worldwide OPERATING INSTRUCTIONS DEDICATED SQUARE DRIVE TORQUE WRENCH HTL-Operating-Instructions-DS.indd 1 11/04/2017 10:15
HTL-Operating-Instructions-DS.indd 2 11/04/2017 10:15
contents... Introduction 03 Worldwide Warranty 03 Important Safety Instructions 04 Instructions Before Use 06 Setting the Torque 11 Setting the Pressure 12 Operating the Wrench 13 Loosening Procedure 14 Maintenance 15 Prior to use 17 Troubleshooting 18 Spare Parts List 21 Pressure/Torque Conversion Chart 22 FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 2 HTL-Operating-Instructions-DS.indd 3 11/04/2017 10:15
Introduction This manual is designed to provide you with the basic knowledge required to operate and maintain your wrench. Please read this manual carefully and follow the instructions provided. If you have any questions regarding your HTL Wrench, please call us on +44 (0) 1670 700 018 or alternatively email us: sales@htl-worldwide.com. Your purchase of this wrench entitles you to the following FREE services: Free training in the application and operation of your HTL equipment. Free engineering assistance. Free loan wrenches in case of failure during the warranty period. Worldwide Warranty HTL equipment is engineered to the latest technological standards and is accompanied by a 12 month warranty. Should your new equipment fail under normal use within 12 months, we will repair or replace your damaged equipment. 3 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 4 11/04/2017 10:15
Important Safety Instructions WARNING: Certain safety precautions should be observed to avoid accidents or personal injury. The following tips will assist you. Read All Instructions. Keep Work Area Clean and Well Lit. Consider Work Area Environment. Electrical pumps should never be used in any atmosphere which can be considered potentially volatile. If there is any doubt, use an air pump. NOTE: Metal to metal contact can cause sparks, precautions should be taken. Avoid Premature Tool Starting. The Pump Remote Control is for the tool operator only. Avoid separate pump and tool operator. Stay Clear During Operation. In most cases, the tool will allow hands free operation. Guard Against Electric Shock. Ensure the pump is properly grounded and the proper voltage is being used. Store Idle Tools. When not in use, tools and accessories should be properly stored to avoid deterioration. Use the Right Tool. Don t force small tools or attachments to do the job of a larger tool. Don t use a tool for purposes not intended. HTL can develop custom accessories for your job to ensure safe and simple operation. Contact your local HTL representative for more information on our custom engineering abilities. Correct Safety Attire. When handling operating hydraulic equipment, use work gloves, hard hats, safety shoes, hearing protection, and other applicable clothing. Use Safety Glasses. Moving Equipment. Do not use hydraulic hoses, uni-swivels, pump power or remote cords as means to moving the equipment. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 4 HTL-Operating-Instructions-DS.indd 5 11/04/2017 10:15
Hoses Do not kink hoses. Inspect and replace if damaged. Shrouds and Cover Plates All tools are equipped with shrouds and/or cover plates to cover up moving internal parts. If shrouds are missing or damaged, please contact your local HTL representative for repair. A free loaner tool will be made available to you during the time of repair. Maintain Tools With Care For top performance, inspect tool powerpack, hoses, connectors, electric lines, and accessories for visual damage frequently. Always follow instructions for proper tool and pump maintenance. Refer to the operations maintenance section for further clarification. Stay Alert Always take care. Do not use power equipment under the influence of any mood altering substances. Prior to Operation Ensure that all hydraulic connections are securely connected. Verify that the hydraulic hoses are not kinked. Ensure the square drive and its retainer are fully and securely engaged. Prior to Use Cycle tool to ensure proper function. Locate a solid, secure reaction point. Be sure the reaction arm retaining clamp is fully engaged. Be sure the hydraulic hoses are free and clear of the reaction point. Pressurise the system momentarily; if the tool tends to ride up or to creep, stop and readjust the reaction arm to a more solid and secure position. Always Use Quality Accessories Always use high quality impact sockets in good condition which are the correct size and fully engage the nut. Hidden flaws, however, remain a possibility which could cause breakage, so stay clear of sockets during operation. Do Not Use Force Do not hammer on the socket or the tool to enhance performance. If the nut will not turn with the wrench you are using, use a larger size HTL tool. Reaction Arm Proper reaction is required. Adjust reaction arm or plate accordingly. Avoid excessive play. In case of questions, consult with your HTL office. 5 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 6 11/04/2017 10:15
Instructions Before Use READ CAREFULLY: Most malfunctions in new equipment are the result of improper operation and/or set-up assembly. PREPARATION: Remove torque wrench from shipping container. INSPECTION: Visually inspect all components for shipping damage. If any damage is found, notify carrier and HTL immediately. Working Pressure The tool s maximum working pressure is 10,000 psi (700 Bar). Make sure that all hydraulic equipment used with this wrench is rated for 10,000 psi maximum operating pressure. Hydraulic Connections When making connections with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as fittings, gauges, etc., must be clean, securely tightened, and leak free. If tool operates backwards, couplings are reversed. HTL hoses may only be joined together in odd numbers only, 1, 3, 5 etc or please contact HTL for bespoke lengths to suit your requirements. CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurised, yet, severe over tightening can cause premature thread failure. Fittings need only to be securely tightened and leak free. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil could penetrate the skin and cause injury. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 6 HTL-Operating-Instructions-DS.indd 7 11/04/2017 10:15
4 6 2 8 0 10 l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l Electrical Connections Ensure correct power availability to prevent motor failure or dangerous electrical overloading. Observe the motor nameplate for required amperage. Do not use electric pump if ground is not connected on plug. Minimise the length of extension cords and be sure they are of adequate wire size with ground connections. Extension cable should be 4mm² and maximum length 10 metres. WARNING: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence of conductive liquids. If using in a hazardous or explosive atmosphere ensure pump is ATEX approved or approved to the relevant zone. Air Connections Ensure that you have sufficient air flow to operate your pneumatic pump. If in doubt, compare the pump manufacturer s recommended air flow rating prior to pressurising pump. Improper air flow may damage the pump motor. For best results use air hoses larger than 3/4 I.D. diameter. Use of a filter regulator lubricator (FRL) is highly recommended (pictured below). AIR FLOW ON/OFF LEVER AIR ADJUSTMENT KNOB OIL LUBRICATOR ADJUSTMENT KNOB OIL FILLER CAP CONDENSATION BOWL OIL BOWL AUTO WATER DRAIN PORT 1. Adjust flow to one drop per 60-90 seconds 2. Fill half way with grade 46 hydraulic oil supplied OUTSIDE UK: +44 (0) 1670 700 018 87 HTL-Operating-Instructions-DS.indd 8 11/04/2017 10:15
OPERATION All HTL torque wrenches are supplied completely assembled and ready for use. A HTL hydraulic power pack (for use with your HTL wrench) is recommended to provide the speed, pressure, and portability that makes your HTL system efficient and accurate. Using calibrated gauges enhances the accuracy of your hydraulic system. The accuracy of your 3-in-1Hydraulic Torque Wrench is +/-3% based upon our specifications. This accuracy is certified through our calibration laboratory, and we recommend that the torque wrench be recalibrated on a 12 month basis and should be calibrated by a qualified calibration facility who is traceable to the United Kingdom Accreditation Standards (UKAS). Please contact HTL or your local distributor for more information. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 8 HTL-Operating-Instructions-DS.indd 9 11/04/2017 10:15
Operation Connecting the System The wrench head and power pack are connected by a 10,000 psi operating pressure (40,000 psi burst) twinline hose assembly. Each end of the hose will have one male and one female connector to ensure proper interconnection between pump and wrench heads. IMPORTANT: To avoid tool malfunction, do not reverse connectors. Connect the twinline hose to the uniswivel as shown below: R A Ensure the connectors are fully engaged and screwed closely and completely together. 10 OUTSIDE UK: +44 (0) 1670 700 018 9 HTL-Operating-Instructions-DS.indd 10 11/04/2017 10:15
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 slide easily 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. Right is Tight. Left is Loose. The above diagram illustrates the direction the Square Drive should face for loosening and tightening of a standard right hand fastener. Reaction Arm All HTL torque wrenches are equipped with a universal reaction arm. These reaction arms are employed to absorb and counteract forces created as the unit operates. The reaction arm 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 into position and relase 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. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 10 HTL-Operating-Instructions-DS.indd 11 11/04/2017 10:15
Setting Torque Once the system is fully connected and proper power supply available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer s specifications to determine the torque value which you will ultimately require. Torque sequence may vary from plant to plant and even within individual plants, depending upon the gasket material, etc. Always abide by local procedures. Next, use the pressure-torque conversion chart that is provided for the individual tool, similar to the one below. 10,000 PSI = 1633 FT. LBS Calibration Readout 1800 1700 1600 1500 1400 Torque Values FT/Lbs 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 1000 PSI= 1171FT.LBS IN PUT (PSI) An example of finding the torque required is as follows: Assume you are going to use a HTL-W2 tool to torque a 1 ¼ bolt to 835 ft.lbs. 1. First check the serial no. on the tool corresponds to the torque chart. On the left hand side of the chart is the torque values. Find 835 ft.lbs on column 2. Then move across the chart until you come to a diagonal line. 3. At this point, move down to the bottom of the chart. The corresponding pressure value can be found 4. For example the pressure is 5,300 psi on a tool to produce 835 ft.lbs. 5. Now set pressure on pump as follows in next section. 11 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 12 11/04/2017 10:15
Setting the Pressure To set the pressure on the pump, follow this procedure: 1. Loosen the knurled locking ring below the T handle on the pump s external pressure regulator. Then turn the T handle as shown below, CCW (counterclockwise) until it turns freely and easily. 2. Turn the pump on. Using the pump s remote control pendant, push down the advance switch (or button on air pumps) and hold it. 3. While holding the pump in the advance mode, slowly turn the T handle clockwise and observe the pump pressure gauge rise. 4. When your gauge reaches 4,000 psi, stop turning the T handle and let the gauge settle out. 5. If the pressure continues to rise (above 4,000), release the advance button and back off your pressure slighitly - by turning CCW on the T handle. 6. Then re-depress the advance switch on your remote and slowly bring pressure up to 4,000 psi again. 7. When the pressure is correct, turn the pump off and tighten the knurled lock nut provided under the T handle. This sets pump pressure, which determines torque wrench output. 8. Once your target pressure is set and locked, cycle the pump once more to ensure that your pressure setting did not change as you turned down the knurled knob NOTE: Always adjust the regulator pressure up, never down. T Handle Locking Ring FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 12 HTL-Operating-Instructions-DS.indd 13 11/04/2017 10:15
Operating the Wrench The 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 that the system is operating properly and removes trapped air, if any. 2. Place the proper 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 harm s way. 5. THEN, AND ONLY THEN, 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 you hear a click which will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket further. 3. Continuing to hold down the remote control button will result in a rapid build up of pressure to the point of where the gauge reads what was preset prior to applying the wrench. IMPORTANT: 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. Releasing the remote control button will retract the cylinder. The wrench will automatically reset itself and the operator will hear a click indicating they can again push the remote control button and the socket will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the wrench stalls at the preset torque. 13 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 14 11/04/2017 10:15
IMPORTANT: 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 remote control button down. Pressure will decrease as the socket begins 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 does not loosen with the above procedure. it is an indication that you require the next larger size tool to loosen the bolt. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 14 HTL-Operating-Instructions-DS.indd 15 11/04/2017 10:15
MAINTENANCE Tool failure, although rare, does occur. Such failure is most often in the hydraulic couplers or hoses. These items are repairable or replaceable immediately, since they are available universally. Failure of structural members of the tool are quite rare, but replacement parts are available from stock. All repairs to HTL tools may be made by experienced individuals according to these instructions. 15 OUTSIDE UK: +44 (0) 1670 700018 HTL-Operating-Instructions-DS.indd 16 11/04/2017 10:15
Preventative Maintenance Lubrication All moving parts should periodically be coated with HTL Pro-Moly grease. Under harsh environmental conditions, cleaning and lubricating should be performed more frequently. Hydraulic Hoses 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. Quick Connects 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. Springs Springs are used for the drive pawl assembly and for the accuracy assurance pawl. These springs can be replaced if necessary. Cylinder Seals If the cylinder requires disassembly, it is recommended that the cylinder seals be replaced at the same time. Seal kits are readily available. Structural Members All structural parts on the tool should be inspected once a year to determine if there are any cracks, chips, or deformities. If so, immediate replacement is required. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 16 HTL-Operating-Instructions-DS.indd 17 11/04/2017 10:15
Prior to Use THIS TEST SHOULD BE RUN PRIOR TO EVERY USE OF A HTL TOOL. Connect the tool, pump, and hoses together as normal. Cycle the pump several times. Cycle the system once more and observe the sequence of operation. As you depress the advance button, the tool drive should turn about 24 degrees and you should hear a click. On square drive tools, you will also notice that the accuracy assurance levers will move to the rear of the tool and spring forward. At this point, release the advance button. You should see no further movement and after a moment you will hear another click. This is how the tools are designed to operate. If you observe any other sequence of operation, the system is out of order and cannot deliver more than 10% of its designed capacity. Take immediate corrective action. For reference, tools and pumps are designed from the factory plumbed as follows. This ensures that the tool, pump and ONE hose cannot possible be connected up incorrectly. Tool Advance Side - Male Retract Side - Female Hose Advance Side - Female to Female Retract Side - Male to Male Pump Advance Side - Male Retract Side - Female NOTE: Connecting two or any even number of hoses together creates one hose which is plumbed backwards! Male to Female and Female to Male. This will cause the system to operate backwards. If your hose isn t long enough, connect 3 hoses together, move your pump or call HTL for a longer hose assembly. 17 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 18 11/04/2017 10:15
Troubleshooting Symptom Probable Cause Action Required Gauge shows pressure build-up but the tool will not cycle. 1. Couplings loose or inoperative. 2. Solenoid inoperative. 1. Tighten and/or replace couplings. 2. If solenoid is bad, replace. Cylinder will not retract. 1. Voltage to electric pump is too low to line drop or inadequate amperage is available. 2. Linkage between piston rod and drive arms are broken. 1. Get shorter extension cord. If shop power is adequate, draw power from welding machine or cal rod transformer. 2. Replace part as necessary Wrench pressure will not build. 1. Oil blow by in wrench (Piston seal leak, blown O-ring, cracked piston). 2. Pump problem. 1. Replace defective parts. Return to HTL. 2. Check to see if sub plate is worn. Remove screws from pump motor to reservoir, slide pump motor to the side, turn pump on and while holding down on the button, put your finger on the dump tube (round tube under the directional control valve) if you feel pressure, then replace the subplate and shear seals. 3. Check to see if you have leaks from the external relief valve and the 2 oil line connections (bottom of relief valve and connection into pump body s other end) of oil line. If leaking, retighten with 9/16 open end wrench. Return to HTL. 4. If pump sounds like there is rattling in the air motor, take pump to your local HTL office or Distributor. 5. Air Pumps - Faulty air valve due to excessive moisture and/or dirt in air supply. Disassemble air valve and wipe any residue from air valve piston. Spray brake cleaner into air valve body, dry thoroughly. Disassemble all small air lines and blow out with compressed air. Lubricate both air valve piston and body with hydraulic oil (sparingly) and reassemble. Return to HTL. 6. Air pumps - Faulty. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 18 HTL-Operating-Instructions-DS.indd 19 11/04/2017 10:15
Troubleshooting Symptom Probable Cause Action Required Gauge records no pressure. 1. Gauge connection is loose. 2. Bad gauge. 3. Pump will not build pressure. 4. Tool seals are blown. 1. Tighten coupling. 2. Replace gauge 3. Return to HTL 4. Replace defective seals. Return to HTL. Pump will not build pressure. Motor slow and inefficient Sounds laboured. Slow to build pressure. Pump heats up. Hose or tool fitting is damaged or leaks. 1. Air or electric supply is low. 2. Defective relief or regulator valve. 3. Low oil or clogged filter. 4. Internal leak in oil line from external relief valve to pump body. 5. Worn sub-plate. 1. Air or electric supply is low. 2. Clogged filter. 1. Improper use. 2. Remote control is left in. 3. On position when pump is not actively in use. 1. Broken or melted plastic outer covering. 2. Frayed Kevlar or steel strands. 3. Oil leaks through fibers. 4. Broken fittings. 1. Check air pressure or voltage. 2. Replace valve Return to HTL. 3. Fill reservoir and clean filter. 4. Open reservoir, inspect oil line while trying to build pressure if leaking tighten fittings or replace. 5. See cylinder pressure will not build pressure above. 1. See #1 in preceding block 2. Clean or replace filter 1. Have operator release advance stroke after accuracy assurance levers spring forward. 2. Turn pump off whenever not actually being used. DO NOT leave pump running when tool is not in use. 1. If underlying Kevlar or steel is still intact continue operation. Inspect frequently. 2. Cut hose in half and discard. Replace hose. 3. Remove old fitting and replace with STEEL high pressure fittings only. Electric pump will not run. 1. Loose electric connections in control box. 2. Bad brushes. 3. Motor burned up. 1. Replace motor components whichever is necessary. Return to HTL. 2. Change defect fuse. Tool locks on to nut. 1. Drive segment is loaded when the tool is maxed out in torque. 2. Tool is operating backwards. 3. Tool is wedged under a fixed object. 1. Press advance button 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. 2. Push advance button down - tool should immediately fall free. 3. Remove shroud from around ratchet. Using any tool available, 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 burnaway the socket or obstruction. OUTSIDE UK: +44 (0) 1670 700 018 20 19 HTL-Operating-Instructions-DS.indd 20 11/04/2017 10:15
Troubleshooting Symptom Probable Cause Action Required Cylinder/Tool leaks. 1. Safety relief valve on swivel has lifted. 2. Blown O-ring in cylinder. 3. Defective gland seal. 1. Tighten and/or replace couplings. 2. If solenoid is bad, replace. Tool operates backwards. 1. Couplings reversed. 2. Multiple hoses in even numbers. 1. Check couplings and correct 2. Configure hoses in odd multiples only Ratchet Returns with retract stroke. 1. Broken or otherwise inoperable drive segment. 1. Replace drive segment and/or spring. Return to HTL. Ratchet will not take successive strokes. 1. Broken or otherwise inoperative drive segment I or spring. 2. Cylinder not retracting completely. 3. Linkage between piston rod and drive plates is broken. 1. Replace drive segment and/or spring. Return to HTL. 2. Remove tool from nut and cycle freely for several strokes. If problem persists, check pawls. 2A. Allow adequate time for cylinder to retract fully. 3. Replace parts as necessary - Return to HTL. Tool locks onto nut. 1. Drive segment is loaded when the tool is maxed out in torque. 2. Tool is operating backwards. 3. Tool is wedged under a fixed object. 1. Press advance button 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. 2. Push advance button down - tool should immediately fall free. 3. Remove shroud from around ratchet. Using any tool available, 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. FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 20 HTL-Operating-Instructions-DS.indd 21 11/04/2017 10:15
Spare Parts List 57 56 47 7 22 20 19 32 29 46 27 23 17 1 26 59 24 10 16 31 21 28 58 2 38 9 8 3 18 33 25 35 36 37 50 40 11 41 3 4 39 34 6 ITEM No. PART DESCRIPTION QTY 1 BODY 1 2 REACTION ARM 1 3 DRIVE PLATE 2 4 RATCHET 1 5 PAWL 1 6 PAWL TOOTH 1 7 PISTON SLEEVE 1 8 SQUARE DRIVE 1 9 DRIVE BUSHING 2 10 DRIVE SLEEVE SPLINE 2 11 DISENGAGEMENT PAWL 1 16 DISENGAGEMENT LEVER 2 17 ROD END 1 18 ROD END PIN 1 19 PISTON 1 20 PISTON ROD 1 21 ACCESS PLUG 2 22 PISTON HEAD 1 23 PISTON BUSH 1 24 REACTION ARM PLATE 1 ITEM No. PART DESCRIPTION QTY 25 REACTION ARM BOOT 1 26 SEAL KIT 1 27 SHROUD 1 28 DISENGAGEMENT LEVER 2 SCREW 29 SHROUD SPRING SCREW 1 30 HOUSING GRUB SCREW 1 31 REACTION ARM PLATE SCREW 2 32 SHROUD SCREW 2 33 REACTION BOOT ROLL PIN 2 34 PAWL SPRING ROLL PIN 1 35 DRIVE PLATE SPRING ROLL PIN 1 36 PAWL TOOTH RETAINER ROLL PIN 1 37 REACTION PAWL SPRING 1 PIN 38 DRIVE BUSHING SPIROLOX RING 2 39 PAWL SPRING 2 40 REACTION PAWL SPRING 1 41 PAWL TOOTH SPRING 1 42 DRIVE RETAINER SPRING 1 43 DRIVE RETAINER CIRCLIP 1 44 REACTION ARM RETAINER 1 CIRCLIP 45 REACTION ARM RETAINER 1 SPRING ITEM No. PART DESCRIPTION QTY 46 SHROUD SPRING 1 47 SWIVEL 1 48 DRIVE RETAINER BALL BEARING 3 49 REACTION ARM RETAINER 3 BALL BEARING 50 DISENGAGEMENT PAWL HOUSING PIN 1 56 MALE COUPLER 2 57 FEMALE COUPLER 2 58 DRIVE RETAINER 1 59 REACTION ARM RETAINER 1 21 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 22 11/04/2017 10:15
Pressure/Torque Conversion Chart Lbs/ft PSI HTL-DS1 HTL-DS3 HTL-DS5 HTL-DS10 HTL-DS25 BAR 1500 200 480 835 1755 3960 104 1600 214 512 890 1864 4216 110 1800 242 576 1000 2082 4728 124 2000 270 640 1110 2300 5240 138 2200 298 704 1222 2526 5752 152 2400 326 768 1334 2752 6264 165 2600 354 832 1446 2978 6776 179 2800 382 896 1558 3204 7288 193 3000 410 960 1670 3430 7800 207 3200 438 1024 1782 3656 8318 220 3400 466 1088 1894 3882 8836 234 3600 494 1152 2006 4108 9354 248 3800 522 1216 2118 4334 9872 262 4000 550 1280 2230 4560 10390 276 4200 578 1346 2342 4792 10898 290 4400 606 1412 2454 5024 11406 303 4600 634 1478 2565 5256 11914 317 4800 662 1544 2678 5488 12422 331 5000 690 1610 2790 5720 12930 345 5200 718 1674 2902 5948 13450 358 5400 746 1738 3014 6176 13970 372 5600 774 1802 3126 6404 14490 386 FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 23 22 HTL-Operating-Instructions-DS.indd 23 11/04/2017 10:15
PSI HTL-DS1 HTL-DS3 HTL-DS5 HTL-DS10 HTL-DS25 BAR 5800 802 1866 3238 6632 15010 400 6000 830 1930 3350 6860 15530 414 6200 858 1994 3462 7094 16040 427 6400 886 2058 3574 7328 16550 441 6600 914 2122 3686 7562 17060 455 6800 942 2186 3798 7796 17570 468 7000 970 2250 3910 8030 18080 482 7200 998 2316 4022 8264 18602 496 7400 1026 2382 4134 8498 19124 510 7600 1054 2448 4246 8732 19646 524 7800 1082 2514 4358 8966 20168 538 8000 1110 2580 4470 9200 20680 552 8200 1138 2646 4582 9432 21214 565 8400 1166 2712 4694 9664 21738 579 8600 1194 2778 4806 9896 22262 593 8800 1222 2844 4918 10128 22786 607 9000 1250 2910 5030 10360 23310 620 9200 1278 2974 5142 10592 23826 634 9400 1306 3038 5254 10824 24342 648 9600 1334 3102 5366 11056 24858 662 9800 1362 3166 5478 11288 25734 676 10000 1390 3230 5590 11520 25890 690 OUTSIDE UK: +44 (0) 1670 700 018 24 23 HTL-Operating-Instructions-DS.indd 24 11/04/2017 10:16
Pressure/Torque Conversion Chart N/M PSI HTL-DS1 HTL-DS3 HTL-DS5 HTL-DS10 HTL-DS25 BAR 1500 271 651 1132 2379 5368 104 1600 290 694 1206 2527 5715 110 1800 328 781 1356 2822 6409 124 2000 366 868 1505 3118 7103 138 2200 403 954 1657 3424 7797 152 2400 439 1041 1808 3731 8491 165 2600 476 1128 1960 4037 9186 179 2800 512 1215 2112 4343 9880 193 3000 549 1301 2264 4650 10574 207 3200 584 1388 2416 4956 11276 220 3400 620 1475 2568 5262 11978 234 3600 655 1562 2719 5569 12680 248 3800 690 1648 2871 5875 13382 262 4000 725 1735 3023 6182 14085 276 4200 762 1825 3175 6496 14773 290 4400 798 1914 3327 6811 15462 303 4600 835 2004 3478 7125 16151 317 4800 872 2093 3630 7440 16839 331 5000 908 2183 3782 7754 17528 345 5200 945 2269 3934 8063 18233 358 5400 981 2356 4086 8372 18938 372 5600 1018 2443 4238 8681 19643 386 FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 25 24 HTL-Operating-Instructions-DS.indd 25 11/04/2017 10:16
PSI HTL-DS1 HTL-DS3 HTL-DS5 HTL-DS10 HTL-DS25 BAR 5800 1055 2530 4389 8990 20348 400 6000 1091 2616 4541 9299 21052 414 6200 1128 2703 4693 9617 21744 427 6400 1164 2790 4845 9934 22435 441 6600 1201 2877 4997 10251 23127 455 6800 1238 2963 5149 10568 23818 468 7000 1274 3050 5300 10885 24509 482 7200 1311 3140 5452 11203 25217 496 7400 1347 3229 5604 11520 25924 510 7600 1384 3319 5756 11837 26632 524 7800 1421 3408 5908 12154 27340 538 8000 1457 3497 6060 12472 28047 552 8200 1493 3587 6211 12786 28758 565 8400 1528 3676 6363 13101 29468 579 8600 1563 3766 6515 13415 30178 593 8800 1598 3855 6667 13730 30889 607 9000 1633 3945 6819 14044 31599 620 9200 1670 4032 6970 14359 32299 634 9400 1707 4118 7122 14673 32998 648 9600 1743 4205 7274 14988 33698 662 9800 1780 4292 7426 15302 34397 676 10000 1817 4379 7578 15617 35096 690 OUTSIDE UK: +44 (0) 1670 700 018 26 25 HTL-Operating-Instructions-DS.indd 26 11/04/2017 10:16
EC DECLARATION OF CONFORMITY Name of Manufacturer: Address: HTL Worldwide 45 Colbourne Avenue, Nelson Park Ind. Estate, Cramlington, Northumberland NE23 1WD United Kingdom Description of product: Hydraulic Torque Wrench HTL-DS, HTL-L, HTL-R, HTL-S & HTL-W Model No s: DS-1, DS-3, DS-5, DS-10 & DS-25 L-2, L-4, L-8, L-14 & L-30 R-2, R-4, R-8 & R14 S-2, S-4, S-8, S-14 & S30 W-2, W-4, W-8, W-14 & W-30 This is to certify that the aforementioned equipment fully conforms to the protection requirements of the following EC Council Directive on the approximation of the laws of the member states relating to the Safety of Machinery 2006/42/EC by the application of standard EN ISO 12100: 2010. This is to certify that the aforementioned equipment fully conforms to the essential safety requirements of Group II Category 2G ct6 of the following EC Council Directive on the approximation of the laws of the member states relating to the 94/9/EC: Equipment & Protective Systems Intended For Use In Potentially Explosive Atmospheres by the application of standards EN 13463-1: 2009, EN 13463-5: 2011 and EN 15198: 2007. A technical dossier has been lodged with the following notified body. CSA Group (EU Notified Body # 0518) Unit 6 Hawarden Industrial Park Hawarden, CH5 3US United Kingdom Name : Mike Johnson Position : Group Technical Manager Signature : Date : 22 nd October, 2015 FOR OUR LATEST PRODUCTS & OFFERS VISIT WWW.HTL-WORLDWIDE.COM 27 26 HTL-Operating-Instructions-DS.indd 27 11/04/2017 10:16
28 OUTSIDE UK: +44 (0) 1670 700 018 HTL-Operating-Instructions-DS.indd 28 11/04/2017 10:16
HTL-Operating-Instructions-DS.indd 29 11/04/2017 10:16
HTL-Operating-Instructions-DS.indd 30 11/04/2017 10:16
HTL-Operating-Instructions-DS.indd 31 11/04/2017 10:16
HTL Worldwide Ltd 45 Colbourne Avenue, Nelson Park Industrial Estate, Cramlington, Northumberland, NE23 1WD OUTSIDE UK: +44 (0) 1670 700 018 32 worldwide Telephone: +44 (0) 1670 700018 Email: sales@htl-worldwide.com Visit: www.htl-worldwide.com HTL-Operating-Instructions-DS.indd 32 11/04/2017 10:16