Table of Contents
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Table of Contents
Related Manuals for Hytorc HY-1XLT
Summary of Contents for Hytorc HY-1XLT
- Page 1 XLT/MXT/MXT-SA SERIES OPERATIONS MANUAL 7th Edition: Aug. 2017...
- Page 2 Details and values given in this manual are average values and have been compiled with care. Details and values are not binding. HYTORC disclaims any liability for damage or detriments suffered as a result of reliance on the information given herein or the use of products, processes or equipment to which this document refers.
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Page 3: Table Of Contents
Contents Contents About the document ..................Purpose of the document How to work with the document Languages Illustrations Safety symbols in the document Related documents Revision history Contact information Safety ......................... General safety instructions 2.1.1 Personnel 2.1.2 Work area 2.1.3 Equipment Additional safety instructions 2.2.1 Pump units 2.2.2 Electric pump units... - Page 4 Maintenance by HYTORC Storage ......................Storing the cables Troubleshooting ....................Tests ........................XLT dimensional data ..................MXT dimensional data ..................MXT-SA dimensional data ................Bolt / Torque / HYTORC ................. Square / Allen drive working torque .............. Customer service policy ...................
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Page 5: Illustrations
About the Document About the document Purpose of the document The document shows the information to do these steps: • Install the equipment • Operate the equipment • Maintain the equipment The document contains the original instructions for the XLT, MXT, & MXT-SA hydraulic systems, which is referred with the term ‘tool’. -
Page 6: Related Documents
Target Group XLT/MXT/MXT-SA series operations Personnel who operates the equipment. manual Revision history Date Revision Number Comment 08-16-2017 Second Version Contact information Division UNEX Corporation 333 State Route 17N Mahwah, New Jersey 07430 1-800-FOR-HYTORC Tel: 201-512-9500 E-Mail: info@HYTORC.com Web: www.HYTORC.com... -
Page 7: Safety
• Only use the tools for the purposes for which they have been designed. Do not force small tools or accessories to do the job of a larger tool. HYTORC can develop customized accessories to ensure safe and simple operation. Contact your local HYTORC representative for more information. -
Page 8: Additional Safety Instructions
• Do not use an extension cable longer than necessary. • Make sure the extension cable is at least 12 awg and 25 ft. in length* *refer to extension cord chart on HYTORC.com. • Fully unroll the extension cable from the cable drum. -
Page 9: Reaction Arms
• Make sure that the reaction point is at least 0.4” (10 mm) from the end of the reaction arm. If a distance of at least 0.4” (10 mm) is not possible, choose another reaction point or contact HYTORC to find an appropriate reaction fixture. • Make sure that the reaction arm is locked onto the spline of the tool. -
Page 10: Sockets
Liability HYTORC cannot be held responsible for injury or damage that results from unintended use of the equipment. The equipment is designed and intended only for the purpose described in the relevant documents. -
Page 11: Description
Intended use The XLT, MXT, & MXT-SA are bolting systems used for both torque and tension applications. Various reaction arms and sockets are available from HYTORC for use with the tool. HYTORC hydraulic tools have an accuracy of ± 3%. -
Page 12: Electric Pump Unit
Description (Cont’d.) 3.2.1 Electric pump unit The pressure range of the pump unit is 1500 psi - 10,000 psi (100 bar - 700 bar). 1. Hose connection (male coupling) (supply hose) (A) 2. Hose connection (female coupling) (return hose) (B) 3. -
Page 13: Led Indicators (Electric Pump Unit)
Description (Cont’d.) LED indicators (electric pump unit) 3.2.2 1 15V and 230V pump unit Indication Description Green, continuous The pump unit is ready for use. 400V pump unit Indication Description Green, continuous The pump unit is ready for use. Red, flashing (2x) The direction of rotation is incorrect. -
Page 14: Pneumatic Pump Unit
Description (Cont’d.) 3.2.3 Pneumatic pump unit The pressure range of the pump unit is 1500 psi - 10,000 psi (100 bar - 700 bar). 1. Hose connection (male coupling) (supply hose) 2. Hose connection (female coupling) (return hose) 3. Oil filling point 4. -
Page 15: Hydraulic Socket Wrench
Description (Cont’d.) 3.2.4 Hydraulic wrench 1. Hose connection (male coupling) (supply hose) 2. Hose connection (female coupling) (return hose) 3. Square drive for socket connection 4. Drive retainer 5. Disengagement lever 6. Mounting point for safety handle 7. Spline for connection of reaction arm... -
Page 16: Installation
Installation (Cont’d.) Installation Hydraulic hoses The working pressure of the hydraulic hoses is 10,000 psi (700 bar). The safety factor of the hydraulic hoses is 4:1. 4.1.1 Hydraulic hose connections Use a twin hose to connect the pump unit to the tool. A twin hose consists of two hoses. The supply hose has two ends with female couplings. -
Page 17: Connecting The Hydraulic Hoses
Installation (Cont’d.) Screw-type safety couplings • To tighten the couplings, make sure that the system is depressurized. Push the couplings completely together to full engagement, and tighten the locking ring of the female coupling to the male coupling. If the couplings are not fully tightened, the tool will not operate. -
Page 18: Disconnecting The Hydraulic Hoses
Installation (Cont’d.) 1. If the hose couplings are dirty, clean them with a lint-free cloth. 2. Fully tighten the female couplings to the male couplings. 3. Manually tighten the hose couplings. Do not use pliers. Disconnecting the hydraulic hoses 4.1.3 Warning: •... -
Page 19: Connecting The Power Supply (1 15V)
2. Use an extension cable that is as short as possible. 3. Make sure the extension cable is at least 12 awg and 25 ft. in length* *refer to extension cord chart on HYTORC.com 4.2.2 Connecting the power supply (230V) 1. -
Page 20: Air Supply (Pneumatic Pump Units)
Installation (Cont’d.) Air supply (pneumatic pump units) 1. Connect an air hose to the compressed-air inlet 2. It is recommended to use a filter regulator lubricator (FRL): a) Remove the filter cap (B). b) Fill the air lubricator (C) halfway with hydraulic oil. -
Page 21: Reaction Arms
The XLT, MXT, and MXT-SA have an extensive range of reaction arms for different scenarios. The image above shows the most common types of reaction arms which vary in both length and size. Please contact your local HYTORC representative for all available options. -
Page 22: Sockets
Sockets Sockets There are different types of heavy-duty sockets to use with the tool: 1. 6-point sockets / 12-point sockets (regular / high) 2. 6-point Allen sockets / 12-point Allen sockets(regular / high) 3. Eccentric sockets 4. Customized sockets The heavy-duty sockets are available in the sizes ½, ¾, 1, 1½, 2½ and 3½. Warning: •... -
Page 23: Operation
Operation Operation Check the following items before each use: • Oil level in the oil tank is between the minimum mark and the maximum mark. • Power supply is correct. • Power cable is fully unrolled and not kinked, twisted, or damaged. •... -
Page 24: Pneumatic Pump Unit
4. Move the disengagement lever to position A. Torque Pressure/torque chart 7.4.1 The maximum operating pressure for all HYTORC pump units is 10,000 psi (700 bar). Warning: • Make sure that the maximum operating pressure of the pump unit is not higher than the maximum permitted pressure of 10,000 psi (700 bar). -
Page 25: Setting The Torque
Operation (Cont’d.) Example (MXT 3) Pressure Torque ft.lbs 1,500 1 10 1,600 1,800 2,000 2,200 2,400 1041 2,600 1 128 7.4.2 Setting the torque Warning: • Always set the pressure from low pressure to high pressure. 1. Loosen the wingnut on the pressure control valve (A) of the pump unit. -
Page 26: Direction Of Rotation
Operation (Cont’d.) 8. Set the correct torque. a) Press and hold the start button (B) on the control. b) Turn the pressure control valve (A) until the pressure gauge shows the correct pressure. c) Release the start button (B) on the control. d) After a few seconds, press and hold the start button (A) on the remote to check the pressure. -
Page 27: Tightening And Loosening A Bolted Flange Connection
• Always set the pressure as low as possible to loosen the nut or the bolt. • If you must constantly use a high pressure to loosen the nut or the bolt, use a larger tool. Contact your local HYTORC representative for more information. -
Page 28: Automatic Shutoff System
Operation (Cont’d.) 1. Turn the pressure control valve (A) clockwise to set the maximum pressure (10,000 psi, 700 bar). If you use Allen sockets, there are restrictions to make sure that the sockets do not break. 2. Place the tool onto the nut or the bolt correctly. Refer to the marking “LOOSEN”... -
Page 29: Maintenance
• Have the spring-loaded buttons on the remote control inspected if they do not operate smoothly. • Have the pressure control valve of the pump unit cleaned at least once a year. • Contact HYTORC to learn more about the TORCsafe preventative maintenance program. -
Page 30: Storage
Storage Storage Storing the cables 1. Wind the remote control cable around the frame. 2. Place the remote control in the remote control clamp. 3. Electric pump unit: Wind the power supply cable around the frame. -
Page 31: Troubleshooting
Troubleshooting Troubleshooting Try to find a solution for the problem using the tables. If you cannot find a solution for the problem, contact your local HYTORC representative. SYMPTOM PROBABLE CAUSE REQUIRED ACTION Gauge shows pressure build-up but 1. Couplings loose or inoperative 1. - Page 32 1. Run test #5. Re-Plumb system as necessary. 2. Multiple hoses in even numbers 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 an adapter from spare high pressure couplings and nipples.
- Page 33 Troubleshooting (Cont’d.) SYMPTOM PROBABLE CAUSE REQUIRED ACTION Gauge records no pressure 1. Gauge connection is loose 1. Tighten coupling. 2. Bad gauge 2. Replace gauge 3. Pump will not build pressure 3. See cylinder pressure will not build pressure- above 4.
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Page 34: Tests
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. - Page 35 Male to Female and Female to Male. This will cause the system to operate backwards per Test #5 above. If your hose isn’t long enough, connect 3 hoses together, move your pump or call HYTORC for a longer hose assembly.
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Page 36: Xlt Dimensional Data
± 3% ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension pell *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm. - Page 37 ± 3% ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension absorbing *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm.
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Page 38: Mxt Dimensional Data
± 3% ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension absorbing *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm. - Page 39 ± 3% ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension absorbing *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm.
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Page 40: Mxt-Sa Dimensional Data
Accuracy ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension absorbing *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm. - Page 41 Accuracy ± 3% ± 3% ± 3% ± 3% ± 3% Swivel 360º x 180º STANDARD Uni-Body Housing TITAL399 Click-On Reaction Arm TITAL300, Vertical, 360°, Tension absorbing *The weight listed is for the complete ready-to-use HYTORC tool with reaction arm.
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Page 42: Bolt / Torque / Hytorc
Bolt / Torque / HYTORC Bolt / Torque / HYTORC The data below is based on bolts lubricated to manufacturer’s specifications. Due to variations in friction, we recommend in extreme cases to check with the bolt manufacturer, as this chart represents a guideline only. -
Page 43: Square / Allen Drive Working Torque
Square / Allen drive working torque DRIVE SIZE: The square or hex drive of each HYTORC is limited in its maximum output by its material and its engagement area. Since your HYTORC uses specially suited alloy steel for its drive members, the following maximum torque output can be achieved without drive failure, provided the reaction member abuts close to the same plane as the nut to be turned. -
Page 44: Customer Service Policy
Repairs: • All Repairs are Guaranteed for 6 Months • Repairs are Subject to Labor and Part Cost, as Outlined in the Official HYTORC Price List • All Warranty Repairs are FREE of All Charges Including Return-Freight • All Repairs Will be Tested and Calibrated to Ensure the Highest Quality Repairs... - Page 46 Since 1968, HYTORC has been the worldwide leader in industrial bolting systems & solutions. Supplying and supporting Industrial bolting is our complete and total focus. HYTORC is the only company that can provide you with significant productivity enhancements to your bolting work. These enhancements provide our customers with tremendous value, giving them the opportunity to receive a return on their investment after the first job together.
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