Operating Manual & Safety Instructions ProTorc Hydraulic Torque Wrench Model # PTLC - Please read in full before operating ProTorc Torque Wrench - ProTorc
Important Safety Instructions READ ALL INSTRUCTIONS before using the equipment KEEP WORK AREA CLEAN and free from potential hazards WORK AREA ENVIRONMENT Electrical Pumps should never be used in any area which can be considered potentially dangerous, i.e. gaseous or wet areas. If there is any doubt, use an air pump. SAFE PREMATURE TOOL STARTING The Pump Remote Control should only be used by the Tool Operator only. Avoid having two separate people operating the pump and wrench. SAFETY DURING OPERATION Where possible, use the wrench with the hands-free operation. If the tool must be held or steadied during operation, use alternative means of securing the wrench to the application. Keep hands and fingers away for the wrench moving parts and reaction area. GUARD AGAINST ELECTRIC SHOCK Ensure the pump is properly grounded and the proper voltage is being used. Only use Extension Leads of the correct wire gauge. STORAGE Keep all Wrenches and Pumps in a well-ventilated, clean environment to avoid deterioration. CORRECT TOOL SELECTION Do not use smaller wrenches or attachments to do a job above their torque range. Use a larger wrench to prevent damaging the wrench. Do not use any wrench for any purpose for which it is not designed. CORRECT SAFETY ATTIRE When handling / operating hydraulic equipment, wear safety glasses, work gloves, hard hats, safety shoes, hearing protection and other applicable clothing. HANDLING EQUIPMENT Never use Hydraulic Hoses, Swivels, Pump Power or Remote Cords as means when moving the equipment. HOSES Inspect and replace hoses if damaged prior to use. SHROUDS AND COVER PLATES All wrenches and Pumps are equipped with shrouds and/or cover plates to cover up moving internal parts. Do not use tools without shrouds or cover plates removed or missing. MAINTAINENCE For ongoing performance, inspect Wrenches, Power Pack, Hoses, Connectors, Electric Lines and Accessories for any visual damage, prior to each operation. Always follow instructions for proper wrench and pump maintenance. Refer to the Operations Maintenance Section for further clarification. SAFE OPERATION Always be aware of what you are doing. Use common sense. Never use Hydraulic Wrenches or Pumps under the influence of alcohol or any mood altering substances. PRIOR OPERATION Ensure that all hydraulic connections are securely connected. Verify that the hydraulic hoses are not kinked, and will not be crushed in the reaction area. Insure the link is fully fitted over the nut. 1 Operating & Instruction Manual - Model PTLC
PRIOR TO USE Cycle the wrench to ensure proper function. Locate a solid, secure reaction point. Always ensure the reaction is correctly engaged. Be sure the hydraulic hoses are free of the reaction points. Pressurize the system for a test; if the tool tends to ride up or to creep, stop and re-adjust the reaction arm to achieve a more solid and secure position. NOTE: Remain clear of the reaction arm during operation and never put body parts between reaction arm and reaction surface. DO NOT USE FORCE Do not hammer on the wrench. If the nut will not turn with the wrench you are using, use a larger size Protorc wrench. Model Description The Protorc Hydraulic Torque Wrenches are manufactured from high strength Aluminium-Titanium alloy and super high strength alloy steel for increased strength, intensity and durability. High repeatability, along with a precise design provide an accuracy of ±3%. PTLC - Square Low Height Link Torque Wrenches ITEM NAME 1 - Cassette 2 - Pin 3 - Power Head 4 - Quick Coupling 5-360 x 360 Swivel Joint 6 - Reaction Arm 7 - Link Pin 8 - Ratchet 9 - Quick Release Arm Operating & Instruction Manual - Model PTLC 2
WARNING To avoid personal injury and equipment damages, ensure that all hydraulic components are rated for 10,000PSI (700Bar) Operating Pressure. WARNING Do not use the Wrench above its designed working pressure. Use hydraulic gauge to indicate the working pressure in the system WARNING Replace any worn or damaged components of the Protorc, with new components as soon as possible. WARNING WARNING To avoid personal injuries and equipment damages, do not remove any shrouds or covers of the wrench. Do not modify any component of the wrench. Do not change or alter the relief valve which is inside the swivel couplings. CAUTION Do not subject the components to potential hazards such as fire, sharp surfaces, extreme heat or cold, or heavy impact. CAUTION CAUTION Never place your hands onto hoses or fittings. The force of escaping hydraulic fluid can cause serious injury. Do not let the hose kink, twist, curl or bend so tightly that oil flow within the hose is blocked or reduced. Do not use the hose to move attached equipment. Stress caused can damage the hose, causing hose failure and personal injury. CAUTION Ensure the hoses are correctly connected. Before connection, make sure the swivel couplings are clean and free of dirt. After use, the swivel couplings must have the dust caps fitted to prevent ingression of dirt. CAUTION During operation or when nut is finally tightened, if the tool locks onto the nut, press advance button on remote and build pressure. Continue to press down on remote while pushing down on the reaction pawl release lever. Hold reaction pawl release lever down and release the advance button allowing the wrench to retract. This will allow the wrench to be removed from the nut. Push down Reaction Pawl Release Lever to retract wrench 3 Operating & Instruction Manual - Model PTLC
OPERATION CONNECTING THE TOOL The wrench and power pump are connected by a 700 BAR operating pressure, twin-line hose assembly. Each end of the hose will have one male and one female connector. Ensure proper connection between pump and wrench is established.. ENSURE THAT THE CONNECTORS ARE FULLY ENGAGED AND SCREWED SNUGLY AND COMPLETELY TOGETHER SETTING THE TORQUE After determining the desired torque, use the torque conversion chart relevant to the model of the wrench being used, to determine the pressure that is necessary to achieve that torque. 1. Connect the wrench to the power supply and turn the pump on. (Do not place wrench onto job) 2. Depress the advance remote control button causing the pressure to be shown on the gauge 3. Adjust the pressure by first loosening the nut that locks the pressure adjustment handle and then 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 pressure back up to the desired pressure as display on the pressure gauge. 4. Adjust the pressure by first loosening the nut that locks the pressure adjustment handle and then 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 pressure back up to the desired pressure as display on the pressure gauge. Pressure Adjusting Knob Locking Nut Operating & Instruction Manual - Model PTLC 4
PTLC WRENCH POSITIONS The position of the tool relative to the nut determines whether the action will tighten or loosen the nut. The power stroke of the piston assembly will always turn the ratchet head towards the shroud. OPERATING THE WRENCH 1. Place the ratchet link on the nut. Make certain it is the correct size for the nut and that it fully engages the nut. 2. Position the reaction surface against an adjacent nut, flange or solid system component. Make certain that there is clearance for the hoses and swivel couplings. Do not allow the tool to react against the hoses, or swivel couplings. Reaction Surface 3. After having turned the pump on and pre-setting the pressure for the correct torque, depress the remote control advance button to advance the piston assembly. 4. When the cassette is placed onto the nut and the pump is started, the reaction surface of the wrench or reaction arm will move against the reaction point and the nut will begin to turn. Once the piston reaches the end of its stroke release the remote control advance button to retract the piston. 5. Continue this cycling operation of advance and retract until the nut is no longer turning and the pump gauge reaches the pre-set pressure. The piston rod will retract when the retract button is pressed and under normal conditions, an audible click will be heard as the tool resets itself. 6. Continue to cycle the tool until it stalls and the pre-set psi/torque has been attained. Ensure that the wrench is not at full stroke. If unsure, cycle the wrench again to see if the nut continues to rotate. 7. Once the nut stops rotating, cycle the tool one last time to ensure you have achieved the final total torque. 5 Operating & Instruction Manual - Model PTLC
INSTRUCTIONS TO CHANGE THE LINK CASSETTE STEP 1 Remove long pin from top of top of wrench STEP 2 Remove short pin from wrench STEP 3 Remove the power head from the link assembley Operating & Instruction Manual - Model PTLC 6
STEP 4 Ensure the replacement link cassette is placed on a supportive flat surface STEP 5 Pull the drive plate fully back towards the rear of the cassette STEP 6 Lie Link down and place the power head over the link cassette and install the long pin 7 Operating & Instruction Manual - Model PTLC
STEP 7 Ensure that the Drive Piston is on top of the Piston Hook STEP 8 Push the Power Head torwards the cassette STEP 9 Use you finger to push the Drive Plate towards the Hex Drive Operating & Instruction Manual - Model PTLC 8
STEP 10 Push the Power Head towards the cassette ensuring the Drive Plate is fully down and the drive plate and slide plate are in line STEP 11 Line up pin holes and re-insert short pin STEP 12 The Link has been successfully changed and the ProTorc PTLC Torque Wrench is ready for use 9 Operating & Instruction Manual - Model PTLC
TROUBLE SHOOTING GUIDE Problem Probable Cause Solution Piston will not advance or retract Piston will not retract Cylinder will not build up pressure Link will not turn Pump will not build up pressure Nut returns with retract stroke Couplers are not securely attached at the wrench of pump Couplers are faulty Faulty Remote Control Dirty or faulty Directional Control Valve on pump Hose connection reversed Retract hose not connected Retract pin and/or spring broken Piston seal and/or end plug seal leaking Pump not developing pressure Grease or dirt build up in the teeth of the ratchet and segment pawl Worn or broken teeth on ratchet and/or ratchet pawl Wrench too small for job Defective relief valve Electric power source os too low or air supply is insufficient to operate pump Defective gauge Low oil level Clogged filter Reaction pawl release lever spring broken Check the coupler connections and make certain that they are fully engaged Replace any faulty couplers Replace Remote Control button or complete unit Dissasemble the Control Valve, inspect, clean & repair or replace Ensure the the advance on the pump is connected to the advance on the wrench, and the retract on the pump is connected to the retract on the wrench Connect the retract hose correctly Replace the broken pin and/or spring Replace any defective seals Check pump for pressure without wrench attached - if faulty, replace pump Disassemble the ratchet and clean the grease and dirt from the teeth Replace any worn or damaged parts Use a larger wrench Inspect, adjust or replace relief valve Ensure the voltage, amperage and any extension cords comply with the pumps manual requirements (Electric). Ensure you have sufficient air supply and pressure (Air) Replace gauge Check and fill the pump reservoir Inspect, clean or replace the pump filter Inspect and replace the reaction pawl release lever and/or spring Cylnder or wrench leaks Seals in cylinder or swinvel faulty Replace faulty seals ProTorc Operating & Instruction Manual - Model PTLC 10
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