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Hytorc XLCT Series Operational And Spare Parts Manual

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XLCT SERIES
OPERATIONAL AND SPARE PARTS MANUAL

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  • Page 1 XLCT SERIES OPERATIONAL AND SPARE PARTS MANUAL...
  • Page 3 The tool you have purchased permits hands-free operation from a safe distance in conjunction with a HYTORC Washer™. We recommend the use of a HYTORC Washer™ to avoid finger-pinching, over-crowded sites and to ensure hands-free bolting at least on all vertical and inverted applications, while eliminating improvisation and the use of reaction members or backup wrenches.

  • Page 4: Table Of Contents

    The World’s Most Trusted Industrial Torque and Tension Systems CONTENTS XLCT SERIES OPERATIONAL AND SPARE PARTS MANUAL INTRODUCING HYTORC SECTION I IMPORTANT SAFETY INSTRUCTIONS SECTION II INSTRUCTIONS BEFORE USE 2-1 Working Pressure 2-2 Hydraulic Connections 2-3 Electrical Connections 2-4 Air Connections...

  • Page 5: Introducing Hytorc

    If you maintain your new tool properly, it will last for years to come. This manual is designed to provide you with the basic knowledge required to operate and maintain your HYTORC tool. Please read this manual carefully and follow the instructions provided. If you have any questions regarding your HYTORC tool, please call us directly at 201-512-9500 or fax 201-512-0530.

  • Page 6: Section I

    Don’t force small tools or attachments to do the job of a larger tool. Don’t use a tool for purposes not intended. HYTORC can develop custom accessories for your job to ensure safe and simple operation. Contact your local HYTORC representative for more information on our custom engineering abilities.
  • Page 7 “ride up” or to “creep”, stop and re-adjust the reaction arm to a more solid and secure position. NOTE: For additional safety, a HYTORC Washer can be used in place of the reaction arm; call your HYTORC representative for more information.

  • Page 8: Instructions Before Use

    All fittings will then be hand tight again. Newer style pumps (HYTORC 115, HYTORC 230, HYTORC AIR) are equipped with an auto-pressure relief. Never disconnect or connect any hydraulic hoses or fittings without first unloading the wrench and the pump. If the system includes a gauge, double check the gauge to ensure pressure has been released.

  • Page 9: Electrical Connections

    The World’s Most Trusted Industrial Torque and Tension Systems 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 the 3-prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connections.

  • Page 10: Operation

    All HYTORC Torque Machines are supplied completely assembled and 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.

  • Page 11: Inserting The Ratchet Link

    Operation with the Square Drive As with other HYTORC models, if the square drive extends towards the right, the tool is set to tighten; if towards the left, its set to loosen. To change drive direction, press in on the drive retainer button, remove drive, place in opposite direction, and replace retainer, insuring it is secure.

  • Page 12: Loosening Procedures

    The World’s Most Trusted Industrial Torque and Tension Systems By pushing down on the remote control button, the tool’s cylinder will extend and the reaction arm will contact its reaction point. Continue to hold down the button as the socket turns. When the hydraulic cylinder inside the tool is fully extended, the socket will no longer turn, and you will notice a buildup of pressure to the point where the pressure was preset prior to applying the wrench (See SETTING TORQUE).
  • Page 13 The World’s Most Trusted Industrial Torque and Tension Systems If, however, bolt spacing is such that the reaction block does not reach an adjacent bolt, use of the short reaction arm is indicated. This will allow reaction to be taken against the side of the flange. To attach the short reaction arm, remove the standard link retaining pin, align the holes of the short reaction arm with that of the reaction block, insert the long retaining pin to secure.

  • Page 14: Setting Torque

    An example of finding the desired torque required is as follows: Assume you are going to use a HYTORC XLCT tool to torque a 1-1/4” bolt to 1,265 ft. lbs. Start by referring to the pressure-torque conversion table for the tool you are using and read left-to-right across the top line to the rightmost column.

  • Page 15: Applying The Torque Machine

    The World’s Most Trusted Industrial Torque and Tension Systems 3-10 Applying the Torque Machine - the Tightening Process 1. Having set your target pressure, cycle the tool three or four times to full pressure prior to putting it on the application.

  • Page 16: Hytorc Power Packs

    POWER PACKS General Information All HYTORC Power Packs operate in 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. Before using your HYTORC power pack, check the following points: •...

  • Page 17: Electrical Power

    Your HYTORC 115/230 hydraulic pump has been designed with an auto shut off system. The pump will shut off after about 30 seconds of non-cycling. This will prevent overheating and unnecessary wear, which will prolong the life of your pump.

  • Page 18: Preventive Maintenance

    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 these instructions.

  • Page 19: Preventive Maintenance - Hydraulic Power Packs

    The World’s Most Trusted Industrial Torque and Tension Systems Preventive Maintenance - Hydraulic Power Packs HYTORC Hydraulic Power Packs are precision-built units and, as such, require a certain amount of care and maintenance. • Hydraulic Oil Oil should be completely changed after every 40 hours of operation, or at least twice a year. Always make sure the reservoir is filled with fluid.

  • Page 20: Troubleshooting

    The World’s Most Trusted Industrial Torque and Tension Systems SECTION VI TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REQUIRED ACTION Gauge shows pressure build-up but the 1. Couplings loose or inoperative 1. Tighten and/or replace couplings. Use Test #1 tool will not cycle listed below to isolate problem.
  • Page 21 1. Run test #5. Replumb 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 22 The World’s Most Trusted Industrial Torque and Tension Systems 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.
  • Page 23 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.

  • Page 24: Appendices

    The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX A XLCT HOUSING PARTS LIST Technical data and specifications are subject to change without notice. Leading Innovation in Torque and Tension Since 1968...
  • Page 25 The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX A XLCT HOUSING PARTS LIST ITEM DESCRIPTION XLCT-2 XLCT-4 XLCT-8 XLCT-14 XLCT-18 XLCT-30 HOUSING XLCT-02-01 XLCT-04-01 XLCT-08-01 XLCT-14-01 XLCT-18-01 XLCT-30-01 HOUSING "C" SERIES XLCT-02-01-C XLCT-04-01-C XLCT-08-01-C XLCT-14-01-C CYLINDER END CAP XLCT-02-02 XLCT-04-02 XLCT-08-02...

  • Page 26: B Xlct Square Drive Parts List

    The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX B XLCT SQUARE DRIVE PARTS LIST Technical data and specifications are subject to change without notice. Leading Innovation in Torque and Tension Since 1968...
  • Page 27 The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX B XLCT SQUARE DRIVE PARTS LIST ITEM DESCRIPTION XLCT-2 XLCT-4 XLCT-8 XLCT-14 XLCT-18 XLCT-30 SQUARE DRIVE HOUSING XLCT-02-15 XLCT-04-15 XLCT-08-15 XLCT-14-15 XLCT-18-15 XLCT-30-15 DRIVE PLATE (02) XLCT-02-35 SQ XLCT-04-35 SQ XLCT-08-35 SQ XLCT-14-35 SO XLCT-18-35 SO...
  • Page 28 The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX C XLCT HEX LINK PARTS LIST NOTE: “#” DESIGNATES BLANK SIZE OR RATCHET SIZE ITEM DESCRIPTION XLCT-2 XLCT-4 XLCT-8 XLCT-14 XLCT-18 XLCT-30 REACTION BLOCK SPACER XLCT-02-45 XLCT-04-45 XLCT-08-45 XLCT-14-45 XLCT-18-45 XLCT-30-45 REACTION BLOCK SPACER EXTENDED XLCT-02-45-C...
  • Page 29 The World’s Most Trusted Industrial Torque and Tension Systems APPENDIX D XLCTB HEX LINK PARTS LIST NOTE: “#” DESIGNATES BLANK SIZE OR RATCHET SIZE ITEM DESCRIPTION XLCT-2 XLCT-4 XLCT-8 XLCT-14 XLCT-18 XLCT-30 LOWER SPACER XLCT-02B-45-# XLCT-04B-45-# XLCT-08B-45-# XLCT-14B-45-# XLCT-18B-45-# XLCT-30B-45-# TOP SPACER XLCT-02-46 XLCT-04-46...
  • Page 30 16.8 10.71 3.33 5.17 3.02 to 4.71 4,578 30,982 23.8 Call for more information, 800-FOR-HYTORC XLCT-45 Call for more information, 800-FOR-HYTORC XLCT-60 Technical data and specifications are subject to change without notice. Leading Innovation in Torque and Tension Since 1968...
  • Page 31 426.7 272.0 84.6 131.32 76.7 to 119.6 6,207 42,005 10.8 Call for more information, 800-FOR-HYTORC XLCT-45 Call for more information, 800-FOR-HYTORC XLCT-60 Technical data and specifications are subject to change without notice. Leading Innovation in Torque and Tension Since 1968...
  • Page 32 Worldwide Warranty, Service & Expertise! Find your nearest HYTORC at www.hytorc.com/worldwide CALL: 1-800-FOR- We are always within 1 hour from you! Division UNEX Corporation 333 State Route 17N, Mahwah, New Jersey 07430 U.S.A. 800-FOR-HYTORC • Tel: 201-512-9500 • E-Mail: info@hytorc.com • Web: www.hytorc.com MAN-XLCT-2012...

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