Hytorc LION GUN X Assembly instructions

LION GUN® X Electric Torque Tool
Basic Operations Manual
FORHYTORC
(800-367-4986)
201-512-9500
hytorc.com333 Route 17 N.
Mahwah, NJ 07430
USA

TABLE OF CONTENTS
ORIGINAL INSTRUCTIONS
WARNING Read all safety warnings, instructions, illustrations and specifications provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and/or injury.
Save all warnings and instructions for future reference.
1. TOOL DESCRIPTION 1
2. CARE & MAINTENANCE 2
Case Contents 2
Inspection & Calibration 2
Environmental Considerations 2
Maintenance 2
3. PREP & SETUP 3
Charge The Battery Pack 3
Charging/Fault Indicator 3
Test The Battery Pack 3
Install The Battery Pack 3
4. OPERATION & USAGE 4
Power On & Off 4
Tool Modes 4
Main Bolting Features 4
Home Screen 4
Menu Map 4
Basic Bolting Operations 5
Adjust Torque & Angle 5
Increase Torque 5
Decrease Torque 5
Change Torque Units 5
Change Drive Direction 5
5. MENU NAVIGATION 6
Adjust Torque & Angle 6
Set Release Angle 6
6. MENU 7
Entering Characters 7
Angle Only 7
Release / Set Release Angle 8
Document Job 9
Templates 10
Sequence 11
Settings 16
Admin 21
Service 22
Error Messages 23
Data Fields 24
7. CONVENTIONAL BOLTING 25
Install Reaction Arm 25
Install Socket 25
Conventional Torque Setup 26
Conventional Torque Tightening 26
Conventional Torque Loosening 27
8. BOLTING WITH HYTORC ACCESSORIES 28
Install HYTORC Washer Driver 28
Tighten With The HYTORC Washer Driver 29
Loosen With The HYTORC Washer Driver 29
Install The HYTORC Nut Driver 30
Tighten With The HYTORC Nut 30
Loosen With The HYTORC Nut 30
CHANGELOG 31
Worldwide Commitment to Customized Bolting Excellence for Over 50 Years

The LION GUN® X Electric Torque Tool has built-in data recording, a torque capacity of up to 3,000 ft.-lbs. (4067 Nm) and is
powered by a 36V high-density battery pack. Users can record jobs via Bluetooth or USB cable. This tool is compatible with
conventional sockets with reaction arms, the HYTORC Washer and the HYTORC Nut.
CASE CONTENTS
•LION GUN X
•Battery pack
•Battery pack charger
•Battery pack charger power cable
•Operations manual
•Standard reaction arm
•Side safety handle
•Calibration certificate
•Data cable
•Compliance and battery books
Reaction Spline
Square Drive
Battery Charge Gauge
V Battery Pack
Status LED
USB Port
Side Safety Handle Attachment
Directional Switch
1
. TOOL DESCRIPTION

INSPECTION & CALIBRATION
•Inspect all components. If damaged report any sign of damage and do not use the tool.
•Inspect the tool before each use. Repair or replace any obviously worn or damaged parts.
•When not in use, store all tool components, instructions, and calibration certifications in the plastic storage case.
•Modifying any of the components invalidates the warranty.
•Customer/user is responsible for arranging testing and recalibration.
•Contact FORHYTORC for assistance or further information. HYTORC recommends all tools be tested and
recalibrated periodically. More frequent calibration may be appropriate depending on local practice, usage, and
conditions. Check the certificate or label on the tool for the most recent calibration date.
For Maintenance Guidelines see this document in the HYTORC Library - https://library.hytorc.com/posts/749
MAINTENANCE
ENVIRONMENTAL CONSIDERATIONS
•The LION GUN X Electric Torque Tool is a rugged industrial tool with an electric motor and electronic control. The
following environmental considerations will help maintain reliable tool operation.
•The tool should not be exposed to moisture. Do not operate in rain, snow or extreme humidity.
•The operating temperature range of the tool and battery pack is -4°F (-20°C) to 140°F (60°C).
•The ambient temperature range for tool and battery pack storage is -4°F (-20°C) to 122°F (50°C).
•The ambient temperature range for the charging system during charging is 32°F (0°C) to 104°F (40°C).
•All Cooling Vents should be kept clear of dust, dirt and debris to allow internal fans to maintain airflow to keep the motor
and electronics within temperature limits.
•Do not subject the tool to extremely dusty environments. Do not cover or obstruct vents during operation.
•The tool and electronic components are not certified or approved for explosive environments or areas containing
combustible chemical materials.
•Secure the tool per local practice to protect from dropping.
LION GUN X Operations Manual 2
. CARE & MAINTENANCE

CHARGE THE BATTERY PACK
•The tool comes with the HYTORC Battery Pack Charger (Model: A000791) and one long-life HYTORC 36V battery pack
(Model: P003286).
•Connect the charging cradle to the power supply and plug the power cord into a grounded outlet.
•Make sure the power indicator light is green.
•Push button to test battery pack.
•Insert the battery pack by sliding it into the charger and locking it into place.
•36V battery pack will take approximately 90 minutes to charge.
CHARGING/FAULT INDICATOR
•Flashes green while battery pack is charging.
•Shows continuous green when battery pack is charged.
•Flashes red to indicate fault/battery pack not charging.
TEST THE BATTERY
INSTALL THE BATTERY
Attach: Align the base of the tool with the rails on the
battery pack and slide the battery pack firmly into the handle
until you hear (or see) the lock snap in place.
Remove: Press the release button on the battery pack and
firmly pull the battery pack off of the tool.
•The Lithium-Ion battery pack has a long run life and
will power the tool at full speed until the battery pack is
depleted, so there is no gradual drop in power during use.
•For continuous use, have one or more spare battery
packs charging while the tool is in use.
•Push the TEST button on the side of the battery pack and
the LEDs indicate remaining life.
1 LED On ≤ 25% Battery Charge Left
2 LEDs On ≤ 50% Battery Charge Left
3 LEDs On ≤ 75% Battery Charge Left
4 LEDs On ≤ 100% Battery Charge Left
Test Button
3
. PREP & SETUP

POWER ON & OFF
•On: Push any button on the rear control panel. The HYTORC logo is displayed for a few seconds while the unit powers
up. When the tool is fully powered up, the Home Screen is displayed. A green light indicates that the tool is on.
•Off: (3 options)
• Press center button to go to the Main Menu, scrolls to choose Power Off. OR
• Remove the battery pack from the tool. OR
• From the Home Screen, push and hold center button for 3 seconds.
•The tool always saves current settings when powered off and returns to the same settings and access security level
when the power is turned back on.
TOOL MODES
•TORQUE: Push directional switch down on right side (past the center position) to set the tool to TORQUE.
•LOOSEN: Push directional switch down on the left side (past the center position) to set the tool to LOOSEN.
•TRIGGER LOCK: Slide the switch to the middle position. Users will not be able to engage the trigger when the tool is
on this setting.
HOME SCREEN
This is what the screen looks like
when the tool is turned on. If it does
not, contact FORHYTORC for
assistance or further information.
MENU MAP
MAIN BOLTING FEATURES
LION GUN X Operations Manual 4
. OPERATION & USAGE

BASIC BOLTING OPERATIONS
INCREASE TORQUE
•From the Home Screen, push the left
button (↑), to increase torque.
•At first the torque value will increase
by increments of 1 ft.-lb. Continuing
to hold the left button (↑) down
will increase the torque by 10 ft.-lbs.
Holding it down even longer will
increase the torque by 100 ft.-lbs. until
reaching the maximum calibrated
capability of the tool.
DECREASE TORQUE
•Push the right button (↓) to decrease
torque.
•At first the torque value will decrease
by increments of 1 ft.-lb. Continuing
to hold the right button (↓) will
decrease the torque by 10 ft.-lbs.
Holding it down even longer will
lower the torque by 100 ft.-lbs. until
reaching the maximum calibrated
capability of the tool.
CHANGE TORQUE UNITS
•Go to Main Menu, scroll to
Settings, and press center button
to choose Units.
•Scroll to desired unit. Push center
button to choose unit and it will
return to the Home Screen.
•The tool drive rotates with either
Right Hand (RH) or Left Hand (LH)
operations. (RH = clockwise. LH =
counterclockwise.)
•The tool is initially set to RH
drive, which is the most common
direction.
•Go to Main Menu and push
center button.
•Scroll to Fastener type and push
center button.
•Choose the desired option and
push center button to return to
the Home Screen.
CHANGE FASTENER
HOME SCREEN
•The tool direction is displayed on the
Home Screen along with TORQUE,
ANGLE, RELEASE, FASTENER, and
ACCESS LEVEL.
•Only TORQUE can be adjusted from
the Home Screen.
5
(CONT’D.)

ADJUST TORQUE & ANGLE
This is used for applications that
require turning the fastener through
a specified angle in addition to or
instead of a specified torque value.
SET RELEASE ANGLE
After the tool completes a tightening
operation the gear box may cause
the tool to lock onto the nut. When
a RELEASE ANGLE is programmed
the tool will reverse the motor slightly,
taking force off the gear box and
reaction point to release the tool
without loosening the nut.
•From Main Menu scroll to the Torque & Angle menu and use center button to
select.
•Use the left (↑) and right (↓) buttons to set the desired angle in degrees. Push
the center button to set that value and return to the Home Screen.
•On the Home Screen the angle value can be seen in the top left corner.
•The angle will be added to the TORQUE-ANGLE sequence and will activate
after the completed torque operation, turning the fastener through the specified
angle (up to the maximum output of the tool).
•If an ANGLE DELAY has been set the angle is applied after that specified delay
(from 0-3,000ms; default =500ms).
•From Main Menu scroll to the Release menu and use center button to select the
release angle.
•Use the left (↑) and right (↓) buttons to set the desired release angle. Push the
center button to set that value and return to the Home Screen.
•The angle required will vary depending on the application; set the angle to the
minimum necessary to release the tool without loosening the nut.
•The RELEASE angle is applied after the TORQUE operation (and ANGLE, if set).
•If an ANGLE DELAY has been set, the release angle will be applied after that
specified delay (from 0-3000ms; default = 500ms).
LION GUN X Operations Manual 6
. MENU NAVIGATION

ENTERING CHARACTERS
Use the left (↑) and right (↓) buttons to select character, then press the center button to choose it. Press the center button
twice when finished.
ANGLE ONLY
This applies an angle to the bolt after SNUG. It sets an angle for the nut to rotate.
•From the Settings Menu scroll to Angle Only and press
the center button. Use the left (↑) and right (↓) buttons to
select a value and press the center button.
7
MENU

RELEASE/SET RELEASE ANGLE
Scroll to the Release menu and use the center button. Use the left (↑) and right (↓) buttons to set the desired release angle. Push
the center button to set that value and return to the Home Screen.
•The angle required will vary depending on the application; set the angle to the minimum necessary to release the tool without
loosening the nut.
•The optional RELEASE angle is applied after the TORQUE operation (and ANGLE, if set).
•If an ANGLE DELAY has been set, the release angle will be applied after that specified delay (from 0-3000ms; default = 500ms).
(This feature is optional.)
The LION GUN X’s gear box relaxes automatically to prevent the tool from locking onto the nut, even when release is set to
0°. When an optional RELEASE ANGLE is set for more than 0° the tool will reverse the motor slightly, taking force off the gear
box and reaction point to release the tool.
LION GUN X Operations Manual 8
(CONT’D.)

DOCUMENT JOB
Job ID
• Associates a project with a specific Job ID.
• Use the current Job ID or enter a new one.
• If a Job ID was not set, the prompt will show [NO_
JOBID] and this will become the default Job ID.
• A Job ID can be up to 8 characters.
Create Job ID
• From the Document Job Menu scroll to Create Job ID
and press the center button to select. Use the left (↑)
and right (↓) buttons to select a value and press the
center button.
Import Job IDs
• From the Document Job Menu scroll to Import Job ID
and press the center button. Use the left (↑) and right
(↓) buttons to select a value and press the center
button.
Documents jobs and saves to the tool’s internal memory. That data can later be exported to an app or PC. (While Job Data
can be exported from the tool, it cannot be imported into the tool.)
Start Job Doc
• From the Document Job Menu scroll to Start Job Doc
and press the center button. Use the left (↑) and right
(↓) buttons to select a value and press the center
button.
Export Job Doc
• From the Document Job Menu scroll to Export Job ID
and press the center button. Use the left (↑) and right
(↓) buttons to select a value and press the center
button.
End Job Doc
• From the Document Job Menu scroll to End Job Doc
and press the center button. Use the left (↑) and right
(↓) buttons to select a value and press the center
button.
Delete Job Doc
• From the Document Job Menu scroll to Delete Job
Doc and press the center button. Use the left (↑)
and right (↓) buttons to select a value and press the
center button.
9
(CONT’D.)

TEMPLATES
Create Template
• From the Templates Menu scroll to Create and press
the center button.
• Enter a Template name with the left (↑) and right (↓)
buttons. Press the center button again to end and
save the Template ID.
• Select a Template Type and enter the appropriate
values for that type. There are 2 types — Torque or
Angle Only. Then press the center button.
Select Template Type
• From the Templates Menu scroll to Select and press
the center button. Choose a template from the list
provided and press the center button.
Delete Template
• From the Templates Menu scroll to Delete Template
and press the center button. Choose a template and
press the center button.
Start Multi
• From the Templates Menu scroll
to Start Multi and press the
center button.
• Select the template run order
from the tool’s current saved
template list. Select done when
finished.
LION GUN X Operations Manual 10
(CONT’D.)

SEQUENCE
Guides users through a bolting project that has multiple fasteners and applications. The tool displays the count of each
successful fastener tightening, number of passes performed, and series of items (such as flanges or wheels). Built-in data
recording provides complete and detailed documentation of the project.
User ID
Associates the job with a specific User ID.
• From the Sequence Menu scroll to General/Wheel and press the center button, then scroll to Enter User ID and
press the center button to Accept, or create a new User ID.
• The job data still is recorded if no User ID is documented or if the User ID is left blank [ ].
• There is a 10 character limit. Alphanumeric characters and “_” only.
Set Job ID
Associates the job with a specific Job ID.
• From the Sequence Menu scroll to General/Wheel and press the center button, then scroll to Set Job ID and press
the center button to Accept, or create a new Job ID.
• There is an 8 character limit. Alphanumeric characters and “_” only.
• If the Job ID is left blank [ ], it will default to “NO_JOBID.”
General Sequence
• Collects job-related data fields such as User ID, Job ID, Component ID, Number of Bolts, Number of Passes, and
Bolting Template.
FROM THE SEQUENCE MENU SCROLL TO GENERAL TO SELECT A VALUE AND PRESS THE CENTER BUTTON.
FROM THE SEQUENCE SCREEN YOU WILL BE ABLE TO COMPLETE THE FOLLOWING OPERATIONS.
11
(CONT’D.)

Component ID (General)
• Select the option to either Accept the current component ID or create a new component and press the center
button to confirm selection or Exit Sequence.
• Create a Component:
• This is an optional documentation field to identify the application being worked on.
• There is a 10 character limit (Ex: FLANGE_ID).
• All characters entered will be upper case.
• If a Component ID was not set, the prompt will show empty brackets [ ]. Leaving it blank means this data will not be
documented.
• The term “Component” and the Component ID can be changed by the Admin. (See Edit Sequence Label section.)
Number of Bolts
• Enter the Number of Bolts and press the center button to Accept, Adjust Number or Exit Sequence.
• The sequence is defined by the number of bolts on the application.
• Use the current number of bolts or adjust the value between 1 and 100.
Number of Passes
• Enter the Number of Passes and press the center button to Accept, Adjust Number or Exit Sequence.
• Select the number of passes for the bolting operation.
• Use the current number of passes or adjust the value between 1 and 10.
Bolting Template
• Use the current bolting template or set a different one. (See Creating Template section.)
• To set a different bolting template, choose Select Other.
• You can select a different bolting template at the start of each pass, even if multiple passes are set for that
sequence.
Start Bolting Sequence
• The bolting sequence starts with the first pass and first bolt.
• The tool displays a count of the current pass and current bolt. (See green box to the left.)
• The counters advance in real time with each successful tightening as the bolting sequence
progresses.
Failed Operation (General)
• If an operation fails you can either Retry Bolt or Skip Bolt.
• Retry Bolt - redo the tightening on the same bolt without advancing the counter.
• Skip Bolt - continue to the next bolt, while still advancing the sequence counter.
• All failed operations, retries, and skips are recorded in the documentation data.
LION GUN X Operations Manual 12
(CONT’D.)

Pass Complete
• At the end of each pass you can:
• Confirm and proceed with the sequence by selecting Continue.
• Retry the last bolt.
• Restart the current pass.
• All Retry operations are recorded in the documentation data.
Component Done
• When all bolts on a component are successfully completed, you can continue onto the next
component, start a new job, or exit the sequence.
• Upon exiting, the sequence is terminated, and all counters are reset. The sequence cannot be
resumed.
Exit Sequence (General)
• A bolting sequence can be interrupted at any time by pressing the center button.
• There is an option to exit the sequence once a pass or component is complete.
• Once a sequence is terminated all counters are reset and the sequence cannot be resumed.
• Selecting End Sequence will terminate the current sequence while keeping the Job ID
active.
• Selecting End Job & Seq will terminate the current sequence and end the current JOB ID.
Wheel Sequence
This feature starts
by collecting job-
related data fields
(User Id, Job Id,
Vehicle Id, Bolting
Template, Number
Of Wheels And
Number Of
Lugs on each
wheel). For each
wheel, you can
indicate the axle
number and the
side of the vehicle
for each wheel.
FROM THE SEQUENCE MENU SCROLL TO WHEEL TO SELECT A VALUE AND PRESS THE CENTER BUTTON.
FROM THE SEQUENCE SCREEN YOU WILL BE ABLE TO COMPLETE THE FOLLOWING OPERATIONS.
13
(CONT’D.)

Set Component/Component ID (Wheel)
• Select the option to either Accept the current component ID or create a new component and press the center
button to confirm selection or Exit Sequence.
• Create a Component:
• This is an optional documentation field to identify the application being worked on.
• There is a 10 character limit (Ex: FLANGE_ID).
• All characters entered will be upper case.
• If a Component ID was not set, the prompt will show empty brackets [ ]. Leaving it blank means this data will not be
documented.
• The term “Component” and the Component ID can be changed by the Admin. (See Edit Sequence Label section.)
Number of Wheels
• Enter the Number of Wheels. Press center button to Accept. Or use left (↑) and right (↓) buttons to Adjust Number
and press the center button.
• Use the current number of wheels or adjust the value between 1 and 100.
Number of Lugs
• Enter the Number of Lugs. Press Accept or use the left (↑) and right (↓) buttons to select a value and press the
center button.
• Use the current number of lugs or adjust the value between 1 and 100.
Axle Number
• Select Axle Num. Use the left (↑) and right (↓) buttons to select a value and press the center button. There is also
an option to Revise the number.
• Select the axle number of the wheel to be serviced on the vehicle. This will be documented in the job data.
• Use the current number of axles or adjust the value between 1 and 5.
Select Side (Wheel Side)
• Select Side or Skip. Use the left (↑) and right (↓) buttons to select a value and press the center button.
• This will be documented in the job data.
Start Wheel Sequence
• Confirm Axle + Side. Use the left (↑) and right (↓) buttons to select a value and press the center button.
• The wheel bolting sequence starts with the first wheel and first lug. The tool displays counters of the current wheel
and lugs in the lower right corner.
• The counters advance in real time with each successful tightening during the bolting sequence.
• Loosening operation or unsuccessful bolting does not advance the sequence bolt counter.
LION GUN X Operations Manual 14
(CONT’D.)

Failed Operation (Wheel)
• In the event of a failed operation, there is the option to either Retry Lug or Skip Lug.
• Retry Lug: Redo the tightening on the same lug without advancing the counter.
• Skip Lug: Continue to the next lug, while advancing the sequence counter.
• All failed operations, retries, and skips are recorded in the documentation data.
Wheel Complete
• At the end of each wheel, you can
• Confirm and proceed to the next wheel by selecting Continue
• Retry the last lug
• Restart the current wheel
• All retry operations are recorded in the documentation data.
Exit Sequence (Wheel)
• Interrupt a sequence at any time by pressing the center button.
• Selecting End Job & Sequence will terminate the current sequence and end the active Job ID.
• Once a sequence is terminated, all counters are reset, and the sequence cannot be resumed.
Vehicle Done
• The tool can provide a summary with the vehicle and Job ID once all wheels are serviced.
• You can choose to start a new job or exit the sequence.
• On the summary screen scroll to the desired option and press the center button to select.
Exceptions:
• A sequence project is done only when all of the specified number of passes, bolts, and components are successfully
completed
• Only successful tightening to the required torque value is counted in a sequence.
• Loosening or under-torqued operations do not advance the sequence counter.
• You have the option to skip or redo a bolt.
15
(CONT’D.)

SETTINGS
Units
• From the Settings Menu scroll to Units and press the center button. Use the
left (↑) and right (↓) buttons to select a value and press the center button.
• Foot pounds (ft.-lbs.), Newton-meters (Nm) or kilogram force meters
(kgf-m).
Bluetooth
• From the Settings Menu scroll to Bluetooth and press the center button. Use the left (↑) and
right (↓) buttons to select ON/OFF and press the center button.
Main Menu
Time & Date
• From the Settings Menu scroll to Time/Date and press the center button. Use the left (↑) and right
(↓) buttons to select the time and press the center button to select and move to the next position.
• Use the same method to enter the date.
• Once complete the user can either Accept, Retry or Cancel entry.
LION GUN X Operations Manual 16
(CONT’D.)

Torque Limit
• From the Settings Menu scroll to Torque Limit and press the center button. Use the left (↑) and right (↓) buttons to
select a value and press the center button.
• Limits the available torque range on the tool.
Angle Limits
• From the Settings Menu scroll to Angle Limits and press the center button. Use the left (↑) and right (↓) buttons to
select a value and press the center button.
• Limits the Angle operations on the tool.
• The default minimum and maximum angle limits are 0° and 360°. Any angle limits must fall within that range.
• The Angle selected on this screen is always applied in a ‘Torque & Angle“ sequence within the same trigger event.
17
(CONT’D.)