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THANK YOU FOR PURCHASING THE VERY FIRST TORQUE/TENSION SYSTEM AND THE VERY FIRST HANDS-OFF BOLTING TOOLS IN THE WORLD!!!
OPERATING CD: Please show the enclosed CD prior to each tool use to your staff to familiarize them with the tools. FREE SAFETY TRAINING: To assure a safe operation, please request a FREE Safety Training prior to use by calling your local HYTORC Representative or Jimmie Davis at 1 201 628-5221 (JDavis@HYTORC.com). We do recommend one Safety Training every 6 months. These trainings are free of charge. Just call us. PLEASE READ THE SAFETY INSTRUCTIONS HEREIN. SYSTEM INSPECTION: Prior to any use, please inspect the entire tool system, including hoses, gauge, sockets and backup wrenches. Do not use kinked hoses, oversized or heavily worn sockets, backup wrenches, damaged tools, pumps, connectors or gauges. Connect system to operate from a safe distance. Assure fasteners are in good shape. Check out tool functioning with drive or hex ratchet turning in one direction only and check out gauge from a safe distance that needle is on Zero at no pressure and at 10,000 psi at high pressure. Keep high pressure on and check system visually for leaks. Please keep in mind that hydraulic tools are very strong and work at high pressure. HAND-OFF BOLTING: The tool you purchased permits hands-free operation from a safe distance in conjunction with a safety Washer. We do recommend the use of the Safety Washer to avoid fingerpinching, over-crowded sites and to assure hands-off bolting at least on all vertical and inverted applications, while eliminating improvising and use of reaction members or backup wrenches. Otherwise set up the tool in a way that it does not have to be held by hand. For more information, please contact Jimmie Davis or Eric Junkers at 1 201 512-9500 or go to www.HYTORC.com. HANDS-FREE WASHER APPLICATION: Make sure Drive and Tool is locked on securely. FREE ANNUAL TOOL INSPECTION: With the purchase of HYTORC, you have the right of a FREE annual tool inspection, which includes free seals, springs and connectors and free lubrication. In case of damaged or worn parts, the first inspection within 18 months of purchase is free of charge. Thereafter, you will be informed of any cost prior to replacement. Any part replaced and charged by us will be sent to you for your inspection upon request when P.O. is issued. FREE LOANER TOOLS: In case of tool failure during the warranty or rental period, please contact your local HYTORC Agent for a free Loaner tool 24/7. HOSE REPLACEMENT: We do recommend replacing hydraulic hoses and oil at least once a year. PLEASE WEAR REQUIRED SAFETY ATTIRE and use common sense with power tools. HELP: If you require any further assistance, please call your local HYTORC Representative or 1-800-FOR-HYTORC worldwide 24/7! Its live!
No.Safety121009
No.Safety121009
CONTENTS
INTRODUCING HYTORC
SECTION I
4 5 7
SECTION III
OPERATION
3-1 General 3-2 Connecting the System 3-3 Drive Direction Change 3-4 Reaction Arm 3-5 Setting Torque 3-5 Setting Pressure 3-7 Applying Torque 3-8 Operating the Torque Machine 3-9 Loosening Procedures SECTION IV
14
PREVENTIVE MAINTENANCE
5-1 Preventive Maintenance - Torque Machines 5-2 Preventive Maintenance - Hydraulic Power Packs SECTION VI
16
TROUBLESHOOTING
SECTION VII
18 22 24
INTRODUCING HYTORC
World-wide Warranty
HYTORC equipment is engineered to the latest technological standards and are accompanied by our exclusive 12-word, 12-month warranty. YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE! If a HYTORC MXT or XLT cannot be repaired on site, FREE loaner HYTORC equipment will be made available to you upon request.
UNex COrpORATION OR ITS DEAlerS Shall NOT bE liAblE FOr LOSS OF PROdUCT OR other INcidentaL or CONSEQUeNTiAL COstS INCURRED bY ThE buyer OR the user.
Offices Worldwide
Europe Japan Australia Brazil All Others HYTORC Europe HYTORC Japan HYTORC Australia Tel. 33-1-4288-6745 Tel. 81-3-3314-3315 Tel. 61-8-8293-8411 Tel. 44-16-7036-3800 Tel. 55-21-2223-2944 Tel. 201-512-9500 / 1-800-FOR-HYTORC (800-367-4986)
SECTION I
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. If the tool must be held or steadied during operation, use alternative means of securing the tool to the application. 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 Dont force small tools or attachments to do the job of a larger tool. Dont use a tool for purposes not intended. PROPER 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, uniswivels, pump power or remote cords as means of moving the equipment.
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. Do not use tools without shrouds but contact your local HYTORC office to fix. 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 Watch what you are doing. Use common sense. 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. Insure 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 of the reaction point. Pressurize the system momentarily; if the tool tends to ride up or to creep, stop and re-adjust the reaction arm to 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. ALWAYS USE QUALITY ACCESSORIES Always use top 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 socket or tool to enhance performance. If the nut will not turn with the wrench you are using, use a larger size HYTORC tool. REACTION ARM Proper reaction is required Adjust reaction arm or plate accordingly. Avoid excessive play. In case of questions, consult with your local HYTORC office.
SECTION II
1. ADJUST flOW TO one DROP PER 60 - 90 seconds 2. fill half WAY WITH GRADE 46 HYDRAUliC oiL SuppliED
SECTION III
OPERATION
3-1 General
All HYTORC Torque Machines are supplied completely assembled, ready for use. A HYTORC Hydraulic Power Pack, for use with your HYTORC machine, is recommended to provide the speed, pressure and portability that makes your HYTORC System efficient and accurate. The System accuracy of your MXT Series tool is +/- 3% based upon manufacturers specifications. This accuracy may be certified through calibration by HYTORC or any other qualified calibration facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.). Using a calibrated gauge enhances the accuracy of your HYTORC 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 assure proper interconnection between pump and wrenchheads. IMPORTANT To avoid tool malfunction, do not reverse connectors. Connect the twinline hose to the uniswivel as shown below:
Insure the connectors are fully engaged and screwed snugly and completely together.
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 above diagram illustrates the direction the square drive should face for loosening and tightening of a standard right hand fastener.
The reaction arm for all MXT/XLT Series tools are splined to slide over the rear (cylinder) portion of the tool. In operation, the reaction arm must be fully engaged and secured by inserting the spring loaded reaction arm clamp at the base of the housing into the groove of the reaction arm.
10
11
MXT SERIES
Pressure in PSI 1500 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 9200 9400 9600 9800 10000 P7MXT 118 126 143 160 176 193 209 226 242 259 275 292 308 325 342 359 375 392 409 425 442 458 475 491 508 524 541 557 574 591 608 625 642 659 675 691 706 722 738 755 772 788 805 822 1MXT 200 214 242 270 297 324 351 378 405 431 457 483 509 535 562 589 616 643 670 697 724 751 778 805 832 859 886 913 940 967 994 1021 1048 1075 1101 1127 1153 1179 1205 1232 1259 1286 1313 1340 3MXT 480 512 576 640 704 768 832 896 960 1024 1088 1152 1216 1280 1346 1412 1478 1544 1610 1674 1738 1802 1866 1930 1994 2058 2122 2186 2250 2316 2382 2448 2514 2580 2646 2712 2778 2844 2910 2974 3038 3102 3166 3230 5MXT Torque in Ft. Lbs 835 890 1000 1110 1222 1334 1446 1558 1670 1782 1894 2006 2118 2230 2342 2454 2566 2678 2790 2902 3014 3126 3238 3350 3462 3574 3686 3798 3910 4022 4134 4246 4358 4470 4582 4694 4806 4918 5030 5142 5254 5366 5478 5590 10MXT 1755 1864 2082 2300 2526 2752 2978 3204 3430 3656 3882 4108 4334 4560 4792 5024 5256 5488 5720 5948 6176 6404 6632 6860 7094 7328 7562 7796 8030 8264 8498 8732 8966 9200 9432 9664 9896 10128 10360 10592 10824 11056 11288 11520 20MXT 2960 3158 3555 3950 4345 4740 5135 5530 5930 6325 6720 7115 7510 7905 8300 8695 9090 9485 9880 10275 10670 11065 11460 11860 12250 12645 13040 13435 13830 14225 14620 15020 15415 15810 16200 16600 16995 17390 17785 18180 18575 18970 19365 19760 25MXT 3960 4216 4728 5240 5752 6264 6776 7288 7800 8318 8836 9354 9872 10390 10898 11406 11914 12422 12930 13450 13970 14490 15010 15530 16040 16550 17060 17570 18080 18602 19124 19646 20168 20690 21214 21738 22262 22786 23310 23826 24342 24858 25374 25890 35MXT 5400 5772 6516 7260 8021 8782 9543 10304 11065 11817 12569 13321 14073 14825 15572 16319 17066 17813 18560 19306 20052 20798 21544 22290 23027 23764 24501 25238 25975 26716 27457 28198 28939 29680 30422 31164 31906 32648 33390 34132 34874 35616 36358 37100
MXT SERIES
Pressure in PSI 1500 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000 8200 8400 8600 8800 9000 9200 9400 9600 9800 10000 1MXT-SA 200 214 242 270 297 324 351 378 405 431 457 483 509 535 562 589 616 643 670 697 724 751 778 805 832 859 886 913 940 967 994 1021 1048 1075 1101 1127 1153 1179 1205 1232 1259 1286 1313 1340 3MXT-SA Torque in Ft. Lbs 480 512 576 640 704 768 832 896 960 1024 1088 1152 1216 1280 1346 1412 1478 1544 1610 1674 1738 1802 1866 1930 1994 2058 2122 2186 2250 2316 2382 2448 2514 2580 2646 2712 2778 2844 2910 2974 3038 3102 3166 3230 5MXT-SA 835 890 1000 1110 1222 1334 1446 1558 1670 1782 1894 2006 2118 2230 2342 2454 2566 2678 2790 2902 3014 3126 3238 3350 3462 3574 3686 3798 3910 4022 4134 4246 4358 4470 4582 4694 4806 4918 5030 5142 5254 5366 5478 5590 10MXT-SA 1755 1864 2082 2300 2526 2752 2978 3204 3430 3656 3882 4108 4334 4560 4792 5024 5256 5488 5720 5948 6176 6404 6632 6860 7094 7328 7562 7796 8030 8264 8498 8732 8966 9200 9432 9664 9896 10128 10360 10592 10824 11056 11288 11520
MXT SERIES
Pressure in 100 x Kpa 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 690 P7MXT 154 188 220 254 285 317 351 382 414 447 482 513 546 579 611 644 675 709 741 775 808 841 874 907 938 967 1000 1033 1065 1098 1114 1MXT 261 317 371 426 478 531 584 635 685 736 791 843 895 950 1002 1055 1107 1162 1214 1269 1321 1374 1426 1479 1530 1580 1633 1686 1738 1790 1817 3MXT 626 756 880 1010 1134 1259 1388 1513 1636 1760 1895 2023 2151 2282 2405 2530 2654 2783 2908 3037 3165 3293 3421 3555 3683 3811 3945 4070 4192 4317 4379 5MXT Torque in NM 1088 1312 1527 1754 1971 2189 2416 2633 2849 3067 3294 3511 3727 3956 4172 4389 4607 4834 5052 5278 5496 5712 5930 6156 6374 6590 6819 7036 7252 7470 7578 10MXT 2288 2731 3163 3618 4060 4501 4956 5397 5830 6271 6743 7192 7642 8108 8546 8990 9434 9911 10364 10840 11293 11747 12199 12673 13123 13571 14044 14494 14942 15393 15617 20MXT 3858 4664 5432 6231 7000 7768 8574 9343 10103 10871 11670 12439 13199 14007 14767 15535 16310 17103 17871 18670 19439 20206 20974 21766 22542 23302 24109 24878 25638 26407 26787 25MXT 5162 6203 7206 8234 9237 10238 11276 12285 13280 14289 15309 16303 17274 18335 19337 20348 21358 22384 23381 24408 25420 26429 27441 28503 29519 30532 31599 32604 33596 34601 35096 35MXT 7039 8548 9984 11544 13009 14475 16019 17475 18932 20388 21903 23354 24795 26317 27756 29205 30654 32141 33579 35066 36508 37933 39376 40875 42319 43747 45263 46707 48135 49579 50293
MXT SERIES
Pressure in 100 x Kpa 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 690 1MXT-SA 261 317 371 426 478 531 584 635 685 736 791 843 895 950 1002 1055 1107 1162 1214 1269 1321 1374 1426 1479 1530 1580 1633 1686 1738 1790 1817 3MXT-SA Torque in NM 626 756 880 1010 1134 1259 1388 1513 1636 1760 1895 2023 2151 2282 2405 2530 2654 2783 2908 3037 3165 3293 3421 3555 3683 3811 3945 4070 4192 4317 4379 5MXT-SA 1088 1312 1527 1754 1971 2189 2416 2633 2849 3067 3294 3511 3727 3956 4172 4389 4607 4834 5052 5278 5496 5712 5930 6156 6374 6590 6819 7036 7252 7470 7578 10MXT-SA 2288 2731 3163 3618 4060 4501 4956 5397 5830 6271 6743 7192 7642 8108 8546 8990 9434 9911 10364 10840 11293 11747 12199 12673 13123 13571 14044 14494 14942 15393 15617
12
Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the operator will hear an audible click indicating he can again push the remote control button and the socket will tum. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the tool stalls at the pre-set Torque/PSl with an accuracy of +1- 3%. Repeatability is +1- 1%.
IMPORTANT: ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE STALL POINT HAS BEEN REACHED.
Should the tool lock-on after the final cycle, push down on the remote control button once more (to build pressure) and, while maintaining this pressure, pull back on the accuracy assurance pawl lever (see-15XLT/-14XLT on parts list for location). Releasing the remote control while continuing to hold back the on the accuracy assurance pawl lever will allow the tool to be removed easily.
13
SECTlON IV
14
3. Compare motor nameplate against power availability to prevent motor burnout or dangerous electrical overloading.
4-6 Operation
Before starting your Electric Pump (HYTORC 115/230), connect your hydraulic hoses to both the pump and torque wrench. Place the toggle switch in the ON position and the rocker switch on the hand control pendant in the OFF position. To start the pump, depress and release the yellow safety button. NOTE: The safety button is an added feature designed to prevent premature starting and should ouly be depressed by the tool operator. Push the rocker switch to advance and release. This will start your pump and place it in the retract position. NOTE: Read the section labeled HYTORC OPERATIONS and SETTING TORQUE prior to installing the torque wrench onto the application. Your HYTORC 115/230 hydraulic pump has been designed with an auto shut off system. The pump will shut off after approximately 30 seconds of non-cycling. This will prevent overheating and unnecessary wear which will prolong the life of your pump. To restart the pump, the yellow safety button must again be depressed prior to use.
15
SECTION V
PREVENTIVE MAINTENANCE
5-1 Preventive Maintenance Torque Machines
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 HYTORC tools may be made by reasonably experienced individuals according to the aforementioned instructions. Lubrication All moviag parts should periodically be coated with a good quality NLGI #2 molybdenum disulfide grease. Under harsh environmental conditions, cleaning and lubricating should be performed more frequently. Hoses should be checked for cracks and leaks after each job. Hydraulic fittings can become plugged with dirt and should be flushed periodically. 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 are used for the drive pawl assembly and for the accuracy assurance pawl. These springs can be replaced if necessary. If the cylinder requires disassembly, it is recommended that the cylinder seals be replaced at the same time. Seal kits are readily available. 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.
Hydraulic Hoses
Quick-Connects
Springs
Cylinder Seals
Structural Members
16
Quick-Disconnects
Hydraulic Gauge
Filter on Pump
Remote Control
Air Valve
Armature
17
SECTION VI
TROUBLESHOOTING
SYMPTOM
Gauge shows pressure build-up but the tool will not cycle.
PROBABLE CAUSE
1. Couplings loose or inoperative 2. Solenoid inoperative
REQUIRED ACTION
1. Tighten and/or replace couplings. Use Test #1 listed below to isolate problem. 1. Check using test #2 below. If solenoid is bad, replace. 1. See Above 2. Get shorter extension cord or upgrade to 12AWG, 25 amp rating or better. If shop power is adequate, draw powcr from welding machine or cal rod transformer.
1. See above 2. Voltage to electric pump is too low to line drop or inadequate amperage is available. 3. Linkage between piston rod and drive arms are broken.
3. Replace parts as necessary. 1. Replace defective parts. SHOP JOB 2. Check to see if sub-plate is worn by; a) 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.
1. Oil blow by in tool (Piston seal leak, blown O-ring, cracked piston) 2. Pump Problem
2A. 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 other end of oil line. If leaking, retighten with 9/16 open end wrench. SHOP JOB 2B. lf punp sounds like alot of pebbles in a tin can, the problem may be a worn motor coupling - remove motor from base plate - using a pair of needle nose pliers remove the motor coupling - if worn replace. SHOP JOB 2C. 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. SHOP JOB 2D. Air pumps - Faulty remote control valve cartridge. Replace.
18
SYMPTOM
Cylinder/Tool leaks
PROBABLE CAUSE
REQUIRED ACTION
1. Safety relief valve on swivel has lifted. 1A. Tighten all hose and couplers. If leak continues, adjust safety setting - Test #4 1B. Check to see if the system is properly plumbed by running test #5 (high pressure on retract side will lift the safety relief valve) 2. Blown O-ring in cylinder 3. Defective gland seal. 2. Replace O-RIng with proper high pressure O-Ring. SHOP JOB 3. Replace gland seal. SHOP JOB 1. Run test #5. Replumb system as necessary. 2. As plumbed, HYTORC hoses may only be joined together in odd numbers ONLY. If it is necessary to use 2,4,6 hoses - make un adapter from spare high pressure couplings and nipples.
1. Broken or otherwise inoperative drive 1. Replace drive pawl and/or spring. SHOP JOB pawl or spring 2. Cylinder not retracting completely 2. Remove tool from nut and cycle freely for several strokes. If problem persists, check pawls. 2A. Operator not allowing adequate time for cylinder to retract fully. 3. Linkage between piston rod and drive plates is broken 3. Replace parts as necessary - SHOP JOB. 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
1. Reaction pawl is loaded when the tool is maxd out in torque 2. Tool is operating backwards 3. Tool is wedged under a fixed object
2. Push advance button down - tool should immediately fall free- Run test #5 3. Remove shroud from around ratchet. Using any tool available, pry the drive pawl 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.
19
SYMPTOM
Gauge records no pressure
PROBABLE CAUSE
1. Gauge connection is loose 2. Bad gauge 3. Pump will not build pressure 4. Tool seals are blown
REQUIRED ACTION
1. Tighten coupling. 2. Replace gauge 3. See cylinder pressure will not build pressure-above 4. Replace defective seals. SHOP JOB 1. Check air pressure or voltage. 2. Replace valve. SHOP JOB 3. Fill reservoir and clean ftlter. 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 fllter 1. Operator is continuing to hold down on the advance stroke after the cylinder has reached end of stroke - this causes a lot of oil to go through a very small hole in relief-valve - causing heat build-up. Have operator release advance stroke after accuracy assurance levers spring forward.
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
Pump heats up
2. Turn pump off whenever not actually being used. DO NOT leave pump running when tool is not in use. If underlying Kevlar or steel is still intact continue operation. Inspect frequently. Cut hose In half and discard. Replace Hose.
1. Broken or melted plastic outer covering 1. 2. Frayed Kevlar or steel strands 3. Oil leaks through fibers 2. 4. Broken fittings
3. Cut hose in half and discard. Replace hose. 4. 1. Loose electric connections in control box. 2. Bad brushes 3. Motor burned up 1. Remove old fitting and replace with STEEL high pressure fittings only. After changing fittings, always run test #5 to insure proper plumbing. Open control box and visually inspect for loose threaded or push-on connectors. Reconnect loose wires. If in doubt check wiring diagram. DANGER BOX CONTAINS HIGH VOLTAGEALWAYS UNPLUG PRIOR TO TOUCHING ANYTHING IN CONTROL BOX.
2. Change brushes. SHOP JOB 3. Replace motor or components whichever is necessary. SHOP JOB.
20
TEST #1
Attach hoses to pump and tool in the normal manner. Press the advance button and hold it down. If the pump pressure builds and the hoses flex but the tool still refuses to cycle, the problem is most likely a loose or defective coupling connection. To find out where the bad coupling is, remove the tool from the hoses and marry the loose ends together and cycle the pump. If the gauge pressure reads no more than 500 PSI, then the bad fitting is on the tool. A significantly greater pressure indicates that the problem is in either the pump or a hose fitting.
TEST #2
Place a welding rod or thin screwdriver in the opening of either side of the solenoid. Press and then release the advance button. Repeat this process on the opposite side of the solenoid. You should feel the solenoids moving back and forth. If either side is dead the solenoid is bad and needs to be replaced. Note: if in an urgent situation, the tool may be cycled manually by pushing the solenoids back and forth through these access holes.
TEST #3
Remove tool from hoses. Cycle pump. If pump fails to build pressure, the problem is with the pump. If it does build pressure, the problem is with hydraulic blow-by in the tool.
TEST #4
Connect tool, pump and hoses together normally and turn pump on. As oil leaks from the small port under the uniswivel, use a proper size Allen wrench and slowly tighten (clockwise) the set screw positioned between the couplings on the uni-swivel. Continue to tighten until the flow stops plus a quarter turn.
TEST #5
THIS TEST SHOULD BE RUN PRIOR TO EVERY USE OF A HYTORC 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 an audible 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 audible 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 Hose Pump Advance Side - Male Retract Side - Female Advance Side - Female to Female Retract Side - Male to Male Advance Side - Male Retract Side - Female
Note that 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 per Test #5 above. If your hose isnt long enough, connect 3 hoses together. move your pump or call HYTORC for a longer hose assembly.
21
SECTION VII
DISASSEMBLY
1. Make sure the tool is fully retracted. 2. Remove the reaction arm. 3. Remove shroud (#31) by removing the two buttonhead cap screws at the base of the housing. Unhook the spring. Or, if equipped with four screws, remove the remaining two screws. 4. Remove square drive (#5) by pressing center button of drive retainer (#11) while pulling square drive out of tool. NOTE: If you have an A series tool (square drive is square the entire length of drive), you must first remove the retaining rings on the outside edge of both drive sleeves (#8) and tap the square drive through the tool.
5. Remove the 2 square drive sleeves (#8). To remove drive sleeve, line up a round punch with groove in sleeve from the opposite side and tap punch with hammer, or if equipped, remove retaining rings on outside of edge of drive sleeve and slide drive sleeves out. 6. Carefully remove serial plates (NOTE: save serial plates as they must be glued back when tool is assembled) to uncover housing access holes. 7. Line up rod pin (#19) with access holes in housing and punch rod pin through housing (NOTE: Some models may have a set screw at the end of the connector rod (#17). This must be removed prior to removing the rod pin. This set screw is no longer required and may be discarded.) 8. Remove ratchet (#6), 2 drive plates (#4), and drive pawl assembly (#63) 9. Remove screw from each lever (#15), and pull levers out of housing. 10. Remove the accuracy assurance pawl (#10) along with the accuracy assurance pawl spring (#18). 11. Remove the end cap using the proper size of hex stock (#26-E) ; Or remove the 8 end cap bolts (#34) and tighten both jacking screws to remove the end cap (#26) 12. Remove the piston rod assembly which consists of parts (17,24,25,29) by tapping connector rod (#17) with a punch and a hammer through the cylinder. 13. To change the seals, refer to the diagram below. Note: For assembly. follow the instructions in reverse. Be sure to properly lubricate all components prior to use.
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23
APPENDIX
24
APPENDIX
* E Series Housing includes 01-E, 07-1, 26-E and 31-U,32 ,58, and 59 ** Piston Rod Assembly includes 24, 25 and 29. ++ Drive Pawl Assembly Kit includes parts 17, 19 & 27 on the XLT. 5, 8, & 25. Part 17 not included with XLT 1, 3, 5, 10 & 20 # Available only as an assembly. Revised Jan. 7, 2010
25
APPENDIX
* E Series Housing includes 01-E, 07-1, 26-E and 31-U, 32, 58 & 59 ** Piston Rod Assembly includes 24, 25 and 29. ++ Drive Pawl Assembly Kit includes 19 and 27. # Available only as an assembly.
26
APPENDIX
DIMENSIONAL DATA
HYTORC
HY-.5XLT
HY1XLT
HY-3XLT
HY-5XLT
HY-8XLT
HY-10XLT
HY-20XLT
HY-25XLT
HY-50XLT
Min. ft/lbs 55 200 480 835 1200 1755 2960 Max. ft/lbs. 397 1340 3230 5590 8000 1l520 19760 Accuracy 3% 3% 3% 3% 3% 3% 3% Housing TITAL399 Uniswivel Standard Reaction Arm TITAL 399, Vertical, 360 Degree, torsion-absorbing Weight (Lbs)* 1.85 4.45 9.95 16.75 24.95 29.5 51.5
*The weight listed is for the complete rendy-to-use HYTORC tool with reaction member. HYTORC L1 L2 H1 H2 H3 H4 R1
3960 25890 3%
7875 52500 3%
68.5
124
R2
SQ
27
APPENDIX
28
APPENDIX
29
APPENDIX
30
APPENDIX
MAXIMUM WORKING TORQUE 350 ft./lbs. 385 ft./lbs. 685 ft./lbs. 1,185 ft./lbs. 1,390 ft./lbs. l,880 ft./lbs. 2,810 ft./lbs. 3,230 ft./lbs. 4,000 ft./lbs. 5,500 ft./lbs. 7,300 ft./lbs. 9,500 ft./lbs. 11,520 ft./lbs. 12,000 ft./lbs. 15,000 ft./lbs. 18,500 ft./lbs. 22,500 ft./lbs. 32,000 ft./lbs. 44,000 ft./lbs. 52,500 ft./lbs.
PROBABLE FAILURE 380 ft./lbs. 425 ft./lbs. 750 ft./lbs. 1,300 ft./lbs. 1,485 ft./lbs. 2,065 ft./lbs. 3,100 ft./lbs. 3,400 ft./lbs. 4,400 ft./lbs. 6,100 ft./lbs. 8,000 ft./lbs. 10,400 ft./lbs. 12,475 ft./lbs. 13,200 ft./lbs. 16,500 ft./lbs. 20,300 ft./lbs. 24,700 ft./lbs. 35,100 ft./lbs. 48,200 ft./lbs. 63,625 ft./lbs.
If the reaction arm cannot abut on the same plane as the nut to be turned, less torque should be applied, as the additional side load has to be taken into consideration. When torque requirements are close or in excess of the values listed above, use HYTORCs Socket Hex - Drive with replaceable Hex Insert Bits.
31
APPENDIX
BOLT/TORQUE/HYTORC
The data below is based on bolts lubricated to manufacturers specifications. Due to a variation in friction, we recommend in extreme cases to check with the bolt manufacturer, as this chart represents a guide line only.
SAE1 ASTM SAE2 B7 30,000 PSI BOLT 1 1-1/8 1-1/4 1-3/8 1-1/2 1-5/8 1-3/4 1-7/8 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4 4-1/4 4-1/2 4-3/4 6-1/2 5 7/8 1 1-1/8- 1-1/4 1-3/8 1-1/2 1-5/8 1-3/4 1-7/8 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4-1/4 4 4-1/2 4-3/4 5 B-7 A/F HEAVY HEX NUT 1-7/16 1-5/8 1-13/16 2 2-13/16 2-3/8 2-9/16 2-3/4 2-15/16 3-1/8 3-1/2 3-7/8 4-1/4 4-5/8 5 5-3/8 5-3/4 6-1/8 6-7/8 7-1/4 7-5/8 ASTM 354 B-8 60.000 PSI 7/8 1 1-1/8 1-1/4 1-3/8 1-5/8 1-3/4 1-7/8 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4 4-1/4 4-1/2 4-3/4 5 RECOMMENDED MXT MODELS MXTSERIES MXT SERIES FT./LBS. MAKE-UP ONLY MAKE-UP/BREAK-OUT 300 425 500 600 700 800 900 1,000 1,250 1,350 1,500 1,600 1,800 2,000 2,200 2,600 3,000 3,700 4,000 4,400 5,100 6,000 7,000 8,000 9,000 10,000 11,500 13,000 14,500 15,500 16,500 19,500 20,500 21,500 24,500 25,500 29,500 30,500 35,500 37,000 41,000 44,000 47,500 52,000 61,000 71,500 HY-.5XLT/MXT .7 HY-1MXT HY-1MXT HY-1MXT HY-1MXT HY-1MXT HY-1MXT HY-1MXT HY-1MXT HY-3MXT HY-3MXT HY-3MXT HY-3MXT HY-3MXT HY-3MXT HY-5MXT HY-5MXT HY-5MXT HY-5MXT HY-8XLT HY-8XLT HY-10MXT HY-10MXT HY-10MXT HY-10MXT HY-20MXT HY-20MXT HY-20MXT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-80SL HY-80SL HY-80SL HY-80SL HY-.5XLT/MXT .7 HY-1XLT HY-1XLT HY-1XLT HY-1XLT HY-1XLT HY-1XLT HY-3XLT HY-3XLT HY-3XLT HY-3XLT HY-3XLT HY-5XLT HY-5XLT HY-5XLT HY-5XLT HY-5XLT HY-8XLT HY-8XLT HY-10XLT HY-10XLT HY-10XLT HY-20XLT HY-20XLT HY-20XLT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-25XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-50XLT HY-80SL HY-80SL HY-80SL HY-80SL HY-80SL HY-80SL HY-80SL
32
APPENDIX
NOTE: If the nut does not loosen using the maximum torque output of the tool, it is an indication that you require the next larger size tool to loosen the bolt.
33
Division UNEX Corporation 333 State Route 17N Mahwah, N.J. 07430, U.S.A. Tel.: (201) 512-9500 Fax.: (201) 512-9615 E-Mail: INFO@HYTORC.COM
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