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

11
3-5
Setting Torque
Once the system is fully connected and the proper power supply available, it is time to adjust the pump
pressure to the level needed on your job.
When tightening, use the manufacturer’s specications to determine the torque value which you will
ultimately require.
Appendix I - which is presented as a guideline for comparison only - gives typical torque values specied for
the most commonly encountered fasteners.
Torque sequence may vary from plant to plant and even within individual plants, depending upon the gasket
material, etc. Always abide by local procedures.
Next, nd the pressure-torque conversion table applicable to the tool which you intend to use. A complete
copy of that chart appears in Appendix II.
An example of nding the desired torque required is as follows:
Assume you are going to use an MXT-3 to torque a 1-114” bolt to 1,265 ft lbs.
Start by going to the chart on the following pages and read left-to-right across the top line to the column MXT.
Read straight down to the number closest to 1,265 ft lbs, which in this case is 1,280 - about 1.5% over the
targeted torque value.
Now, using 1,280, read back to the left on that same line and read the pump pressure, under the PSI column,
4,000 PSI.
To be technically correct, you should diminish that 4,000 PSI by 1.5% (to 3940), but 1,280 is well within the
tool’s +/- 3% accuracy range, so proceed to set 4,000 PSI on your pump’s regulator valve.

12
3-6
Setting the Pressure on the Pump
To set the pressure on the pump, follow this procedure:
1. Loosen the knurled locking ring below the “T” handle on the pump’s external pressure regulator. Then
tum the “T” handle (shown in gure 6) counterclockwise (CCW) until it turns freely and easily.
2. Tum the pump “on”. Using the pump’s remote control pendant, push down the advance switch (or button
on air pumps) and hold it.
3. While holding the pump in the advance mode, slowly tum the “T” handle clockwise and observe the pump
pressure gauge rise.
NOTE: Always adjust the regulator pressure up - never down.
4. When your gauge reaches 4,000 PSI, stop turning the “T” handle and let
the gauge settle out.
5. If the pressure continues to rise (above 4,000), release the advance button
and back off your pressure slighitly - by turning CCW on the “T” handle.
Then re-depress the advance switch on your remote and slowly bring pressure
up to 4,000 again.
6. When the pressure is correct, tum the pump “off’ and tighten the knurled
lock nut provided under the “T” handle. This sets pump pressure, which
determines torque tool output.
7. Once your target pressure is set and locked, cycle the pump once more to
ensure that your pressure setting did not change as you turned down the
knurled knob.
3-7
Applying the Torque Machine - the Tightening Process
1. Having set your target pressure, cycle the tool three or four times to full pressure prior to putting it on the
application. Cycling the tool ensures that the system is operating properly and removes trapped air, if any.
2. Place the proper size impact socket on the square drive and secure properly with a locking ring and pin.
3. Place the tool and the socket on the nut, making sure that the socket has fully engaged the nut. Further
ensure that the drive retainer is engaged.
4. Make sure the reaction arm is rmly abutted against a stationary object (i.e. an adjacent nut, ange,
equipment housing etc.)
5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions, and
that all body parts are safely out of harm’s way.
6. THEN, AND ONLY THEN, apply momentary pressure to the system to ensure proper tool placement. If it
doesn’t look or act right, stop and re-adjust the reaction arm.
Locking
Ring
T-Handle

13
3-8
Operating the Torque Machine
1. By pushing down on the remote control button in the advance position, the rear of the tool will be
pushed back until its reaction arm will contact its reaction point.
2. Continue to hold down the button as the socket turns until you hear an audible “click” which will signify
the hydraulic cylinder inside the tool is fully extended and will not tum the socket further.
3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to the
point of where the gauge reads what was preset prior to applying the wrench.
IMPORTANT: The reading of full preset pressure after the cylinder is extended DOES NOT
INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder
is fully extended and cannot turn the socket further until the tool automatically resets itself.
Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the
pperator will hea)” an audible “click” indicating he can again push the remote control button and the socket
will tum. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made
until the tool “stalls” at the pre-set Torque/PSI with an accuracy of + 1- 3%. Repeatability is + 1- 1 %.
IMPORTANT: ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE “STALL” POINT HAS BEEN
REACHED.
3-9
Loosening Procedures
First, set the pump to 10,000 PSI. Change the drive and the reaction arm to the loosening mode, assurring the
reaction am abuts squarely off a solid reaction point. Press and hold the remote control button down.
Pressure will decrease as the socket begins to tum. As the cylinder extends fully, you will hear an audible
“click”. Release the remote control button, and the cylinder automatically retracts, at which time you again
hear the audible “click”. Repeat this process until the fastener can be removed by hand.
NOTE: IF THE BOLT DOES NOT LOOSEN WITH THE ABOVE PROCEDURE. IT IS AN INDICATION
THAT YOU REQUIRE THE NEXT LARGER SIZE TOOL TO LOOSEN THE BOLT.

14
SECTION IV
HYTORC
POWER PACKS
4-1
General Information
All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable.
They have been engineered and designed for portability and high ow for increased speed. Before using your
HYTORC power pack, check the following points:
• Is the reservoir lled with oil?
• Where is the closest electrical outlet at the job site?
• Is there enough air pressure (100 PSI) and ow at the job site? (Air units only)
• Is the gauge mounted and rated for 10.000 PSI?
• 15 the oil ller plug securely in place?
4-2
Working Pressure
The Pump’s maximum working pressure is 10,000 PSI(700 kg/cm2). Make sure all hydraulic equipment and
accessories are rated for 10,000 PSI operating pressure.
4-3
Hydraulic Connections
Never disconnect or connect hydraulic hoses or ttings without rst unloading the wrench. Unplug the
electrical cord of the pump, and open all hydraulic controls several times to assure that the system has been
depressurized. If the system includes a gauge, double check the gauge to assure pressure has been released.
When making a connection 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 improperly threaded couplers can be potentially dangerous if
pressurized. however. severe over tightening can cause premature thread failure. Fittings
need to be only tightened secure and leak free. Never grab. touch or in any way come in
contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.
Do not subject the hose to potential hazard such as sharp surfaces, extreme heat or heavy.
Do not allow the hose to kink and twist. Inspect the hose for wear before it is used.

15
4-4
Electrical Power
1. CHECK FOR PROPER ELETRICAL SUPPLY BEFORE CONNECTING.
2. THIS MOTOR MAY SPARK. DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE OR IN PRESENCE
OF CONDUCTIVE LIQUIDS.
a. Do not use a power or extension cord that is damaged or has exposed wiring.
b. All single phase motors come equipped with a three prong grounding type plug to t the proper
grounded type electrical outlet. Do not use a two prong ungrounded extension cord as the pump’s
motor must be grounded.
3. COMPARE MOTOR NAMEPLATE AGAINST POWER AVAILABILITY TO PREVENT MOTOR BURN
OUT OR DANGEROUS ELECTRICAL OVERLOADING.
4-5
Prior to Use
Check hydrauilc oil level to prevent possible pump burnout. Open the ller plug located on the reservoir
plate. Look at oil ll level on the oil sight gauge. The oil level should be approximately 2” from the top of the
reservoir plate- with motor off. Add HYTORC oil as necessary. Do not mix different grades of oil.
Make sure all desired gauge, valve, hose and quick coupler connections are tight and secure before operating.
The use of a pressure gauge is required for normal pump operation. Mounted on the manifold, the gauge
permits the operator to monitor the load on the wrench. 114% calibrated gauges are available for most
applications.
4-6
Operation
Before starting your Electric Pump (HYTORC 115/230), connect your hydraulic hoses to both the pump and
torque wrench.
Place the toggle switch in the ON position and the rocker switch on the hand control pendant in the OFF
position. To start the pump, depress and release the yellow safety button.
NOTE: The safety button is an added feature designed to prevent premature starting and should
ouly be depressed by the tool operator.
Push the rocker switch to advance and release. This will start your pump and place it in the retract position.
NOTE: Read the section labeled HYTORC OPERATIONS and SETTING TORQUE prior to installing
the torque wrench onto the application.
Your HYTORC 115/230 hydraulic pump has been designed with an auto shut off system. The pump will shut
off after approximately 30 seconds of non-cycling. This will prevent overheating and unnecessary wear which
will prolong the life of your pump. To restart the pump, the yellow safety button must again be depressed
prior to use.

16
SECTION VI
PREVENTIVE
MAINTENANCE
5-1
Preventive Maintenance -
Torque Machines
Tool failure, although rare, does occur. Such failure is most often in the hydraulic couplers or hoses. These
items are repairable or replaceable immediately, since they are availablehuniversally. Failure of structural
members of the tool are quite rare, but replacement parts are available from stock. All repairs to HYTORC
tools may be made by reasonably experienced individuals according to the aforementioned instructions.
• Lubrication
All moving parts should periodically be coated with a good quality NLGI #2 molybdenum disulde
grease. Under harsh environmental conditions, cleaning and lubricating should be performed more
frequently.
• Hydraulic Hoses
Hoses should be checked for cracks and leaks after each job. Hydraulic ttings can become plugged
with dirt and should be ushed periodically.
• Quick-Connects
Fittings should be kept clean and not allowed to be dragged along the ground or oor, as even small
particles of dirt can cause the internal valves to malfunction.
• Springs
Springs are used for the drive pawl assembly and for the accuracy assurance pawl. These springs can be
replaced if necessary.
• Cylinder Seals
If the cylinder requires disassembly, it is recommended that the cylinder seals be replaced at the same
time. Seal kits are readily available.
• Structural Members
All structural parts on the tool should be inspected once a year to determine if there are any cracks,
chips or deformities. If so, immediate replacement is required.

17
5-2
Preventive Maintenance -
Hydraulic Power Packs
HYTORC Hydraulic Power Packs are precision-built units and, as such, do require a certain amount of
care and maintenance.
• Hydraulic Oil
Oil should be completely changed after every 40 hours of operation, or at least twice a year. Always
make sure the reservoir is lled with uid. If additional oil is required, use only high-grade hydraulic
oil.
• Quick-Disconnects
Fittings should be checked periodically for leaks. Dirt or foreign materiais should be kept away from
ttings. Clean before use.
• Hydraulic Gauge
Some gauges are liquid lled. Should this liquid level drop, it indicates external leakage, and replacement
is necessary. Should the gauge ll with hydraulic oil, it indicates internal failure and it should be discarded.
• Filter on Pump
The lter should be replaced twice a year in normal use and more often if the pump is used daily or in a
dirty, harsh environment.
• Remote Control
(Air Unit) The air line to the remote control unit should be checked for obstructions or kinks in the line
periodically. If there is a bend or break in the line, it must be replaced. The spring-loaded buttons on the
remote handle should be checked in the event of operating difculties. (Electric Unit) The rocker switch
should be checked periodically if any indication of problems exist.
• Air Valve
This valve should be checked twice a year.
• Brushes and Brush Holders
(Electric Unit) Check and replace, if worn.
• Armature
(Electric Unit) Check yearly.

18
SECTION VI
TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REQUIRED ACTION
Gauge shows pressure build-up but the
tool will not cycle
1. Couplings loose or inoperative
2. Solenoid inoperative
1. Tighten and/or replace couplings. Use Test #1
listed below to isolate problem.
2. Check using test #2 below. If solenoid is bad,
replace.
Cylinder will not retract. 1. See above
2. Voltage to electric pump is too low
to line drop or inadequate amperage is
available.
3. Linkage between piston rod and drive
arms are broken.
1. See Above
2. Get shorter extension cord or upgrade to
12AWG, 25 amp rating or better. If shop power is
adequate, draw powcr from welding machine or cal
rod transformer.
3. Replace parts as necessary.
Cylinder pressure will not build. 1. Oil blow by in tool (Piston seal leak,
blown O-ring, cracked piston)
2. Pump Problem
1. Replace defective parts. SHOP JOB
2. Check to see if sub-plate is worn by; a) Remove
screws from pump motor to reservoir, slide Pump
motor to the side, tum pump on and while holding
down on the button, put your nger on the dump
tube (round tube under the directional control
valve) - if you feel pressure, then replace the sub-
plate and shear seals.
2A. Check to see if you have leaks from the
external relief valve and the 2 oil line connections
(bottom of relief valve and connection into pump
body’s other end, of oil line. If leaking, retighten
with 9/16” open end wrench. SHOP JOB 2B. If
punp sounds like alot of pebbles in a tin can, the
problem may be a worn motor coupling - remove
motor from base plate - using a pair of needle nose
pliers remove the motor coupling - if worn replace.
SHOP JOB
2C. AIR PUMPS - Faulty Air Valve due to exces-
sive moisture and/or dirt in air supply. Disassemble
air valve and wipe any residue from air valve
piston·spray brake cleaner into air valve body, dry
thoroughly. Disassemble all small air lines and
blow Out with compressed air.
Lubricate both air valve piston and body with hy-
draulic oil (sparingly) andreassemble. SHOP JOB
2D. Air pumps - Faulty remote control valve
cartridge. Replace.

19
SYMPTOM PROBABLE CAUSE REQUIRED ACTION
Cylinder/Tool leaks 1. Safety relief valve on swivel has lifted.
2. Blown O-ring in cylinder
3. Defective gland seal.
lA. Tighten all hose and couplers. If leakcontinues,
adjust safety setting - Test #4
lB. Check to see ifthe system is properly plumbed
by running test #5 (high pressure on retract side
will lift the safety relief valve)
2. Replace O-Ring with proper high pressure O-
Ring. SHOP JOB
3. Replace gland seal. SHOP JOB
Tool operates backwards 1. Couplings reversed
2. Multiple hoses in even numbers
1. Run test #5. Replumb system as necessary.
2. As plumbed, HYTORC hoses may only be
joined together in odd numbers ONLY. If it is nec-
essary to use 2,4,6 hoses - make un adapter from
spare high pressure couplings and nipples.
Ratchet returns with retract stroke 1. Broken or otherwise inoperable drive
segment.
1. Replace drive segment and/or spring. SHOP
JOB.
Ratchet will not take successive strokes 1. Broken or otherwise inoperative drive
segment I or spring
2. Cylinder not retracting completely
3. Linkage between piston rod and drive
plates is broken
1. Replace drive segment and/or spring. SHOP JOB
2. Remove tool from nut and cycle freely for sev-
eral strokes. If problem persists, check pawls.
2A. Operator not allowing adequate time for cylin-
der to retract fully.
3. Replace parts as necessary - SHOP JOB.
Tool locks onto nut 1. Drive segment is loaded when the tool is
max’ d out in torque
2. Tool is operating backwards
3. Tool is wedged under a xed object
1. Press advance button on remote and build pres-
sure - continue to press down on remote while
pulling back on one of the accuracy assurance
levers - release remote while continuing to hold
back on levers
2. Push advance button down - tool should immedi-
ately fall free- Run test #5
3. Remove shroud from around ratchet. Using any
tool available, pry the drive segment out of the
ratchet
and at the same time pull back on the accuracy
assurance levers. Tool should swing free or burn
away the socket or obstruction.

20
SYMPTOM PROBABLE CAUSE REQUIRED ACTION
Gauge records no pressure 1. Gauge connection is loose
2. Bad gauge
3. Pump will not build pressure
4. Tool seals are blown
l. Tighten coupling.
2. Replace gauge
3. See cylinder pressure will not build pressure-
above
4. Replace defective seals. SHOP JOB
Pump will not build pressure 1. Air or electric supply is low
2. Defective relief or regulator valve
3. Low oil or clogged lter
4. Internal leak in oil line from external
relief valve to pump body.
5. Worn sub-plate
1. Check air pressure or voltage.
2. Replace valve. SHOP JOB
3. Fill reservoir and clean ftIter.
4. Open reservoir, inspect oil line while trying to
build pressure - if leaking tighten ttings or replace.
5. See cylinder pressure will not build pressure-
above
Motor sluggish and inefcient “sounds
sick” slow to build pressure
1. Air or electric supply is low
2. Clogged lter
1. See #1 in preceding block
2. Clean or replace lter
Pump heats up 1. Improper use
2. Remote control is left in “on” position
when pump is not actively in use.
1. Operator is continuing to hold down Pump heats
up on the advance stroke after the cylinder has
reached end of stroke - this causes a lot of oil to go
through a very small hole in relief-valve - causing
heat build-up. Have operator release advance stroke
after accuracy assurance levers spring forward.
2. Turn pump off whenever not actually being used.
DO NOT leave pump running when tool is not in
use.
Hose or tool tting is damaged or leaks 1. Broken or melted plastic outer covering
2. Frayed Kevlar or steel strands
3. Oil leaks through bers
4. Broken ttings
1. If underlying Kevlar or steel is still intact con-
tinue operation. Inspect frequently.
2. Cut hose In half and discard. Replace Hose.
3. Cut hose in half and discard. Replace
hose.
4. Remove old tting and replace with
STEEL high pressure ttings only.
After changing ttings, always run test
#5 to insure proper plumbing.
Electric pump will not run 1. Loose electric connections in control
box.
2. Bad brushes
3. Motor burned up
1. Open control box and visually inspect for loose
threaded or push-on connectors. Reconnect loose
wires. If in doubt check wiring diagram. DANGER·
BOX CONTAINS HIGH VOLTAGE· ALWAYS
UNPLUG PRIOR TO TOUCHING ANYTHING
IN CONTROL BOX.
2. Change brushes. SHOP JOB
3. Replace motor or components whichever is
necessary. SHOP JOB .