SPX TWSD Series Bedienungsanleitung

Operating Manual for:

TWSD Series

Square Drive Hydraulic Torque

Wrench

Original Instructions

Unit 4, Wansbeck Business Park

Rotary Parkway

Ashington

Northumberland NE63 8QW

Tel: +44 (0) 1670 850580

Fax: +44 (0) 1670 850655

[email protected]

SPX Bolting Systems

Form No. 1000528

Rev. 1 December 2, 2011

Form No. 1000528

Rev. 1 December 2, 2011

Table of Contents

Torque Wrench Square Drive (TWSD) ........................................................................................2

Safety Symbols and Denitions...................................................................................................3

Safety Precautions ......................................................................................................................3

Pump ............................................................................................................................... 3

Electric Motor................................................................................................................... 4

Hoses............................................................................................................................... 4

Initial Setup..................................................................................................................................6

Power Requirements ....................................................................................................... 6

Torque Wrench Usage..................................................................................................... 7

Connecting the System.................................................................................................... 7

Hydraulic Connections..................................................................................................... 7

Use of Sockets................................................................................................................. 7

Safety............................................................................................................................... 8

Preparing the Torque Wrench for Use ............................................................................. 9

Changing the Drive Direction........................................................................................... 9

Setting Torque.................................................................................................................. 9

Operating Instructions ...............................................................................................................11

Positioning the Hydraulic Torque Wrench on the Nut .....................................................11

Using the Reaction Arm..................................................................................................11

Reaction Point Safety .....................................................................................................11

Use of Backing Wrenches ............................................................................................. 12

Torque Wrench Selection............................................................................................... 12

Tightening Bolts ............................................................................................................. 12

Tightening a Flanged Joint ............................................................................................ 12

Loosening Bolts ............................................................................................................. 13

Performance Specications.......................................................................................................15

Technical Specications................................................................................................. 15

Pressure/Torque Conversion Chart ...........................................................................................16

General Maintenance ................................................................................................................17

Maintenance, Service, and Warranty............................................................................. 17

End of Life and Disposal................................................................................................ 18

Troubleshooting.........................................................................................................................19

Repair Procedures.....................................................................................................................20

Drive Component Disassembly ..................................................................................... 20

Drive Component Assembly .......................................................................................... 23

Multiswivel Manifold Disassembly ................................................................................. 25

Multiswivel Manifold Assembly ...................................................................................... 27

Hydraulic Cylinder Disassembly .................................................................................... 28

Hydraulic Cylinder/Body Assembly................................................................................ 29

Parts Lists..................................................................................................................................31

TWSD1/3 Torque Wrench Parts List.............................................................................. 31

TWSD6/11/25 Torque Wrench Parts List ....................................................................... 33

EC Declaration of Conformity....................................................................................................36

Form No. 1000528

Rev. 1 December 2, 2011

Torque Wrench Square Drive (TWSD)

Description: The TWSD torque wrench is a ratchet-type torque tool used in conjunction with

standard impact sockets to hydraulically tighten nuts and bolts. It is powered using a 690 bar

(10,000 psi) hydraulic pump unit. The torque output from the TWSD torque wrench is proportional

to the pump-pressure applied.

HYDRAULIC

COUPLINGS

MULTISWIVEL

MANIFOLD

SQUARE DRIVE

RELEASE BUTTON

REACTION ARM

RELEASE BUTTON

REACTION ARM

PROTECTION PAD

SQUARE DRIVE

Figure 1. TWSD Hydraulic Torque Wrench

Form No. 1000528

Rev. 1 December 2, 2011

The safety signal word designates the degree or level of hazard seriousness.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death

or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor

or moderate injury.

CAUTION: Used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in property damage.

IMPORTANT: Important is used when action or lack of action can cause equipment failure, either

immediate or over a long period of time.

Safety Symbols and Denitions

WARNING: To prevent personal injury,

The following procedures must be performed by qualied, trained personnel who •

are familiar with this equipment. Operators must read and understand all safety

precautions and operating instructions included with the device. If the operator

cannot read these instructions, operating instructions and safety precautions must

be read and discussed in the operator's native language.

These products are designed for general use in normal environments. These•

products are not designed for use in special work environments such as: explosive,

ammable, or corrosive. Only the user can decide the suitability of this product in

these conditions or extreme environments. Power Team will supply information

necessary to help make these decisions. Consult your nearest Power Team facility.

Safety glasses must be worn at all time by the operator and anyone within sight of•

the unit. Additional personal protection equipment may include: face shield, goggles,

gloves, apron, hard hat, safety shoes, and hearing protection.

The owner of this tool must verify that safety-related decals are installed, maintained,•

and replaced if they become hard to read.

Shut• OFF the motor before opening any connections in the system.

Pump

WARNING: To prevent personal injury,

Do not exceed the hydraulic pressure rating noted on the pump nameplate or•

tamper with the internal high pressure relief valve. Creating pressure beyond rated

capacities can result in personal injury.

Retract the system before adding uid to prevent overlling the pump reservoir. An •

overll can cause personal injury due to excess reservoir pressure created when

cylinders are retracted.

Safety Precautions

Form No. 1000528

Rev. 1 December 2, 2011

Electric Motor

WARNING: To prevent personal injury,

Electrical work must be performed and tested by a qualied electrician per local •

directives and standards.

Disconnect the pump from the power supply and relieve pressure before removing•

the motor case cover or performing maintenance or repair.

Check the total amperage draw for the electrical circuit you will be using.• For

example: Do not connect a pump that may draw 25 amps to a 20 amp fused electrical

circuit.

Never use an ungrounded power supply with this unit.•

Changing the voltage is an involved and, if incorrectly performed, hazardous procedure.•

Consult the manufacturer for specic information before attempting rewiring.

Wire pump motors for counterclockwise rotation when viewed from the shaft end of•

the motor.

Do not attempt to increase the power line capacity by replacing a fuse with another•

fuse of higher value. Overheating the power line may result in re.

Exposing electric pumps to rain or water could result in an electrical hazard.•

Avoid conditions that can cause damage to the power cord, such as abrasion,•

crushing, sharp cutting edges, or corrosive environment. Damage to the power cord

can cause an electrical hazard.

Hoses

WARNING: To prevent personal injury,

Before operating the pump, tighten all hose connections using the correct tools. Do•

not overtighten. Connections should be only secure and leak-free. Overtightening

can cause premature thread failure or high pressure ttings to split at pressures

lower than their rated capacities.

Should a hydraulic hose rupture, burst, or need to be disconnected, immediately•

shut off the pump and shift the control valve twice to release pressure. Never

attempt to grasp a leaking hose under pressure with your hands. The force of

escaping hydraulic uid could cause serious injury.

Safety Precautions continued

Form No. 1000528

Rev. 1 December 2, 2011

Do not subject the hose to potential hazard, such as re, sharp surfaces, heavy •

impact, or extreme heat or cold. Do not allow the hose to kink, twist, curl, or bend

so tightly that the uid ow within the hose is blocked or reduced. Periodically

inspect the hose for wear, because any of these conditions can damage the hose and

possibly result in personal injury.

Do not use the hose to move attached equipment. Stress can damage the hose and•

possibly cause personal injury.

Hose material and coupler seals must be compatible with the hydraulic uid used. •

Hoses also must not come in contact with corrosive material such as creosote-

impregnated objects and some paints. Consult the manufacturer before painting a

hose. Never paint the couplers. Hose deterioration due to corrosive materials may

result in personal injury.

Safety Precautions continued

Form No. 1000528

Rev. 1 December 2, 2011

Initial Setup

Each hydraulic torque wrench is supplied completely assembled and ready for use. A hydraulic pump

is required to provide the speed and pressure that makes the hydraulic wrench system efcient and

accurate.

Read and understand all instructions before operating the hydraulic torque wrench. It is the1.

operator's responsibility to read, understand, and follow all safety instructions.

Remove the hydraulic torque wrench from the shipping container and visually inspect all2.

components for any shipping damage. If any damage is found, notify the carrier immediately.

DO NOT USE TOOL.

Power Requirements

The TWSD hydraulic torque wrench requires a hydraulic pump unit, twin-line connecting hose, and

couplings to operate. All components must be capable of operating at the system maximum working

pressure of 690 bar (10,000 psi). Note that the system maximum working pressure is dynamic, not

static.

Pump unit specication varies between manufacturers; however, for correct torque wrench operation,

the pump unit must include the following:

Double Acting—Pump unit must be capable of double acting operation for advancing and retracting

the Torque Wrench.

Variable Pressure Output—For torque setting, the pump unit must be able to be easily adjusted by the

operator for different pressure outputs.

Retract Pressure—Sometimes termed 'idle' pressure, this is the pressure used for torque wrench

retraction and must be xed at approximately 103 bar (1,500 psi). This pressure must not be operator

adjustable.

Remote Handset Controls—The preferred conguration for the handset is such that, upon starting the

pump unit, the pump enters retract or idle mode (pressure xed at 103 bar (1,500 psi)). To advance the

torque wrench, the handset advance/pressure button or lever is pressed and held, upon release of the

button, retract mode is automatically entered. A separate button or lever is used to stop the pump.

Automatic Pressure Release—The pump must automatically release system pressure when switching

between advance and retract modes.

Pump Flow Rate—The speed at which the hydraulic torque wrench operates is proportional to the oil

ow rate. In general, 2-stage pump units are preferred for torque wrench use as this allows rapid nut

rotation under low loads, with fast wrench retraction. As a minimum, 250 cm³/min @ 7 bar (15 ci/min @

100 psi) to 20 cm³/min @ 690 bar (1.2 ci/min @ 10,000 psi) should be specied; however, for optimum

speed and performance, at least 360 cm³/min @ 7 bar (22 ci/min @ 100 psi) to 30 cm³/min @ 690 bar

((1.8 ci/min @ 10,000 psi) is recommended.

Pressure Gauge—Clarity is important for accurate torque setting; therefore, a pressure gauge of at

least 100-mm (4-in.) diameter should be tted.

Hydraulic Couplings—TWSD hydraulic torque wrenches are tted with CEJN 230 screw-to-connect

couplings (1/4-in. NPT) as standard. Verify any couplings that are used are compatible with these

couplings and rated to the same working pressure, e.g. Parker 3000 couplings.

SPX Bolting Systems will not be responsible for torque wrench damage, malfunction or operator injury

caused by the use of an incorrect pump unit; therefore, check the compatibility of your pump unit before

operating the hydraulic torque wrench.

Form No. 1000528

Rev. 1 December 2, 2011

Torque Wrench Usage

To ensure reasonable life and performance from the torque wrench and system (pump and hoses),

these guidelines should be followed:

Under normal use, the torque wrench should be limited to 75–80% of its maximum achievable torque•

output.

Under breakout conditions, because the bolt can suddenly break free and result in shock loads,•

jumping/jolting, it is recommended to limit the wrench output torque to 60–70% of maximum

achievable torque output. It is also a good idea to have torque in reserve for the odd stubborn bolt/

nut.

Once a corroded bolt has broken free, do not use a torque wrench to wind the nut from the bolt. This•

can cause the nut to bind and lock onto the bolt and make it impossible to remove. It is preferred

that a nut runner or impact wrench be used to remove the nut following initial breakout by hydraulic

torque wrench.

Occasional use of the torque wrench at full pressure/torque is acceptable, but unnecessary•

continuous use at full pressure will reduce the life of the torque wrench and system.

In elevated temperature environments, it is advisable to cool the torque wrench as much as practical•

to maintain the sealing systems in good order. Depending upon the pressure applied to the wrench,

repeated use in temperatures in excess of 40°C (104°F) will affect the life of the hydraulic seals.

If the temperatures are likely to exceed 40°C (104°F), it is advisable to use a larger capacity wrench

so that the pressure to achieve the required torque is reduced. This will result in less temperature

buildup and less softening of the seals.

Seals should be replaced regularly because, at elevated temperatures, the extrusion resistance of

the seal is reduced.

Connecting the System

The hydraulic wrench head and power pack are connected by a 690 bar (10,000 psi) twin-line hose

assembly. Refer to the power-unit manufacturer's operating instructions for proper use.

Hydraulic Connections

Never connect or disconnect any hydraulic hoses or fittings without first unloading the•

wrench and the pump.

Open all hydraulic controls several times to verify the system has been completely•

depressurized.

If the system includes a gauge, double check the gauge to verify pressure has been•

released.

When making connections with quick-disconnect coupling, verify the couplings are fully•

engaged. Threaded connections such as fittings, gauges, etc., must be securely tightened

and leak-free.

Use of Sockets

Use high-quality, industrial impact sockets at all times. Verify that sockets are rated to accept the full

torque output of the torque wrench they are used with. Regularly check the socket for cracks and aws.

If any sign of damage is evident, discard immediately. A damaged socket breaking under load can

cause equipment damage or operator injury.

Initial Setup continued

Form No. 1000528

Rev. 1 December 2, 2011

Long-reach or deep sockets are not recommended for use with hydraulic torque tools because they

can make the wrench and socket unstable. However, some applications demand the use of long-reach

sockets. When long-reach sockets are used, support for both the socket and reaction facility must

be provided. The same applies to socket accessories, such as extension bars, knuckle joints (not

recommended), etc.

Safety

The TWSD hydraulic torque wrench is a high-power hydraulic tool. It is strongly recommended that

all users are fully trained and competent in the use of hydraulic torque wrench systems. Incorrect use

of the equipment or failure to follow any of the safety precaution included herein could lead to serious

injury.

NOTE: The TWLC torque wrench is designed for torque tightening of engineering nuts only. Do

not use it for any other purpose.

Never exceed the hydraulic torque wrench maximum working pressure of: Advance 690 bar (10,000•

psi) and Retract 103 bar (1,500 psi).

Keep hands and fingers clear of the hydraulic torque wrench head and reaction pad area, before and•

during operation.

Keep other personnel clear of the working area and only allow trained personnel to use the•

equipment.

Before operation, verify all hoses and equipment are in proper working order. Verify all hydraulic•

torque wrench components (i.e. square drive, reaction arm, etc.) are properly attached and secure.

Verify the square drive retainer button is properly located.

Do not strike any of the components, including the socket, to shock the nut free.•

Verify reaction structures are strong and rigid enough to accept the torque tool reaction forces. Do•

not use wedges, packing pieces, etc. as temporary reaction structures.

If backing wrenches are used, keep hands and limbs well clear of the backing wrench.•

Do not tighten any equipment while under pressure. Do not move or rotate the multiswivel manifold•

while under pressure.

Verify that any sockets to be used with the hydraulic torque wrench are of impact quality and capable•

of withstanding the full torque output of the tool.

Some hydraulic torque wrenches weigh in excess of 20 Kg (44 lb). If necessary, lifting equipment•

can be used.

In some instances, it may be necessary for the operator to support the hydraulic torque wrench while•

it is tightening, i.e. upside-down operations. If the hydraulic torque wrench cannot be strapped into

position using ropes, etc., the operator must take care to avoid pinch points.

Verify hoses are in good condition and undamaged. Do not bend hoses beyond their safe bend•

radius limit or kink the hose.

Never use the hydraulic torque wrench with just one hose connected to the Advance port (Port A).•

This will cause the pressure to intensify within the retract chamber possibly leading to tool damage.

Always verify that both hoses are correctly connected.

Take care when handling equipment. Quick connect couplings are especially susceptible to knocks•

and damage and therefore care must be taken. Note that damaged couplings are difficult to connect.

Do not force couplings.

Do not strike, misuse or abuse any of the equipment. If any abuse or misuse of the equipment is•

Initial Setup continued

Form No. 1000528

Rev. 1 December 2, 2011

Initial Setup continued

evident, the warranty shall be invalid and the Manufacturer shall not be responsible for any injuries

or failures as a result.

If not in use, and when practical, disconnect the wrench and pump from the power supply to prevent•

accidental starting.

Preparing the Torque Wrench for Use

IMPORTANT: For a copy of the calibration certificate for a specific hydraulic torque wrench,

e-mail [email protected] with serial number of the hydraulic torque wrench.

CAUTION: For top performance, frequently inspect wrench, pump, and accessories for visual

damage. Always follow instructions for proper wrench and pump maintenance. Do not use other

equipment to increase the capability (i.e., hammering on socket wrench).

Changing the Drive Direction

To change the drive direction:

Press and hold the drive-release button and pull out the square drive. The square drive, retainer cap,1.

and button assembly are now free.

To reinstall, insert the square drive into the opposite side of the tool head, aligning the splines, and2.

replace the retainer cap assembly.

Pull the square drive to verify that it is locked in position.3.

Item Description

1 Square drive release button

2 Square drive cap

Figure 2. Square Drive Operation

Setting Torque

Verify the system is fully connected and the proper power supply is available.1.

Refer to the Pressure/Torque Conversion Chart in the Performance Specications section. Note that 2.

this pressure is set on the pump.

Turn on the pump.3.

Press and hold the remote control button.4.

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