Hytorc LION-.25 User manual

1st. Edition Jan. 2017

This manual applies to all tool part numbers in the LION Product Families. The complete
part number matrix which applies to this manual can be found in Appendix A and
B respecvely. 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 HYTORC website and
downloading a copy of the most recent edion as needed.
HYTORC Corporate Headquarters
333 Route 17 North
Mahwah, NJ 07430, USA
Noce: The informaon contained in this document is subject to change without noce. HYTORC
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. HYTORC 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 HYTORC representave. It is recommended that proper
training for the equipment outlined in this manual be conducted by a HYTORC 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: HYTORC Corporaon 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 HYTORC representave and
they will be able to obtain the assistance for any modicaon that may be required.
© Copyright HYTORC Corporaon 2017: All Rights Reserved. Reproducon, adaptaon, or translaon
without prior wrien permission is prohibited, except as allowed under the copyright laws.
1st. Edion. Printed in USA. January 2017
Complies with standards publicaon BS EN 82079-1:2012
LION GUN PRODUCT FAMILY:
LION-.25, LION-.7
EN, EN-ISO, ISO Standards:
For a complete EC declaraon of conformity
or if you require any further assistance please
contact your local HYTORC representave or
1-800-FOR-HYTORC (1-800-367-4986) or on
the web at www.hytorc.com.
EN 982:2009
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

OPERATIONS MANUAL CONTENTS
LIMITED WARRANTY 4
IMPORTANT SAFETY INFORMATION
Personal Protective Equipment 5
LION Gun Safety Warnings 6
Reaction Assembly and Drive 8
Basic Safety Instructions for Handling 11
IMPORTANT BATTERY PACK SAFETY INSTRUCTIONS 12
THE RBRC™ SEAL 13
OPERATION
General 15
SETUP
Battery Pack Installation and Removal 16
Charging Procedure 16
LED 17
Power 18
Reaction Arm 18
Basic Operation 18
Setting Torque and Release Angle 19
Basic Function Description 19
LION GUN OPERATION
Tightening 20
Loosening 20
ACCESS MAIN AND SUB MENUS 21
Operation 22
Job Data 24
System 27
Admin 28
Calibration 30
Shortcuts 31
MAINTENANCE
Preventive Maintenance 32
CALIBRATION 33
APPENDIX
LION Gun Block Diagram 34
LION Gun Dimensions 35
The World’s Most Trusted Industrial Bolting Systems 3

4The World’s Most Trusted Industrial Bolting Systems
LIMITED WARRANTY
This limited warranty gives you specific legal rights and you may also have other rights, which
vary from state to state. The limited warranty can also be found online at www.hytorc.com and in
the documentation we provide with the product. We warrant that during the warranty period, the
product will be free from defects in material and workmanship. We expressly disclaim any and all
implied warranties, including without limitation the warranties of merchantability and fitness for
a particular purpose to the duration of this express limited warranty. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
Our responsibility for defective goods is limited to repair or replacement as described below in this
warranty statement.
Who may use this warranty? The HYTORC Industrial Bolting Company located at 333 State Rt. 17,
Mahwah NJ 07430 extends this limited warranty only to the individual who originally purchased the product
(“you”). It does not extend to any subsequent owner or other transferee of the product.
What does this warranty cover? This limited warranty covers defects in materials and workmanship of
the LION Gun (the “product”) for the Warranty Period as dened below.
What does this warranty not cover? This limited warranty does not cover any damage due to: (a)
transportation; (b) storage; (c) improper use; (d) failure to follow the product instructions or to perform any
preventive maintenance; (e) modications; (f) unauthorized repair; (g) normal wear and tear; or (h) external
causes such as accidents, abuse, or other actions or events beyond our reasonable control.
What is the period of coverage? This limited warranty starts on the date of your purchase and lasts
for one (1) year (the “Warranty Period”). The Warranty Period is not extended if we repair or replace the
product. We may change the availability of this limited warranty at our discretion, but any changes will not
be retroactive.
What are your remedies under this warranty? With respect to any defective product during the Warranty
Period, we will repair or replace such product or the defective part free of charge. We will also pay for
shipping and handling fees to return the repaired or replacement product to you, if we elect to repair or
replace the defective product.
How do you Obtain warranty service? To obtain warranty service, you must call 800-FOR-HYTORC
or email our Customer Service Department at [email protected] during the Warranty Period to obtain
a Defective Merchandise Authorization (“DMA”) number. No warranty service will be provided
without a DMA number.
Limitation of liability. The remedies described above are your sole and exclusive remedies and our
entire liability for any breach of this limited warranty. Our liability shall under no circumstances exceed
the actual amount paid by you for the defective product, nor shall we under any circumstances
be liable for any consequential, incidental, special or punitive damages or losses, wether direct
or indirect. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitations or exclusion may not apply to you.

IMPORTANT SAFETY INFORMATION
Read and understand this material before operating or servicing this equipment. Failure to understand
how to safely operate this tool could result in an accident causing serious injury or death.
• Inspect all LION Gun components as they are removed from the shipping container. If damage is
found to any component, contact the 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.
• LION maintenance and repair must be performed by a qualied technician.
• Modifying a LION Gun or accessory is dangerous and invalidates the warranty.
• Inspect the tool before each use. Have any obviously worn or damaged parts replaced.
• When not in use, store the LION Gun and accessories in the plastic storage case
supplied with the tool. Do not expose the gun to high humidity or large temperature variations.
Personal Protective Equipment
• Always wear the appropriate personal protective equipment when operating a LION Gun
including gloves, safety goggles, hearing protection, hard hat, and safety shoes.
The World’s Most Trusted Industrial Bolting Systems 5

LION Gun Safety Warnings:
WARNING Read all safety warnings and all instruction. Failure to follow the warnings and
instructions may result in electric shock, re, and/or serious injury.
Save all warnings and instructions for future reference.
1) Work Area Safety
• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate the LION Gun in explosive atmospheres, such as in the presence of
flammable liquids, gases or dusts. The LION Gun can create sparks which may ignite the
dusts or fumes.
• Keep children and bystanders away while operating the LION Gun. Distractions can cause
you to lose control.
2) Personal Safety
• Stay alert, watch what you are doing and use common sense when operating the
LION Gun. Do not use the LION Gun while you are tired or under the influence of
drugs, alcohol, or medication. A moment of inattention while operating the LION Gun may
result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off-position before
connecting to power source and or battery pack, picking up or carrying the tool.
Carrying the LION Gun with your nger on the switch or energizing power tools that have the
switch on invites accidents.
• Remove any adjusting key or wrench before turning the LION Gun on. A wrench or a
key left attached to a rotating part of the LION Gun may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better
control of the LION Gun in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and
gloves away from the moving parts. Loose clothes, jewelry or long hair can be caught in
moving parts.
• If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust collection can
reduce dust-related hazards.
3) LION Gun use and care
• Do not force the LION Gun. Use the correct LION Gun for your application. The
correct LION Gun will do the job better and at a safe rate for which it is designed.
• Do not use the LION Gun if the switch does not turn it on and off. Any LION Gun that
cannot be controlled with the switch is dangerous and must be repaired.
• Disconnect the plug from the power source and/or the battery pack from the LION
Gun before making any adjustments, changing accessories, or storing LION Gun.
Such preventive safety measures reduce the risk of starting the LION Gun accidentally.
6The World’s Most Trusted Industrial Bolting Systems

• Store idle LION Guns out of the reach of children and do not allow persons
unfamiliar with the LION Gun or these instructions to operate the LION Gun. LION
Guns are dangerous in the hands of untrained users.
• Maintain LION Guns. Check the misalignment or binding of moving parts, breakage
of parts and any other condition that may affect the power of tool’s operation. If
damaged, have the LION Gun repaired before use. Many accidents are caused by poorly
maintained LION Gun.
• Use the LION Gun and accessories in accordance with these instructions, taking
into account the working conditions and the work to be performed. Using the LION
Gun for the operations different from those intended could result in a hazardous situation.
4) Service
• Have your LION Gun serviced by a qualified repair person using identical
replacement parts. This will ensure that the safety of the LION Gun is maintained.
IMPORTANT BATTERY PACK INSTRUCTIONS
• NEVER drop the LION Gun battery.
• NEVER hit or puncture the battery.
• DO NOT splash or immerse in water or other liquids.
• The LION Gun battery should be stored at 30 degrees or cooler. Batteries can only be used
from -20C to 40C.
• Do not incinerate the battery pack even if it is severely damaged or is completely worn out.
The battery pack can explode in a re. Toxic fumes and materials are created when LION Gun
battery packs 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 battery from 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.
• Recharge the LION Gun only with the charger specified by the manufacturer. A charger
that is suitable for one type of battery pack may create as risk of re when used with another
battery pack.
• Use the LION Gun only with specifically designated battery packs. Use of any other
battery pack my risk injury and re.
The World’s Most Trusted Industrial Bolting Systems 7

• When the battery pack is not in use, keep it away from other metal objects, like
paper clips, coins, keys, nails, screws and other small metal objects that can make a
connection from one terminal to another. Shorting the battery terminals together may cause
burns or a re.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. If
contact accidentally occurs, flush it with water. If liquid contacts eyes, additionally
Reaction Arm
Use the appropriately sized reaction arm or HYTORC Washer based on your application. The LION Gun
is usually supplied with a reaction arm in standard length. However, a custom reaction arm may have
been delivered for your special application.
WARNING!
Never modify a Reaction Arm! Changes in the reaction arm may lead to
personal injury or damage to the tool.
NOTE:
Reaction modications result in loss of warranty for the reaction arm and the
LION Gun. If you need a custom reaction arm, please consult with your local
HYTORC dealer.
Reaction Assembly and Drive
• Please clean the splined surface of the LION Gun before mounting the reaction arm.
• Slide the reaction arm over the square drive with the extension of the arm facing away from the tool.
• Press the lock button on the side of the reaction arm and slide onto the housing spline until it seats
against the shoulder, then release the button.
8The World’s Most Trusted Industrial Bolting Systems

WARNING!
Always attach the reaction arm so that the foot points away from the body of
the gun. Incorrect installation of the reaction arm can cause the reaction arm to
come into contact with your hand or other body parts causing injury.
The World’s Most Trusted Industrial Bolting Systems 9
Hold the button on the reaction arm while sliding it onto the splined section past the square drive and
release the button once the arm is fully seated. Test the connection by attempting to pull the arm off
without pushing the release button.

10 The World’s Most Trusted Industrial Bolting Systems
Store the reaction arm and LION gun in the tool box supplied after use and during work breaks.
Secure the socket using a locking pin through the square drive and a retaining ring.

Basic Safety Instructions for Handling
Make sure the reaction arm sits directly in contact with a suitable immovable object before you start to
tighten the nut.
• Keep all body parts from the reaction point.
• Make sure the operator is safe and secure in place before starting.
• Make sure the square drive is seated correctly and completely onto the socket.
WARNING!
If the reaction arm is not rmly seated and in direct contact with an immovable
object before the fastening process is started, serious injury may occur. Make
sure that all body parts and clothing are clear from the reaction area during the
bolting process. To eliminate the exposed reaction area please inquire about the
HYTORC Washer with your local representative or dealer.
The World’s Most Trusted Industrial Bolting Systems 11

• Charge the battery packs only in battery chargers supplied for charging this product.
• DO NOT pack with conductive items.
WARNING: Never attempt to open the battery pack for any reason. If battery pack
case is cracked or damaged, do not insert into charger or tool. Do not crush, drop,
or damage battery pack. Do not use a battery pack or charger that has received a
sharp blow, has been dropped or has been run over or damaged in any way (i.e.
pierced with a nail, hit with a hammer, stepped on). Damaged battery packs should
be returned to an authorized HYTORC service center for recycling.
WARNING: Fire hazard. Do not store or carry battery so that metal objects can
contact exposed battery terminals. For example, do not place battery in aprons,
pockets, tool boxes, product kit boxes, drawers with loose nails, screws, keys
etc. Transporting batteries can possibly cause fires if the battery terminals
inadvertently come in contact with conductive materials such as keys, coins,
hand tools and the like.
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 LION batteries, consult your Transportation Carrier.
WARNING: Burn hazard. Battery liquid may be ammable if it’s exposed to other
liquids, air, spark or ame.
12 The World’s Most Trusted Industrial Bolting Systems

THE RBRC™ SEAL
The RBRC™ (Rechargeable Battery Recycling Corporation) Seal on the LION Gun battery (or battery
pack) indicates that the costs to recycle the battery (or battery pack) at the end of its useful life have
already been paid by HYTORC.
The RBRC™ in cooperation with HYTORC and other battery users, has established programs in the
United States to facilitate the collection of spent LION Gun batteries. Help protect our environment and
conserve natural resources by returning the spent LION Gun 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. RBRC™ is a registered trademark of the Rechargeable Battery Recycling Corpora-
tion.
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, battery pack and
product using battery pack.
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. Other types of batteries may burst causing personal injury and damage.
CAUTION: Under certain conditions, with the charger plugged into the power supply,
the charger can be shorted by foreign material. Foreign materials of a conductive
nature such as, but not limited to, steel wool, aluminium foil, or any buildup of
metallic particles should be kept away from charger cavities. Always unplug the
charger from the power supply when there is no battery pack in the cavity. Unplug
charger before attempting to clean.
• DO NOT attempt to charge the battery pack with any chargers other than the one in this
manual. The charger and battery pack are specically designed to work together.
• These chargers are not intended for any uses other than batteries supplied with LION and
Lithium 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
pulling 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.
The World’s Most Trusted Industrial Bolting Systems 13

• 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 mount charger on wall or permanently fix charger to any surface. The charger is
intended to be used on a at surface (i.e. table top, bench top).
• 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 HYTORC service center when service
or repair is required.
• This charger is designed to operate on standard household electrical power (100-240 VAC
50/60hz).
14 The World’s Most Trusted Industrial Bolting Systems

OPERATION
General
Each 18V LION Gun is supplied completely assembled and ready for use. A full kit contains:
• LION Gun
• One 18V LION 4.1Ah Battery Pack
• 18V Battery Charger
• Battery Charger Power Supply
• Reaction Arm
Reaction Arm
Status LED
Display
Vents
18V Battery Pack
Battery Fuel Gauge
Trigger Switch
Directional Switch
The World’s Most Trusted Industrial Bolting Systems 15

SETUP
Battery Pack Installation and Removal
To install the battery pack into the tool handle, align the base of the tool with the rails in the tool handle
and slide the battery pack rmly into the handle until you hear the lock snap in to place.
To remove the battery pack from the tool, press the release button (as shown below) and rmly slide the
battery pack out of the tool handle.
Charging Procedure
1. Plug the charger power supply into the charger cradle using the coax barrel.
2. Plug the charger power supply into an appropriate outlet before inserting a battery pack.
3. Insert the battery pack into the charger cradle. The charger is equipped with a two light charge
indicator that will be either red or green according to the charged level of the battery pack.
Battery Pack Release Button
16 The World’s Most Trusted Industrial Bolting Systems

4. The completion of the charge is indicated by a green light which also indicates an idle state. The
pack is fully charged and may be used at this time or left on the charger.
LED Indicators:
• No Battery Solid Green Light
• Charging Blinking Green Light
• Fully Charged Solid Green Light
• Short Circuit Flashing Red Light
• Reverse Polarity Flashing Red Light
• Damaged Battery Flashing Red Light
The World’s Most Trusted Industrial Bolting Systems 17

Power
The LION Gun battery charger can operate at 110V or 220V AC. The plug is congured for the required
market.
Reaction Arm
Each LION Gun is equipped with a universal reaction arm. The reaction arm is used to absorb and coun-
teract any opposing forces created by the operation of the gun. Use the appropriately sized reaction arm
or HYTORC Washer based on your application.
Basic Operation
Press any button to start the gun. The gun will shut itself off after 3 minutes of inactivity. See the image
below for the LION Gun’s Main Screen Display. All gun parameters will be saved from the most recent
session.
Angle Release
Rotation Direction Arrow
Rotating Directional Icon
Fastener Type
Battery Charge Indicator
Job On Indicator
Job Number
Torque, Angle,
Release Setting
Status LED
Menu Shortcut Key
Soft Buttons Indicators
Soft Buttons
18 The World’s Most Trusted Industrial Bolting Systems

Setting Torque and Release Angle
Press and hold center key to toggle through screens for setting Torque, Angle and Release Angle. While
on screen, use the up and down arrow keys to select value.
Basic Function Descriptions
Torque: Allows the operator to enter the target torque that the gun will seek when the trigger is pulled and
held.
Angle: If an angle setting is above “0” the gun will add this angle of rotation to a completed torque
operation using the maximum output of the unit.
Release Angle: After completing an operation, the gun will automatically run backwards to the specied
angle to release windup from reaction torque. This will allow the operator to remove the tool without
loosening the fastener.
Torque and Angle Operation Caution: If the torque required to rotate the fastener through the selected
angle is unknown the torque may exceed the capacity of the tool in which case a failure warning will be
displayed: “Motor Stalled at Full Power.”
In order to determine if the tool is capable of meeting the requirement the following is suggested:
1. Tighten the fastener to the desired torque in Torque Mode.
2. Mark the position of the fastener.
3. With the tool still in Torque Mode set the tool to max output and measure how far the fastener
rotates.
4. If the fastener does not meet the angle requirement (with some margin) the torque to achieve the
angle is beyond the tools capacity and a larger tool should be used.
Note: This procedure will subject the fastener to max tool output torque. If unsure the fastener
can safely handle max torque do not perform this operation.
Go to Next
Screen
Decrease
Value
Increase
Value
The World’s Most Trusted Industrial Bolting Systems 19

LION GUN OPERATION
Tightening
1. Use the options menu to specify the type of fastener being used.
2. Set the tool to the desired torque level.
3. Set the tool to the desired post-torque angle. (REMEMBER: the gun will apply AT LEAST its
maximum rated torque while turning the fastener through this requested angle. Accidental
application of this post-torque angle feature, or accidental retorqueing of a fastener while using
angle feature, can lead to damage of the fastener and fastened equipment.)
4. Set the tool to the desired release angle. (REMEMBER: the gun will apply AT LEAST its maximum
rated torque while turning the system in the “Loosen” direction. Depending on the reaction
arrangement of your system, and the requested release angle, this could cause the fastener itself
to loosen.)
5. Make sure the LION Gun and fastener equipment are positioned properly.
6. Make sure the reaction xture is placed securely (Reaction Arm).
7. Pull the trigger to start the torqueing operation.
8. The tool will torque the fastener until the requested torque value is reached.
9. If a post-torque angle has been set, the tool will turn the fastener the requested angle after the
torqueing operation.
10. If a release angle has been specied the tool will back-off the requested angle at the end of
the operation.
11. The tool will now indicate the status of the operation.
Loosening
1. Use the options menu to specify the type of fastener being used.
2. Make sure the LION Gun and fastener equipment are positioned properly.
3. Make sure the reaction xture is placed securely (Reaction Arm).
4. Put the tool into loosening mode by pressing the center button. CAUTION: the tool will use AT
LEAST the maximum rated torque of the tool to loosen the fastener.
5. Pull the trigger to start the loosening operation.
6. Release the trigger to stop loosening the fastener.
CAUTION
In reverse direction, the gun is set to the MAXIMUM torque setting in order
to loosen the nut. Use extreme caution when running in this mode.
20 The World’s Most Trusted Industrial Bolting Systems