Advanced Torque Products

Advanced Torque Products Torque Cart Operation Manual 1

Click It or Risk It How many times do you believe the average operator uses a click-style torque wrench over the course of a day? Every time a torque wrench clicks, the operator is depending on his or her tool to accurately apply the same amount of torque. But improper maintenance, lack of care, and just general use can severely affect the accuracy of click-style torque wrenches. And some of these wrenches are only checked for accuracy every six months or more! How many products could one unchecked wrench put at risk over the course of six months? Advanced Torque Products Torque Cart is meant to alleviate any present and future issues with click-style torque wrenches by giving operators the power to check their tools any time they would like. The Torque Cart s three easy-to-use checking systems display how much torque any type of torque wrench applies, anywhere from fractions of an inch-pound to 750 foot-pounds. The displays can show torque in foot-pounds, inch-pounds, and Newton-meters, and can be used for click or dial style torque wrenches. Also, each checker can easily be set up to display a green light for a passing torque value and high/low red lights for a failing tool. 2

Contents Torque Cart Components... 4 TRUCHECK Display and Controls... 5 General Operation... 6 Proper Standing Location... 7 Proper Wrench Position... 8 Advanced TRUCHECK Functions... 9 MODE BUTTON... 9 UNIT BUTTON... 9 RESET BUTTON... 9 LIMIT BUTTON... 9 Calibration and Maintenance... 10 Calibration... 10 Removal of TRUCHECKs for Calibration... 10 Reinstallation of TRUCHECKs... 12 Torque Cart Maintenance... 12 Troubleshooting... 13 About Advanced Torque Products... 15 3

Torque Cart Components 4

TRUCHECK Display and Controls LOW LIGHT HIGH LIGHT LIMIT BUTTON PASS LIGHT MODE BUTTON RESET BUTTON FOOT-POUND LIGHT UNIT BUTTON NEWTON-METER LIGHT INCH-POUND LIGHT 5

General Operation 1. Engage both of the BRAKES located on the swivel wheels under the HANDLE. The cart should now be stationary. 2. Locate the extension cord and plug the female end of the cord into the RECEPTACLE under the cart s HANDLE. 3. Plug the male end of the extension cord into a wall outlet. Make sure the cord does not cross any walk ways. The three TRUCHECK torque checkers will turn on and make a sound. The middle shelf will be illuminated after a short delay. 4. Determine which torque checker to use. Recommended torque checkers are tabulated below. Torque Torque Checker Less than 15 Ft-Lbs TRUCHECK 15 10 150 Ft-Lbs TRUCHECK 250 100 750 Ft-Lbs TRUCHECK 750 5. With a torque checker chosen, determine which adapter, if any, is required to mate the wrench to the torque checker. The wrench is now ready to be validated. 6. Before any attempt at validating a wrench, ensure the torque checker is zeroed. This is accomplished by pressing the RESET BUTTON and the LIMIT BUTTON at the same time while the wrench is NOT mated to the torque checker. 7. With the display reading zero, attach any adapters and mate the wrench to the appropriate TRUCHECK s input with the wrench s handle parallel to the TOP of the cart. Reference Proper Wrench Position on page 8 to see an example of proper wrench position. 8. Stand on the side of the cart opposite the handle when operating any TRUCHECK. Apply slow and uniformly increasing pressure to the wrench s handle until the wrench clicks, the TRUCHECK beeps, and the display reads the torque value. Reference Proper Standing Location on page 7 to see an example of proper standing location. 9. Compare the TRUCHECK s value to the wrench s setting. 6

Proper Standing Location For the safety of the user, it is important to only use the Torque Cart when standing on the side of the cart that is opposite the cart s handle. 7

Proper Wrench Position For accurate and safe operation, wrenches must be checked while in the correct position. The handle of the wrench must be close to parallel to the top of the cart, such that the handle of the wrench will be pushed down towards the ground when being checked. 8

Advanced TRUCHECK Functions MODE BUTTON 1. Briefly press the MODE BUTTON to temporarily display the current mode of operation. 2. Press and hold the MODE BUTTON to toggle through the modes of operation. Release the MODE BUTTON at the appropriate mode to select. 3. There are three modes of operation: Track Mode ( trac is displayed on the TRUCHECK). Display follows the torque being applied Click Mode ( CLIC is displayed on the TRUCHECK). This mode is for use with click-style torque wrenches. Display shows the first peak of torque that is applied. Display automatically resets after 3 seconds. Dial Mode ( dial is displayed on the TRUCHECK). This mode is for use with dial-type or electronic-style torque wrenches. Display shows the peak value of the torque being applied. The RESET BUTTON must be pressed to clear the display in this mode. UNIT BUTTON Pressing the UNIT BUTTON toggles which unit of measurement is displayed on the TRUCHECK. The current unit of measurement is indicated with a light below the display. RESET BUTTON Pressing the RESET BUTTON resets the display in dial mode. LIMIT BUTTON The LIMIT BUTTON allows the operator to set a target torque value and accuracy. With this information, the TRUCHECK can use three lights to quickly convey to the operator whether the tool passes, has a high value, or has a low value. 1. Press the LIMIT BUTTON to enter the target torque value. The display will quickly display SEt and the target torque value. Press the MODE BUTTON to increase the target value. Holding the MODE BUTTON will increase the speed at which the target torque value is changing. Press the UNIT BUTTON to decrease the target value. Holding the UNIT BUTTON will increase the speed at which the target torque value is changing. 2. Press the LIMIT BUTTON again to enter the ± percentage tolerance or accuracy value from 1 to 10%. % and the accuracy value is displayed constantly. - Press the MODE BUTTON to increase the accuracy value. - Press the UNIT BUTTON to decrease the accuracy value. 3. Press the LIMIT BUTTON once more to finish. The display will briefly show FIN. 9

Calibration and Maintenance Calibration The TRUCHECKs require calibration on a yearly basis to ensure accuracy. For calibration, the TRUCHECKs must be taken off the Torque Cart and sent to Advanced Torque Products at: Removal of TRUCHECKs for Calibration 1. Make sure the cart is unplugged. Advanced Torque Products 56 Budney Rd Newington, CT 06111 2. Locate the power plugs under the TOP of the cart. Wiring in the Torque Cart is shielded with conduit and an electrical box to provide a robust product. There should be a small length of red and black wire protruding from the conduit under each TRUCHECK. 3. Lightly extract each of these wires to expose the power plugs. 10

4. Unplug each TRUCHECK. 5. Remove the bolts holding the TRUCHECK in place and slowly remove the TRUCHECK from the cart, taking care to draw the power cord out along with it. 6. Place the nuts and bolts back into the empty holes for the TRUCHECKs so they do not get lost during calibration. Package the TRUCHECKs in the cases they were shipped with and send with a purchase order to: Advanced Torque Products 56 Budney Rd Newington, CT 06111 11

Reinstallation of TRUCHECKs After the TRUCHECKs have been checked, calibrated, and returned, they must be reinstalled onto the Torque Cart. The installation procedure is simply the reverse of the removal procedure. 1. Make sure the Torque Cart is unplugged. 2. Insert the TRUCHECK s power plug through the hole. Make sure the plug is coming out of the other side before continuing. NOTE: It is critical that the 750 Ft-Lb TRUCHECK is placed in the position closest to the handle. 3. Place the TRUCHECK into its position while lightly pulling on its power plug to make sure the wire is not pinched under the TRUCHECK. Double check that the TRUCHECK is sitting flat on the Torque Cart and not pinching the power wire. 4. Plug the TRUCHECK s power plug into its mating plug on the cart. Push the wires into the conduit to avoid them from being snagged, broken, pinched, or unplugged. 5. Locate the nuts and bolts and fasten the TRUCHECK to the cart. Be careful not to pinch the power wire between the cart and the nut. Ensure the TRUCHECKs are properly tightened to the Torque Cart. 6. After all TRUCHECKs are installed, plug in the Torque Cart and make sure everything functions normally. Torque Cart Maintenance Other than the yearly calibration of the TRUCHECKs, the Torque cart does not require any extraordinary maintenance practices. The TOP and shelves of the cart should be kept clean and free of parts and debris. The cart should remain unplugged when not in use. A copy of this manual and the calibration certificates should be kept in a secure location for reference. Any repairs of the cart should only be completed by Advanced Torque Products. 12

Troubleshooting The wrench I am trying to check does not mate to the TRUCHECK Make sure you are using the appropriate TRUCHECK. Refer to General Operation for a recommended TRUCHECK. Try using an adapter to adapt the TRUCHECK to the wrench you are trying to check. The adapters are located on the MIDDLE SHELF. The TRUCHECK is reporting very low/very high values The TRUCHECK is a very sensitive instrument that senses the slightest change in applied torque. The wrench must be operated slowly and uniformly with a consistently increasing pressure to properly read the wrench s value. When first learning to use the TRUCHECK, try it at lower values to get a hang of how to apply torque. Not matter what I do, the wrench will not pass If several people have tried and cannot make a wrench provide a passing value, the wrench is most likely out of calibration, and should be reported to the proper authorities. The TRUCHECK does not read zero If the wrench is installed in the TRUCHECK, remove the wrench. If the display is still not reading zero, zero the display by pressing the RESET BUTTON and the LIMIT BUTTON at the same time. The TRUCHECK shows a value when the wrench is inserted If the wrench is inserted into the TRUCHECK and left to hang, the weight of the wrench will register on the TRUCHECK. This is normal, and the TRUCHECK should not be zeroed with the wrench inserted into it. The TRUCHECK should only be zeroed without a wrench inserted into it. The lights on the TRUCHECK are red even though the wrench is working properly The TRUCHECK must be programmed to properly show a passing or high/low light. Refer to Advanced TRUCHECK Functions for more information. 13

The rest of the cart has power but the TRUCHECK is not turning on Check under the TOP of the cart to see if the power connection to the TRUCHECK separated. See Calibration and Maintenance for more information on where to find the power connection for each TRUCHECK. Make sure the power plug under the TRUCHECK is properly mated. Check the power wire to see if it was pinched during reinstallation. The TRUCHECK display is frozen Try unplugging and plugging the Torque Cart back in. The cart is not powering on when plugged in Check both ends of the extension cord to make sure they are entirely plugged in. Try a different wall outlet. If these two steps do not work, try a new extension cord. Do not open the electrical box and attempt to fix the cart. The lights do not immediately turn on when the cart is plugged in This is normal. There is a small delay between being the lights being plugged in and actually turning on. The adapter I need is missing The adapter will have to be replaced. Note which adapter needs to be replaced, and contact Advanced Torque Products at 1-860-828-1523 or email sales@advancedtorque.com to order a replacement. The cart s wheels are not turning Make sure the brakes are in the off position when moving the cart. 14

About Advanced Torque Products Advanced Torque Products offers a diverse line of torque systems that range from several inch pounds to 40,000 foot pounds. Torque can be measured in seven different scales in American standard as well as metric. All digital devices are equipped with a programmable overload alarm that has an audio as well as visual signal. The measured torque value can also be routed to a computer into an application or a printer. Measured torque can be displayed in real time in track mode or stored as a peak value. 15