Hytorc Torque Gun FLASH-5 Quick start guide

3
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
This manual applies to all tool part numbers in the Flash Electric Gun Product Family. It
is recommended the manual is kept up-to-date by checking the edion and date code at
the boom of this page by ulizing the Torque Gun Company website and downloading
a copy of the most recent edion as needed.
TORQUE GUN
A HYTORC COMPANY
120 Wesley Street,
Hackensack, New Jersey 07606 U.S.A.
Noce: The informaon contained in this document is subject to change without noce. The Torque
Gun Company makes no warranty of any kind with regard to this material, including but not limited
to, the implied warranes of merchantability and tness for a parcular purpose. The Torque Gun
Company shall not be liable for errors contained herein or for incidental or consequenal damages in
connecon with the furnishing, performance, or use of this material. It is further recomended that the
end-user or repair technician insure they have obtained and are familiar with the latest revision of the
manual for the equipment outlined in this document.
Restricted Rights Legend: Use and duplicaon of the informaon contained within this manual is
limited to the purchaser, end user, or licensed Torque Gun Company representave. It is recommended
that proper training for the equipment outlined in this manual be conducted by a Torque Gun Company
authorized training representave for any person who is operang or repairing the equipment outlined
in this document. Modicaon, or disclosure by any other agency or representave is strictly forbidden.
Product Modicaons: Torque Gun DOES NOT ALLOW any of the products listed in this manual to be
modied by any end user without excepon. Should an applicaon require a modicaon to the tool, or
any of the standard accessories please consult with your local Torque Gun Company representave and
they will be able to obtain the assistance for any modicaon that may be required.
© Torque Gun 2014: All Rights Reserved. Reproducon, adaptaon, or
translaon without prior wrien permission is prohibited, except as allowed under the copyright laws.
4th. Edion. Printed in USA. August 2015
Complies with standards publicaon BS EN 82079-1:2012
FLASH ELECTRIC GUN PRODUCT FAMILY:
FLASH-.5, FLASH-1, FLASH-2, FLASH-3
EN, EN-ISO, ISO Standards:
For a complete EC declaraon of conformity
or if you require any further assistance please
contact your local Torque Gun representave
or 1-888-GUN-2-GUN (1-888-486-2486) or on
the web at www.torquegun.com.
EN ISO 4414:2010
EN 61310-2:2008
EN 61310-3:2008
ISO 3744:2011
EN ISO 12100-1:2011
EN ISO 12100-2:2011
EN ISO 14121-1:2007
EN ISO 11148-6:2012

WITH THE PURCHASE OF TORQUE GUN CO. TORQUE MACHINES (PAST,
PRESENT, FUTURE) YOU HAVE OBTAINED THE LATEST TECHNOLOGY AND
LIFETIME, WORLDWIDE LOCAL SERVICE.
HELP: If you require any further assistance, please call your local Torque Gun Co. Representa-
tive or 1-888-GUN-2-GUN (1-888-486-2486), on the web at torcgun.com - 24/7! It’s live!
FIND US ONLINE AT
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FREE SERVICES
♦FREE User Safety Training upon Receipt of Merchandise
♦FREE Semi-Annual User Safety Training on Request
♦FREE Annual Safety Seminar on Appointment
♦FREE Loaner Tools in case of Product Failure within 24 Hours
♦FREE Torque/Tension Consultation/Seminar
♦FREE Half Day, First Use Supervision
♦FREE Annual Product Inspection on Request
♦FREE Product Demonstrations
♦FREE 12 Month No-Questions-Asked Warranty
♦FREE Upgrades during the Lifetime of the Tool to Enhance Safety, Durability, and Function
(Above services are NOT subject to travel expense charges)
REPAIRS
• All Repairs are Guaranteed for 6 Months
• Repairs are Subject to Labor and Part Cost, as Outlined in the Ofcial TORQUE GUN CO. Price List
• All Warranty Repairs are FREE of All Charges Including Return-Freight
• All Repairs Will be Tested and Calibrated to Ensure the Highest Quality Repairs
TOOL RENTALS
• 100% of all Paid Rentals Will be Applied as a Discount Towards any New Purchase
• User Training for First Time Rentals is FREE of All Cost
• Return Freight Charges are FREE
• Rental Tools are Guaranteed to Perform and are Subject to the FREE Loaner Tool Policy of TORQUE GUN CO.
TOTAL SATISFACTION GUARANTEED 1-888-GUN-2-GUN

FLASH™ Electric Gun
OPERATIONAL MANUAL
TABLE OF CONTENTS
WARRANTY 7
IMPORTANT SAFETY INFORMATION 8
Personal Protective Equipment 9
Reaction Arm or HYTORC Washer 10
Reaction Assembly and drive 11
Basic safety instructions for handling 14
OPERATION
General 15
Setup 15
Reaction Arm 15
Power 15
Basic Operation 15
Basic Function Descriptions 15
Direction Switch 17
Setting Torque and Angle 18
TORQUE GUN OPERATION
Tightening 19
Tightening with Angle 19
Loosening 19
Memory Options 20
Additional Options 21
HYTORC Washer Overview 22
HYTORC Washer Requirements 22
HYTORC Washer assembly, use and service (SETUP) 22
Important Preparation Steps for HYTORC Washer 23
Important Installation Steps for HYTORC Washer 23
Installing HYTORC Washer Drive 24
Tightening with HYTORC Washer 24
MAINTENANCE
Preventative Maintenance 25
Calibration 26
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BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

TABLE OF CONTENTS CONT.
APPENDIX
FLASH GUN Block Diagram 27
FLASH GUN Screen Navigation 28
FIGURES
Figure 1: Reaction Arm 10
Figure 2: HYTORC Washer and Drive 10
Figure 3: Reaction Arm Assembly 11
Figure 4: Reaction Arm Attachment 12
Figure 5: Reaction Arm Fastening 12
Figure 6: Socket Drive 13
Figure 7: Socket Drive Attachment 13
Figure 8: Reaction Arm Positioning 14
Figure 9: FLASH Gun Overview 15
Figure 10: Main Display Screen 16
Figure 11: Direction Switch 17
Figure 12: Setting Torque and Angle 18
Figure 13: Memory Options 20
Figure 14: Additional Options 21
Figure 15: HYTORC Washer and Drive 22
Figure 16: HYTORC Washer Installed 23
Figure 17: Installing Set Screw on HYTORC Washer Drive 24
Figure 18: Tighten set screw 24
Figure 19: HYTORC Washer Drive on Flash 25
Figure 20: Calibration procedure 26
Figure 21: FLASH GUN Block Diagram 27
TABLES
Table 1: FLASH GUN Specications 29
Table 2: Bolt Torque Specications 30
6BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

WARRANTY
TORQUE GUN
A HYTORC COMPANY
120 Wesley Street, Hackensack, New Jersey 07606 U.S.A.
Tel: 888-GUN-2-GUN • E-Mail: [email protected] • Web: www.torquegun.
com
The FLASH GUN has a one year limited warranty. Every TORQUE GUN tool
is tested before leaving the factory and is warranted to be free from
defects in workmanship and materials. TORQUE GUN will repair or
replace, without charge, any tool which upon examination proves to be
defective in workmanship or materials for one (1) year after the date of
purchase. This warranty does not cover damage from repairs made or
attempted by other than TORQUE GUN authorized repair facilities.
The repair and replacement remedies described herein are exclusive.
In no event shall TORQUE GUN be liable for any incidental, special, or
consequential damages, including loss of prots. This warranty is
exclusive and in lieu of all other warranties or conditions, written or oral,
expressed or implied for merchantability or tness for particular use or
purpose.
This warranty gives you specic legal rights. You may also have other
rights that vary from state to state and province to province. In those
states that do not allow the exclusion of implied warranties or limitation
of incidental or consequential damages, the above limitations or
exclusions may not apply to you.
If you have questions about the warranty, contact our
customer service center at 888-GUN-2-GUN.
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BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

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. Do not discard these safety instructions or this manual. Instructions in this manual are for
bolting professionals. Non professional users, please contact TGC before use.
• Save all warnings and instructions for future reference.
• Inspect all FLASH components as they are removed from the shipping container. If damage is
found to any component, contact your shipper immediately. Do not use the tool.
• Failure to follow correct tool usage could result in personal injury, co-worker injury, and/or
damaged tools and equipment.
• Ensure your working area is clean and unobstructed before beginning work.
• Do not operate a Flash Gun in explosive atmospheres, such as in the presence of ammable
liquids, gases or dust. Flash Gun create sparks which may ignite the dust or fumes.
• Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded
• If operating a Flash Gun in a damp location is unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk of electric shock.
• When operating a Flash Gun outdoors, use an extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of electric shock.
• Do not force the Flash Gun. Use the correct Flash Gun for your application. The correct Flash
Gun will do the job better and safer at the rate for which it was designed.
• Do not overreach. Keep proper footing and balance at all times. This enables better control of
the Flash Gun in unexpected situations.
• Stay alert, watch what you are doing and use common sense when operating a Flash Gun. Do
not use a Flash Gun while you are tired or under the inuence of drugs, alcohol or medication. A
moment of inattention while operating a Flash Gun may result in serious personal injury.
• 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 Flash Guns with your
nger on the switch or energising Flash Guns that have the switch on invites accidents.
• FLASH maintenance and repair must be performed by a qualied pneumatic technician.
Modifying a FLASH or FLASH accessory is dangerous and invalidates the warranty.
• Do not use the Flash Gun if the switch does not turn it on and off. Any Flash Gun that cannot be
controlled with the switch is dangerous and must be repaired.
• Inspect the tool before each use. Replace any obviously worn or damaged parts
• When not in use, store the FLASH and FLASH accessories in the plastic storage case supplied
with the tool. Do not expose the gun to high humidity or large temperature variations.
• Store idle Flash Gun out of the reach of children and do not allow persons unfamiliar with the
Flash Gun or these instructions to operate the Flash Gun. Flash Guns are dangerous in the
hands of untrained users.
• When using the 220V FLASH guns, the 220V power outlets must have an earth ground pin or a
screw terminal, for ground connection.
• Keep children and bystanders away while operating a Flash Gun. Distractions can cause you yo
lose control.
8BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Personal Protective Equipment
• Always wear the appropriate personal protective equipment when operating a FLASH including
gloves, safety goggles, hearing protection, hard hat, and safety shoes.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away
from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
9
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Reaction Arm or HYTORC Washer
Use the appropriate size reaction arm or HYTORC Washer based on your application. The FLASH GUN
is usually supplied with a standard length reaction arm. However, a custom reaction arm may have
been delivered for special applications for your FLASH GUN.
The HYTORC Washer system can be used for all applications instead of reaction arm.
WARNING!
Never modify a reaction arm! Changes in the reaction arm may lead to personal
injury or damage to the tool.
NOTE:
Reaction arm modications result in loss of warranty for the reaction arm and the Flash
Gun. If you need a custom reaction arm, please consult with your local FLASH Gun dealer.
Figure 1: Reaction Arm
Figure 2: HYTORC Washer and Drive
10 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Reaction Assembly and Drive
• Use the appropriate size reaction arm or HYTORC Washer based on your application. The
FLASH GUN is usually supplied with a standard length reaction arm.
• If you want to use the HYTORC Washer system, please follow the installation and assembly
instructions in the “HYTORC Washer Overview” section.
• Please clean the contact surfaces of FLASH GUN and reaction arm, before mounting the
reaction arm to FLASH GUN.
• Slide the reaction arm on the appropriate gear teeth so that the extension of the reaction arm is
facing outward.
WARNING!
Always attach the reaction arm so that it points away from the handle with the extension
of the FLASH GUN. Incorrect installation of the reaction arm can cause it to come into
contact with your hand or other body parts causing injury.
The reaction arm will start to rotate as soon as the FLASH GUN trigger is pulled. Please
keep all body parts and other objects away from the bolting area when operating the
FLASH GUN. Exposure to vibration with prolonged and repeated use may cause disabling
damage to the nerves and alter blood ow to the hands and arms.
Figure 3: Reaction Arm Assembly
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BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Attach the reaction arm to the FLASH GUN so that the attachment screw with the recess
corresponds to the teeth, tighten and then loosen it a 1/4th turn.
Figure 4: Reaction Arm Attachment
Figure 5: Reaction Arm Fastening
12 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Place an appropriate size socket on the square drive.
Secure the socket by means of the locking pin on the square drive.
Store the reaction arm and FLASH GUN in the tool box supplied after use and during work breaks.
Figure 6: Socket Drive
Figure 7: Socket Drive Attachment
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BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

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.
The use of the HYTORC Washer eliminates the need for external reaction arms and thereby contributes
to an increase in the safety of the user. (Also see the section “HYTORC Washer Overview”)
• Keep all body parts away from the reaction arm and 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
SAFETY WARNING!
TO ENSURE HAND AND BODY PROTECTION AND TO PREVENT INJURIES:
BEFORE START OF FASTENING PROCESS ENSURE
• Reaction Arm is in rm, direct contact with a suitable immovable object.
• Hands and all body parts are never in between the reaction arm and reaction point.
• Hands are away from the sockets.
• Power cord, gloves, loose clothing, neck ware, jewelry, etc. are not entangled with
the rotating parts.
Figure 8: Reaction Arm Positioning
!! CAUTION !!
DANGER OF CRUSHING HANDS. KEEP HANDS AWAY
14 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

OPERATION
General
Each electric torque gun is supplied completely assembled and ready for use. A side handle is supplied
for better hold and grip during operation.
Setup
Reaction Arm
Each electric torque gun is equipped with a universal reaction arm. The reaction arm is used to absorb
and counteract any opposing forces created by the operation of the torque gun. Use the appropriate size
reaction arm or HYTORC Washer based on your application.
Power
The FLASH GUN can operate at 110V or 220V AC based on the model conguration. Ensure proper
voltage is present at the power outlet and insert the power chord into the nearest 110V (black cord)
or 220V (yellow cord) outlet. Upon power up, the FLASH GUN will initialize and show the main display
screen as shown in Figure 10.
FLASH ELECTRIC TORQUE GUN 360° Freely Rotating
Ergonomic Handle
Trigger Switch
Direction Switch
Side Handle
Optional HYTORC
Washer Drive
Gear Box
ID Tag
Vents
Main Display
Figure 9: FLASH Gun Overview
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BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Torque
Line
Frequency
Angle
Soft Button
Indicators
Ready
Green LED
Busy
Yellow LED
Soft Buttons
Error Red
LED
Motor
Temperature
Direction
Indicator
Release
Angle
MAIN DISPLAY SCREEN
Figure 10: Main Display Screen
Basic Operation
At Start up the FLASH GUN is ready to
operate at the initial or the last Torque,
Angle and Release Angle settings. If these
settings are correct and when ready to
tighten a fastener, place the gun on the
application and press the trigger until the
reaction arm rmly makes contact with the
reaction point. Press and hold the trigger
until the gun comes to a complete stop.
While torquing, the YELLOW LED will light
up showing BUSY. When done, the torque
gun will beep once and the GREEN LED will
turn ON. In case of error, the torque gun will
beep 4 times and the RED LED will be ON.
If failed, an error message will be shown on
the display screen. If Release angle is set,
the gun will automatically run backwards to
the specied angle to release windup from
reaction torque.
To change or set Torque, Angle and Release
Angle see the “Setting Torque and Angle”
section.
To loosen, set the direction switch to ‘L’.
See gure 11 for direction switch
operation. The torque setting will be
automatically set to the maximum allowed
torque for the particular type of gun, i.e. for FG3 Series FLASH-3 GUNS, the max torque is 3150 ft. lbs.
Press and hold the power trigger switch while the socket turns and loosens the nut. In reverse direction,
the torque gun is set to maximum torque in order to loosen the nut. Use extreme caution when running
in this mode.
The FLASH GUN can operate on both left hand and right hand threads. See the “Additional Options”
section for changing to/from left hand or right hand thread modes.
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. If the FLASH GUN reaches its maximum torque before
completing the angle then it will stop with an error: “Angle Failure: Out of Torque Range”
Release Angle: After completing an operation, the gun will automatically run backwards to the
specied angle to release windup from reaction torque.
16 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

CAUTION!
In reverse direction, the torque gun is set to the maximum torque setting in order
to loosen the nut. Use extreme caution when running in this mode.
DO NOT toggle the direction switch while the torque gun is in operation.
Direction Switch
1. (R) Tighten
2. (L) Loosen
Figure 11: Direction Switch
2
1
17
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Setting Torque and Angle
Figure 12 shows the ow chart for setting the desired Torque, Angle and Release Angle.
The main screen shows three settings for Torque, Angle and Release Angle. The three settings are
toggled with the left most soft button. Increase and decrease each value by using the center and
right-most soft buttons.
Follow these steps to set the torque and angle:
1. Set the direction switch to ‘R’ to tighten. See gure 11 for directional switch.
2. Set the desired torque by pressing the soft push buttons corresponding to the up/down arrow
key indicators. When desired torque is displayed, press the left-most soft button corresponding
to the “Right Arrow” to go to the next screen for setting the angle.
3. Set the desired angle by pressing the soft buttons corresponding to the up/down arrow key
indicators. When desired angle is displayed, press left-most soft button corresponding to the
“Right Arrow” to go to the next screen for setting the release angle.
4. Set the desired release angle by pressing the soft buttons corresponding to the up/down arrow
key indicators. When desired release angle is displayed, press left-most soft button
corresponding to the “Right Arrow” to go back to main screen with the torque setting.
Note: Set the Angle to 0, if working only in Torque Mode. The FLASH GUN is ready to operate once
the desired torque setting is entered. There is no need to toggle through the Angle and Release Angle
screens if they are already set to 0.
Figure 12: Setting Torque and Angle
18 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
GO TO
NEXT SCREEN
DECREASE
VALUE
INCREASE
VALUE
SOFT KEYS
CORRESPONDING
TO GRAPHIC
INDICATORS
SETTING TORQUE & ANGLE

TORQUE GUN OPERATION
Tightening
1. Set the direction switch to ‘R’ to tighten. See gure 11 for directional switch.
2. Set the desired torque value as described in “Setting Torque and Angle” section.
3. Make sure the torque gun and the reaction arm are in position for tightening.
4. Ensure the reaction arm is squarely against a solid reaction point.
5. Press and hold the power trigger switch while the socket turns.
6. When specied torque is reached, the FLASH GUN will stop, BEEP once and the Green LED
will turn ON.
7. If Release angle is set, the gun will automatically run backwards to the specied angle to release
windup from reaction torque.
8. If the FLASH GUN fails to set the torque properly, it will BEEP 4 times and the Red LED turn ON
while also showing the error on the display. In case of error, try again by repeating process from
Step 3. If error continues, STOP and check for any abnormalities with the FLASH GUN or the
nut/bolt being tightened.
9. Release the power trigger switch.
10. If the trigger is released prematurely, the display will show an error and the Red LED will turn ON.
In this case, restart tightening process from step 3.
11. The nut is now tight at the current torque setting. Proceed to the next nut.
Tightening with Angle
1. Set the direction switch to ‘R’ to tighten. See gure 11 for directional switch.
2. Set the desired pre-torque and angle values as described in the “Setting Torque and Angle”
section.
3. Follow the steps 3 to 5 for Tightening above.
4. When preset torque is reached, the FLASH GUN will turn the nut in degrees set by the angle.
5. When the specied angle is set, the gun will stop, BEEP once and the Green LED will turn ON. If
the FLASH Gun reaches its maximum torque before completing the angle, then it will stop with
an error: “Angle Failure: Out of Torque Range”
6. Proceed and follow steps 7 to 11 for Tightening above.
Loosening
1. Set the direction switch “L” to loosen. See gure 11 for directional switch. The torque setting will
be automatically set to the maximum allowed torque for the particular type of gun, i.e. for FG3
Series FLASH GUNS, the MAX Torque is 3150 ft. lbs.
2. Make sure the torque gun and the reaction arm are in position for loosening.
3. Make sure the reaction arm is seated squarely against a solid reaction point.
4. Press and hold the power trigger switch while the socket turns and loosens the nut.
5. Release the power trigger switch when the nut is loose enough to be removed by hand.
19
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Memory Options
By pressing the left-most button and holding it, the memory menu will be displayed. Figure 13 shows
the memory options menu. On this menu, you can save the current settings, or load previously stored
settings.
There are 8 memory locations for saving and loading both torque and angle settings. Use the up and
down arrow keys to choose from the highlighted numbered memory locations. Press the left-most button
to select the current memory location. Press the corresponding down arrow key button to save the
current settings to the selected memory location. To load the contents of the memory location, press the
corresponding up arrow key button. To return to main menu without saving/loading, press the left-most
button.
Figure 13: Memory Options
SAVING & LOADING FROM MEMORY
On Main Screen
Press & Hold Right Arrow
Soft Button for 1 second
Select Memory Location Cancel Save Load
20 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING