction Point Safety Extreme care must be taken when selecting appropriate reaction points and the following must be borne in mind at all times 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 pad 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 e Don t improvise Packing pieces spacers etc are dangerous and must never be used as a makeshift reaction point Sheet No 6 of 14 Rev Date 16 July 2007 Operating Instructions 5
8. 8 900 kPa maximum pressure 2 Connect the hand pump to the hydraulic wrench with a single line hose assembly Sheet No 8 of 14 Rev Date 16 July 2007 Operating Instructions FormNo Tightening 1 Determine the required pressure 2 Make sure the hydraulic wrench and the reaction arm are in the tightening mode 3 Pump the hand pump to advance the hydraulic cylinder inside the wrench until the socket stops turning 4 Release the pump pressure The hydraulic cylinder inside the wrench will automatically retract and an audible click will be heard This completes one cycle Manual Pumps Tightening continued 5 Continue to tighten the nut with successive cycles until the needle on the pump gets close to the required pressure NOTE The final torque check is made by paying close attention to the needle on the pressure gauge 6 Pressurize the wrench until the needle stops on the required pressure NOTE When the pressure is released the wrench will not make the audible chick 7 Proceed to the next nut 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 pump pressure The hydraulic cylinder inside the wrench will automatically retract and an audible click will be heard T
9. POWER TEAM Form No 2XXXXXX Operating Instructions and SPX Fluid Power Tech Services 800 477 8326 j 5885 11th Street Fax 800 765 8326 Parts List for Rockford IL 61109 3699 USA Order Entry 800 541 1418 Fax 800 288 7031 TWLC Series www powerteam com LOW CLEARANCE 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 eq
10. 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 torque 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 Apply the torque wrench to the nut to be tightened ensuring that the reaction pad butts firmly and squarely against the selected reaction point Start the pump and advance the torque wrench As the wrench strokes forward the reaction pad 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 a
11. 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 11 of 14 Rev Date 16 July 2007 Operating Instructions 3 8 y y yFomNo LDF Parts List Here Sheet No 12 of 14 Rev Date 16 July 2007 Operating Instructions FormNo
12. he wrench operator A WARNING Do not use hydraulic hoses pump power or remote control cords as means of moving the equipment Read and understand this material before operating or servicing this equipment Failure e Make sure all hydraulic connections are securely could result in a accident causing serious injury kinked or death m Remain clear of the reaction arm during operation adjust maintain clean repair or transport this the reaction point machinery Always use top quality impact sockets in good condi tion and remain clear of sockets during operation Inspect tool before use Replace any worn or i because hidden flaws could cause breakage damaged parts Failure to observe these warnings n i inj h can result in severe injury or death To prevent wrench damage Keep work area clean and well lit CAUTION always use the properly sized tool and accessories Do not use a When not in use wrenches and accessories wrench for anything other than the should be properly stored to avoid deterioration intended purpose Operating Instructons FormNo SWIVEL MANIFOLD lt a t DO S Am L B LZ l an CHANG Sh a QUICK CHANGE gt HYDRAULIC Tn f COUPLINGS a N BODY REACTION PAD HEAD RELEASE PIN OPERATION For top performance freguently inspect wrench pump and accessories for visual damage CAUTION k Always follow instructions for prope
13. his 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 The following procedure is for use with SDT 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 helmet 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 authorised 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 flanged joint STAGE 3 Working in a diametrical sequence tightening opposite bolts apply the minimum torque available i e set pump to lowest
14. ing is present and fitted correctly Re lubricate the areas of the body as shown below using KSP Easyrun 100 MoS2 Anti Scuffing Paste It is recommended that the drive head is re assembled onto the body for storage to prevent ingress of dirt into the drive mechanism HYDRAULIC COUPLINGS SWIVEL MANIFOLD RETAINING RING com SHUTTLE PINS APPLY LUBRICANT TO PISTON DRIVE HEAD BODY PIN RETAINER PAD AND UNDERSIDE OF BODY IN AREAS SHOWN Note that the torque tool drive components must be lubricated using the specified product only Using alternative lubricants will affect the torque tool output and possibly lead to premature component failures 3 It is 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 Sheet No 10 of 14 Rev Date 16 July 2007 Operating Instructions Form No 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 will not build
15. pply another forward stroke Several forward strokes are made until the nut ceases to rotate during the stroke known as stalling but bear in mind that 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 6 Retract the torque wrench stop the pump unit and remove from the nut Sheet No 7 of 14 Rev Date 16 July 2007 Operating Instructions _ FormNo 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 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 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 delivers full pressure Blanking the pump outlets using blank couplings can also be done to carry out the pump pressure setting 3
16. r wrench and pump maintenance Do not use other eguipment 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 reguired 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 hose connector from female to male It is necessary for the hose to have a female con nector to engage the male connecter on the hydraulic wrench Electrical Connections Make sure the power supply is compatible with the reguirements of the electric pump motor Minimize the length of extension cords and be sure they are of adeguate gauge and grounded Air Connections Make sure the air flow rating is adeguate and compatible prior to pressuring the pump Make sure all connections are tight and leak free Sheet No 3 ot 14 Rev Date 16 July 2007 Operating Instructons FormNo Safety a Never exceed the torque wrench maximum working pressure Advance 689 Bar 10 000 psi Retract 69 Bar 1000 psi b Keep hands and fingers clear of the torque wrench head and reaction pad area before and during operation Fingers could be inadvertently trapped if care is not taken c Keep o
17. ther 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 Ensure that all torque wrench components i e head body etc are properly attached and secure Ensure that the head release pin is properly located e Do not strike any of the components including the socket with a hammer in order to shock the nut free f 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 g Take care when handling equipment Do not manoeuvre or carry the torque wrench by its couplings Quick con nect 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 j Do not retighten any equipment whilst under pressure Do not move or rotate the swivel manifold whilst under pressure 1 Some torque wrenches weigh in excess of 20Kg therefore ensure that lifting equipment is available and used m 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 n
18. tions Form Noo Preparing the Torque Qrench for Use Assembling Removing the Drive Head Before the TWLC torque wrench can be used the correct drive head for the nut must be fitted to the TWLC body Note that no special tools or spanners are needed to change the drive head If a drive head is already assembled it can be detached by pushing out the head retainer pin and simply lifting out the body The drive assembly will auto disengage NOTE THE HEAD RETAINER PIN IS HELD CAPTIVE WITHIN THE HEAD SIDEPLATE IT CANNOT BE COMPLETELY REMOVED To assemble a drive head position the drive head onto the body engaging the keyways on the inner surface of the drive head sideplates with the keys on the body Slide the drive head fully onto the body and push the head retain ing pin back into position See Fig 2 below Note that the body to head drive mechanism will auto engage during the drive head assembly process If it does not it will automatically attach during the first power stroke of the torque wrench NOTE The torque wrench must be fully retracted before the head can be removed or attached CE so MI U NOTE HEAD RETAINING PIN DOES NOT DETACH FROM THE BODY IT IS HELD CAPTIVE WITHIN THE SIDEPLATE DO NOT PUNCH OUT Fig 2 BODY AND DRIVE HEAD REMOVAL AND ATTACHMENT Sheet No 5of 14 Rev Date 16 July 2007 Operating Instructions FormNo Positioning the Torque Tool onto the Nut The TWLC
19. uipment used with this wrench 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 Open all hydraulic controls several times to make A WARNING sure the system has been completely depressurized 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 14 Rev Date 16 July 2007 Operating Instructions FormNo 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 m Always wear eye protection whenever operating ards Obey all safety messages that follow this sym hydraulic eguipment bol to avoid possible injury or death O e Always wear hearing protection as required Operation repair or maintenance of hydraulic equipment should be performed by a qualified Denotes an imminently hazardous situation which if person who understands the
20. ust 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 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 torque wrench or nut bolt in an attempt to shock the nut free This will cause damage to the torque wrench and could result in operator injury Evidence of torque wrench abuse will invalidate the Manufacturer s Warranty Loosening 1 Set the pump to 10 000 psi 68 900 kPa 2 Make sure the hydraulic wrench and the reaction arm are positioned for loosening 3 Make sure the reaction arm is squarely against a solid reaction point 4 Press and hold the remote control button NOTE Pressure will build up as the socket begins to turn l 5 When an audible click is heard the hydraulic cylinder inside the wrench is fully extended and will not turn the socket further 6 Release the remote control button to allow the hydraulic cylinder inside the wrench to automatically retract until an audible click is heard This completes one cycle 7 Continue to loosen the nut with successive cycles until the nut can be removed by hand Manual Pumps 1 To operate the hydraulic wrench with a hand pump make sure the pump is rated at 10 000 psi 6
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