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Hytorc XXI series Operational Manual

Hydraulic torque wrench
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XXI/Avanti/Stealth SERIES
Operational Manual
July 2004

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Summary of Contents for Hytorc XXI series

  • Page 1 XXI/Avanti/Stealth SERIES Operational Manual July 2004...

  • Page 2: Table Of Contents

    4-6 Clamp-nut De-tensioning 4-7 Clamp Lubrication SECTTION V 5-1 General Information OPERATION 5-2 Hydraulic Connections HYTORC POWER PACKS 5-3 Prior to Use 5-4 Operation –Electric Pump-- 5-5 Operation –Air Pump-- 5-6 Automatic Pump 5-7 Starting with Automatic System SECTION VI Tool Dimensions &...
  • Page 3 If you have any questions regarding HYTORC bolting equipment, please call us at 201-512-9500 or contact us at hytorsales@hytorc.com. Your purchase of HYTORC bolting equipment entitles you to the following services at no extra cost to you. Free on-site training in the application and operation of your HYTORC bolting equipment * Free semi-annual training * Free annual tool inspection.
  • Page 6 HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner. SECTION I IMPORTANT SAFETY INSTRUCTIONS HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain safety precautions should be observed to avoid accidents or personal injury. The following tips will assist you.

  • Page 7: Electrical Connections

    SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page- 2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors.
  • Page 8 INSTRUCTIONS BEFORE USING YOUR NEW HYTORC READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation and/or set-up. PREPARATION: Remove HYTORC equipment from shipping container. INSPECTION: Visually inspect all components for any damage during transportation. If damages are found, notify HYTORC immediately.
  • Page 9 SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page- 2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors.

  • Page 10: Connecting The System

    All HYTORC tools are supplied completely assembled and are ready to use. A HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate.

  • Page 11: Drive Direction Change

    SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page- 3-3 Drive Direction Change Avanti tools To remove the square drive, disengage the drive retainer assembly by depressing the retaining round button and gently pulling on the square end of the square drive. The square drive will slide out.

  • Page 12: Setting Torque

    SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page- 3-5 Setting Torque Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer’s specifications to determine the torque value ultimately required.
  • Page 13 SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page- 3-7 Applying the Stealth – the Tightening Process 1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure proper operation.
  • Page 14 SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page- 3-8 Operating the Avanti and Stealth SYSTEMS Releasing “LOCKED-ON” tools. Should the tool “LOCK-ON” after the final cycle, slide the slider (or the lever on Avanti) with the pump off or in retract position.

  • Page 15: Loosening Procedures

    If the bolt does not loosen with the above procedure, it is an indication that you may require the next larger size tool to loosen the bolt. Corroded nuts and thread galling on bolts can cause difficulty in loosening. Please consult your HYTORC bolt specialist.

  • Page 16: Tool Set Up And Operation

    OPERATION – HYTORC and Clamp LoaDISC 4-1 Tool Set up and Operation When used in conjunction with the HYTORC Washer or Clamp, the operation is essentially LoaDISC the same as with the conventional nuts, but with one notable exception: THERE ARE NO REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed through the fastener assembly itself.
  • Page 17 SECTION IV OPERATION – HYTORC and Clamp -continued from the previous page- LoaDISC 4-2 HYTORC Tensioning LoaDISC 6. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until tool “STALLS OUT” 7. Should tool rotate during initial pressurizing: A.

  • Page 18: Loadisc De-Tensioning

    SECTION IV OPERATION – HYTORC and Clamp -continued from the previous page- LoaDISC 4-3 HYTORC De-tensioning LoaDISC 1. Set pump to maximum pressure. 2. Place tooling to disengage the nut and the with “LOOSENING” side facing the operator. LoaDISC 3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until the nut is loose.

  • Page 19: Loadisc Lubrication

    SECTION IV OPERATION – HYTORC and Clamp -continued from the previous page- LoaDISC 4-4 HYTORC Lubrication Instruction & Trouble Shooting LoaDISC STEP 1: Make sure all threads and surfaces are free of dirt or grit. STEP 2: Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow spray lube to dry (spray lube is shipped with order).
  • Page 20 LoaDISC 4-5 HYTORC Clamp Installation - Tensioning The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication, please refer to lubrication Instructions. (4-6) 1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the flange or the spot face firmly.
  • Page 21 -continued from the previous page- LoaDISC 4-6 HYTORC Clamp Installation - Detensioning 1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the left side for detensioning.
  • Page 22 Clamp -continued from the previous page- LoaDISC 4-7 HYTORC Clamp Lubrication Instruction The Clamp Lubrication Instructions: (Use a clean stiff bristle brush) STEP 1: Make sure all threads and splines are free of dirt or grit. Generously grease internal threads on the Jack-up Sleeve with a brush to get full coverage to the thread root.

  • Page 23: Hydraulic Connections

    OPERATION – HYTORC Power Packs 5-1 HYOTRC Power Packs General Information All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed.

  • Page 24: Operation Electric Pump

    *Calibrated gauges are available for most application. Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque wrench. (Refer to 3-2) 5-4 Operation Electric Pump Push the rocker switch on the hand control pendant in the OFF position.

  • Page 25: Automatic Pump

    SECTION V OPERATION – HYTORC Power Packs -continued from the previous page- 5-5 Operation Air Pump To start the pump, depress the advance button and release it. This will put the tool in the retract mode. To advance the tool, depress the advance button and hold it down.
  • Page 26 SECTION V OPERATION – HYTORC Power Packs -continued from the previous page- 5-7 Starting with automatic operation MANUAL MODE For manual operation, depress the Mode [M] 3-position rocker switch to the ‘MANUAL’ position. Hold down the Control [C] rocker switch in the ‘RUN’ position to advance the tool(s).

This manual is also suitable for:

Avanti seriesStealth series

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