Hytorc jGun Series User manual

5th Edition / December 2017
Digital jGun™
Operations Manual

This manual applies to all tool part numbers in the Digital jGun Single Speed Product
Family. It is recommended the manual is kept up-to-date by checking the edion and
date code at the boom of this page by ulizing the Torque Gun Company website and
downloading a copy of the most recent edion as needed.
TORQUE GUN LLC
A HYTORC COMPANY
333 Route 17 North,
Mahwah, New Jersey 07430 U.S.A.
Noce: The informaon contained in this document is subject to change without noce. The Torque
Gun Company makes no warranty of any kind with regard to this material, including but not limited
to, the implied warranes of merchantability and tness for a parcular purpose. The Torque Gun
Company shall not be liable for errors contained herein or for incidental or consequenal damages in
connecon with the furnishing, performance, or use of this material. It is further recommended that the
end-user or repair technician insure 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 duplicaon of the informaon contained within this manual is
limited to the purchaser, end user, or licensed Torque Gun Company representave. It is recommended
that proper training for the equipment outlined in this manual be conducted by a Torque Gun Company
authorized training representave for any person who is operang or repairing the equipment outlined
in this document. Modicaon, or disclosure by any other agency or representave is strictly forbidden.
Product Modicaons: Torque Gun DOES NOT ALLOW any of the products listed in this manual to be
modied by any end user without excepon. Should an applicaon require a modicaon to the tool, or
any of the standard accessories please consult with your local Torque Gun Company representave and
they will be able to obtain the assistance for any modicaon that may be required.
© Torque Gun 2017: All Rights Reserved. Reproducon, adaptaon, or translaon without prior writ-
ten permission is prohibited, except as allowed under the copyright laws.
5th Edion. Printed in USA. December 2017
Complies with standards publicaon BS EN 82079-1:2012
DIGITAL jGun PRODUCT FAMILY:
DJ-.25, DJ-.5, DJ-1, DJ-2, DJ-3, DJ-5, DJ-8
EN, EN-ISO, ISO Standards:
For a complete EC declaraon of conformity
or if you require any further assistance please
contact your local Torque Gun representave
or 1-888-GUN-2-GUN (1-888-486-2486) or on
the web at www.torquegun.com.
EN ISO 4414:2010
EN 61310-2:2008
EN 61310-3:2008
ISO 3744:2011
EN ISO 12100-1:2011
EN ISO 12100-2:2011
EN ISO 14121-1:2007
EN ISO 11148-6:2012

WITH THE PURCHASE OF TORQUE GUN CO. TORQUE MACHINES (PAST,
PRESENT, FUTURE) YOU HAVE OBTAINED THE LATEST TECHNOLOGY AND
LIFETIME, WORLDWIDE LOCAL SERVICE.
HELP: If you require any further assistance, please call your local Torque Gun Co. Representative
or 1-888-GUN-2-GUN (1-888-486-2486), on the web at torquegun.com - 24/7! It’s live!
FIND US ONLINE AT
facebook.com/hytorc twitter.com/hytorc youtube.com/hytorcnj
TOTAL SATISFACTION GUARANTEED 1-888-GUN-2-GUN
FREE SERVICES
♦FREE User Safety Training upon Receipt of Merchandise
♦FREE Semi-Annual User Safety Training on Request
♦FREE Annual Safety Seminar on Appointment
♦FREE Loaner Tools in case of Product Failure within 24 Hours
♦FREE Torque/Tension Consultation/Seminar
♦FREE Half Day, First Use Supervision
♦FREE Annual Product Inspection on Request
♦FREE Product Demonstrations
♦FREE 12 Month No-Questions-Asked Warranty
♦FREE Upgrades during the Lifetime of the Tool to Enhance Safety, Durability, and Function
(Above services are NOT subject to travel expense charges)
REPAIRS
• All Repairs are Guaranteed for 6 Months
• Repairs are Subject to Labor and Part Cost, as Outlined in the Ofcial TORQUE GUN CO. Price List
• All Warranty Repairs are FREE of All Charges Including Return-Freight
• All Repairs Will be Tested and Calibrated to Ensure the Highest Quality Repairs
TOOL RENTALS
• 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
• Return Freight Charges are FREE
• Rental Tools are Guaranteed to Perform and are Subject to the FREE Loaner Tool Policy of TORQUE GUN CO

Digital jGUN™ Torque Gun
OPERATIONAL MANUAL
TABLE OF CONTENTS
Warranty 6
Digital jGun Overview 7
Digital jGun Safety 8
Personal Protective Equipment 8
Air Supply Requirements 9
Digital jGun Safety Button 9
Important Li-Ion Battery Instructions 9
THE RBRC Seal 10
Reaction Arm or Washer 12
Reaction Arm and Socket Installation 13
Key Operating Safety Points 16
Digital jGun Setup and Use 17
Setting a Torque Value 17
Changing the Drive Direction 17
Charging the Digital jGun 18
Operating the Digital jGun 19
Loosening a Fastener 20
HYTORC Reaction Washer Overview 22
Safety 23
Personal Protective Equipment 23
HYTORC Washer Requirements 23
HYTORC Washer Assembly, Use and Service (SETUP) 23
Important Preparation Steps for the HYTORC Washer 23
Important Installation Steps for the HYTORC Washer 24
Installing HYTORC Washer Driver 25
Tightening with HYTORC Washer 26
Digital jGun Maintenance and Troubleshooting Tips 26
5
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

TORQUE GUN LLC
A HYTORC COMPANY
333 Route 17 North, Mahwah, New Jersey 07430 U.S.A.
Tel: 888-GUN-2-GUN • E-Mail: [email protected] • Web: www.torquegun.com
The Digital jGun has a one year limited warranty. Every TORQUE GUN tool
is tested before leaving the factory and is warranted to be free from
defects in workmanship and materials. TORQUE GUN 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 from repairs made or
attempted by other than TORQUE GUN authorized repair facilities.
The repair and replacement remedies described herein are exclusive.
In no event shall TORQUE GUN be liable for any incidental, special, or
consequential damages, including loss of prots. This warranty is
exclusive and in lieu of all other warranties or conditions, written or oral,
expressed or implied for merchantability or tness for particular use or
purpose.
This warranty gives you specic 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 888-GUN-2-GUN..
WARRANTY
6BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

DIGITAL jGUN OVERVIEW
The Digital jGun pneumatic torque wrench is designed to safely and accurately deliver up to 8,000 ft-
lbs of torque onto a fastener. This is accomplished using a patented planetary gearbox torque multiplier
system and an appropriate reaction arm or HYTORC Reaction Washer™ and HYTORC Nut™. The torque
multiplier produces torque ratios of up to 4180:1 while the Reaction Arm or Washer is used to absorb the
high counter rotational force produced as the nal torque value is reached. At nal torque value, the Digital
jGun safely stalls out, leaving the fastener tightened to specication.
Unlike impact wrenches, the Digital jGun never transmits working torque to the operator. The torque is
applied between the fastener and the reaction surface. The Digital jGun has a built-in pressure sensor
and signal conditioner. During calibration the tool’s torque chart is established and stored in the display
electronics. Desired torque is selected simply by adjusting the regulator until the torque value is displayed.
The Digital jGun additionally has an integral Filter-Regulator and through the use of corrosion resistant
internal components does not require continuous lubrication obviating the need for a stand alone FRL.
This manual provides information for the standard Digital jGun.
7
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

DIGITAL jGUN SAFETY
Only qualied personnel who have thoroughly read this document may operate this tool. Failure to safely
operate this tool may result in serious injury or death.
• Inspect all Digital jGun components as they are removed from the shipping container. If damage
is found to any component, contact your shipper immediately. Do not use the tool.
• Failure to follow correct tool usage could result in personal injury, co-worker injury, and/or
damaged tools and equipment.
• Ensure your working area is clean and unobstructed before beginning work.
• Digital jGun maintenance and repair must be performed by a qualied pneumatic technician.
• Modifying a Digital jGun or Digital jGun accessory is dangerous and invalidates the warranty.
• Inspect the tool before each use. Replace any obviously worn or damaged parts.
• When not in use, store the Digital jGun and Digital jGun accessories in the plastic storage case
supplied with the tool. Do not expose the gun to high humidity or large temperature variations.
• Do not discard the safety instruction.
• Loose clothing, personal jewelry, neckwear, hair, hands and gloves should be kept away from
rotating tool and accessories.
• Do not wear loose tting gloves, or gloves with cut or frayed ngers.
• Operators and maintenance personnel should be physically able to handle the bulk, weight and
power of 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.
• Release the trigger in case of an interruption of the air supply.
• Do not use in conned space.
• Always shut off air supply before changing accessories or making repairs.
• Never carry the tool by the hose.
• Do not exceed the maximum air pressure stated in the manual.
• Do not touch sockets or accessories during the torqueing.
• Beware of slippery surfaces and trip hazards caused by the air line.
• Proceed with care in unfamiliar surroundings. Hidden hazards such as electric or other utility
lines can exist.
• This tool is not intended for use in potentially explosive atmosphere. It is not insulated against
coming into contact with electric power.
• Make sure there are no electrical cables, gas pipes, etc. that can cause a hazard if damaged by
the use of the tool.
• Wear warm clothing when working in cold conditions and keep your hands warm and dry.
• Do not use worn or ill-tting sockets or extensions as this is likely to cause substantial increase
in vibration.
8BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

DIGITAL jGUN SAFETY BUTTON
The Directional Control Selector Button must rst be
pushed in the desired direction (clockwise or counter-
clockwise) before the trigger can be depressed. This
safety feature reduces the chance for operator error.
Personal Protective Equipment
• Always wear the appropriate personal protective equipment when operating a Digital jGun
including gloves, impact resistant eye protection, hearing protection, hard hat, and safety shoes.
The grade of protection required should be assessed for each use.
Air Supply Requirements
• The air supply line must be ½-inch minimum diameter to allow adequate air ow to the
Digital jGun.
• The air supply must provide a minimum of 90 psi at 50 cfm.
• Ensure that air line ttings are tight and leak free. Do not over tighten air line ttings.
• Open the air supply connected to the Digital jGun unit and run the Digital jGun while setting the
torque on the display.
IMPORTANT LI-ION BATTERY
INSTRUCTIONS
The Digital jGun contains a non-removable rechargeable Li-Ion Battery that powers the Display Elec-
tronics. The following instructions, concerning the Li-Ion Battery shall be followed:
• DO NOT splash or immerse 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 re. 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.
• 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.
9
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

• Charge the battery only with charger supplied for charging this product.
• DO NOT pack with conductive items.
WARNING: Burn hazard. Battery liquid may be ammable if exposed to spark or ame.
The US Department of Transportation Hazardous Materials Regulations (HMR)
actually prohibit transporting batteries in commerce or on airplanes, (i.e. packed
in suitcases and carry-on luggage). When transporting individual batteries, make
sure that the battery terminals are protected and well insulated from materials that
could contact them and cause a short circuit. For any other concerns in regarding the
transportation of LI-ION batteries, consult your Transportation Carrier.
THE RBRCTM SEAL
The RBRCTM (Rechargeable Battery Recycling Corporation) Seal on the lithium ion battery (or battery
pack) indicates that the costs to recycle the battery at the end of its useful life have already been paid
by HYTORC.
The RBRCTM in cooperation with HYTORC and other battery users, has established programs in the
United States to facilitate the collection of spent lithium ion batteries. Help protect our environment and
conserve natural resources by returning the spent lithium ion battery to an authorized HYTORC service
center for recycling. You may also contact your local recycling center for information on where to drop off
the spent battery. RBRCTM is a registered trademark of the Rechargeable Battery Recycling Corporation.
IMPORTANT BATTERY CHARGER SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers:
• Before using charger, read all instructions and cautionary markings on charger and product using
the battery.
WARNING: Shock hazard. Do not allow any liquid to get inside charger.
CAUTION: Burn Hazard. To reduce the risk of injury, charge only Torque Gun batteries.
10 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Other types of batteries may burst causing personal injury and damage.
CAUTION: Under certain conditions, with the charger plugged into the power source, the
charger can be shorted by foreign material. Foreign materials of a conductive nature such
• DO NOT attempt to charge the battery with any chargers other than the one in this manual.
The charger and battery are specically designed to work together.
• These chargers are not intended for any uses other than batteries supplied with Digital jGun
series guns as described in this manual. Any other uses may result in risk of re, electric shock
or electrocution.
• Do not expose charger to rain or snow.
• To disconnect charger, firmly grasp plug and remove. Do not disconnect the charger by pull-
ing on the cord.
• Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise
subjected to damage or stress.
• Do not use an extension cord unless it is 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 block any ventilation slots on charger power supply.
• Do not operate charger with damaged cord or plug. Have any damaged plug or cord replaced
immediately.
• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged
in any way.
• Do not disassemble charger; take it to an authorized Torque Gun service center when
service or repair is required.
• This charger is designed to operate on standard household electrical power (120V/220V
60hz/50hz).
11
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Reaction Arm or HYTORC Washer
Choose the correct reaction arm for the job. The Digital jGun is shipped with a standard length reaction
arm, but your gun may have been ordered with a custom reaction arm for a specic purpose.
Reaction Arm
The HYTORC Washer system can be used for all applications instead of the reaction arm.
HYTORC Washer and Drive
WARNING!
Never modify a reaction arm! Changes in the reaction arm may lead to personal
injury or damage to the tool.
NOTE:
Reaction arm modications result in loss of warranty for the reaction arm and the Digital
jGun. If you need a custom reaction arm, please consult with your local Torque Gun dealer.
12 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Reaction Arm and Socket Installation
• Choose the correct reaction arm for the job. The Digital jGun is shipped with a standard length
reaction arm, but your gun may have been ordered with custom-length reaction arm for a
specic purpose.
• If using the HYTORC Washer™, follow installation instructions in HYTORC Washer™
Overview.
• Clean the reaction arm and Digital jGun barrel mating surfaces before installing the
reaction arm.
• Slide the reaction arm onto the Digital jGun barrel with the reaction arm extension facing
out.
Installing a Reaction Arm
!! CAUTION !!
ALWAYS INSTALL THE REACTION ARM WITH THE EXTENSION
FACING AWAY FROM THE GUN.
FAILURE TO INSTALL THE REACTION ARM CORRECTLY COULD
RESULT IN THE REACTION ARM COMING IN CONTACT WITH YOUR
HAND OR OTHER ANOTHER PART OF YOUR BODY, CAUSING
PERSONAL INJURY.
13
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Reaction Arm Installed
• Lock the reaction arm to the Digital jGun by aligning the set-screw with the
hole in the splined section and then tightening the set screw rmly.
Tightening Reaction Arm Set Screw
• Place the appropriately sized socket onto the Digital jGun barrel.
14 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Installing Digital Digital jGUN Socket
• Install the socket locking pin and retaining ring.
Installing Socket Locking Pin and Retaining Ring
15
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Key Operating Safety Points
• Ensure that the reaction arm is in direct contact with an appropriate immovable object before
beginning to tighten the fastener.
Placement of Reaction Arm
• Using the HYTORC Washer™ eliminates external moving parts and increases worker safety.
Refer to HYTORC Reaction Washer Overview.
• Keep all body parts clear of the reaction arm and reaction arm contact point (immovable object).
• Ensure the Digital jGun barrel is in a straight line with relation to the stud and that the socket is
fully engaged onto the fastener.
• As the tool takes up the bolt load, the Digital jGun may shift.
!! CAUTION !!
FAILURE TO HAVE THE REACTION ARM IN DIRECT CONTACT WITH
AN APPROPRIATE IMMOVABLE OBJECT BEFORE BEGINNING TO
TIGHTEN THE FASTENER COULD RESULT IN LOSS OF CONTROL OF
THE TOOL AND PERSONAL INJURY.
!! CAUTION !!
DO NOT PLACE ANY PART OF YOUR BODY BETWEEN THE REACTION
ARM AND AN APPROPRIATE IMMOVABLE OBJECT AT ANY TIME
WHILE A FASTENER IS BEING IS BEING TORQUED.
PERSONAL INJURY MAY OCCUR IF ANY PORTION OF YOUR BODY
IS LOCATED BETWEEN THE REACTION ARM AND THE IMMOVABLE
OBJECT WHEN THE FASTENER IS BEING TORQUED.
16 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

DIGITAL jGUN SETUP AND USE
Proper setup and use of the Digital jGun before and during installation ensures accurate results and safe
operation.
Setting a Torque Value
1. Connect an adequate air supply to the input of the tool's regulator.
2. Select desired Torque units via the right most push button.
3. Adjust the regulator until desired torque is displayed.
NOTE
While setting torque the trigger should be pulsed until the displayed
torque value is stable.
Digital jGun Display
Changing the Drive Direction
1. To change the square drive direction from clockwise to counter clockwise.
2. Move the direction selector behind the trigger as indicated on the back of the unit.
3. Left button – Toggle between TORQUE and PRESSURE mode on the display.
4. Center button – Toggle on-off.
5. Right button – When in TORQUE mode, toggle between units of PSI, bar and KPa. When in
PRESSURE mode, toggle between units of ft-lbs and Nm.
17
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Charging the Digital jGUN
1. There is a three-segment battery charge indicator on the lower right side of the screen. When the
level drops plug it in until it is fully charged as indicated by three bars.
2. A charger with USB cable is provided in the case with the tool.
3. Connect the charger to the USB connector on the right side of the display housing on the rear of
the gun.
NOTE
The trigger cannot be depressed unless the directional button is
displaced. Once depressed the trigger will hold the directional button in
position and both hands can be used to hold the tool.
Digital jGun Battery Indicator and USB Connector
Digital jGun Drive Direction Selector
18 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Operating the Digital jGUN
To operate the Digital jGun:
1. Make sure the jGun has been calibrated.
2. Set desired direction (clockwise or counter clockwise).
3. Place the correct size impact socket on the square drive and secure it with the locking pin and ring.
4. Ensure that the square drive is fully engaged into the socket.
5. Engage the socket onto the nut.
6. Make sure the socket is fully engaged onto the nut.
7. Ensure that the reaction arm is placed rmly against a stationary surface such as an adjacent
nut, a ange, or equipment housing. (If using the HYTORC™ Reaction Washer in place of a
standard reaction arm ensure that it is setup according to the steps in the HYTORC Reaction
Washer Overview section).
8. Apply momentary pressure to the torque gun trigger to ensure proper socket engagement and
reaction arm placement.
Digital jGun Operation
9. Verify the desired torque is indicated in the jGun screen.
10. Torque the fastener by depressing the trigger until socket stops turning and air bypasses the
motor.
19
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

!! CAUTION !!
BE SURE THE REACTION ARM IS FULLY ENGAGED AND LOCATED ON
A SOLID, SECURE REACTION POINT. FOR ADDED SAFETY, REMAIN
CLEAR OF THE REAR OF THE REACTION ARM DURING OPERATION.
ALSO, WHEN INITIALLY APPLYING THE TOOL, PRESSURIZE THE
SYSTEM MOMENTARILY; IF THE TOOL TENDS TO RIDE UP OR CREEP,
STOP AND READJUST THE REACTION ARM TO A MORE SOLID AND
SECURE POSITION.
Loosening a Fastener
To operate the Digital jGun:
1. Make sure the jGun has been calibrated.
2. Adjust the regulator until the display indicates maximum torque setting.
3. Set desired direction (clockwise or counter clockwise).
4. Place the correct size impact socket on the square drive and secure it with the locking pin and ring.
5. Ensure that the square drive is fully engaged into the socket.
6. Engage the socket onto the nut.
7. Make sure the socket is fully engaged onto the nut.
8. Ensure that the reaction arm is placed rmly against a stationary surface such as an adjacent
nut, a ange, or equipment housing. (If using the HYTORC™ Reaction Washer in place of a
standard reaction arm ensure that it is setup according to the steps in the HYTORC Reaction
Washer Overview section).
9. Apply momentary pressure to the torque gun trigger to ensure proper socket engagement and
reaction arm placement.
10. Loosen the fastener by depressing the trigger until socket turns freely.
Digital jGun Operation
20 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING