Hytorc VERSA Series User manual

USER MANUAL
VERSA - series
Model 1 Model 2

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 2
INDEX
1. WELCOME AT HYTORC.................................................................................................................. 3
2. GENERAL INFORMATION............................................................................................................... 3
3. SAFETY INSTRUCTIONS ................................................................................................................ 3
4. INTRODUCTION............................................................................................................................... 6
5. BEFORE USE ................................................................................................................................... 6
6. CONNECTING THE HYDRAULIC PUMP UNIT............................................................................... 6
6.1 BEFORE USE –CHECK PUMPS ...................................................................................................... 6
6.2 HOSE CONNECTION...................................................................................................................... 7
6.3 AFTER USE.................................................................................................................................. 7
7. SETTING OF TORQUE VALUE / BOLT LOAD............................................................................... 8
8. USE OF THE LOW CLEARANCE WRENCH................................................................................... 9
8.1 CHANGE THE RATCHETS............................................................................................................... 9
8.1.1 Versa - Model 1 ..................................................................................................................... 9
8.1.2 Versa- Model 2 .................................................................................................................... 10
8.2 ROTATING DIRECTION................................................................................................................. 10
8.3 REACTION POINT........................................................................................................................ 10
8.4 TO TIGHTEN A BOLTED CONNECTION ........................................................................................... 11
8.5 TO LOOSEN A BOLTED CONNECTION............................................................................................ 11
9. MALFUNCTIONS AND SOLUTIONS............................................................................................. 12
9.1 TORQUE WRENCH ............................................................................................................................ 12
9.2 DRIVING PISTON............................................................................................................................... 12
9.3 PUMPS ............................................................................................................................................ 12
9.3.1 Air pump units......................................................................................................................... 12
9.3.2 Electrical pump units .............................................................................................................. 12
10. MAINTENANCE.............................................................................................................................. 13
10.1 INSPECTION BEFORE EACH USE....................................................................................................... 13
10.2 SMALL MAINTENANCE..................................................................................................................... 13
10.3 MAINTENANCE AT HYTORC........................................................................................................... 13
11. PART LIST VERSA-SERIES (MODEL 1)....................................................................................... 14
12. PART LIST VERSA-SERIES (MODEL 2) - HOUSING .................................................................. 15
13. PART LIST VERSA-SERIES (MODEL 2) –LOW CLEARANCE LINK......................................... 16
14. PART LIST VERSA-SERIES SLIM LINK....................................................................................... 17

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 3
1. WELCOME AT HYTORC
Thank you for buying HYTORC equipment.
This user manual and safety instructions is designed to provide you with the basic knowledge
required to operate and maintain your new HYTORC equipment.
Please read this manual carefully and follow the instructions provided. If you still have any
questions regarding HYTORC bolting equipment, please do not hesitate and call us at
[phone] or contact us at [e-mail].
You also find more information on our website www.hytorc.nl.
2. GENERAL INFORMATION
Your purchase of HYTORC equipment entitles you to the following HYTORC services:
Instructions to your employees within your organization by a HYTORC specialist
Free annual inspection of your HYTORC equipment
24-hour service
When you need help abroad? No problem! We help you!
HYTORC equipment according to the newest technology
A full year complete warranty
In case of failure under warranty of standard tools, substitutional rental equipment can be
supplied at request
Qualified work force employable for solutions at difficult challenges
3. 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
instructions will assist you.
Read all instructions.
Keep work area clean and well lit.
Consider work area environment. Electrical Pumps should never be used in an
atmosphere that 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.

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 4
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 equipment properly. When not in use, tools and accessories should be properly
stored to avoid deterioration.
Use right tool. Do not force small tools or attachments to do the job of a larger tool. Do
not use a tool for purposes not intended.
Proper safety attire. When handling/operation hydraulic equipment use work gloves, hard
hats, safety shoes and other applicable clothing.
Use safety glasses with side covers.
Moving equipment. Do not use hydraulic hoses, uni-swivels, pump power or remote
cords as means of moving the equipment.
Maintain your HYTORC equipment with care. For top performance, inspect tools, power
pack and accessories for visual damage frequently and always prior to use. Always follow
instruction for proper tool and pump maintenance. Refer to the Operations Maintenance
Section in chapter 10 for further clarification.
Stay alert! Watch what you are doing. Use Common sense. Do not use power equipment
under the influence of any mood altering substances.
Prior to operation:
-Ensure that all hydraulic connections are securely connected and there is no leakage;
-Verify that the hydraulic hoses are not kinked or otherwise damaged;
-Ensure the square drive and its retainer are fully and securely engaged;
-Be certain that all connectors, elbows, fitting and swivels are not bent, loose or
damaged.
Prior to use:
-Check sockets for size, quality and flaws (do not use if questionable);
-Cycle tool to ensure proper function;
-Locate a solid, secure reaction point;
-Be sure the reaction arm retaining 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.
Stay away of the reaction points. Remain clear of the reaction arm during operation and
never punt body parts between reaction arm and reaction surfaces!

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 5
Always use quality accessories. Always use top quality impact sockets in good
condition that are the correct size and fully engage the nut. Hidden flaws, however, remain
a possibility that could cause breakage, so stay clear of sockets during operation.
Do not use other equipment to enhance performance. For example a hammer on the
socket or tool.
Comment:
HYTORC pumps are designed to operate HYTORC tools only and vice versa. Damage may
occur to the pump or the product that is being operated due to misuse.
You can find a version of the instructions on the reverse side of the torque charts.
STORE THESE SAFETY INSTRUCTIONS WITH YOUR HYTORC TOOL!

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 6
4. INTRODUCTION
The VERSA-series is a low clearance torque wrench, specially designed for applications with
limited clearance above the nut or bolt head. The small radius of the ratchet link needs little
space and the long neck can also reach deep-lying nuts.
To tighten or loosen nuts with sockets, HYTORC has different tools with square drive, such as
the Avanti, MXT and EDGE.
5. BEFORE USE
All HYTORC products have been tested and are ready for use at delivery. In some cases, you
need to fill the supplied hydraulic oil in the pump unit before use.
The system accuracy of your HYTORC tool is within ± 3%. This accuracy can be certified
through calibration by our own calibration system. All new tools are delivered with a calibration
certificate.
A HYTORC torque tool is only complete with a hydraulic pump and a high-pressure twin hose.
To assure a safe and good operation of your equipment it is necessary to operate correctly
and maintain regularly
6. CONNECTING THE HYDRAULIC PUMP UNIT
Important
Before use you have to fill the HYTORC pump units with, the separate delivered, hydraulic
oil (if it is not already done prior to delivery).
If you operate your HYTORC torque tool with another pump brand, please note the
restricted pressure of 700 BAR maximum
6.1 Before use –Check pumps
Air driven pump units
Use at least an ¾” air hose and ½” couplers. The working pressure is 6-10 BAR. During
running the air pressure is not allowed to drop under 4,5 BAR.
Check the water separator by opening the drain.
Check if the oil level in the lubricator is sufficient. And check during running if the lubricator
drops the subscribed drops of oil, approximately 4-6 drops per minute for most pumps.
Electrical driven pump units
Assure yourself of using the right voltage according the pump specifications. You find
these on the pump cover or electrical box.
Beware of overvoltage and undervoltage! (too long or too thin extension cable will cause a
voltage decrease).
Use the hydraulic pomp only if the green/yellow grounding cables are connected.
If needed, use an 2,5 mm² electrical extension cable, unreel the cable wince completely.

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 7
6.2 Hose connection
A twin hose connects the torque wrench and the hydraulic pump unit. Each hose has couplers
at each end. One hose has female couplers at both ends and the other hose has male
couplers at both ends. To avoid tool malfunction, do not reverse connectors!
We have three different types of couplers; rotating couplers, rotating couplers with locking
devices and quick couplers. The different types cannot be connected between each other.
IMPORTANT
You cannot connect 2 or 4 hoses to each other. If necessary, you can connect 3 or 5 hoses.
Use always an odd number of hoses.
Push the hose parts and couplers to each other.
Screw the couplers hand tight. Do not use locking pliers.
If you want to detach, disconnect the return hose first. If impossible, press once briefly on
the remote control push button.
Attention! During operation the couplers can become loose unnoticed, this makes oil flow
impossible. The tool operates no longer.
ASSURE YOURSELF THAT ALL COUPLERS ON THE PUMP
AS WELL AS ON THE TOOL ARE TIGHTENED PROPERLY!
THIS IS THE MOST COMMON OPERATION FAILURE!
6.3 After use
Reel the hoses.
Protect the couplers against dirt and damage by connecting the end parts of the hose to
each other.
PUMP
TOOL
PUMP
TOOL
PUMP
TOOL
WRONG
RIGHT

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 8
7. SETTING OF TORQUE VALUE / BOLT LOAD
The HYTORC hydraulic pump unit has a working range of 20 BAR until maximum 700 BAR.
Within this range the pressure is infinitely adjustable.
Follow the next steps to adjust the right torque:
1. Every tool type has his own pressure/torque chart, supplied with your HYTORC tool.
Search for the right torque in the preferable column (Nm, kgm or ft.lbs.) in the chart and
read the right pressure to adjust the
pump in BAR (right) or PSI (left).
2. Turn the wing nut (on the tank cover of the pomp unit) completely leftwards = upwards. If a
locking knob exists, please release this one first.
3. Put the torque tool somewhere on the ground or another safe place without placing on a
nut.
4. Pick up the remote control and push the start/run button. The pump starts running
and the tool makes one stroke. Repeat twice and check if the tool turns fine.
5. NEXT: AS FROM NOW KEEP THE START BUTTON PRESSED!
6. Turn the wing nut to the right until
the pressure gauge presents the
desirable pressure. After setting, you can
release the start button.
7. Push the button after several
seconds again and check the pressure.
Fix the locking if adjustment is fine.
Finally, check the pressure again.
Important
To change the pressure you first have to turn
the wing nut back to lower pressure (0). Next
you can set the desired pressure like explained
in this chapter.

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 9
8. USE OF THE LOW CLEARANCE WRENCH
Place the hydraulic cylinder with the low clearance ratchet on the nut and beware to place the
ratchet over the nut completely. Even when the nut is painted or rusted!
8.1 Change the ratchets
The VERSA-series use interchangeable ratcheting links. It is possible to use the hydraulic
cylinder with different sizes of ratchets. Every size has its own ratchet. Before you change the
ratchet, run the pump unit connected to the hydraulic cylinder to retract the pistons to start
position. Change the ratchet as follows:
8.1.1 Versa - Model 1
1. Firmly hold the cylinder and pull out the two safety pins as shown
on the picture.
2. Next you slide the cylinder out of the ratchet. Inside you will find
another safety pin. Push out the pin.
3. You can take the ratchet from the cylinder and replace it for
another one.
4. Before assembling, place the third safety pin inside first. Next,
you slide the cylinder in the ratchet and ensure that the safety
pin holes of cylinder and ratchet are in line.
5. Finally, you replace the safety pins. After changing the ratchet,
you have to test if the hexagon of the tool turns and everything
operates as desired, before placing the tool on the nut.

FOR MORE INFORMATION
HYTORC Nederland BV |Platinawerf 8 - 6641 TL Beuningen - NEDERLAND | Tel: +31(0)24 - 3 660 660 | www.hytorc.nl
HYTORC Benelux BVBA |Ysselaarlaan 65B - 2630 Aartselaar - BELGIË | Tel : +32(0)38 - 705 220 |www.hytorc-benelux.be
ENG-versa- User manual.docx Version 2.5 / Mar-16 10
8.1.2 Versa- Model 2
Model 2 has only 1 link pin. If you pull out this one, you can easily swung up the hydraulic
cylinder and take off the ratchet.
Next you take another ratchet link, place the ‘hook’ on the end of the cylinder into the cutout
on the top of the ratchet link. The cylinder is then swung down to rest along the base of the
link side plate. At this point, the link pin hole of the cylinder and the ratchet link will align. Insert
the link pin to secure both parts.
8.2 Rotating direction
For tightening, simply engage the nut with the right side of the link facing down. For loosening,
the left side of the link faces down. The direction is indicated with an arrow sign on the tool.
Loosening Tightening
8.3 Reaction point
Place the tool at the bolted connection and move the tool by hand towards the reaction
point. Ensure if hoses are clear of any obstacles.
Ensure if the steel reaction pad protion of the ratchet abuts solidly to the chosen reaction
point.
Ensure that no odd parts are in the operation zone. Keep in mind that the tool can move a
bit while operating. Ensure hydraulic hoses and couplers are clear of any obstacles during
operation.
Stay clear of the tool and reaction point with your fingers or other body parts!
Press the start button for one second button to find out if everything works properly.
Cutout
Hook
Link pin