Hytorc jGun DIGITAL Assembly instructions

jGun® DIGITAL Pneumatic Torque Tool
Basic Operations Manual
Preliminary March 17, 2020
333 Route 17 N.
Mahwah, NJ 07430
USA
800-FOR-HYTORC
(800-367-4986)
201-512-9500
hytorc.com
Firmware Version 2.73

This manual provides information for the standard jGun® DIGITAL Pneumatic Torque Tool.
Models: jGun® DIGITAL: DJ-.25, DJ-.5, DJ-1, DJ-2, DJ-3, DJ-5, DJ-8
Notice. The information contained in this document is subject to change without notice. HYTORC makes no warranty of any kind with regard to
this material, including but not limited to, the implied warranties of merchantability and fitness for a particular purpose. HYTORC shall not be liable
for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. It is
further recommended that the end-user or repair technician ensure they have obtained and are familiar with the latest revision of the manual for the
equipment outlined in this document.
Restricted Rights Legend. Use and duplication of the information contained within this manual is limited to the purchaser, end user, or licensed
HYTORC representative. It is recommended that proper training for the equipment outlined in this manual be conducted by a HYTORC-authorized
training representative for any person who is operating or repairing the equipment outlined in this document. Modification of, or disclosure by any
other agency or representative is strictly forbidden.
Product Modifications. HYTORC DOES NOT ALLOW any of the products listed in this manual to be modified by any end user without exception.
Should an application require a modification to the tool or any of the standard accessories please consult with your local HYTORC representative and
they will be able to obtain the assistance for any modification that may be required.
jGun® is a registered trademark of HYTORC.
Copyright © 2020 HYTORC All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as
allowed under the copyright laws.
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and
can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment o and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
- Reorient or relocate the receiving antenna.
- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a circuit dierent from that to which the receiver is connected.
- Consult the dealer or an experienced radio/TV technician for help.
Warranty. The jGun® DIGITAL Pneumatic Torque Tool has a one-year limited warranty. Every tool is tested before leaving the factory and is warranted
to be free from defects in workmanship and materials. HYTORC will repair or replace, without charge, any tool which, upon examination, proves to
be defective in workmanship or materials for one (1) year after the date of purchase. This warranty does not cover damage resulting from repairs
made or attempted by unauthorized repair facilities. The repair and replacement remedies described herein are exclusive. In no event shall HYTORC
be liable for any incidental, special, or consequential damages, including loss of profits. This warranty is exclusive and in lieu of all other warranties
or conditions, written or oral, expressed or implied for merchantability or fitness for particular use or purpose. This warranty gives you specific legal
rights. You may also have other rights that vary from state to state and province to province. In those states that do not allow the exclusion of implied
warranties or limitation of incidental or consequential damages, the above limitations or exclusions may not apply to you. If you have questions about
the warranty, contact our customer service center at 201-828-5270.
Printed in the USA. March 2020
Complies with standards publication BS EN 82079-1:2012
ORIGINAL INSTRUCTIONS
ABOUT THIS DOCUMENT
jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual
TABLE OF CONTENTS
1. GENERAL SAFETY INFORMATION 1
2. SERVICE 7
3. TOOL DESCRIPTION 8
4. CARE AND HANDLING 9
5. CHARGING THE BATTERY 10
6. CLEANING FILTERS 11
7. CONNECTING THE AIR SUPPLY 12
8. TURNING POWER ON OR OFF 13
9. ADJUSTING TORQUE AND LOCKING THE REGULATOR 14
10. ADJUSTING UNITS 15
11. SCREEN FREEZE AND RELEASING THE DISPLAY 16
12. BOLTING WITH A CONVENTIONAL REACTION ARM 17
13. BOLTING WITH THE HYTORC WASHER 20
14. BOLTING WITH THE HYTORC NUT 22
15. MAINTENANCE 23
CHANGELOG
MISSION STATEMENT


1. GENERAL
•Employer Responsibility: The user’s employer shall assess the specific risks that can be present as a result of
each use.
•Maintenance Instructions: General maintenance recommendations included in this document include care and
handling instructions (see Section 4) and cleaning the filters (see Section 6).
•Special Markings on the Tool: There are no special markings or symbols on the tool.
•Residual Risks: When this tool is used for its intended purpose by trained individuals equipped with adequate
personal protective equipment according to the instructions in this document, there are no known residual risks.
•Statement of Use: The jGun DIGITAL Pneumatic Torque Tool is intended for use in tightening fasteners with
controlled torque in heavy duty industrial bolting applications.
•Trained User Only: This tool should be used only by fully trained personnel, and this document is written only for
trained professionals. This tool should not be used without proper training and supervision. Contact HYTORC for
additional information on receiving proper training for this tool.
2. GENERAL SAFETY RULES
•Maintenance must be performed by a qualified HYTORC technician.
•Operating the tool in any fashion other than as described herein can result in serious bodily injury and is
forbidden.
•For multiple hazards, read and understand the safety instructions before installing, operating, repairing,
maintaining, changing accessories on, or working near the assembly power tool for threaded fasteners (the “tool”).
Failure to do so can result in serious bodily injury.
•Only qualified and trained operators should install, adjust or use the tool.
•Do not modify this tool. Modification of the tool invalidates the warranty and can reduce the eectiveness of safety
measures and increase the risks to the operator.
•Do not discard the safety instructions; give them to the operator.
•Do not use the tool if it has been damaged.
•Tools shall be inspected periodically to verify that the ratings and markings are legibly marked on the tool. The
employer/user shall contact the manufacturer to obtain replacement marking labels when necessary.
Instructions in this section are compliant with ISO-11148-6:2012 and ISO-12100:2010.
3. PROJECTILE HAZARD
•Failure of the workpiece, of accessories or even of the inserted tool itself can generate high-velocity projectiles.
•Always wear impact-resistant eye protection during operation of the tool. The grade of protection required should
be assessed for each use.
•Ensure that the workpiece is securely fixed.
WARNING! Read all safety warnings designated by the symbol and all instructions.
WARNING! Read all instructions before use. To reduce the risk of injury user must read manual.
. GENERAL SAFETY INFORMATION

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
4. ENTANGLEMENT HAZARDS
•Entanglement hazards can result in choking, scalping and/or lacerations if loose clothing, personal jewelry,
neckwear, hair or gloves are not kept away from the tool and accessories.
•Gloves can become entangled with the rotating drive, causing severed or broken fingers.
•Rotating drive sockets and drive extensions can easily entangle rubber-coated or metal-reinforced gloves.
•Do not wear loose-fitting gloves or gloves with cut or frayed fingers.
•Never hold the drive, socket or drive extension while operating tool.
•Keep hands away from rotating drives.
5. OPERATING HAZARDS
•The use of the tool can expose the operator’s hands to hazards including crushing, impacts, cuts and abrasions
and heat. Wear suitable gloves to protect hands.
•Operators and maintenance personnel must be physically able to handle the bulk, weight and power of the tool.
•Hold the tool correctly; be ready to counteract normal or sudden movements and have both hands available.
•Maintain a balanced body position and secure footing.
•In cases where the means to absorb the reaction torque are requested, it is recommended to use a suspension
arm whenever possible. If that is not possible, side handles are recommended for straightcase and pistol-grip
tools. Reaction bars are recommended for angle nutrunners. In any case, it is recommended to use a means to
absorb the reaction torque above 4 N·m for straight tools, above 10 N·m for pistol-grip tools, and above 60 N·m for
angle nutrunners.
•Release the start-and-stop device in case of an interruption of the energy supply.
•Use only lubricants recommended by the manufacturer.
•Beware of crushing hands between tool and workpiece, especially when unscrewing.
6. REPETITIVE MOTIONS HAZARDS
•When using tool the operator can experience discomfort in hands, arms, shoulders, neck, or other parts
of the body.
•The operator should adopt a comfortable posture while maintaining secure footing and avoiding awkward or o-
balanced postures. The operator should change posture during extended tasks to help avoid discomfort and fatigue.
•If the operator experiences symptoms such as persistent or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or stiness, these warning signs should not be ignored. The operator should tell the
employer and consult a qualified health professional.
7. ACCESSORY HAZARD
•Disconnect tool from the energy supply before changing the inserted tool or accessory.
•Do no touch sockets or reaction arms during use, as this can cause serious injury.
•Use only sizes and types of accessories that are recommended by the tool manufacturer.
•Use only impact grade sockets in good condition, as sockets in poor condition can shatter and become a projectile.
8. WORKPLACE HAZARDS
•Slips, trips and falls are major causes of workplace injury. Be aware of slippery surfaces caused by the use of the
tool and also of trip hazards caused by the air line or hydraulic hose.
•Proceed with care in unfamiliar surroundings. Hidden hazards, such as electricity or other utility lines, can exist.
•The tool is not intended for use in potentially explosive atmospheres and is not insulated against electric power.
•Make sure there are no electrical cables, gas pipes, etc., that can cause a hazard if damaged by use of the tool.
(CONT’D.)


9. DUST AND FUME HAZARDS
•Where dust or fumes are present in the environment where this tool is used, follow instructions as required by the
employer and occupational health and safety regulations to provide respiratory protection for tool users.
•Dust and fumes generated when using power tools can cause ill health (for example cancer, birth defects, asthma
and/or dermatitis); risk assessment and implementation of appropriate controls for these hazards are essential.
10. NOISE HAZARDS
•Exposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus
(ringing, buzzing, whistling or humming in the ears). Therefore a risk assessment and implementation of
appropriate controls for these hazards are essential.
•Appropriate controls to reduce risk may include damping materials to prevent workpieces from “ringing”.
•Use hearing protection in accordance with instructions and as required by health and safety regulations.
•Operate and maintain the tool as recommended in instructions, to prevent increase in noise levels.
•If the tool has a silencer, always ensure it is in place and in good working order when operating.
•Select, maintain and replace tool as required to prevent an unnecessary increase in noise.
11. VIBRATION HAZARDS
•Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms.
•Keep hands away from the nutrunner sockets.
•If you experience numbness, tingling, pain or whitening of the skin in your fingers or hands, stop using the tool, tell
your employer and consult a physician.
•Operate and maintain the tool as recommended, to prevent unnecessary increase in vibration levels.
•Do not use worn or ill-fitting sockets or extensions, as this is likely to cause a substantial increase in vibration.
•Select, maintain and replace tool as required to prevent an unnecessary increase in vibration levels.
•Sleeve fittings should be used where practicable.
•Hold the tool lightly but securely; the risk from vibration is generally greater with a tighter grip.
12. ADDITIONAL SAFETY INSTRUCTIONS FOR PNEUMATIC POWER TOOLS
•Air pressure has a safety critical eect on performance. Be sure to follow requirements for hose length and
diameter as air under pressure can cause severe injury.
•Always shut o air supply, drain hose of air pressure and disconnect tool from air supply when not in use, before
changing accessories or when making repairs.
•Never direct air at yourself or anyone else.
•Whipping hoses can cause severe injury. Always check for damaged or loose hoses and fittings.
•Cold air shall be directed away from the hands.
•Do not use quick-disconnect couplings at tool inlet for impact and air-hydraulic impulse wrenches. Use hardened
steel (or material with comparable shock resistance) threaded hose fittings.
•Whenever universal twist couplings (claw couplings) are used, lock pins shall be installed and whip check safety
cables shall be used to safeguard against possible hose-to-tool and hose-and-hose connection failure.
•Do not exceed the maximum air pressure stated on the tool.
•Never carry tool by the hose.
(CONT’D.)

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
15. PERSONAL PROTECTIVE EQUIPMENT (PPE)
•Always wear appropriate protective equipment, including gloves, impact-resistant eye protection, hearing
protection, hard hat and safety shoes, when operating tool. The grade of protection required should be assessed
for each use.
13. EMISSIONS STATEMENT
•The noise emission, measured in accordance with EN ISO 15744, using, as basic standards, EN ISO 3744 and EN
ISO 11203, is as follows:
– A-weighted sound pressure level LpA = 99.3 70 dB(A) and its uncertainty KpA = 3dB(A)
– A-weighted sound power level LWA = 110.3 dB (A) and its uncertainty KWA = 3dB(A)
– Operating conditions: No load
NOTE: The sum of a measured noise emission value and its associated uncertainty represents an upper boundary of the
range of values, which is likely to occur in measurements.
•The declared vibration emission value and its uncertainty measured in accordance with EN ISO 28927-2, is:
– The declared vibration emission value ahd = 1.10 m/s2 and its uncertainty K = 1.50 m/s2
•The declared vibration total value has been measured in accordance with a standard test method and may be
used for comparing one tool with another.
•The declared vibration total value may also be used in a preliminary assessment of exposure.
•The vibration emission during actual use of the tool can dier from the declared total value depending on the ways
in which the tool is used.
•Identify safety measures to protect the operator that are based on an estimation of exposure in the actual
conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched o
and when it is running idle in addition to the trigger time).
14. GENERAL OPERATOR GUIDELINES
Only qualified personnel who have thoroughly read this document may operate this tool. Failure to safely operate
this tool may result in serious injury or death.
•Do not submerge in water or subject tool to extreme humidity.
•Do not subject tool to extreme temperature variations.
•Do not operate tool in temperatures above 140°F (60°C) or below -14°F (-25°C).
•Do not subject tool to dusty environments that could clog the vents. Keep vents clear and uncovered.
•Wear warm clothing when working in cold conditions and keep hands warm and dry.
16. BATTERY SAFETY
The tool contains a non-removable integral rechargeable Li-Ion Battery that powers the Display Electronics.
•DO NOT splash or immerse battery in water or other liquids.
•Do not incinerate the battery even if it is severely damaged or is completely worn out. The battery can explode in
a fire. Toxic fumes and materials are created when lithium ion batteries are burned.
•Do not charge or use the battery in explosive atmospheres, such as in the presence of flammable liquids, gases or
dust. Inserting or removing the charger may ignite dust or fumes.
•If battery contents come into contact with the skin, immediately wash area with mild soap and water.
(CONT’D.)


WARNING
Shock hazard. Do not allow any liquid to get inside power adapter.
CAUTION
Under certain conditions, with the power adapter plugged into the power source, the power adapter can
be shorted by foreign material of a conductive nature such as steel wool, aluminum foil, or any buildup of
metallic particles. Such materials should be kept away from power adapter USB connectors. Always unplug
the power adapter from the power source when not connected to the tool. Unplug power adapter before
attempting to clean.
17. POWER ADAPTER SAFETY
•To disconnect power adapter, firmly grasp plug and remove. Do not disconnect by pulling on the cord.
•Make sure cord is located so it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
•Do not use an extension cord unless absolutely necessary.
•An extension cord must have adequate wire size (AWG) for safety. In general, the larger the wire size the greater
the capacity of the cable.
•Do not operate power adapter with damaged cord or plug. Have any damaged plug or cord replaced immediately.
•Do not operate power adapter if it has received a sharp blow, been dropped, or otherwise damaged in any way.
•This power adapter is designed to operate on standard household electrical power (120V/220V 60hz/50hz).
16. BATTERY SAFETY (CONT’D.)
•If battery liquid gets into the eyes, rinse over the open eye for 15 minutes or until irritation ceases. If medical
attention is needed, the battery electrolyte is composed of a mixture of liquid organic carbonates and lithium
salts. Contents of opened battery cells may cause respiratory irritation.
•Provide fresh air. If symptoms persist, seek medical attention.
(CONT’D.)

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
18. TOOL SPECIFICATIONS
MODEL RPM MASS/WEIGHT
IMPERIAL lbs. METRIC kg
jGun DIGITAL .25 65 8.25 3.75
jGun DIGITAL .5 24 8.85 4.00
jGun DIGITAL 1 6.5 9.80 4.40
jGun DIGITAL 2 5.5 16.50 7.50
jGun DIGITAL 3 517. 70 8.00
jGun DIGITAL 5 2.5 28.30 12.80
jGun DIGITAL 8 1.5 38.40 17.40
(CONT’D.)


FREE SERVICES*
FOLLOW US ONLINE
REPAIRS TOOL RENTALS
HELP
•User safety training upon receipt of merchandise
•Semi-Annual user safety training on request
•Annual safety seminar on appointment
•Loaner tools in event of product failure within 24 hours
•Torque/Tension consultation/seminar
•Half-Day, first-use supervision
•Annual product inspection on request
•Product demonstrations
*Above services are not subject to travel expense charges.
•All repairs are guaranteed for 6 months
•All repairs are subject to labor and part cost as outlined
in the oicial HYTORC price list
•All repairs will be tested and calibrated to ensure the
highest quality repairs
•All warranty repairs are free of all charges including
return-freight
•100% of all paid rentals will be applied as a discount
towards any new purchase in that calendar year
•User training for first-time rentals is free of all cost
•Rental tools are guaranteed to perform and are subject
to the free loaner tool policy of HYTORC
If you require any further assistance, please call your local HYTORC Representative or 1-800-FOR-HYTORC
(1-800-367-4986). Please visit us at HYTORC.com.
•12-Month no-questions-asked warranty
•5-Year tool housing warranty
•User training for first-time rentals
•Warranty repairs including return-freight
•Upgrades during the lifetime of the tool to enhance
safety, durability, and function
•Free calibration with new tool purchase
. SERVICE

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
The jGun DIGITAL Pneumatic Torque Tool is designed with an industrial grade compressed-air motor allowing the tool
to be operated without the need for a separate Filter, Regulator, Lubricator (FRL). High torque is achieved with a rugged
planetary gearbox torque multiplier system. The tool is available in a range of sizes with progressively larger drives and
gearboxes delivering up to 8,000 ft-lbs of torque.
The jGun DIGITAL Tool is the first pneumatic torque tool with digital display. The tool has a pressure sensor that
measures the applied air pressure. During calibration the relationship between pressure and torque is established and
stored in tool memory. The torque is set by adjusting the pressure regulator until the desired torque value is displayed on
the digital display. The regulator has a locking mechanism that allows it to be locked so that it cannot be inadvertently
moved until the next torque adjustment. The directional switch allows the tool to be set to tighten or loosen. The
directional switch is spring loaded and requires a second hand to push the switch in the desired direction, to ensure
the hand is kept free of dangerous reaction points. After reaching the specified torque value, the jGun DIGITAL tool
automatically stops, leaving the fastener tightened to specification. The digital display is powered by a rechargeable
battery that is charged through the USB port.
The jGun DIGITAL Tool is equipped with a standard square drive that can accommodate conventional sockets as well as
drivers designed for the HYTORC Reaction Washer and HYTORC Nut.
Reaction Spline
Square Drive
USB Port
Planetary Gearbox
Directional Switch
Trigger
Pistol Grip
Locking Regulator
Industrial Motor
Digital Display
Push Buttons
. TOOL DESCRIPTION


•Inspect all components supplied with the tool.
•If damaged, report any sign of damage and do not use the tool.
•Inspect the tool before each use; repair or replace any obviously worn or damaged parts.
•When not in use store all tool components in the plastic storage case.
•Save all instructions and calibration reports in the storage case.
•Dispose of the tool in an environmentally friendly manner through the manufacturer.
Contents Include:
•jGun DIGITAL Pneumatic Torque Tool
•Reaction Arm
•USB Cable (part no. K000809)
•AC/DC Wall Mount Adapter (part no. K000735)
•Operations Manual
•Calibration Document
. CARE AND HANDLING

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
The Power Adapter and USB cable (shown above) are supplied with the tool. The digital display and electronic circuit are
powered by a Lithium-Ion rechargeable battery. The battery charge indicator is in the lower right corner of the display
(shown above). When the charge drops the tool is easily recharged with the USB cable provided. To charge the battery
plug the USB cable into the tool and the opposite end into the local power supply with the appropriate plug adapter. The
tool will be fully charged in less than an hour as indicated by three bars.
Power AdapterUSB Cable
. CHARGING THE BATTERY


A steady, unobstructed flow of air is critical for proper performance of the jGun DIGITAL Tool. The filter in the regulator
intake should be cleaned frequently. In heavy use applications this filter may need to be cleaned every day. Apply
forced air to unclog and clean the filter for most applications.
It may also be necessary to clean the larger mesh air escape filters. Inspect and clean filters as needed.
AIR INTAKE
AIR ESCAPE
Air Intake Filter
Air Escape Filter
. CLEANING FILTERS

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
VERIFY AIR SUPPLY REQUIREMENTS
•The air supply line must be ½-inch minimum diameter
to allow adequate air flow.
•The air supply must provide a minimum of 90 psi
at 50 cfm.
•Ensure that the air-line fittings are tight and leak free.
Do not over tighten air-line fittings.
•Maximum air pressure is 100psi.
•Maximum hose length is 100 feet.
CONNECT TOOL
•Connect the tool to the air supply with high quality
fittings and best practices for ensuring there are no
leaks in the air system.
•Open the air supply to the tool and ensure there are
no leaks in the system.
. CONNECTING THE AIR SUPPLY


Push the center button on the rear control panel to turn the tool on. Push and hold the center button to power the tool o.
. TURNING POWER ON OR OFF

jGun® DIGITAL Pneumatic Torque Tool Basic Operations Manual 
The torque value is shown on the digital display. The torque can be increased and decreased by turning the
pressure regulator.
The locking collar on the regulator is designed to keep air pressure and torque constant during operation. The locking
collar is actuated with a simple push-pull. To adjust the torque first unlock the regulator, make the desired adjustment,
then lock the regulator in place again. Once the desired torque is selected slide the locking collar in place to lock the air
regulator so it cannot turn. The locking collar on the regulator is intended to keep the air pressure and torque constant
at the specified level during operations. This locking collar is actuated with a simple push-pull on the collar. To adjust the
torque the operator unlocks the regulator, makes the adjustment to a new torque value, and then locks the regulator in
place again.
. ADJUSTING TORQUE AND LOCKING THE REGULATOR


The torque value is shown on the digital display. Press the right button to toggle between units of ft-lbs
(pictured above left), and Nm (pictured above right).
. ADJUSTING UNITS