hytorc t-tool manual · hydraul press a piston h pressur finally, warning larger to-tool ing: e is...

HYD

OP

DRAUL

PERAT

LIC TEN

TING A

INST

H333

Mahwinfo

800-

NSION

AND MRUCT

HYTOR3 Rt. 17 Nwah, NJ 0

[email protected]

N NUT

MAINT

TIONS

C orth

07430 com ORC

RUNN

TENAN

NERS

NCE

HYTORC T-Tool Operating and Maintenance Instructions 2010

HYTORC of 19

TABLE OF CONTENTS

1. HYTORC T-Tools .......................................................... 03 1.1 General information before using the HYTORC equipment ........................ 03

1.2 Getting the system ready for operation ....................................................... 03

1.3 Checking the functional capability of the system ......................................... 04 1.4 Direction of rotation ..................................................................................... 04 1.5 Adjusting the pre-tensioning force ............................................................... 05 1.6 Working with the tension nut runner …………............................................. 06 1.7 Tightening the HYTORC tension nut ........................................................... 07 1.8 Loosening the HYTORC tension nut ........................................................... 07 1.9 Overhead working (special equipment) ...................................................... 08

2. High pressure hydraulic pumps ................................. 10 2.1 Electrical high pressure hydraulic aggregates ............................................. 10 2.2 Pneumatic high pressure hydraulic aggregates .......................................... 13 2.3 Automatic operation mode .......................................................................... 15 2.4 Safety couplings .......................................................................................... 16 2.5 Maintenance ................................................................................................ 17

3. Safety notes .................................................................. 18

4. Service addresses ........................................................ 19


HYTORC of 19

1. HYTORC T-TOOLS

The HYTORC T-series tension nut runners should only be used for operating HYTORC tension nuts and HYTORC smart studs. As these tools along with the HYTORC fixing elements tension the bolts without torsion or lateral forces, there is no use of torque but direct pre-tensioning force.

1.1 General information before using the HYTORC equipment

A HYTORC tension nut runner system consists of a tension nut runner, an electrically or pneumatically driven high pressure hydraulic power pack with a twin high pressure hose and the HYTORC fixing element.

All HYTORC tension nut runners are high-quality and technically fully perfected bolting tools.

In order to maintain the functional reliability and the value of the equipment for a long period, proper operation and maintenance is of tremendous importance.

It is essential that the following steps are read and followed before using the equipment.

1.2 Getting the system ready for operation

Check the level of the oil in the hydraulic power pack. The oil level should be visible in the top inspection glass.

Check the electrical connecting cable and the twin high-pressure hose for damage.

Check the direction of rotation of the motor on the three-phase AC power pack. Connect the HYTORC tension nut runner to the high-pressure hydraulic power pack by means of the twin hose. Optimum oil flow is only guaranteed if the couplings are fully closed.

HYTORC T

HYTORC

1.3

Briefly (dependpistons castellapressur

1.4 D For strudirectiondrive mthe hydscrew ocomplet

Special There isin the to

Spiral T-9

Fixing s

T-Tool

Checkin

press the ding on thein the tool

ated drive rre. If the sw

Directio

uctural reason. In orderust be chan

draulic conon the drivtely unscrew

feature of Ts a circlip beool. This mu

ring in 900

screw with rea

ng the f

green bute type of puare moved rotates. Whitch is relea

on of ro

ons the torqr to changenged. Placenections fa

ve in an anwed.

T-900: The etween the ust be remo

Castellateddrive

action cogwh

R

Operating an

function

ton or theump). The forward by

hen the enased the cas

otation

que wrenche the direce the tool onacing upwanticlockwise

reaction cocastellated

oved when d

d

heel

Reaction shaft

d Maintenanc

of 19

nal capa

brass togpower pack

y pressing thnd position stellated dri

h can only tuction of rotn a level suards. Turn e direction

Now thcan bcogwhback ininsert tThe oufirst anreactioturning

ogwheel cand drive and tdisassembli

t

ce Instruction

ability o

ggle switchk will now rhe green oris reached

ive turns ba

urn in one tation, the urface with

the fixing until it is

he castellatebe removeeel can nownto the oththe reactionuter cogs mnd then th

on shaft. Tg the fixing s

nnot be septhe reactioning the drive

s

of the sy

h on the rerun on no-lr brass-colod, the pow

ackwards.

ed drive wited from tow be removher side of n cogwheel must be inse inner on

The parts ascrew in a c

parated fromn shaft whice.

ystem

emote conload. The hored button

wer pack b

th the reactiool. The ved. Insert t

the tool. Linto the too

serted into nes by turnare then joclockwise d

m the reactioch secures t

2010

trol unit hydraulic

and the uilds up

ion shaft reaction

the drive Likewise, ol again. the tool

ning the oined by irection.

on shaft. the drive

HYTORC T

HYTORC

Tighten

The drivtool, vie

Loosen

The drivtool, vie

1.5 A

A table tension

Note: U

The reqhydraul

Press apiston hpressurFinally,

Warninglarger to

T-Tool

ning:

ve is on theewed from th

ning:

ve is on theewed from th

Adjusti

of the prenuts. Every

se only the

quired pre-teic power pa

and hold thehas reachere. You canmaintain th

g: If a presool is availa

right side ohe front

left side of he front

ng the p

essure pre-ty table show

table applic

ensioning fack. To do t

e green or bed its end pn set this tohe set press

ssure of oveable for ope

Operating an

of the

the

pre-tens

tensioning ws the alloc

cable to the

force is set his, place th

brass-coloreposition, theo the requirsure by scre

er 500 bar ning.

d Maintenanc

of 19

sioning

forces is scated thread

e thread dim

directly usihe tool on th

ed button oe manometred value bewing down

is required

ce Instruction

g force

supplied witd dimension

mension and

ing the preshe floor.

on the remoter on the y turning th the wing n

for tighten

s

th every den and a tool

d the tool ty

ssure adjus

ote control. Wpower pac

he pressureut.

ning it must

elivery of Htype and lu

ype used.

stment valve

When the hck indicatese adjustmen

t be ensure

2010

HYTORC ubricant.

e on the

hydraulic the set nt valve.

ed that a

HYTORC T

HYTORC

1.6 W

As the externaheld. Th

Do not t

After sepre-tenson the away astool opeplay in tmm oppextensioshould tighteninmust beIf the tomust be

Note: Breactiontension

This pois fully project

T-Tool

Workin

HYTORC l reaction, i

herefore:

touch the to

etting the dsioning forcnut. Make s possible ferates withothe drives tposite the sons increascome into ng or releae stopped imool cannot be released a

Both the n shaft munut.

int can be engaged abeyond the

g with t

tension nut does not r

ool. Keep a

irection of ce, the tenssure that tfrom projec

out any reacthe housingset directioses this rocontact wi

asing, then mmediatelybe moved band moved

castellated ust engage

recognized and the rea tool.

Operating an

the tens

ut runner srequire a re

safety dista

rotation andsion nut runhe tool hou

cting edgesction outwag moves by n of rotatiootary motioith the equ

the screwy and the toby one tootby one toot

drive ande fully into

when the action cogw

d Maintenanc

of 19

sion nut

screws theeaction arm

ance of at le

d the requinner is placusing is as . Although rds, due to approx. 10

on. The useon. If the tuipment durwing procedool remountth on the reth relative to

d the toothe HYTO

castellated wheel does

ce Instruction

t runne

HYTORC . In addition

east 1 m!

red ced far the the

0-20 e of tool ring ure ted. eaction shao the housin

thed ORC

part s not

s

r

fixing elemn, the tool d

ft, then theng.

ments withdoes not ha

reaction co

2010

hout any ave to be

ogwheel


HYTORC of 19

1.7 Tightening the HYTORC tension nut

Press the green or brass-colored button on the remote control until the outer sleeve of the fixing element stops rotating. Now release the button again. The hydraulic cylinder moves the ratchet back to its initial position. The ratchet will be heard to click into place a max. of two times. When tightening, repeat the procedure until the outer sleeve no longer turns. Check that the required pre-tensioning force has been reached by means of a test stroke.

Note: The screwing sequence and the number of stages required to pre-tension the screws are specified by the equipment manufacturer.

1.8 Loosening the HYTORC tension nut Preparatory measures

Clean the HYTORC tension nuts by blowing off loose dirt and dust. Then lubricate the nuts with penetrating oil in the area between the stud bolt and the inner sleeve and between inner and outer sleeves. Allow the penetrating oil to take effect for at least 1 hour.

Loosening the HYTORC tension nuts

Irrespective of the manufacturer's instructions nuts must be loosened gradually to avoid overloading and a resulting "no release" situation. Set the pressure on the hydraulic power pack to approx. 650 bar. Now place the tool onto the HYTORC tension nut and ensure that both the reaction shaft and the castellated drive engage fully with one another. As with tightening, it must be ensured that the tool housing does not come into contact with the equipment (see: Working with the tension nut runner). If the outer sleeve does not turn with 650 bar then this pressure should be maintained for approx. 20 seconds. If the sleeve does not release, the pressure must be increased to 700 bar.

For releasing, each nut should only be unscrewed by one tool stroke (approx. 25°) and the tool then placed on the next nut and this one unscrewed by one stroke only. Continue this procedure until all nuts have been loosened by one stroke. Then loosen the first bolt by an additional stroke. Repeat this procedure until the working pressure required to loosen the screw has dropped to less than 200 bar. Only then can the bolts be fully slackened.

HYTORC T

HYTORC

If a nut possibleprocedu

Compleaccordinpossiblelubricate

If it is stnewly lu

1.9 HYTORdevice twith the

Take ca"Hands-sleeve athe drive

When rplay is the oute

If the "positionhappenfurther b

T-Tool

cannot be e due to a ure:

etely loosenng to the ine to releasee, and retig

till not possubricated ad

Overhe

RC suppliesto connect t

e same scre

are when re-free drivesand the oute can be da

releasing ovmaintained

er sleeve.

Hands-freens, keep chs, the tool by hand.

released, clack of spa

n the nut anstructions e the neighbhten the se

sible to releadjacent scre

ead work

s "Hands-frethe tension

ew which is

eleasing thes": As the ter sleeve mamaged.

verhead, md between t

e drive" is hecking whmust no lo

Operating an

heck first wace or avail

adjacent toand then re

boring bolt wecond adjac

ase the jamews after ob

king (sp

ee drives" fnut runner used for ch

e HYTORC tool interlo

moves upw

make sure tthe tool's c

used to rehether the tonger be u

d Maintenanc

of 19

whether it is ability of a

o the jamme-tightenedwithout diffi

cent screw.

mmed screwbtaining app

pecial e

for overheato the fixing

hanging the

fixing elemocks with ards when

hat a min. castellated d

lease HYTtool can besed for scr

ce Instruction

possible tolarger tool,

med nut. Cl to the rateculty. If not

w, increase proval from

equipme

ad working.g element. Tdirection of

ment using the inner released,

of 1 mm drive and

ORC fixinge turned wrewing. The

s

o use a larg, we recom

ean and reed pressuret, completel

the pre-tenthe machin

ent)

These drivThe lockingf rotation.

g elements with the nute nut can t

er tool. If thmend the f

e-lubricate e. It should y loosen, c

sioning forcne manufact

ves have ag device is o

in other mt. As soonthen be un

2010

his is not following

this nut now be

lean, re-

ce of the turer.

a locking operated

mounting as this screwed

HYTORC T

HYTORC

Fitting

Turn thethe stopso that is now i

Remov

As the wreleasinlocking

Note: N

T-Tool

the tension

e screw on p and hold the spring-lnterlocked

ing the ten

whole weigng. Now tursystem and

ever stand

n nut runne

the reactionin place. Aloaded latchwith the nut

nsion nut ru

ht of the toorn the screwd the tool ca

under the t

Operating an

er

n cogwheelAfter fitting thes can engt.

unner

ol is loadedw in a clockan be remov

tool while us

d Maintenanc

of 19

l in a clockwthe tool, relgage with th

d on the latckwise direcved.

sing the ten

ce Instruction

wise directioease the sche nut. The

ches it has tion and ho

nsion nut run

s

on to crew

e tool

to be raiseold in place

nner overhe

d somewhae. This relea

ead.

2010

at before ases the

HYTORC T

HYTORC

2.

All the and arein an exfilled intbiologicfollowinthe doupressur

2.1

In the cthe red screw d

T-Tool

HIGH

HYTORC he filled with axternal caseto the agg

cally degradg the opera

uble hose. Tre relief valv

Electr

Electric

case of 400 control lam

driver throug

PRES

high performa correspone you mustregate aftedable oil ination of theThe double ve and the c

rical

cal high

Volt aggremp is on afgh 180°.

Operating an

SSURE

mance hydrnding quantt fill the pumr consulting

n the case e torque wre

hose becocouplings ca

h pressu

egates it is ifter switchin

Pres

d Maintenanc

of 19

E HYDR

raulic aggretity of hydramp with thisg the manuof new sy

ench then somes free oan be detac

ure hydr

imperative tng on the a

ssure release

ce Instruction

9

RAUL

egates are aulic oil types oil yourseufacturer. It

ystems. If asome resid

of pressure ched withou

raulic a

to ensure thaggregate t

e valve

Phase invert

s

IC PU

delivered ine HLP 32. Ifelf. Other oit is only to

a safety coual pressurby pressing

ut applying a

P

aggrega

he right direturn the ph

ter

MPS

n full workinf the oil is dl viscosities

o be equippoupling is dre is still prg the buttonany force.

Pneumatic

tes

ection of roase inverto

2010

ng order delivered s can be ped with detached resent in n on the

otation. If or with a

HYTORC T

HYTORC

All the e20 to 30off. Thebutton oaggrega

The newelectroluprovide

T

T-Tool

electrical ag0 seconds

e aggregateof the remoate.

w digital muminescentexact value

Tendency dis

ggregates aafter the gr is started uote control

manometerst diodes anes. Therefo

splay

Operating an

are equippereen push bup once mois an eme

have two nd a precisre you mus

Sto

Oper

Auto

d Maintenanc

of 19

d with an abutton was ore by pressrgency off

displays: Ase digital dst always us

op button

rating button

matic Butto

ce Instruction

9

automatic mlast pressesing the greswitch and

A tendency display. These the digita

n

on

s

motor disableed and switceen push bu immediate

display in e tendency

al display wh

Digita

er. This is aches the agutton. The rely switches

the form oy display dhen tighteni

l display

2010

activated ggregate red push s off the

of round does not ing.

HYTORC T

HYTORC

The eletemperaexceedeoff by automa

Press

Coup

T-Tool

ectrical aggature and ted then a remeans of tic control f

ure release v

pling connect

gregates ahe oil temped control lia bimetalliunction the

valve

tions

Operating an

re equippeperature areght on the sc release. remote con

d Maintenanc

of 19

ed with a e monitoredswitch box In the cas

ntrol has a t

ce Instruction

9

dual temped. If the seis illuminatese of the third black p

s

erature fuset maximumed and switaggregate push button

P

se. The mom temperatuches the agwith an ad

n.

Control l

Pressure sett

2010

otor coil ures are ggregate dditional

ight

ing valve

HYTORC T

HYTORC

2.2

In the cmaintencooling and enrmay be per minbeen ida separto start pressing

P

Ma

T-Tool

Pneuma

case of thenance unit coils in the

riched with filled into t

nute is necele for a longrate dewateup and stog the push

Pressure sett

Automaticsepara

nometer comair supp

atic hig

e pneumaticand the ai

e hydraulic 3-4 oil drophe oil cup.

essary to opger period oering unit. Top the aggrebutton.

ing valve

c water ator

mpressed ply

Operating an

gh press

c aggregater on the sooil. The air

ps per minuMinimum aperate the pof time shouhe pneumaegate. The

d Maintenanc

of 19

sure hyd

e the workiound absoris automat

ute for the pair pressure pneumatic auld always batic aggregabuildup of

ce Instruction

9

draulic

ng air is surber is ejectically dewapurposes of

of 4 bar anaggregate. be blown ouate has a flipressure in

Flip swit

Operation b

Automatic b

s

aggreg

upplied to tcted once atered in thf lubricationnd a quantitPneumatic

ut beforehap switch on

n the aggreg

Settingdrip

Pressu

Oil

tch

button

button

gates

the air motmore by me maintena. Only resinty of approx systems thnd or opera

n the remotegate is achi

g of the oil cpping speed

re release va

level gauge

2010

tor via a means of ance unit n free oil x. 1.8 m³ hat have ated with e control ieved by

up

alve

HYTORC T

HYTORC

If the agwall of pressingby four under tproblem

As soonmotor re

T-Tool

ggregate hathe air motg the buttonsocket scr

he cover (m should be

n as the moeally very s

as not beintor corroden at the remrews) and bsee fig.) T solved.

otor starts thortly!

Operating an

g used for es. In this cmote controbriefly moveherefore yo

he Allen wr

d Maintenanc

of 19

more thancase you wl. Open thee the motoou need an

rench will a

ce Instruction

9

six monthswill not be ae cover on tor manually n Allen wre

lso rotate. T

s

s it may occable to starhe top of thby turning

ench WS 5

That’s why

Screw for m

cur that thert the motorhe air motor the screw

5 mm. Ther

you may m

manual start

2010

e internal r by just r (locked

w located reby the

move the

t

HYTORC T

HYTORC

2.3 A

The autautomaworkingtighteninthe endmanual

Using talways

T-Tool

Automa

tomatic opetic button. W

g stroke andng bolts; ho

d of each bly to be sure

he automahave to tigh

atic ope

eration modWhen you d reverse stowever you olting evene that the b

atic operatiohten them m

Operating an

eration m

de (if availahold the butroke. This fwill never rt with auto

bolt has reac

on mode wmanually!

A

d Maintenanc

of 19

mode

able at the utton the agfunction is vreach the pmatic operached its fina

will never tig

utomatic butt

ce Instruction

9

aggregateggregate auvery time-sa

precise pre-ation you hal pre-tensio

ghten the

ton

s

) is activateutomaticallyaving and wtensioning

have to do oning force.

bolts precis

ed by presy switches bwork-savingforce. Therat least on.

sely. Therfo

2010

sing the between

g for pre-efore, at e stroke

ore, you

HYTORC T

HYTORC

2.4 S

A pair otypes of

Typpussecthisthe renlockthe

Typcoutightha

Typcourighcou

Plu

T-Tool

Safety c

of safety cof couplings:

pe 716: Thshed in an acure couplins end the ha plug’s tootdered presking must b hasp can ope 1008 (nupling box htened. Whet the hasp mpe 1008 (oupling box eht and pulleupling box!)

ug

couplin

ouplings co

e plug is eaxial directiong is only poasp is screwthed wheelw

ssure free abe pulled inonly be detaew): The pengages toen detachinmust be pul

old): The plengages to ted in axial d

Operating an

ngs

onsists of a

equipped wion. The couossible by pwed onto thwork. If thisand connecn an axial dached and tplug is just o the plug. ng the coupled in axial ug is just tthe plug. Wdirection at

Ty

Type

Type

d Maintenanc

of 19

plug and a

ith a torsionupling box isprecisely puhe screw ths should nocted once mdirection in the couplingto put into Then the s

pling the safdirection.

to put into tWhen detach

the same t

Type 716

1008 (new)

e 1008 (old)

ce Instruction

9

a coupling

n resistant s equipped ushing bothread of the ot be possimore. To beorder to degs pulled apthe couplinsafety ring fety ring mu

the couplinhing the coutime. (Pay

s

box. There

locking ringwith a scre

h coupling flplug and loble then alegin with th

etach the sapart followinng box so th

of the couust be open

g box so thupling the hattention to

are three

g that is onew locking dlanges togeocks into pll the balls he torsion rafety coupling this. hat the hasupling box ned again a

hat the hasasp must b

o the arrows

Coup

2010

different

nly to be device. A ether. To ace with must be resistant ngs and

sp of the must be and after

sp of the e turned s on the

ling box


HYTORC of 19

2.5 Maintenance

Hydraulic oil Check the oil level in the aggregate prior to starting work. It should be visible in the upper level gauge. Only use clean hydraulic oil. We recommend HLP 46 hydraulic oil. The oil should be changed at least once a year. If the color or the consistency of the oil changes (e.g. becomes milky) then the oil must be changed immediately. A resin free oil should be used for the oil cup, e.g. Aral Vitam 22 DE.

Rapid couplings Check whether the coupling plugs, hasp and the hydraulic hoses are clean, impermeable, and have a perfect threaded joint prior to commencing work. Use the protective covers for the couplings on the aggregate and on the tool. Roll the hydraulic hoses together and plug the couplings together.

Manometer The manometer is filled with glycerin for the purposes of damping. If the fluid level should drop due to damage then the glass or the manometer must be exchanged. We recommend an annual inspection of the manometer with a calibrated inspection manometer. To this end an inspection certificate is then produced.

Air filter (only in the case of pneumatic aggregates) The air filter must be regularly inspected that it is clean and if necessary cleaned and blown out or exchanged.

Hydraulic tool Inspect that it is impervious prior to starting work. Clean the tool and all the other components following use. Regularly lubricate the square drive and the bearing bushes with a Molykote paste. The wrench should be cleaned and completely lubricated at least once every 6 months. We recommend annual maintenance with an inspection on the testing stand and issuing of an inspection certificate


HYTORC of 19

3. SAFETY NOTES

Do not adjust any valves on the pump besides the pressure setting valve!

Please wait for the first instructions by the HYTORC staff and read the operating and maintenance instructions thoroughly before using the tool!

Pay attention to your working environment! Metal to metal can result in arcing! Caution is advised here: Never take an electric aggregate to the hazardous area!

The tool should only be operated by one person.

Use protective gloves, a safety helmet, goggles, safety boots and reasonable protective clothes while working.

Use the right tools! Do not employ smaller tools for bolting they are not designed for.

Store the tools properly and clean before and after usage. Control the tools Check the tools for impurities and good lubrication.

Pay attention to the tool during the whole working time!

It is absolutely necessary to prevent early activation of the tool! The remote control may only be handled by the person working with the tool.

If you want to change the location of the aggregate carry it only by using the carrying gadget. Do not pull the twin hoses or the main cable!

Control the twin hoses! Hoses must be marked with the quarter of manufacturing. Overlaid hoses must be exchanged. Damaged couplings or hoses may not be repaired!

Never use additional tools to increase performance, e.g. pounding the tension nut or the housing of the tool!


HYTORC of 19

4. SERVICE ADDRESSES

HYTORC Corporate Office Service and Sales 333 Rt. 17 North Mahwah, NJ 07430 Phone: 201-512-9500 Toll Free: 800-GO-HYTORC [email protected] www.hytorc.com

hytorc t-tool manual · hydraul press a piston h pressur finally, warning larger to-tool ing: e is...

Documents