Hytorc Lithium BTM-0250 User manual

Lithium Gun electric socket wrench
Technical manual

Copyright
© 2016 HYTORC. All rights reserved.
This document or parts thereof may not be reproduced, copied, distributed, stored in a retrieval
system, or transmitted, in any form or by any means, electronically nor otherwise, without the prior
written consent of HYTORC.
Specifications and illustrations are subject to change without prior notice. HYTORC will not accept
liability for any alteration or typing error. Details and values given in this manual are average
values and have been compiled with care. Details and values are not binding. HYTORC disclaims
any liability for damage or detriments suffered as a result of reliance on the information given
herein or the use of products, processes or equipment to which this document refers.
Introduction
2

Contents
1 About the document.................................................................................6
1.1 Purpose of the document.............................................................................................................6
1.2 How to work with the document...................................................................................................6
1.3 Languages................................................................................................................................... 6
1.4 Illustrations...................................................................................................................................6
1.5 Safety symbols in the document..................................................................................................6
1.6 Revision history............................................................................................................................7
1.7 Contact information......................................................................................................................7
2 Safety.......................................................................................................8
2.1 General safety instructions.......................................................................................................... 8
2.1.1 Personnel..........................................................................................................................8
2.1.2 Work area..........................................................................................................................8
2.1.3 Equipment.........................................................................................................................8
2.2 Additional safety instructions....................................................................................................... 9
2.2.1 Reaction arms...................................................................................................................9
2.2.2 Sockets............................................................................................................................. 9
2.2.3 Battery packs and battery chargers................................................................................ 10
2.3 Safety symbols on the tool.........................................................................................................10
2.4 Qualified personnel....................................................................................................................10
2.5 Liability.......................................................................................................................................11
3 Description............................................................................................. 12
3.1 Intended use.............................................................................................................................. 12
3.2 Device........................................................................................................................................12
3.3 Display....................................................................................................................................... 13
3.3.1 LED indicator...................................................................................................................13
3.3.2 Fastener type indicator....................................................................................................13
3.4 Battery charger.......................................................................................................................... 14
3.4.1 LED indicator...................................................................................................................14
4 Installation..............................................................................................15
4.1 Connecting and disconnecting the battery pack........................................................................ 15
5 Reaction arms........................................................................................16
5.1 Standard reaction arm (360°).................................................................................................... 16
5.2 Standard reaction arm (360° x 360°)......................................................................................... 16
5.3 Straight TPF reaction arm..........................................................................................................17
5.4 Straight WTCT reaction arm with reaction cup.......................................................................... 18
5.5 Curved WTCT reaction arm with reaction pin cup..................................................................... 18
5.6 Curved reaction arm with dual-end reaction cup....................................................................... 19
5.7 Reaction arm for recessed installation.......................................................................................19
5.7.1 Fixed length.....................................................................................................................19
5.7.2 Adjustable length.............................................................................................................20
5.8 Straight dual-tool interconnect reaction arm.............................................................................. 20
5.9 U-shaped dual-tool interconnect reaction arm...........................................................................21
5.10 Multi-tool interconnect reaction arm...........................................................................................21
Contents
- - 3

5.11 Reaction ring..............................................................................................................................22
5.12 Reaction strip (recessed bolt heads)......................................................................................... 23
5.13 HYTORC Washer™ double-drive socket................................................................................... 23
5.14 HYTORC LoadDISC™ double-drive socket...............................................................................23
5.15 HYTORC Nut™ drive................................................................................................................. 24
6 Securing the sockets and reaction arms................................................25
6.1 Securing the socket (type 1)...................................................................................................... 25
6.2 Securing the sockets (type 2).................................................................................................... 26
6.3 Securing the reaction arm onto the spline shaft.........................................................................26
7 Operation............................................................................................... 27
7.1 Inspections before use...............................................................................................................27
7.2 Charging the battery pack..........................................................................................................27
7.3 Starting the tool..........................................................................................................................27
7.4 Automatic shut-off system..........................................................................................................28
7.5 Determining the gearbox mode..................................................................................................28
7.6 Setting the torque, angle and release angle.............................................................................. 28
7.7 Direction of rotation....................................................................................................................29
7.7.1 Determining the direction of rotation............................................................................... 29
7.7.2 Changing the direction of rotation................................................................................... 30
7.8 Tightening and loosening a bolted flange connection................................................................30
7.8.1 Tightening a bolted flange connection............................................................................ 30
7.8.2 Loosening a bolted flange connection.............................................................................31
7.9 Saving and loading settings.......................................................................................................32
7.9.1 Saving settings................................................................................................................32
7.9.2 Loading settings..............................................................................................................32
7.10 Setting the options..................................................................................................................... 33
7.10.1 Navigating through the options....................................................................................... 33
7.10.2 Options............................................................................................................................33
7.10.3 Setting the beeper...........................................................................................................34
7.10.4 Setting the output units of the torque.............................................................................. 34
7.10.5 Setting the display rotation..............................................................................................35
7.10.6 Setting the fastener type................................................................................................. 35
7.10.7 Showing the shortcuts.....................................................................................................36
7.10.8 Setting the display polarity.............................................................................................. 36
7.10.9 Showing the cycle counter.............................................................................................. 37
7.10.10 Showing the version information.....................................................................................37
7.10.11 Showing the error log......................................................................................................38
7.10.12 Setting the angle delay....................................................................................................38
8 Maintenance.......................................................................................... 39
8.1 Preventive maintenance............................................................................................................ 39
8.2 Maintenance by HYTORC......................................................................................................... 39
9 Troubleshooting..................................................................................... 40
9.1 Tools.......................................................................................................................................... 40
9.2 Battery chargers.........................................................................................................................40
10 Technical data........................................................................................41
10.1 Lithium Gun BTM-0250..............................................................................................................41
Contents
4- -

10.2 Lithium Gun BTM-0700..............................................................................................................41
10.3 Lithium Gun BTM-1000..............................................................................................................42
10.4 Lithium Gun BTM-2000..............................................................................................................42
10.5 Lithium Gun BTM-3000..............................................................................................................42
10.6 Physical conditions.................................................................................................................... 43
10.7 Battery and battery charger....................................................................................................... 43
11 Declaration of Conformity...................................................................... 44
Contents
- - 5

1 About the document
1.1 Purpose of the document
The document shows the information to do these steps:
• Install the equipment
• Operate the equipment
• Maintain the equipment
The document contains the original instructions for the Lithium Gun electric socket
wrench, to which is referred with the term ‘tool’. The term ‘equipment’ is used as a more
general term to refer to the entire system: the tool, its parts and its accessories, including
the pump unit.
1.2 How to work with the document
1. Read the document completely. Make sure that you understand all the instructions.
2. Obey the safety instructions to prevent injury or damage to equipment.
3. Do the procedures completely and in the given sequence.
4. Keep a copy of the latest version of the document and all related documents near the
equipment.
1.3 Languages
The original language of the document is English. All other language versions are
translations of the original instructions.
1.4 Illustrations
It is not always possible to provide a detailed illustration of every single item of the
equipment. The illustrations in the document show a typical setup and are for instructional
use only.
1.5 Safety symbols in the document
Safety symbol Function Description
Warning “Warning” means that injury or death is possible if you
do not obey the instructions.
Caution “Caution” means that damage to equipment is possible
if you do not obey the instructions.
About the document
620 - 001 -

Safety symbol Function Description
Note “Note” is used to give additional information.
1.6 Revision history
Date Revision number Comment
16-08-2016 001 First version
1.7 Contact information
HYTORC Nederland BV
Platinawerf 8
6641 TL Beuningen
The Netherlands
Phone: [phone]
Website: www.hytorc.nl
Email: [email protected]
HYTORC Benelux BVBA
Ysselaarlaan 65B
2630 Aartselaar
Belgium
Phone: [phone]
Website: www.hytorc.be
Email: [email protected]
About the document
20 - 001 - 7

2 Safety
2.1 General safety instructions
2.1.1 Personnel
• Do not allow unqualified personnel to perform tasks on or with the equipment.
• Keep unqualified personnel, children and animals away from the equipment.
• Wear personal protective equipment (PPE): safety helmet, safety goggles, hearing
protection, safety gloves, safety shoes and coverall.
• Keep loose clothing, long hair and jewelry away from the moving parts.
• Stay alert. Use common sense. Do not use the equipment under the influence of
mood-altering substances.
• Always stand in a firm position.
• Avoid body contact with earthed or grounded surfaces such as pipes, radiators,
ranges and refrigerators.
• Keep your hands away from the nut or the bolt being loosened or tightened.
• Do not stand in the line of movement of the tool during operation. If the tool separates
from the nut or the bolt, it will detach in that direction.
• Be aware that a fastener that breaks off during operation will become a high-velocity
projectile.
• Obey the local labor and safety laws and environmental regulations.
2.1.2 Work area
• Keep the work area clean and well lit.
• Keep the work area free of unwanted obstacles. Ensure free passages in the work
area during operation.
2.1.3 Equipment
• Only use equipment that is approved by HYTORC.
• Only use equipment that is appropriate or compatible with the HYTORC equipment.
• Do not modify the equipment in any way.
• Only use the tools for the purposes for which they have been designed. Do not force
small tools or accessories to do the job of a larger tool. HYTORC can develop
customized accessories to ensure safe and simple operation. Contact your local
HYTORC representative for more information.
• When you move the tool, make sure that the tool does not operate.
• Remove any adjusting key or wrench before turning the tool on.
• Inspect the equipment for visual damage before each use. Obey the instructions for
maintenance of the equipment.
• If you cannot start or stop the tool, do not use the tool.
• Do not remove or disable the safety provisions on the equipment.
• Make sure that the cover plates are not damaged and installed correctly. All HYTORC
tools are equipped with cover plates to cover moving parts. If cover plates are missing
or damaged, contact your local HYTORC representative for repair.
• Do not hit reaction arms or sockets with heavy objects (e.g. hammers). If the nut or the
bolt does not turn with the tool you are using, use a tool of a larger size.
• Do not cut, weld or otherwise modify reaction arms or sockets.
• Do not expose reaction arms or sockets to extremely high or low temperatures.
Safety
820 - 001 -

• Do not use the equipment in explosive atmospheres (e.g. in the presence of
flammable liquids, gases or dust).
• Do not expose the tool to rain, snow or wet conditions.
• Do not splash or immerse the tool in water or other liquids.
• Do not leave tools with reaction arms and sockets hanging on the nut or the bolt.
• Store tools and accessories which are not in use properly.
2.2 Additional safety instructions
2.2.1 Reaction arms
• Only use HYTORC reaction arms.
• Do not modify the reaction arms in any way.
• Place the reaction arm against a solid reaction point that can handle the load.
• Only place the reaction area against the reaction point.
• Make sure that the end of the reaction arm has both horizontally and vertically at least
10 mm overlap with the reaction point. If a distance of at least 10 mm is not possible,
choose another reaction point or use an appropriate reaction arm.
ุPP
• Make sure that the reaction arm is locked onto the spline of the tool.
• Avoid excessive play. Pressurize the system momentarily. If the tool tends to creep or
stand askew, stop immediately and adjust the reaction arm to a more solid and secure
position.
• Do not place the reaction arm against a round or inclined reaction point.
• Do not place any part of your body between the reaction arm and the reaction point.
• Do not place objects between the reaction arm and the reaction point.
• When you use a reaction cup, make sure that the reaction cup is placed over the
reaction point completely.
• When you use a reaction pin cup, make sure that the pin reaches the bottom of the
hex bolt.
2.2.2 Sockets
• Only use HYTORC sockets.
• Do not modify the sockets in any way.
• Do not use sockets that have been excessively heated or cooled.
Safety
20 - 001 - 9

• Use thick-walled heavy-duty sockets only. Do not use thin-walled sockets.
• Only use deep well sockets when strictly necessary. The excessive height causes
unnecessary bending forces.
• Do not use sockets that are used on impact wrenches. The impact deforms the drive
hole of the socket and hardens and brittles the steel. This can cause fracture of the
steel and increases the risk of flying objects.
• Make sure that the width across flats of the socket corresponds to the width across
flats of the nut or the bolt. Note the difference between metric and imperial
measurements.
• Place the tool with the socket on the nut or the bolt. Make sure that the socket is
placed over the nut or the bolt as far as possible.
• Make sure that the socket is secured to the tool.
• Do not use common extension pieces or step-up/step-down adapters. HYTORC can
develop customized accessories to ensure safe and simple operation. Contact your
local HYTORC representative for more information.
2.2.3 Battery packs and battery chargers
• Use the tool only with the supplied battery packs.
• Charge the battery packs with the supplied battery charger.
• Do not use a damaged battery charger. Replace the damaged battery charger.
• Do not use an extension cord unless it is strictly necessary.
• Before you connect the battery pack to the battery charger, make sure that the battery
pack is dry and clean.
• Make sure the cord is in a position in which the risk of damage or injury is mimimum.
• When you do not use battery pack, keep the battery pack away from metal objects
(e.g. paper clips, coins, keys, nails and screws).
• Do not hold or pull the cord of the battery charger.
• Keep the cord of the battery charger away from heat, oil and sharp edges.
• Do not open the battery pack.
• If the battery contents touch the skin, clean the skin with mild soap and water
immediately. If the battery contents touch the eyes, clean the eyes with water for 15
minutes or until irritation stops. Get medical help.
Note:
• The battery electrolyte is a mixture of liquid organic carbonates and
lithium salts.
• When you have respiratory irritation, breathe fresh air. If the symptoms continue, get
medical help.
2.3 Safety symbols on the tool
The tool has no warning labels. Warning labels can only be applied on locations where
they will become damaged or illegible immediately.
2.4 Qualified personnel
The term ‘qualified personnel’ refers to persons who thoroughly understand the
equipment and its safe installation, operation and maintenance. Qualified personnel are
physically capable of performing the required tasks, familiar with all relevant safety
instructions and regulations and trained to safely install, operate and maintain the
equipment. It is the responsibility of the company operating the equipment to see that the
personnel meet these requirements.
Safety
10 20 - 001 -

2.5 Liability
HYTORC cannot be held responsible for injury or damage that results from unintended
use of the equipment. The equipment is designed and intended only for the purpose
described in the relevant documents. Uses not described in the relevant documents are
considered unintended uses and can result in injury or damage.
Unintended uses include:
• Using equipment that is not approved by HYTORC
• Using equipment that is inappropriate or incompatible with the HYTORC equipment
• Altering or modifying equipment in any way
• Allowing unqualified personnel to perform tasks on or with the equipment
Safety
20 - 001 - 11

3 Description
3.1 Intended use
The Lithium electric socket wrench is a tool used for both your torque and tension
applications with the same system. Different reaction arms and sockets can be used with
the tool. HYTORC electric tools have an accuracy of ± 5%.
3.2 Device





1. Trigger switch
2. Battery pack
3. Battery pack release button
4. Gearbox switch
5. Square drive for socket connection
Description
12 20 - 001 -

3.3 Display
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5(/($6(
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OEIW
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2.
187
+:








1. Display button indicators
2. Display buttons
3. Status LED
4. Angle value
5. Release angle value
6. Torque value
7. Fastener type
8. Battery monitor
3.3.1 LED indicator
Color Status
Green Ready
Yellow Busy
Red Error. See Tools on page 40.
3.3.2 Fastener type indicator
The fastener type indicator shows the current setting for the Fastener type option. See
Options on page 33.
Display Setting
RH Right hand
LH Left hand
HN HYTORC Nut™
HW HYTORC Washer™
Description
20 - 001 - 13

3.4 Battery charger


1. Battery charger power supply
2. Battery charger cradle
3.4.1 LED indicator
Color Status
Solid green Fully charged/no battery
Solid red Charging
Flashing red Error. See Battery chargers on page 40.
Description
14 20 - 001 -

4 Installation
4.1 Connecting and disconnecting the battery pack
Procedure
1. Connect the battery pack (A) to the
tool. Make sure that you hear a
click.
2. To disconnect the battery pack (A),
push the battery pack release
button (B) and remove the battery
pack.
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Installation
20 - 001 - 15

5 Reaction arms
The reaction arms can be used together with hydraulic tools, pneumatic tools and electric
tools.
There are different types of reaction arms to operate the tool.
5.1 Standard reaction arm (360°)
The length of the reaction arm is fixed. One standard heavy-duty socket must be used
together with the reaction arm.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Place the tool as shown.
5.2 Standard reaction arm (360° x 360°)
The length of the reaction arm is fixed. The height of the reaction arm is adjustable. One
standard heavy-duty socket must be used together with the reaction arm.
Note:
The best reaction point is immediately above the flange surface. When the
reaction point is higher we recommend to limit the torque output to the
percentages as shown.
Reacting higher creates unwanted bending forces in the boltshaft and the
bolting tool. Avoid these bending forces to improve torque- and boltload
accuracy, and to improve durability of the tool and socket driver (especially for
allen hex sockets).
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Reaction arms
16 20 - 001 -

Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Adjust the reaction arm as close to
the flange surface as possible.
4. Place the tool as shown.
5.3 Straight TPF reaction arm
The length of the reaction arm is adjustable. Two standard heavy-duty sockets must be
used together with the reaction arm.
Procedure
1. Place the sockets over the nuts as
far as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction socket
used is placed over the reaction
point completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.

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Reaction arms
20 - 001 - 17

5.4 Straight WTCT reaction arm with reaction cup
The length of the reaction arm is adjustable. One standard heavy-duty socket must be
used together with the reaction arm.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction pin cup
is placed over the reaction point
completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.
5.5 Curved WTCT reaction arm with reaction pin cup
The length of the reaction arm is adjustable. One standard heavy-duty hex socket must
be used together with the reaction arm.
Procedure
1. Place the male hex socket in the
bolt head as far as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction pin cup
is placed into the bolt head
completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.
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Reaction arms
18 20 - 001 -

5.6 Curved reaction arm with dual-end reaction cup
The length of the reaction arm is fixed.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Make sure that the reaction cups
are placed over the reaction points
completely.
4. Place the tool as shown.
5.7 Reaction arm for recessed installation
5.7.1 Fixed length
The length of the reaction arm is fixed. One standard heavy-duty socket must be used
together with the reaction arm.
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Reaction arms
20 - 001 - 19

Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Place the tool as shown.
5.7.2 Adjustable length
The length of the reaction arm is adjustable. One standard heavy-duty socket must be
used together with the reaction arm.
Procedure
1. Loosen the lock nut.
2. Place the socket over the nut as far
as possible.
3. Tighten the lock nut.
4. Place the reaction arm as shown.
5. Place the tool as shown.
5.8 Straight dual-tool interconnect reaction arm
The length of the reaction arm is adjustable. Two standard heavy-duty sockets must be
used together with the reaction arm.
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+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
20 20 - 001 -