OPERATING INSTRUCTIONS HTL-DSX Dedicated Square Drive Wrench
CONTENTS Contents 2 Safety 2-3 Warranty 3 Connecting the tool 3-4 Setting the torque 4-5 Operating the wrench 5-6 Maintenance 6 Troubleshooting guide 6-7 Declaration 8 Notes 9-11 Spare parts 12-15 Contact us 16 SAFETY Please read this manual before operating the equipment. Prior to commencement of bolt torqueing, ensure that: All necessary safety precautions have been carried out. Personnel involved in bolt torqueing are competent and fully trained in the use of torque wrenches 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. Bolt torqueing pressures, specific to the flanged joint to be tightened, are available. Tips Always wear the appropriate safety equipment when operating this equipment; such as safety goggles or safety glasses and protective gloves. Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with your hands. Use only a hydraulic pump capable of generating a maximum of 10,000 psi (700 Bar) with this equipment. Never exceed the rated working pressure of the wrench. Do not place your hands between the wrench and the reaction point. Use the torque values specified by your equipment manufacturer whenever it is available. 2
Warnings Any residual risks are identified within this manual with the equipment marked where appropriate. Ensure these warnings are maintained. The following label (s) are displayed on the machine for your safety, please observe all warnings. You can be injured if you do not obey the safety instructions as indicated on warning stickers. Observe all safety instructions and warnings attached to the machine Ensure that safety instructions and warnings attached to the machine are always complete and perfectly legible. Keep warnings and instruction labels clean. Replace unreadable or missing labels with new ones before operating the machine. Make sure replacement parts include warning or instruction labels where necessary. Hazard information signs This warning indicates that there is a potential crush hazard and to keep away from moving parts. WARRANTY HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year from the date of shipment. The guarantee does not include the ordinary wear of both metal and non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd. Please note that if the equipment is disassembled or serviced by anyone other than an authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void. In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty equipment, whichever is deemed most appropriate. CONNECTING THE TOOL The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct interconnection between the pump and wrench. Ensure the connectors are fully engaged and screwed snugly together. NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high pressure on the retract side and your wrench is not able to work properly. To avoid tool 3
R A malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any moment. Connect the twin-line hose to the swivel as shown: Drive direction change To remove the square drive, disengage the drive retainer assembly by depressing the round center button and gently pulling on the square end of the square drive. The square drive will easily slide out. To insert the drive in the tool, place the drive in the desired direction, engage drive and bushing splines, then twist drive and bushing until ratchet spline can be engaged. Push drive through ratchet. Depress drive retainer button, engage retainer with drive and release button to lock. The following diagram illustrates the direction the square drive should face for loosening and tightening of a standard right hand fastener: Right is tight. Left is loose. Reaction arm The reaction arms are employed to absorb and counteract forces created as the unit operates, which should extend in the same direction of the square drive; however, slight adjustments may be made to suit your particular application. In operation, the reaction arm must be fully engaged and secured. To engage the reaction arm, depress the spring loaded button located on the rear of the end cap, push to position and release to lock. Ensure the retainer is locked in place prior to using the wrench. To remove the reaction arm, depress the spring loaded button located on the rear of the end cap and pull to release. SETTING THE TORQUE After determining the desired torque, use the calibration certificate supplied with your wrench to determine the pressure that is necessary to achieve that torque. 1. Connect the tool to the power supply and turn the pump on. 4
2. Depress the advance remote control button, causing the pressure to be shown on the gauge. 3. Adjust the pressure by loosening the locking ring on the T Handle. Rotate the handle clockwise to increase the pressure and counter clockwise to decrease the pressure. When decreasing pressure, always lower the pressure below the desired point and then bring the gauge back up to the desired pressure. 4. When the desired pressure is reached, retighten the locking ring, cycle the tool again to confirm that the desired pressure setting has been obtained. OPERATING THE WRENCH Tightening process 1. Having set your target pressure, cycle the wrench three or four times to full pressure before putting it on the application. Cycling the tool ensures the system is operating properly and removes trapped air, if any. 2. Place the correct size impact socket on the square drive and secure properly with a ring and pin. 3. Place the tool and the socket on the nut, making sure that the socket has fully engaged the nut. Further ensure that the drive retainer is engaged. 4. Make sure the reaction arm is firmly abutted against a stationary object (e.g. an adjacent nut, flange, equipment housing etc.). When positioning the wrench, make sure that the hose connections are well clear of any obstructions, and that all body parts are safely out of harms way. 5. Apply momentary pressure to the system to ensure proper tool placement. If it doesn t look or act right, stop and readjust the reaction arm. In use 1. By pushing down on the remote control button in the advance position, the rear of the tool will be pushed back until the reaction arm makes contact with its reaction point. 2. Continue to hold down the button as the socket turns until the tool is fully extended and will not turn the socket further. Successive cycles are made until the wrench stalls at the preset torque. 3. The wrench will automatically reset itself and the operator will hear a series of clicks, when the clicks finish the operator can again push the remote control button and the socket will turn. 4. Continuing to hold down the remote control button will result in rapid build up of pressure to the point of where the gauge reads what was preset prior to applying the wrench. NOTE: The reading of full preset pressure after the cylinder is extended does not indicate that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the socket further until the wrench automatically resets itself. 5
5. Always attempt one final cycle to ensure the stall point has been reached. Loosening procedure First, set the pump to 10,000 psi. Change the drive and the reaction arm to the loosening mode, ensuring the reaction arm abuts squarely off a solid reaction point. Press and hold the pump advance button down. Pressure will decrease as the socket beings to turn. As the cylinder extends fully, you will hear a click. Release the remote control button, and the cylinder automatically retracts, at which time you again hear the click. Repeat this process until the fastener can be removed by hand. NOTE: If the bolt / nut does not loosen with the above procedure, it is an indication that you require the next larger size DSX to loosen the bolt. MAINTENANCE Lubrication frequency depends on factors known only to the user. The amount of contaminants in the working area is one factor. Wrenches used in a clean room environment will obviously require less maintenance than wrenches used outdoors and dropped in loose dirt or sand. 1. When lubrication is required, lubricate all moving parts. 2. Springs are used for the drive pawl assembly and for the accuracy assurance pawl. These springs can be replaced if necessary. 3. If the cylinder requires disassembly, it is recommended that the cylinder seals be replaced at the same time. Seal kits are readily available. 4. Hoses should be checked for cracks and leaks before, and after each job. Hydraulic fittings can become plugged with dirt and should be flushed periodically. 5. Fittings should be kept clean and not allowed to be dragged along the ground or floor as even small particles of dirt can cause the internal valves to malfunction. All structural parts on the tools should be inspected at least once a year to determine if there are any cracks, chips, or deformities. We recommend you use HTL Group s Pro-Moly Lubricant TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE SOLUTION Wrench pressure will not build Cylinder / Tool Leaks Piston seal and/or end plug seal leaking Coupler is defective Blown o-ring in cylinder Defective piston rod seal Replace any defective o-rings. Replace any defective couplers. Replace seal kit. Return to HTL for repair. 6
Tool operates backwards Pump will not build up pressure Ratchet returns with retract stroke Ratchet will not take successive strokes Cylinder will not retract Tool locks on to nut Couplings reversed Defective relief valve Air supply too low or air hose too small Electric power source is too low Defective gauge Low oil level Clogged filter Broken or otherwise inoperable drive segment Broken or otherwise inoperative drive segment or spring Cylinder not retracting completely Linkage between piston rod and drive plate is broken Voltage to electric pump is too low to line drop or inadequate amperage is available Linkage between piston rod and drive arms are broken Drive segment is loaded when the tool is maxed out in torque Tool is operating backwards Tool is wedged under a fixed object Check couplings and correct. Inspect, adjust or replace the relief valve. Make certain the air supply and hose size comply with the pump manual recommendations. Make certain the amperage, voltage and any extension cord size comply with the pump manual requirements. Replace the gauge. Check and fill the pump reservoir. Inspect, clean and/or replace the pump filter. Replace drive segment and/or spring. Return to HTL. Replace drive segment and/or spring. Return to HTL. Remove tool from nut and cycle freely for several strokes. Allow adequate time for cylinder to retract fully. If problem persists, check pawls. Replace parts as necessary - return to HTL. Get shorter extension cord. If shop power is adequate, draw power from welding machine or cal. rod transformer. Replace part as necessary Pressure advance on remote and build pressure - continue to press down on remote while pulling back on one of the accuracy assurance levers - release remote while continuing to hold back on levers. Push advance button down - tool should immediately fall free. Remove shroud from around ratchet. Pry the drive segment out of the ratchet and at the same time pull back on the accuracy assurance levers. Tool should swing free or burn away the socket or obstruction. Tool operates backwards Multiple hoses in even numbers Configure hoses in odd multiples only. 7
DECLARATION 8
NOTES 9
NOTES 10
NOTES 11
CONTACT US HTL Group Corporate Headquarters 45 Colbourne Avenue Nelson Park Industrial Estate Cramlington Northumberland UK NE23 1WD Phone: +44 (0) 1670 700 000 Email: info@htlgroup.com HTL Europe b.v HTL Australasia Pty Ltd Euroweg 30 466 Victoria Road NL-2988 CM Ridderkerk Malaga, WA 6090 The Netherlands Australia Phone: +31 (0) 88 028 4800 Phone: +61 (0) 89 249 3980 Email: info@htl-europe.com Email: info@htl-australasia.com HTL Group Scotland Raith s Industrial Estate Kirkton Drive Dyce Aberdeen UK AB21 0BG Phone: +44 (0) 1224 728 820 Email: aberdeen@htlgroup.com www.htlgroup.com Rev.1118-1 16