Hytorc TORQUE GUN ZGUN-A.75 User manual

3rd. Edition Aug. 2015

This manual applies to all tool part numbers in the Z-Gun Product Family. It is
recommended that 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: The Torque Gun Company 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.
Copyright © 2015 by HYTORC Division UNEX Corporation. All rights reserved. Reproducon,
adaptaon, or translaon without prior wrien permission is prohibited, except as allowed under the
copyright laws.
3rd. Edion. Printed in USA. August 2015
Complies with standards publicaon BS EN 82079-1:2012
Z-GUN PRODUCT FAMILY:
ZGUN-A.75, ZGUN-A1, ZGUN-A2, ZGUN-A3
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
2BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

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
facebook.com/torcgun twitter.com/torcgun youtube.com/torqueguncompany
TOTAL SATISFACTION GUARANTEED 1-888-GUN-2-GUN
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 in that Calendar Year.
• 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.

Z-GUN™
OPERATIONS MANUAL
CONTENTS
Warranty
Z-Gun Overview
Z-Gun Set Up and Use
Z-Gun Thumbscrew
Z-Gun Safety
Z-Gun Specifications
Handle Installation
Directional Control Settings
Torque/Speed Settings
Maximum Torque Operation
High Speed Operation (Impact)
Auto Release Feature
HYTORC Washer and Accessories
Z-Driver Installation
Typical Usage
FRL (Filter, Regulator, Lubricator) Overview
FRL Setup and Use
FIGURES
Figure 1: Z-Gun with HYTORC Washer Driver
Figure 2:- Thumb Screw Removal and Grip Handle Insertion
Figure 3: Z-Gun Dimensions
Figure 4: Z-Gun Handle Installation
Figure 5: Removing Flathead Screw, Retaining Ring, and Reversing Thumb Switch
Figure 6: Directional Control Settings
Figure 7: High Speed Shifter and Low Speed Shifter
Figure 8: Auto Release Button
Figure 9: HYTORC Washer and Z-Driver Assembly
Figure 10: Z-Driver Alignment and Screw Installation
Figure 11: Knurled Surface facing up
Figure 12: Application of lubricant with knurled side of HYTORC Washer facing the ange.
Figure 13: Z-Gun and Fastener Placement
Figure 14: FRL Unit (Shown without silencer)
Figure 15: FRL Unit
Figure 16: Detaching FRL Reservoir
Figure 17: FRL Unit, Lubricator
Figure 18: Adjusting FRL Regulator
Figure 19: Adjusting FRL Oil Flow
TABLES
Table: Z-Gun Specifications
5
6
7
7
8
9
10
11
11
11
12
13
14
14
15
17
19
6
7
9
10
10
11
12
13
14
14
15
15
16
17
20
20
21
22
23
9
4BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

5
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
The Z-Gun has a one year limited warranty. Every TORQUE GUN tool is tested before leaving the fac-
tory 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 non-TORQUE GUN owned 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 limita-
tion 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.
WARRANTY

Z-GUN OVERVIEW
The Z-Gun is a special implementation of the dual speed pneumatic torque wrench. These pneumatic
tools allow the operator to rundown and tighten nuts without the hassles of installing and removing a
reaction arm. Each Z-Gun is equipped with a special mechanism which allows for switching between
high speed (impact mode) and low speed (maximum torque mode). The Z-Gun is designed for use with
the HYTORC Z-Washer™ and HYTORC Z-Driver™.
6BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
Figure 1 - Z-Gun with Z-Washer Driver

NOTE
The torque wrench must be running while the pressure is being set. When the torque wrench is stopped, the
gauge displays a slightly higher pressure than was set with the Z-Gun running. This is normal, proper torque is
delivered under working load.
Z-GUN SETUP AND USE
Proper setup and use of the Z-Gun before and during installation ensures accurate results and safe op-
eration. The FRL Unit provided with the Z-Gun must be used with the hose provided to ensure the tool’s
durability. See the FRL Unit Overview section below for more information.
Setting a Torque Value
1. Determine the air pressure needed to achieve the desired torque by consulting the Pressure/
Torque Conversion Chart provided with each tool.
2. Open the air supply connected to the FRL unit and run the torque wrench while setting the pres-
sure on the gauge.
Z-Gun Thumb Screw
1. When you receive your Z-Gun It has a red thumb screw (Thumb screw is installed to maintain
shifter bracket alignment)
2. Remove the thumb screw
3. Insert the grip handle, reverse instruction when Z-Gun is stored back in case
7
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
Figure 2 - Thumb Screw (Left) Removal (Center) Grip Handle Insertion (Right)

Z-GUN SAFETY
Only qualied personnel who have thoroughly read this document may operate this tool. Failure to safely
operate this tool may result in serious injury or death.
• Inspect all Z-Gun 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 dam-
aged tools and equipment.
• Ensure your working area is clean and unobstructed before beginning work.
• Z-Gun maintenance and repair must be performed by a qualied pneumatic technician.
• Modifying a Z-Gun or Z-Gun accessory is dangerous and invalidates the warranty.
• Inspect the tool before each use. Replace any obviously worn or damaged parts.
• When not in use, store the Z-Gun and Z-Gun accessories in the plastic storage case supplied
with the tool. Do not expose the gun to high humidity or large temperature variations.
Personal Protective Equipment
• Always wear the appropriate personal protective equipment when operating a Z-Gun including
gloves, safety goggles, hearing protection, hard hat, and safety shoes.
Air Supply Requirements
• The air supply line must be ½-inch minimum diameter to allow adequate air ow to the Z-Gun.
• The air supply must provide a minimum of 90 psi at 30 cfm.
• Ensure that air line ttings are tight and leak free. Do not over tighten air line ttings.
• Always use the Filter Regulator Lubricator (FRL) Unit provided with the Z-Gun. Never use a sub-
stitute oiler and regulator.
• Open the air supply connected to the FRL unit and run the Z-Gun while setting the pressure on
the regulator gauge.
• Set the air pressure to the PSI needed to achieve desired torque shown on the provided pres-
sure/torque conversion chart.
NOTE
Set the air pressure at the FRL while the tool is running as described in FRL Setup and Use.
8BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Z-GUN SPECIFICATIONS
General dimensions for the Z-Gun.
Figure 3 - Z-Gun Dimensions
MODEL JGUN-A.7-Z JGUN-A1-Z JGUN-A2-Z JGUN-A3-Z
TORQUE RANGE 175-750 FT/ LBS
1095.5 NM
300-1200 FT/ LBS
1537.5 NM
531-2237 FT/ LBS
3033 NM
685 - 3083 FT/ LBS
4178.6 NM
DRIVE SIZE 3/4” SQ 3/4” SQ 1” SQ 1” SQ
HEIGHT (H) 9.47” (24.1 CM) 9.47” (24.1 CM) 9.47” (24.1 CM) 9.52” (24.2 CM)
LENGTH (L) 11.27” (28.6 CM) 11.92” (30.3 CM) 14.46” (36.7 CM) 15.64” (39.7 CM)
WIDTH (W) 3.29” (8.4 CM) 3.29” (8.4 CM) 3.40” (8.6 CM) 3.40” (8.6 CM)
RADIUS 1.71” (4.3 CM) 1.71” (4.3 CM) 1.99” (5.0 CM) 2.00” (5.1 CM)
HANDLE LENGTH (HL) 6.94” (17.6 CM) 6.94” (17.6 CM) 7.09” (18.0 CM) 7.15” (18.2 CM)
HANDLE WIDTH (HW) 2.12” (5.4 CM) 2.12” (5.4 CM) 2.24” (5.7 CM) 2.24” (5.7 CM)
RUNDOWN RPM (NO LOAD) 4200 RPM 4000 RPM 3250 RPM 2500 RPM
FINAL TORQUE RPM 12 RPM 7 RPM 5 RPM 4 RPM
Table - Z-Gun Specications
9
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

HANDLE INSTALLATION
• Insert handle into threaded hole located on the shifter mechanism.
• If handle cannot be attached easily, loosen adjacent at head screw. Once handle is secured in
place, retighten screw.
• The Z-Gun can be setup for left handed users by installing the handle and the thumb switch
mechanism on opposite side of the shifter. Setup Requires:
• Removing the at head screw
• Removing retaining ring (using snap ring pliers)
• Reversing the thumb switch mechanism
• Re-installing retaining ring and at head screw
• Make sure to have the handle rmly secured before use.
10 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
Figure 4 - Z-Gun Handle Installation
Figure 5 - Removing Flathead Screw (Left) Removing Retaining Ring (Center) Reversing Thumb Switch (Right)

DIRECTIONAL CONTROL SETTINGS
• To switch the square drives rotational direction push button on either side of gun in until it
locks in place.
• Press button in forward direction for clockwise rotation and in reverse direction for counter
clockwise rotation.
TORQUE SPEED SETTINGS
The Z-Gun has two operation settings: High Speed (Impact mode) and Low speed (Maximum torque)
Maximum Torque Operation
• The Z-Gun functions in maximum torque mode when the handle is pulled closest to the operator.
• No reaction arm is needed because the Z-Washer also serves as a reaction washer.
• The Z-Gun will turn the hex nut while the driver housing is held in place by the Z-Washer.
• During operation the square drive will move while the housing of the Z-Gun will
remain stationary.
• While in maximum torque mode the Z-Gun behaves similar to that of a single speed jGun;
tightening the nuts until the desired bolt load is reached.
Figure 6 - Directional Control Settings
11
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

NOTE
DO NOT TRY TO RUN Z-GUN WHILE SHIFTING UNLESS SHIFTER IS
LOCKED IN EITHER POSITION.
Figure 7 - High Speed shifter position (left) and Low Speed shifter position (right)
High Speed Operation
• The Z-Gun operates in high speed when the handle is in the forward position. Here the handle
attachment will be the furthest from the operator.
• Once fully engaged, the gearbox housing and square drive will begin to rotate at high speed.
Utilize this feature when you want to run nuts on or off a stud quickly. When using the high
speed feature, be sure to hold the handle rmly as the gun reaches high RPM suddenly.
Shifting Between Modes
• To shift into high speed mode (impact), depress thumb switch and push handle forward until it
locks into position.
• For low speed, depress thumb switch and pull handle back towards operator until it locks
in position.
12 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

AUTO RELEASE FEATURE
On occasion, tools that apply high torque values may become locked on to the application. The
HYTORC Z-Gun is equipped with an auto release button for removing the socket with minimal effort.
• There is no longer a need to reverse the direction of square drive to release tension.
• Simply depress the button located on the back cover of the Z-Gun. This will automatically
reverse the direction of the square drive to free the socket from the fastener.
• Press and hold the release button until the gun is free from the application.
Figure 8 - Auto Release Button
13
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Figure 10 - Z-Driver Alignment (Left) Screw Installation (Right)
HYTORC WASHER & ACCESSORIES
In order to provide a safe bolting experience, the Z-Gun is designed for use with the patented
HYTORC Washer & Z-Driver.
• The HYTORC Washer takes the place of the traditional at washer used widely in the bolting
industry. It removes the need for dangerous reaction arms and eliminates the potential for pinch
points.
• The Z-Driver utilizes the HYTORC Washer outer prole to apply torque to the fastener.
• The Z-Driver consists of three parts which are attached directly to body of the gun.
• Driving Socket
• Outer Sleeve
• Spline Adapter
Z-Driver Installation
Figure 9 - HYTORC Washer (Left) Z-Driver Assembly (Right)
14 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Figure 11 - Knurled Surface facing up
• Attach spline adapter by aligning the tapped holes on the Z-Gun with the tapped holes on the
spline adapter.
• Align the square drive with the internal driving socket. Make sure the square is fully engaged.
• Install the outer sleeve by aligning the slots with the taps on the spline adapter.
• Secure the Z-Driver assembly to the Z-Gun using the 3 screws supplied.
Typical Usage
• Install a Z-Washer on application with the knurl ALWAYS FACING THE FLANGE FACE. The
fastener will be in contact with the smooth side of washer.
Figure 12 - Application of lubricant with knurled side of Z-Washer facing the ange.
• Always apply lubrication between HYTORC Washer and the face of fastener.
15
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Figure 13 - Z-Gun and Fastner Placement
• Place gun on fastener aligning outer sleeve with Z-Washer and inner driving socket with
the hex nut.
• The Z-Gun will turn the hex nut while the driver housing is held in place by the Z-Washer.
For a list of all available sizes/tech data on different Z-Driver assemblies
contact Hytorc or visit Hytorc.com
NOTE
DO NOT ADD LUBRICATION ON KNURLED SURFACE. THE SPACE
BETWEEN THE FLANGE AND WASHER MUST REMAIN CLEAN FOR
OPTIMUM PERFORMANCE.
16 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

Figure 14 - FRL Unit (Shown without silencer)
17
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
FILTER/REGULATOR/LUBRICATOR
(FRL) UNIT OVERVIEW
A Filter/Regulator/Lubricator (FRL) Unit is provided with every Z-Gun and must be used in conjunction
with the tool. In addition, the FRL Unit must be used with the 12’ hose provided for connection to the
Z-Gun to ensure the tool’s durability. The FRL Unit removes water and foreign material from your air sup-
ply, regulates the air pressure, and mixes pneumatic tool oil into the air to keep your Z-Gun lubricated.
Operating the Z-Gun without the FRL Unit will void the warranty and may cause damage to the air motor
and gearbox. Incorrect setting of the lubricator unit may result in a shortage of lubrication to the air mo-
tor and gearbox resulting in damage to the tool.
Personal Protective Equipment
Only qualied personnel who have thoroughly read this document may operate this tool. Failure to
safely operate this tool may result in serious injury or death.
• Inspect all FRL 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 dam-
aged tools and equipment.
• Ensure that your working area is clean and unobstructed before beginning work.

Technical data and specifications are subject to change without notice.
• FRL maintenance and repair must be performed by a qualied pneumatic technician.
• Modifying an FRL or FRL accessory is dangerous and invalidates the warranty.
• Inspect the unit before each use. Replace any obviously worn or damaged parts.
• When not in use, properly store the FRL, hoses and couplers.
• Analog gauges are standard to our FRL units. Digital gauges are not recommended for certain
applications. Please consult a Technical Representative before using a digital gauge unit.
• Always wear the appropriate personal protective equipment when operating the FRL and Z-Gun
including gloves, safety goggles, hearing protection, hard hat, and safety shoes
Air Supply Requirements
• Air supply line must be ½-inch minimum diameter to allow adequate air ow to the Z-Gun.
• Air supply must be 90 psi @ 30 cfm minimum.
• Ensure that air line ttings are tight and leak free. Do not over tighten air line ttings.
• Always use the FRL Unit provided with the Z-Gun. Never use a substitute oiler and regulator with
a Z-Gun.
• Open the air supply connected to the FRL unit and run the torque wrench while setting the pres-
sure on the gauge.
• Set the air pressure to the PSI needed to achieve desired torque shown on the provided pres-
sure/torque conversion chart.
• Open the air supply connected to the FRL unit and run the torque wrench while setting the pres-
sure on the gauge.
NOTE
Set the air pressure while the tool is running as described in the Setup and Use section.
18 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

19
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
FRL SET UP AND USE
Proper setup and use of the FRL unit will ensure accurate results and safe operation. The three compo-
nents of the FRL must be checked individually to ensure correct operation.
• Empty the lter reservoir before use.
• If you are using a digital gauge, press the ZERO button on the regulator gauge before setting the
operating pressure.
• Adjust the lubricator ow properly.
• Fill the lubricator reservoir with pneumatic tool oil (provided with the FRL unit).
Important FRL Operating Procedures
• Only operate the unit with the air ow moving in the direction indicated by the arrows on top of
the unit.
• Empty the lter reservoir before each use to remove water and sediment.
• Fill the lubricator reservoir only with pneumatic tool oil before each use.
• Adjust the lubricator ow to one (1) drop per ten (10) seconds (shortage of lubrication may cause
motor to seize).
• Use only the hose provided with the FRL for connection to the unit; a change in hose length may
affect tool durability and accuracy.
Emptying the Filter Reservoir
You may empty the lter reservoir of water and foreign material in two ways:
• Emptying water through the release valve on the underside of the reservoir.
a. To use the release valve, push the valve until the water or debris drains out of the
reservoir.
• Removal of the reservoir. To remove the reservoir from the FRL unit:
a. Push down on the black square button to unlock the reservoir.
b. Twist the lter reservoir until the two lines on the FRL body and the lter reservoir
are aligned.

20 BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
Figure 15 - FRL Unit
c. Pull the lter reservoir down to detach from lubricator body.
d. Discard the contents of the lter reservoir.
Figure 16 - Detaching FRL Reservoir