HTL DSX Series User manual

OPERATING INSTRUCTIONS
HTL-DSX
Dedicated Square Drive Wrench

2
Contents 2
Safety 2-3
Warranty 3
Connecting the tool 3-4
Setting the torque 4-5
Operating the wrench 5-6
Maintenance 6
Troubleshooting guide 6-7
Declaration 8
Notes 9-11
Spare parts 12-15
Contact us 16
Please read this manual before operating the equipment.
Prior to commencement of bolt torqueing, ensure that:
• All necessary safety precautions have been carried out.
• Personnel involved in bolt torqueing are competent and fully trained in the use of torque
wrenches and tightening techniques.
• The procedure and data to be used is authorised by a responsible engineer.
• The joints / pipework to be worked on are not “live”. Joints must be at zero pressure and
free from hazardous substances.
• Bolt torqueing pressures, specific to the flanged joint to be tightened, are available.
Tips
• Always wear the appropriate safety equipment when operating this equipment; such as
safety goggles or safety glasses and protective gloves.
• Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow
within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with
your hands.
• Use only a hydraulic pump capable of generating a maximum of 10,000 psi (700 Bar)
with this equipment.
• Never exceed the rated working pressure of the wrench.
• Do not place your hands between the wrench and the reaction point.
• Use the torque values specified by your equipment manufacturer whenever it is
available.
CONTENTS
SAFETY

3
Warnings
Any residual risks are identified within this manual with the equipment marked where
appropriate. Ensure these warnings are maintained.
The following label (s) are displayed on the machine for your safety, please observe all
warnings.
• You can be injured if you do not obey the safety instructions as
indicated on warning stickers.
• Observe all safety instructions and warnings attached to the machine
• Ensure that safety instructions and warnings attached to the machine
are always complete and perfectly legible.
• Keep warnings and instruction labels clean.
• Replace unreadable or missing labels with new ones before operating
the machine. Make sure replacement parts include warning or
instruction labels where necessary.
Hazard information signs
This warning indicates that there is a potential crush hazard and to keep
away from moving parts.
HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year
from the date of shipment. The guarantee does not include the ordinary wear of both metal and
non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage
incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd.
Please note that if the equipment is disassembled or serviced by anyone other than an
authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void.
In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer
which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty
equipment, whichever is deemed most appropriate.
The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose
assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line
must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct
interconnection between the pump and wrench. Ensure the connectors are fully engaged and
screwed snugly together.
NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high
pressure on the retract side and your wrench is not able to work properly. To avoid tool
WARRANTY
CONNECTING THE TOOL

4
malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any
moment.
Connect the twin-line hose to the swivel as shown:
Drive direction change
To remove the square drive, disengage the drive retainer assembly by depressing the round
center button and gently pulling on the square end of the square drive. The square drive will
easily slide out.
To insert the drive in the tool, place the drive in the desired direction, engage drive and bushing
splines, then twist drive and bushing until ratchet spline can be engaged. Push drive through
ratchet. Depress drive retainer button, engage retainer with drive and release button to lock.
The following diagram illustrates the direction the square drive should face for loosening and
tightening of a standard right hand fastener:
Reaction arm
The reaction arms are employed to absorb and counteract forces created as the unit operates,
which should extend in the same direction of the square drive; however, slight adjustments may
be made to suit your particular application.
In operation, the reaction arm must be fully engaged and secured. To engage the reaction arm,
depress the spring loaded button located on the rear of the end cap, push to position and
release to lock. Ensure the retainer is locked in place prior to using the wrench.
To remove the reaction arm, depress the spring loaded button located on the rear of the end cap
and pull to release.
After determining the desired torque, use the calibration certificate supplied with your wrench to
determine the pressure that is necessary to achieve that torque.
1. Connect the tool to the power supply and turn the pump on.
SETTING THE TORQUE
A
R
Right is
tight.
Left is
loose.

5
2. Depress the advance remote control button, causing the pressure to be shown on the
gauge.
3. Adjust the pressure by loosening the locking ring on the T Handle. Rotate the handle
clockwise to increase the pressure and counter clockwise to decrease the pressure.
When decreasing pressure, always lower the pressure below the desired point and then
bring the gauge back up to the desired pressure.
4. When the desired pressure is reached, retighten the locking ring, cycle the tool again to
confirm that the desired pressure setting has been obtained.
Tightening process
1. Having set your target pressure, cycle the wrench three or four times to full pressure
before putting it on the application. Cycling the tool ensures the system is operating
properly and removes trapped air, if any.
2. Place the correct size impact socket on the square drive and secure properly with a ring
and pin.
3. Place the tool and the socket on the nut, making sure that the socket has fully engaged
the nut. Further ensure that the drive retainer is engaged.
4. Make sure the reaction arm is firmly abutted against a stationary object (e.g. an adjacent
nut, flange, equipment housing etc.). When positioning the wrench, make sure that the
hose connections are well clear of any obstructions, and that all body parts are safely
out of harms way.
5. Apply momentary pressure to the system to ensure proper tool placement. If it doesn’t
look or act right, stop and readjust the reaction arm.
In use
1. By pushing down on the remote control button in the advance position, the rear of the
tool will be pushed back until the reaction arm makes contact with its reaction point.
2. Continue to hold down the button as the socket turns until the tool is fully extended and
will not turn the socket further. Successive cycles are made until the wrench stalls at the
preset torque.
3. The wrench will automatically reset itself and the operator will hear a series of clicks,
when the clicks finish the operator can again push the remote control button and the
socket will turn.
4. Continuing to hold down the remote control button will result in rapid build up of pressure
to the point of where the gauge reads what was preset prior to applying the wrench.
NOTE: 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 wrench automatically resets itself.
OPERATING THE WRENCH

6
5. Always attempt one final cycle to ensure the stall point has been reached.
Loosening procedure
First, set the pump to 10,000 psi. Change the drive and the reaction arm to the loosening mode,
ensuring the reaction arm abuts squarely off a solid reaction point. Press and hold the pump
advance button down. Pressure will decrease as the socket beings to turn. As the cylinder
extends fully, you will hear a click. Release the remote control button, and the cylinder
automatically retracts, at which time you again hear the click. Repeat this process until the
fastener can be removed by hand.
NOTE: If the bolt / nut does not loosen with the above procedure, it is an indication that you
require the next larger size DSX to loosen the bolt.
Lubrication frequency depends on factors known only to the user. The amount of contaminants
in the working area is one factor. Wrenches used in a clean room environment will obviously
require less maintenance than wrenches used outdoors and dropped in loose dirt or sand.
1. When lubrication is required, lubricate all moving parts.
2. Springs are used for the drive pawl assembly and for the accuracy assurance pawl.
These springs can be replaced if necessary.
3. If the cylinder requires disassembly, it is recommended that the cylinder seals be
replaced at the same time. Seal kits are readily available.
4. Hoses should be checked for cracks and leaks before, and after each job. Hydraulic
fittings can become plugged with dirt and should be flushed periodically.
5. Fittings should be kept clean and not allowed to be dragged along the ground or floor as
even small particles of dirt can cause the internal valves to malfunction.
All structural parts on the tools should be inspected at least once a year to determine if there are
any cracks, chips, or deformities.
We recommend you use HTL Group’s Pro-Moly Lubricant
SYMPTOM PROBABLE CAUSE SOLUTION
Wrench
pressure will
not build
Piston seal and/or end plug
seal leaking Replace any defective o-rings.
Coupler is defective Replace any defective couplers.
Cylinder / Tool
Leaks
Blown o-ring in cylinder Replace seal kit.
Defective piston rod seal Return to HTL for repair.
TROUBLESHOOTING GUIDE
MAINTENANCE

7
Ratchet
returns with
retract stroke
Broken or otherwise inoperable
drive segment
Replace drive segment and/or spring. Return
to HTL.
Ratchet will
not take
successive
strokes
Broken or otherwise inoperative
drive segment or spring
Replace drive segment and/or spring. Return
to HTL.
Cylinder not retracting
completely
Remove tool from nut and cycle freely for
several strokes.
Allow adequate time for cylinder to retract
fully.
If problem persists, check pawls.
Linkage between piston rod and
drive plate is broken Replace parts as necessary - return to HTL.
Cylinder will
not retract
Voltage to electric pump is too
low to line drop or inadequate
amperage is available
Get shorter extension cord. If shop power is
adequate, draw power from welding machine
or cal. rod transformer.
Linkage between piston rod and
drive arms are broken Replace part as necessary
Tool locks on
to nut
Drive segment is loaded when
the tool is maxed out in torque
Pressure advance on remote and build
pressure - continue to press down on remote
while pulling back on one of the accuracy
assurance levers - release remote while
continuing to hold back on levers.
Tool is operating backwards Push advance button down - tool should
immediately fall free.
Tool is wedged under a fixed
object
Remove shroud from around ratchet. Pry the
drive segment out of the ratchet and at the
same time pull back on the accuracy
assurance levers. Tool should swing free or
burn away the socket or obstruction.
Tool operates
backwards Multiple hoses in even numbers Configure hoses in odd multiples only.
Pump will not
build up
pressure
Defective relief valve Inspect, adjust or replace the relief valve.
Air supply too low or air hose
too small
Make certain the air supply and hose size
comply with the pump manual
recommendations.
Electric power source is too low
Make certain the amperage, voltage and any
extension cord size comply with the pump
manual requirements.
Defective gauge Replace the gauge.
Low oil level Check and fill the pump reservoir.
Clogged filter Inspect, clean and/or replace the pump filter.
Tool operates
backwards Couplings reversed Check couplings and correct.

8
DECLARATION

9
NOTES

10
NOTES

11
NOTES

16
CONTACT US
HTL Group Corporate Headquarters
45 Colbourne Avenue
Nelson Park Industrial Estate
Cramlington
Northumberland
UK
NE23 1WD
Phone: [phone]
Email: [e-mail]
HTL Europe b.v HTL Australasia Pty Ltd
Euroweg 30 466 Victoria Road
NL-2988 CM Ridderkerk Malaga, WA 6090
The Netherlands Australia
Phone: [phone] Phone: [phone]
Email: [e-mail] Email: [e-mail]
HTL Group Scotland
Raith’s Industrial Estate
Kirkton Drive
Dyce
Aberdeen
UK
AB21 0BG
Phone: [phone]
Email: [e-mail]
www.htlgroup.com
Rev.1118-1