HTL DS Series, Operating Instructions Manual

Page 1: ...w o r l d w i d e DEDICATED SQUARE DRIVE TORQUE WRENCH OPERATING INSTRUCTIONS HTL Operating Instructions DS indd 1 11 04 2017 10 15 ...

Page 2: ...HTL Operating Instructions DS indd 2 11 04 2017 10 15 ...

Page 3: ...mportant 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 HTL Operating Instructions DS indd 3 11 04 2017 10 15 ...

Page 4: ...tl 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 equip...

Page 5: ...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 access...

Page 6: ...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 re...

Page 7: ...ions 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 o...

Page 8: ...vant 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 1 Adjust flow to one drop per 60 90 seconds 2 Fill half way with grade 46 hydraulic oil supplied 1 ...

Page 9: ...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 mo...

Page 10: ...h 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 Ensure the connectors are fully engaged and screwed closely and completely together 9 R A HTL Operating Instructions DS indd 10 11 04 2017 10 15 ...

Page 11: ...r loosening and tightening of a standard right hand fastener Right is Tight Left is Loose 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 ...

Page 12: ...s follows Assume you are going to use a HTL W2 tool to torque a 1 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...

Page 13: ...uge 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 nu...

Page 14: ...ote 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 ...

Page 15: ...oint 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 ind...

Page 16: ...eplaceable 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 OUTSIDE UK 44 0 1670 700018 15 HTL Operating Instructions DS indd 16 11 04 2017 10 15 ...

Page 17: ...lowed 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 ...

Page 18: ...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 S...

Page 19: ...otor 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 ...

Page 20: ...t actually being used DO NOT leave pump running when tool is not in use Hose or tool fitting is damaged or leaks 1 Broken or melted plastic outer covering 2 Frayed Kevlar or steel strands 3 Oil leaks through fibers 4 Broken fittings 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...

Page 21: ...ken 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 Pre...

Page 22: ...CTION 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 PIN 1 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 CIRCLIP 1 45 REACTION ARM RETAINER SPRING 1 20 19 23 57 56 47 32 29 46 27 17...

Page 23: ... 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...

Page 24: ...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 3...

Page 25: ... 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 775...

Page 26: ...96 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 9...

Page 27: ... 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 Poten...

Page 28: ...28 OUTSIDE UK 44 0 1670 700 018 HTL Operating Instructions DS indd 28 11 04 2017 10 16 ...

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Page 32: ...d e HTL Worldwide Ltd 45 Colbourne Avenue Nelson Park Industrial Estate Cramlington Northumberland NE23 1WD 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 ...