Hytorc MXT-XLT032011 Guide

MXT/XLT SERIES
OPERATIONAL AND SPARE PARTS MANUAL
Part No. MXT-XLT032011

STAY SAFE
THANK YOU FOR PURCHASING THE VERY FIRST
TORQUE/TENSION SYSTEM AND THE VERY FIRST
HANDS-OFF BOLTING TOOLS IN THE WORLD!!!
OPERATING CD: Please show the enclosed CD prior to each tool use to your staff to familiarize
them with the tools.
FREE SAFETY TRAINING: To assure a safe operation, please request a FREE Safety Training prior
to use by calling your local HYTORC Representative 1-800-367-4986 or www.hytorc.com. We do
recommend one Safety Training every 6 months. These trainings are free of charge. Just call us.
PLEASE READ THE SAFETY INSTRUCTIONS HEREIN.
SYSTEM INSPECTION: Prior to any use, please inspect the entire tool system, including hoses,
gauge, sockets and backup wrenches. Do not use kinked hoses, oversized or heavily worn sockets,
backup wrenches, damaged tools, pumps, connectors or gauges. Connect system to operate from
a safe distance. Assure fasteners are in good shape. Check out tool functioning with drive or hex
ratchet turning in one direction only and check out gauge from a safe distance that needle is on zero
at no pressure and at 10,000 psi at high pressure. Keep high pressure on and check system visually
for leaks. Please keep in mind that hydraulic tools are very strong and work at high pressure.
HANDS-OFF BOLTING: The tool you have purchased permits hands-free operation from a safe
distance in conjunction with a Safety Washer. We recommend the use of a Safety Washer to avoid
nger-pinching, over-crowded sites and to assure hands-off bolting at least on all vertical and
inverted applications, while eliminating improvising and the use of reaction members or backup
wrenches. Otherwise, set up the tool in a way that it does not have to be held by hand. For more
information, please contact us at 1-800-367-4986 or www.hytorc.com.
HANDS-FREE WASHER APPLICATION: Make sure the drive and the tool are locked on securely.
FREE ANNUAL TOOL INSPECTION: With the purchase of HYTORC, you have the right to a FREE
annual tool inspection, which includes free seals, springs and connectors and free lubrication. In
case of damaged or worn parts, the rst inspection within 12 months of purchase is free of charge.
Thereafter, you will be informed of any cost prior to replacement. Any part replaced and charged by
us will be sent to you for your inspection upon request when P.O. is issued.
FREE LOANER TOOLS: In case of tool failure during the warranty or rental period, please contact
your local HYTORC Agent for a free loaner tool - 24/7.
HOSE REPLACEMENT: We do recommend replacing hydraulic hoses and oil every (3) three months.
PLEASE WEAR REQUIRED SAFETY ATTIRE and use common sense during operation.
HELP: If you require any further assistance, please call your local HYTORC Representative or
1-800-FOR-HYTORC (1-800 -367-4986), on the web at www.hytorc.com - 24/7! It’s live!
PLEASE REVIEW THESE SAFETY
TIPS BEFORE EVERY TOOL USE
No. Safety 1-2-1009

3
CONTENTS
MXT/XLT SERIES
OPERATIONAL AND SPARE PARTS MANUAL
INTRODUCING HYTORC 4
SECTION I
IMPORTANT SAFETY INSTRUCTIONS 5
SECTION II
INSTRUCTIONS BEFORE USE 7
2-1 Working Pressure
2-2 Hydraulic Connections
2-3 Electrical Connections
2-4 Air Connections
SECTION III
OPERATION 9
3-1 General
3-2 Connecting the System
3-3 Drive Direction Change
3-4 Reaction Arm
3-5 Setting Torque
3-6 Setting Pressure
3-7 Applying Torque
3-8 Operating the Torque Machine
3-9 Loosening Procedures
SECTION IV
HYTORC POWER PACKS 14
4-1 General
4-2 Remote Control
4-3 Operation
SECTION V
PREVENTIVE MAINTENANCE 16
5-1 Preventive Maintenance - Torque Machines
5-2 Preventive Maintenance - Hydraulic Power Packs
SECTION VI
TROUBLESHOOTING 18
APPENDICES 22
A Parts Breakdown
B MXT/XLT Dimensional Data
C Square/Allen Drive Working Torque
D Application Bolt Torque

4
INTRODUCING HYTORC
THANK YOU FOR BUYING HYTORC!
YOU ARE NOW HOLDING ONE OF THE WORLD'S LARGEST SELLING AND
MOST ADVANCED HYDRAULIC TORQUE TOOLS.
HYTORC is used more often, by more industries on more applications than all others combined.
If you maintain your new tool properly, it will last for years to come.
This manual is designed to provide you with the basic knowledge required to operate and maintain your
HYTORC tool. Please read this manual carefully and follow the instructions provided. If you have any
questions regarding your HYTORC tool, please call us directly at 201-512-9500 or fax [phone].
Finally, your purchase of this HYTORC tool entitles you to the following FREE services:
• Free on-site training in the application and operation of your HYTORC equipment
• Free semi-annual training
• Free annual tool inspection
• Free loaner tools in case of failure
• Free engineering assistance by calling 1 800 FOR-HYTORC, or our continental ofce
Your local HYTORC ofce was informed of the delivery of this equipment. Should you require immediate
training, please feel free to call us directly to arrange an appointment with you at your convenience.
An instructional CD is also available for basic training and occasional brush up on operating procedures.
For additional information please visit our website at www.hytorc.com
Again, thank you and welcome to HYTORC!
World-wide Warranty
HYTORC equipment is engineered to the latest technological standards and are accompanied by our
exclusive 12-word, 12-month warranty.
"YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!"
If a HYTORC Tool cannot be repaired on site, FREE loaner HYTORC equipment will be made available
to you upon request.
UNEX CORPORATION OR ITS DEALERS SHALL NOT BE LIABlE FOR LOSS OF PRODUCT OR OTHER INCIDENTAL OR CONSEQUENTIAL COSTS INCURRED BY THE BUYER OR THE USER.
Offices Worldwide
Europe HYTORC UK/Europe Tel. [phone]
Japan HYTORC Japan Tel. [phone]
Australia HYTORC Australia Tel. [phone]
Brazil HYTORC South America Tel. [phone]
All Others HYTORC USA Tel. [phone]-FOR-HYTORC

5
SECTION I
IMPORTANT
SAFETY
INSTRUCTIONS
WARNING: Your HYTORC TORQUE MACHINE is a power tool, and as with any power tool,
certain safety precautions should be observed to avoid accidents or personal injury.
The following tips will assist you.
• READ ALL INSTRUCTIONS
• KEEP WORK AREA CLEAN AND WELL LIT
• CONSIDER WORK AREA ENVIRONMENT
Electrical Pumps should never be used in any atmosphere which can be considered potentially volatile.
If there is any doubt, use an air pump. Note: metal to metal contact can cause sparks, precautions
should be taken.
• AVOID PREMATURE TOOL STARTING
The Pump Remote Control is for the TOOL OPERATOR only. Avoid separate pump and tool operator.
• STAY CLEAR DURING OPERATION
In most cases, the tool will allow “hands free” operation. If the tool must be held or steadied during
operation, use alternative means of securing the tool to the application.
• GUARD AGAINST ELECTRIC SHOCK
Ensure the pump is properly grounded and the proper voltage is being used.
• STORE IDLE TOOLS
When not in use, tools and accessories should be properly stored to avoid deterioration.
• USE THE RIGHT TOOL
Don’t force small tools or attachments to do the job of a larger tool. Don’t use a tool for purposes not
intended.
• PROPER SAFETY ATTIRE
When handling/operating hydraulic equipment, use work gloves, hard hats, safety shoes, hearing
protection and other applicable clothing.
• USE SAFETY GLASSES
• MOVING EQUIPMENT
Do not use hydraulic hoses, uniswivels, pump power or remote cords as means of moving the equipment.

6
• HOSES
Do not kink hoses. Inspect and replace if damaged.
• SHROUDS AND COVER PLATES
All tools are equipped with shrouds and/or cover plates to cover up moving internal parts. Do not use tools
without shrouds but contact your local HYTORC ofce to x.
• MAINTAIN TOOLS WITH CARE
For top performance, inspect tool powerpack, hoses, connectors, electric lines and accessories for visual
damage frequently. Always follow instructions for proper tool and pump maintenance. Refer to the Opera-
tions Maintenance Section for further clarication.
• STAY ALERT
Watch what you are doing. Use common sense. Do not use power equipment under the inuence of any
mood altering substances.
• PRIOR TO OPERATION
Ensure that all hydraulic connections are securely connected. Verify that the
hydraulic hoses are not kinked. Insure the square drive and its retainer are fully and securely engaged.
• PRIOR TO USE
Cycle tool to ensure proper function. Locate a solid, secure reaction point. Be sure the reaction arm retain-
ing clamp is fully engaged. Be sure the hydraulic hoses are free of the reaction point. Pressurize the system
momentarily; if the tool tends to “ride up” or to “creep”, stop and re-adjust the reaction arm to a more solid
and secure position.
NOTE: Remain clear of the reaction arm during operation and never put body parts between reac-
tion arm and reaction surface.
• ALWAYS USE QUALITY ACCESSORIES
Always use top quality impact sockets in good condition which are the correct size and fully engage the
nut. Hidden aws, however, remain a possibility which could cause breakage, so stay clear of sockets dur-
ing operation.
• DO NOT USE FORCE
Do not hammer on socket or tool to enhance performance. If the nut will not tum with the wrench you are
using, use a larger size HYTORC tool.
• REACTION ARM
Proper reaction is required Adjust reaction arm or plate accordingly. Avoid excessive play. In case of ques-
tions, consult with your local HYTORC ofce.

7
SECTION II
INSTRUCTIONS
BEFORE
USE
READ CAREFULLY: Most malfunctions in new equipment are the result of
improper operation and/or set-up assembly.
PREPARATION: Remove HYTORC Torque Machine from shipping container.
INSPECTION: Visually inspect all components for shipping damage. If any
damage is found. notify carrier immediately.
2-1
Working Pressure
The tool’s maximum working pressure is 10,000 PSI (700kg/cm2).
Make sure that all hydraulic equipment used with this tool is rated for 10,000 PSI Operating Pressure.
2-2
Hydraulic Connections
With older style pumps (SST-IO, SST-20), the retract side of the system may remain pressurized after the
pump has been switched “off’. This trapped pressure makes it impossible to loosen the retract-side ttings by
hand.
To release the pressure, nd the 5/16” manual override holes in the end ofthe black solenoids on the pump.
With a welding rod, allen key or similar device, push in on the ends of both solenoids, each in tum, and the
residual pressure will be released. All ttings will then be hand tight again.
Newer style pumps (HYTORC 115, HYTORC 230, HYTORC AIR) are equipped with an auto-pressure relief.
Never disconnect or connect any hydraulic hoses or ttings without rst unloading the wrench and the
pump. If the system includes a gauge, double check the gauge to assure pressure has been released.
When making connections with quick disconnect couplings, make sure the couplings are fully engaged.
Threaded connections such as ttings, gauges etc. must be clean and securely tightened and leak free.
CAUTION: Loose or improper threaded ttings can be potentially dangerous if pressurized, yet,
severe over tightening can cause premature thread failure. Fittings need to be only tightened
secure & leak free. Never grab, touch or in any way come in contact witb a hydraulic pressure
leak. Escaping oil can penetrate the skin and cause injury.

8
2-3
Electrical Connections
Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the
motor nameplate for required amperage.
Do not use electric pump if the 3-prong electrical plug is not whole.
Minimize the length of extension cords and be sure they are of adequate wire size, with ground connections.
Extension cord should be #10 AWG gauge.
WARNING: Electric motors may spark. Do not operate in an explosive atmosphere or in the
presence of conductive liquids. Use an air motor pump Instead.
2-4
Air Connections
Ensure that you have sufcient air ow (in cfm) to operate your pneumatic pump. If in doubt, compare the
pump manufacturer’s recommended air ow rating prior to pressurizing pump. Improper air ow may
damage the pump motor. For best results use airhoses larger than 3/4” I.D. diameter.
Use of a lter regulator lubricator (FRL) is highly recommended. (Pictured below.)
1. Adjust flow to one drop per 60 - 90 seconds
2. Fill half way with grade 46 hydraulic oil supplied

9
SECTION III
OPERATION
3-1
General
All HYTORC Torque Machines are supplied completely assembled, ready for use. A HYTORC Hydraulic
Power Pack, for use with your HYTORC machine, is recommended to provide the speed, pressure and
portability that makes your HYTORC System efcient and accurate.
The System accuracy of your HYTORC tool is +/- 3% based upon manufacturer’s specications. This
accuracy may be certied through calibration by HYTORC or any other qualied calibration facility whose
program is traceable to the National Institute of Standards and Technology (N.I.S.T.).
Using a calibrated gauge enhances the accuracy of your HYTORC System.
3-2
Connecting the System
The wrench head and power pack are connected by a 10,000 PSI operating pressure, (40,000 PSI burst)
twinline hose assembly. Each end of the hose will have one male and one female connector to assure proper
interconnection between pump and wrenchheads.
IMPORTANT: To avoid tool malfunction. do not reverse connectors.
Connect the twinline hose to the uniswivel as shown below:
Insure the connectors are fully engaged and screwed snugly and completely together.

10
3-3
Drive Direction Change
To remove the square drive, disengage the drive retainer assembly by depressing the center round button and
gently pulling on the square end of the square drive. The square drive will slide easily out.
To insert the drive in the tool, place the drive in the desired direction, engage drive and bushing splines, then
twist drive and bushing until ratchet spline can be engaged. Push drive through ratchet. Slide the square drive from
side to side to lock or depress drive retainer button, engage retainer with drive and release button to lock
The above diagram illustrates the direction the square drive should face
for loosening and tightening of a standard right hand fastener.
3-4
Reaction Arm
All HYTORC Torque machines are equipped with a universal reaction arm. These reaction arms are employed
to absorb and counteract forces created as the unit operates. The reaction arm should extend in the same
direction of the square drive; however, slight adjustments may be made to suit your particular application.
The MXT Reaction Arm is made of TITAL 399 and is 360 degree adjustable.
NOTE: The standard MXT reaction arm cannot be welded on
and should not be modied.
The reaction arm for all MXT Series tools are splined to slide over the rear
(cylinder) portion of the tool.
In operation, the reaction arm must be fully engaged and secured by inserting
the spring loaded reaction arm clamp at the base of the housing into the
groove of the reaction arm.
RIGHT IS TIGHT.
LEFT IS LOOSE.
Button -
Drive Retainer Square Drive
Loosening Tightening