Hytorc ICE series Operational And Spare Parts Manual
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Hytorc ICE series Operational And Spare Parts Manual

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STEALTH SERIES
OPERATIONAL AND SPARE PARTS MANUAL
6th Edition: Mar. 2016

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  • Page 1 STEALTH SERIES OPERATIONAL AND SPARE PARTS MANUAL 6th Edition: Mar. 2016...
  • Page 2 B respectively. It is recommended the manual is kept up-to-date by checking the edition and date code at the bottom of this page by utilizing the HYTORC website and downloading a copy of the most recent edition as needed.
  • 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

    CONTENTS STEALTH 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 SECTION III OPERATION 3-1 General 3-2 Connecting the System...

  • 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

    If tool operates backwards, couplings are reversed. 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 9: Electrical Connections

    The World’s Most Trusted Industrial Bolting 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: Drive Direction Change

    An example of finding the desired torque required is as follows: Assume you are going to use a HYTORC STEALTH tool to torque a 1-114” bolt to 1,265 ft lbs. Start by referring to the proper torque chart shipped with your tool. Read straight down to the number closest to 1,265 ft lbs, which in this case is 1,280 - about 1.5% over the targeted torque...

  • Page 12: Applying The Torque Machine

    The World’s Most Trusted Industrial Bolting Systems Setting the Pressure on the Pump To set the pressure on the pump, follow this procedure: T-Handle 1. Loosen the knurled locking ring below the “T” handle on the pump’s external pressure regulator. Then turn the “T” handle (shown below) counterclockwise (CCW) until it turns freely and easily.

  • Page 13: Loosening Procedures

    The World’s Most Trusted Industrial Bolting Systems IMPORTANT: The reading of full preset pressure after the cylinder is extended DOES NOT INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the socket further until the tool automatically resets itself. Releasing the remote control button will retract the cylinder.

  • Page 14: 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 15: 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 16: Led Lights For System Monitoring

    Important Instructions for ATEX Certified Pneumatic Pumps for Explosion Protection The device can be used in hazardous areas as follows: Explosion-proof hydraulic torque controlled bolting system HYTORC Division of UNEX Corp. 333 Route 17 North Mahwah, New Jersey 07430 U.S.A. EPS 13 ATEX 2 561 X...
  • Page 17 Modified component: HYTORC HY-AIR Pneumatic pump must be equipped as follows: a) Solid metal spring on each male and female coupling (between coupler and fitting). 2. Component: The HYTORC hydraulic twin hose, with a nominal size of 6 mm (color mint-yellow). ATTENTION: HYTORC hydraulic twin hoses with a diameter smaller than 6mm are not suited for explosion protection.
  • Page 18 The World’s Most Trusted Industrial Bolting Systems 3. Component: The HYTORC hydraulic torque wrench. The torque wrench must be equipped as follows: a) Solid metal spring on each male and female coupling (between coupler and fitting). b) The joints of the swivel on the hydraulic wrench must not be ANODIZED!
  • Page 19 Conductivity of the entire system is ensured by several solid metal springs, - HYTORC Pneumatic Pump JetAIR 12.A connected securely to the hydraulic hose - HYTORC Hydraulic Twin Hose (diameter 6 mm) connected securely to the tool Explosion protection is guaranteed if: The explosion protection is only guaranteed when all springs (pneumatic pump, twin hose and tool) are attached tightly.

  • Page 20: 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 21: Preventive Maintenance - Hydraulic Power Packs

    The World’s Most Trusted Industrial Bolting 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 22: Troubleshooting

    The World’s Most Trusted Industrial Bolting 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. 2.
  • Page 23 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 24 The World’s Most Trusted Industrial Bolting 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 25 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 26 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-STEALTH-2016...

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