Gedore DVV-13Z User manual

02/2012
CN
www.gedore.com
Operating Instructions
Torque MultiplierType
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS,
DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
DVV-13Z
DVV-80ZRS
DVV-40Z
DVV-100ZRS
DVV-40ZRS
DVV-130ZRS
DVV-60ZRS
DVV-540RS

Torque Multiplier
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Multiplicador de torque
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Multiplicateur de couple
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Drehmomentvervielfältiger
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Krachtvermeerderaar
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Moltiplicatore di coppia
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Powielacza momentu obrotowego
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Multiplicador de binário
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Yсилителя крутящего момента
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
Tork Arttırıcıyı
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
扭矩倍增器
DVV-13Z, DVV-40Z, DVV-40ZRS, DVV-60ZRS, DVV-80ZRS, DVV-100ZRS, DVV-130ZRS, DVV-540RS
www.gedore.com

CN
Operating Instructions
AVOID INJURY.You MUST read and
understand these Operating Instructions
before using the torque multiplier.
Instrucciones de Manejo
EVITE LESIONES. UstedTIENE que leer y
entender este manual, antes de usar el
multiplicador de torque.
Instructions d`Emploi
EVITER TOUTE BLESSURE. Vous DEVEZ lire
et comprendre ce mode d’emploi avant
d’utiliser le multiplicateur de couple.
Betriebsanleitung
VERLETZUNGENVERMEIDEN. Sie MÜSSEN
diese Betriebsanleitung lesen und verstehen,
bevor Sie den Drehmomentvervielfältiger benutzen.
Gebruiksaanwijzing
VOORKOM LETSEL. U MOET deze handleiding lezen en
begrijpen alvorens de krachtvermeerderaar te
gebruiken.
Istruzioni d`uso
EVITARE LE LESIONI. È NECESSARIO leggere e
comprendere le presenti istruzioni per l’uso
prima di impiegare il moltiplicatore di coppia.
Instrukcji eksploatacji
UNIKAC OBRAZEN. Przed rozpoczęciem użytkowania
powielacza momentu obrotowego NALEZY
przeczytac ze zrozumieniem instrukcje obsługi.
Manual de funcionamento
EVITE FERIMENTOS. Este manual de instruções
TEM de ser lido e compreendido antes de utilizar o
multiplicador de binário.
Pуководства по эксплуатации
ИЗБЕЖАНИЕ ТРАВМ.
Перед использованием усилителя крутящего
момента Вы ДОЛЖНЫ прочитать и усвоить данную
инструкцию по эксплуатации.
Kılavuzunun çevirisi
YARALANMALARDAN KAÇININ.
Tork Arttırıcıyı kullanmadan önce bu
kullanma talimatlarını OKUMALISINIZ.
供货范围
使用扭矩倍增器前必须阅读并了解本操作
说明。使用不当可能造成严重受伤或死亡。
4 - 32
33 - 61
62 - 90
91 - 119
120 - 148
149 - 177
178 - 206
207 - 235
236 - 264
265 - 293
294 - 322

EN
4
Table of Contents
1Important Safety Information....................................6
1.1Safety Warnings ...................................................................6
1.2Personal Protective Equipment ............................................9
1.3Intended Use ........................................................................9
1.4Handling..............................................................................10
1.5Work Environment..............................................................10
2Product Description.................................................11
3Preparing the Torque Multiplier..............................13
3.1Required Parts and Accessories ........................................14
3.2Assembling the Impact Socket ...........................................15
3.3Attach the Torque Multiplier to the Impact Socket..............16
3.4Attach the Torque Wrench..................................................16
4Safe Use....................................................................17
4.1Attaching the Torque Multiplier to the Bolt..........................17
4.2Placement of the Reaction Arm..........................................19
4.3Setting the Torque..............................................................21
4.4Tightening Bolts and Lug Nuts............................................24
4.5Loosening Bolts and Lug Nuts............................................26
5Removing the Torque Multiplier.............................27
6Care and Storage .....................................................27
7Accessories..............................................................28
7.1Reaction Arm Assembly .....................................................29


EN
5

8Maintenance and Repair............................................30
8.1Output Square Replacement................................................30
9Environmentally Friendly Disposal..........................31
10Technical Data............................................................32



EN
6
1 Important Safety Information
Read and understand these Operating Instructions before using the
Torque Multiplier. SERIOUS INJURIES or DEATH can result from
incorrect use.
These Operating Instructions are part of the Torque Multiplier. They
must be kept in a safe place for later use and be passed along with
the Torque Multiplier if it is sold, loaned, or otherwise transferred.
The Torque Multiplier may only be used by TRAINED PERSONNEL
who have been taught how to safely use and handle the Torque
Multiplier. Using the Torque Multiplier without proper training may
result in SERIOUS INJURY or DEATH. If you are not sure about the
selection or the safe use of the Torque Multiplier, contact GEDORE.
Employers purchasing this Torque Multiplier MUST ensure
employees using the Torque Multiplier have read and understood
these Operating Instructions prior to using the Torque Multiplier. The
Operating Instructions MUST be available to employees for
reference at all times.
1.1 Safety Warnings
Throughout these Operating Instructions WARNING, CAUTION,
NOTICE, and the SAFETY ALERT SYMBOL will be used:
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not
prevented, could result in minor or moderate injury.
Addresses practices not related to personal injury.
Relates to property damage or damage to the Torque
Multiplier.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.

EN
7
OVERLOAD HAZARD
The Torque Multiplier or its reaction arm can overload during
incorrect use and break causing SERIOUS INJURY or DEATH.
To prevent overload, take the following safety precautions:
ALWAYS inspect the Torque Multiplier for damage BEFORE
use.
NEVER use a damaged Torque Multiplier.
NEVER use electric, pneumatic or battery-operated Torque
Multipliers or impact wrenches.
NEVER exceed the specified maximum input torque.
ALWAYS use impact sockets in accordance with DIN 3129 or
ISO 2725-2 and ISO 1174.
NEVER extend the impact socket or connector between bolt
and Torque Multiplier (see section 3.2).
NEVER use a universal or cardan joint.
NEVER hit the Torque Multiplier with a hammer.
DO NOT drop the Torque Multiplier.
NEVER use the Torque Multiplier if it has been dropped, used to
strike other objects, or if anything has fallen on it.

EN
8
CRUSH HAZARD
The reaction arm can create a crush hazard against the anchor
point and can slip or break during use causing SERIOUS INJURY.
To prevent serious crush injuries to your fingers and hands, take the
following safety precautions:
ALWAYS keep hands and fingers away from the reaction arm.
ALWAYS select an anchor point (wall, another bolt) sufficient to
withstand torque reaction forces. Reaction torque equals output
torque.
ALWAYS securely connect the reaction arm to the support bolt
(see section 4.1).
ALWAYS place the reaction arm squarely against a solid object
(anchor point) or surface adjacent to the bolt to be tightened.
NEVER allow the gearbox to touch a wall or other object (see
section 4.1).
NEVER modify the reaction arm without consulting with the
manufacturer.
EXPLOSION AND FIRE HAZARD
Sparks can occur when using the Torque Multiplier, which can
cause an explosion or a fire causing SERIOUS INJURY or DEATH.
NEVER use the torque wrench in areas where sparks can cause
explosions or fires.

EN
9
1.2 Personal Protective Equipment
ALWAYS wear personal protective equipment when using the
Torque Multiplier. The Torque Multiplier can slip or break during use
causing SERIOUS INJURY or DEATH.
EYE PROTECTION (see ANSI Z87.1) designed to protect you from
FLYING OBJECTS must be worn when using the Torque Multiplier.
Particles may fly upward during work with the Torque Multiplier
and cause SERIOUS INJURY to your eyes.
SAFETY GLOVES must be worn when using the Torque Multiplier.
The Torque Multiplier unit can come loose or break during use
causing SERIOUS INJURY to your fingers and hands.
SAFETY SHOES with slip-resistant soles and steel toe caps (see
ASTM F2413-05) must be worn when using the Torque Multiplier.
Falling parts can cause SERIOUS INJURY to feet and toes.
1.3 Intended Use
The Torque Multiplier is a hand-operated tool that is designed
explicitly to remove or tighten bolts and lug nuts. Improper use could
result in the unit coming loose when it is under load causing
SERIOUS INJURY or DEATH.
DO NOT use the Torque Multiplier for any other purpose.
MISUSE can lead to SERIOUS INJURY or DEATH.
DO NOT allow children to use the Torque Multiplier.

EN
10
1.4 Handling
Take the following safety precautions to prevent injuries and property
damage caused by improper handling and unsafe use of the Torque
Multiplier.
Improper handling can result in SERIOUS INJURY or DEATH.
NEVER use the Torque Multiplier when you are tired or under the
influence of alcohol, drugs or medications.
NEVER use the Torque Multiplier if you have not been properly
trained how to safely use and handle it.
ALWAYS check the Torque Multiplier for damage before use.
ALWAYS replace damaged or worn parts before use.
ALWAYS use only GEDORE original replacement and accessory
parts for the Torque Multiplier.
NEVER exceed the specified input torque.
ALWAYS keep hair and clothing away from moving parts.
ALWAYS make sure that your footing is solid while working.
1.5 Work Environment
ALWAYS use the Torque Multiplier in a safe work environment.
Keep the work area clean and tidy.
Use the Torque Multiplier in a large and secured area.
Localized work illumination MUST be adequate.
NEVER use the Torque Multiplier in areas where sparks can
cause fires or explosions.

EN
11
2 Product Description
Type: DVV-13Z and DVV-40Z
A: Input square E: Hole in output square
B: Gear casing F: Retaining ring
C: Reaction arm
D: Output square

D
AB
C
E
F
A
B
F
DE
C
DV
V
-13Z
DV
V
-40Z

EN
12
Type: DVV-40ZRS, DVV-60ZRS, DVV-80ZRS,
DVV-100ZRS, DVV-130ZRS with return stop
A: Input square E: Hole in output square
B: Gear casing F: Retaining ring
C: Reaction arm G: Return stop
D: Output square
A
B
G
F
D E
C
DV
V
-100ZRS
A
B
G
FD E
C
DV
V
-130ZRS
A
B
G
F
D E
C
DV
V
-40ZRS
A
B
G
F
D E
C
DV
V
-60ZRS
A
B
G
F
D E
C
DV
V
-80ZRS

EN
13
Type: DVV-540RS
A: Input square E: Hole in output square
B: Gear casing G: Return stop
C: Reaction plate (blank) M: Eyebolt
D: Output square
C
A
DE
B
M
G

EN
14
3 Preparing the Torque Multiplier
Before using your Torque Multiplier for the first time, confirm that you
have all of the following parts and accessories.
NEVER use the Torque Multiplier if it has been dropped, used to
strike other objects, or if anything has fallen on it. A damaged Torque
Multiplier may slip or break during use causing SERIOUS INJURY or
DEATH.
ALWAYS assemble the Torque Multiplier and its components on a
work bench. During the assembly of the Torque Multiplier, parts can
fall and become damaged.
3.1 Required Parts and Accessories
Before using your Torque Multiplier for the first time, confirm that you
have all of the following parts and accessories:
Required parts included with your Torque Multiplier:
Torque Multiplier
Reaction arm, stepped or straight (except DVV-540RS)
Factory calibration certificate (except DVV-540RS)
Torque calculator
Operating Instructions
Required accessories not included with your Torque Multiplier:
Suitable Torque wrench
Impact socket with rubber ring and locking pin or similar locking
Suitable ratchet



EN
15
3.2 Assembling the Impact Socket
When using the Torque Multiplier, NEVER use extensions. NEVER
use a universal or cardan joint. NEVER use an impact socket that is
too long.
Using any of these accessories could cause the Torque Multiplier to
overload, slip or break leading to SERIOUS INJURY and DAMAGE.
Assemble the impact socket:
1. Insert the locking pin (I) halfway
into the impact socket.



2. Pull the rubber ring over the
impact socket.
NOTE: The rubber ring does not
fit completely around the impact
socket because the locking pin
protrudes halfway out of the
socket.



I

EN
16
D
E
I
3.3 Attach the Torque Multiplier to the Impact Socket
1. Insert the output square (D)
on the Torque Multiplier into
the impact socket.
2. Line up the hole (E) on the
output square (D) with the
locking pin (I) on the impact
socket.
3. Press the locking pin (I)
into the hole (E) on the
output square all the way.
3.4 Attach the Torque Wrench
Insert the torque wrench into
the input square (A) on the
Torque Multiplier.
NOTE: For max. input torque
values, see Section 10,
Technical Data.
A

EN
17
4 Safe Use
ALWAYS read the Important Safety Information (Section 1) BEFORE
using the Torque Multiplier.

OVERLOAD HAZARD. The Torque Multiplier or its reaction arm can
overload during use and break causing SERIOUS INJURY or DEATH.
To prevent overload, take the safety precautions listed in Section 1.


4.1 Attaching the Torque Multiplier to the Bolt

CRUSH HAZARD
The reaction arm can create a crush hazard against the anchor point
and can slip or break during use causing SERIOUS INJURY.
When attaching the Torque Multiplier to the bolt, NEVER allow the
gearbox to touch a wall or other object.
 






EN
18
Straight reaction arm:
1. Fit both the output
square (D) and the
adjustable locking knob
with reaction "slave"
square (J) with an
impact socket (see
section 3.3).
2. Loosen the locking
knob (J) by turning it
counterclockwise.
3. Fit the output square
(D) and the attached
impact socket on the
bolt to be tightened (K).
4. At the same time, fit the
impact socket on the
reaction "slave" square
of the locking knob (J)
on the support bolt (L).
5. Tighten the locking
knob by turning it
clockwise (J).
Stepped reaction arm:
1. Fit both the output square (D) with an impact socket (see section
3.3).
2. Position the output square (D) along with impact socket on the
screw to be screwed down.
NOTE: To make the work easier, the DVV-540RS can be
suspended from the eyebolts employing appropriate sling gear.
KL
J
D

EN
19
C
4.2 Placement of the Reaction Arm
When the Torque Multiplier is in operation, the reaction arm rotates in
the opposite direction to the output square and MUST be placed
squarely against a solid object or surface adjacent to the bolt to be
tightened.
ALWAYS select an anchor point (wall, another bolt) sufficient to
withstand torque reaction forces. Reaction torque equals output
torque.
Straight version reaction arm with adjustable reaction "slave" square:
To brace the reaction arm on a wall:
1. Remove the locking knob on the Torque Multiplier.
2. Brace the reaction arm (C) on a wall.
3. Make sure that the reaction arm is perpendicular to the wall.
Given overturning, torques for this type of torque reaction are limited
to 80% of the maximum permissible torque.
C

EN
20
Stepped Reaction Arm:
Place the reaction arm (C)
squarely against the selected
anchor point so that ONLY the
reaction range area ( ) on both
sides of the reaction arm touch the
anchor point.
If other parts of the reaction arm touch
the anchor point, the reaction arm may
slip or break causing SERIOUS
INJURY and DAMAGE.
Placement of the reaction arm for bolt
tightening:
1. Position the Torque Multiplier and
the impact socket on the bolt to be
tightened.
2. Place the reaction arm on the right
of the anchor point.
Placement of the reaction arm for bolt
loosening:
1. Position the Torque Multiplier and
the impact socket on the bolt.
2. Place the reaction arm on the left
of the anchor point.
Reaction range
area on both sides
C