Power Team TWLC Series Use and care manual

Sheet No. 1 of 28
ev Date: 28 Feb 2008
TWLC Series
Form No. 1000289
LOW CLEARANCE HYDRAULIC WRENCH OPERATING MANUAL
Inst uctions Befo e Use
1. Read and understand all instructions before operating the hydraulic wrench. Most malfunctions in new equip-
ment are the result of improper operation and/or setup. It is the operators responsibility to read, understand, and
follow all safety instructions.
2. Remove the hydraulic wrench from the shipping container and visually inspect all components for any shipping
damage. If any damage is found, notify the carrier immediately. DO NOT USE TOOL.
3. Locate a solid, secure reaction point to absorb and counteract the forces created as the hydraulic wrench is
operated.
4. Make sure the hydraulic hoses are free of the reaction point.
5. Momentarily pressurize the system. If the wrench tends to “ride up” or “creep”, stop and readjust the reaction
arm to a more solid and secure reaction point.
6. Cycle the hydraulic cylinder inside the wrench to ensure proper function.
Note: Each time the hydraulic cylinder inside the wrench is extended
and retracted, it is called a cycle.
Wo king P essu e
The maximum working pressure for this hydraulic wrench is 10,000 psi (68,900 kPa). Make sure all hydraulic
equipment used with this wrench are rated for 10,000 psi (68,900 kPa) operating pressure.
Hyd aulic Connections
• Never connect or disconnect any hydraulic hoses or
fittings without first unloading the wrench and the pump.
• Open all hydraulic controls several times to make
sure the system has been completely depressurized.
• If the system includes a gauge, double check the
gauge to make sure pressure has been released.
• hen making connections with quick disconnect
coupling, make sure the coupling are fully engaged.
Threaded connections such as fittings, gauges, etc.,
must be securely tightened and leak-free.
Loose or improperly threaded fittings can be potentially dangerous if pressurized,
however, over-tightening can cause premature thread failure. Fittings should only be
tightened until they are secure and leak-free.
For a copy of the calibration certificate for a specific torque wrench, email
[email protected] with serial number of the torque wrench
WA NING
IMPO TANT
Operating Instructions and
Parts List for:

Operating Instructions Form No. 1000289
Read and understand this material before
operating or servicing this equipment. Failure
to understand how to safely operate this tool
could result in a accident causing serious injury
or death.
• Only qualified operators should install, operate,
adjust, maintain, clean, repair, or transport this
machinery.
• Inspect tool before use. Replace any worn or
damaged parts. Failure to observe these warnings
can result in severe injury or death.
• eep work area clean and well lit.
• When not in use, wrenches and accessories
should be properly stored to avoid deterioration.
WA NING
To help prevent personal injury,
•Always wear eye protection whenever operating
hydraulic equipment.
• Always wear hearing protection as required.
• Operation, repair, or maintenance of hydraulic
equipment should be performed by a qualified
person who understands the proper function of
hydraulic equipment per local directives and
standards.
• To prevent personal injury, use common sense. Do
not use any power equipment under the influence of
any mood altering substances.
• Never place your hands or other body parts near
a hydraulic fluid leak.
Never use your hands or other body parts to check
for a possible leak.
High pressure fluid can be injected under your skin
causing serious injury and/or infection.
• Electric motors may spark, causing an explosion
when flammable materials are present. Do not
operate in an explosive atmosphere or in the pres-
ence of conductive liquids. Use an air motor or
hand pump instead.
• To prevent electrical shock, make sure the
pump is properly grounded and the proper voltage
is being used.
• To prevent personal injury, the
remote control must only be used by
the wrench operator.
• Do not use hydraulic hoses, pump power, or remote
control cords as means of moving the equipment.
• Make sure all hydraulic connections are securely
attached. Verify that the hydraulic hoses are not
kinked.
• Remain clear of the reaction arm during operation.
Never put body parts between the reaction arm and
the reaction point.
• Always use top quality impact sockets in good condi-
tion and remain clear of sockets during operation
because hidden flaws could cause breakage.
To prevent wrench damage,
always use the properly sized tool
and accessories. Do not use a
wrench for anything other than the
intended purpose.
WA NING
WA NING
This is the safety alert symbol.
It is used to alert you to potential personal injury haz-
ards. Obey all safety messages that follow this sym-
bol to avoid possible injury or death
Denotes an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Denotes a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Denotes a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Caution used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
Denotes an operating or service procedure or condi-
tion considered essential for expedient and efficient
operation and service.
IMPO TANT
CAUTION
CAUTION
WA NING
DANGE
CAUTION

Operating Instructions Form No. 1000289
OPE ATION
For top performance, frequently inspect wrench, pump, and accessories for visual damage
Always follow instructions for proper wrench and pump maintenance.
Do not use other equipment to increase the capability (for example, hammering on socket wrench).
General
Each hydraulic wrench is supplied completely assembled and ready for use. A hydraulic pump is required to pro-
vide the speed and pressure that makes the hydraulic wrench system efficient and accurate.
Connecting the System
The hydraulic wrench head and power pack are connected by a 10,000 psi (68,900 kPa) single-line hose assembly.
Each end of the hose will have one female connector.
NOTE: DO NOT switch the hose connector from female to male. It is necessary for the hose to have a female con-
nector to engage the male connecter on the hydraulic wrench.
Electrical Connections
Make sure the power supply is compatible with the requirements of the electric pump motor. Minimize the length of
extension cords and be sure they are of adequate gauge and grounded.
Air Connections
Make sure the air flow rating is adequate and compatible prior to pressuring the pump. Make sure all connections
are tight and leak-free
Sheet No. 3 of 28
ev Date: 28 Feb 2008
QUICK-CHANGE HEAD
SWIVEL MANIFOLD
HIDRALIC
COUPLINGS
BODY
HEAD RELEASE PIN
REACTIONPAD
CAUTION

Operating Instructions Form No. 1000289
Safety
a) Never exceed the torque wrench maximum working pressure (Advance 689 Bar / 10,000 psi, Retract 69 Bar /
1000 psi)
b) eep hands and fingers clear of the torque wrench head and reaction pad area, before and during operation.
Fingers could be inadvertently trapped if care is not taken.
c) eep other personnel clear of the working area and only allow trained personnel to use the equipment. Ideally
rope off the working area.
d) Prior to operation, ensure that all hoses, sockets and ancillary equipment is undamaged and fit for purpose.
Ensure that all torque wrench components (i.e. head, body, etc.) are properly attached and secure. Ensure that
the head release pin is properly located.
e) Do not strike any of the components, including the socket, with a hammer in order to shock the nut free.
f) Check that reaction structures are strong and rigid enough to accept the torque tool reaction forces. Do not use
wedges, packing pieces, etc as a temporary reaction.
g) Take care when handling equipment. Do not manoeuvre or carry the torque wrench by its couplings. Quick con-
nect couplings are especially susceptible to knocks and damage and therefore care must be taken. Note that
damaged couplings are difficult to connect. Do not force couplings.
j) Do not retighten any equipment whilst under pressure. Do not move or rotate the swivel manifold whilst under
pressure.
l) Some torque wrenches weigh in excess of 28 g, therefore ensure that lifting equipment is available and used.
m) In some instances it may be necessary for the Operator to support the torque wrench whilst it is tightening, i.e.
upside down applications. If the torque tool cannot be strapped into position using ropes, etc, then the operator
must take the utmost care to avoid pinch points.
n) Never use the torque wrench with just one hose connected to the Advance port (port ‘A’). This will cause a pres-
sure intensification within the retract chamber possibly leading to tool damage. Always ensure that both hoses
are connected.
Setting Torque
Electric and Air Pumps
1. Make sure the system is fully connected and the proper power supply is available.
2. Use the Pressure/Torque conversion chart supplied with the wrench to find the required pressure setting.
NOTE: On electric or air pumps, this pressure is set on the pump.
3. Turn on the pump.
4. Press and hold the remote control button.
5. Check the pressure on the gauge.
6. Increase or decrease pressure as required by loosening the locking ring on the pressure regulator valve and
turning the thumb screw.
NOTE: Turn the thumb screw clockwise to increase pressure and counterclockwise to decrease pressure. When decreasing
pressure, it is necessary to turn the thumb screw to a pressure setting below what is desired and gradually increase
pressure to the desired level.
7. Once the desired pressure is stabilized, release the remote control button and tighten the locking ring.
8. Prior to tightening a nut, press the remote control button and confirm the correct pressure has been set.

Operating Instructions Form No. 1000289
Preparing the Torque Qrench for Use
Assembling / Removing the Drive Head
Before the TWLC torque wrench can be used the correct drive head for the nut must be fitted to the TWLC body.
Note that no special tools or spanners are needed to change the drive head. If a drive head is already assembled,
it can be detached by pushing out the head retainer pin, and simply lifting out the body. The drive assembly will
auto-disengage.
NOTE : THE HEAD RETAINER PIN IS HELD CAPTIVE WITHIN THE HEAD SIDEPLATE, IT CANNOT BE
COMPLETELY REMOVED
To assemble a drive head, position the drive head onto the body, engaging the keyways on the inner surface of the
drive head sideplates with the keys on the body. Slide the drive head fully onto the body and push the head retain-
ing pin back into position. See Fig. 2 below.
Note that the body to head drive mechanism will auto engage during the drive head assembly process. If it does
not, it will automatically attach during the first power stroke of the torque wrench.
NOTE: The torque wrench must be fully retracted before the head can be removed or attached.
Sheet No. 5 of 28
ev Date: 28 Feb 2008
NOTE : HEAD RETAINING PIN DOES NOT
DETACH FROM THE BODY. IT IS HELD
CAPTIVE WITHIN THE SIDEPLATE.
DO NOT PUNCH OUT !!
Fig 2. BODY AND DRIVE HEAD REMOVAL AND ATTACHMENT

Operating Instructions Form No. 1000289
Positioning the Torque Tool onto the Nut
The TWLC torque wrench locates directly around the nut, with it’s built-in reaction pad designed to react against an
adjacent nut. Fig. 3 below indicates correct positioning of the torque tool (shown in tightening mode). Always
ensure that the reaction pad butts firmly against an adjacent nut or secure reaction structure.
CORRECT POSITIONING OF TORQUE WRENCH
eaction Point Safety
Extreme care must be taken when selecting appropriate reaction points and the following must be borne in mind at
all times.
• The reaction structure must be rigid enough to accommodate the reaction forces from the torque wrench, which
can be extreme at times. Carefully assess the reaction points for suitability before applying the torque tool. If in
doubt, contact the torque wrench supplier for advice.
• Ensure that the reaction structure is suitably shaped to accommodate the reaction pad, Tapered surfaces are
generally unsuitable as the torque wrench tends to ‘ride up’ the taper, causing adverse tool loads. Flat surfaces
are most preferred.
• If in any doubt over the suitability of the reaction point, contact your torque wrench Supplier as various reaction
accessories are available which may prove more suitable.
• Don’t improvise. Packing pieces, spacers, etc. are dangerous and must never be used as a
makeshift reaction point.
REACTION PAD BUTTED FIRMLY
AGAINST AN ADJACENT NUT

Operating Instructions Form No. 1000289
Operating the Torque Wrench
Setting up prior to operation
Setting up the equipment only takes a few minutes and some simple checks during set up will aid in the success of
the torquing operation.
•Obtain the torque value that is to be used for the tightening operation.
• Ensure that the bolt threads, nut threads and nut to flange contact faces are liberally coated with anti-seize lubri-
cant of known friction co-efficient. Ensure that the lubricant friction co-efficient matches that which has been
used to derive the torque value.
• Make sure that the torque wrench is suitable to deliver the required torque. Should the torque value exceed 80%
of the torque wrench output, consider using a higher capacity torque wrench.
• Use the ‘Pressure – Torque Conversion Chart’ for the particular torque wrench to be used (supplied with the
torque wrench) to obtain the required pump pressure.
• Make sure that the drive head to be used is of the correct type and size. A poor fitting or oversize drive head will
damage nuts, induce inaccurate bolt loads and possible cause operator injury.
Tightening Bolts
1. Connect the torque wrench to the pump unit. Ensure that the couplings are fully screwed together as they are
self-sealing and will restrict oil flow if not fully connected.
2. Prior to applying the torque wrench to the application, the pump output pressure must be pre-set to relieve at
the pressure obtained from the ‘Pressure – Torque Conversion Chart’. This can be done with the torque wrench
connected to the pump and resting on the floor or bench. Applying advance pressure to the torque wrench will
extend the piston until it reaches the end of its stroke whereby the pump pressure will build. Holding the wrench
at the end of its stroke will allow the pump pressure to be adjusted. Retract the torque wrench piston and
advance again making sure that the pump relieves at the desired pressure setting.
Blanking the pump outlets using blank couplings can also be done to carry out the pump pressure setting.
NOTE : Allow time for the wrench to retract. If another advance stroke is made before the torque wrench has
fully retracted, the ratchet mechanism may not engage correctly, causing it to jump a ratchet tooth (probably
damaging the ratchet). Before applying another advance stroke, make sure that the pump is idling at 69 Bar
(1000psi), which indicates full retraction.
3. Apply the torque wrench to the nut to be tightened, ensuring that the reaction pad butts firmly and squarely
against the selected reaction point.
4. Start the pump and advance the torque wrench. As the wrench strokes forward the reaction pad will press
against the reaction point and the nut / socket will rotate. When the torque wrench reaches the end of its stroke,
the pump pressure will build rapidly. Retract the torque wrench (the wrench ratchet mechanism will be heard
clicking as it retracts), and apply another forward stroke
5. Several forward strokes are made until the nut ceases to rotate during the stroke, (known as stalling), but bear
in mind that nut rotation will always cease at the end of the wrench stroke and must not be confused with the
wrench stalling. When the wrench stalls, apply another forward stroke and observe the pump pressure gauge,
which should read the desired pre-set pressure.
6. Retract the torque wrench, stop the pump unit, and remove from the nut.
Sheet No. 7 of 28
ev Date: 28 Feb 2008

Operating Instructions Form No. 1000289
Loosening Bolts
1. Connect the torque wrench to the pump unit. Ensure that the couplings are fully screwed together as they are
self-sealing and will restrict oil flow if not fully connected.
2. Prior to applying the torque wrench to the application, the pump output pressure must be pre-set to deliver the
maximum pressure of 690 Bar (10,000psi). This can be done with the torque wrench connected to the pump and
resting on the floor or bench. Applying advance pressure to the torque wrench will extend the piston until it
reaches the end of its stroke whereby the pump pressure will build. Holding the wrench at the end of its stroke
will allow the pump pressure to be adjusted. Retract the torque wrench piston and advance again making sure
that the pump delivers full pressure.
Blanking the pump outlets using blank couplings can also be done to carry out the pump pressure setting.
3. Apply the torque wrench and socket to the nut to be loosened, ensuring that the reaction pad butts firmly and
squarely against the selected reaction point.
4. Start the pump and advance the torque wrench. As the wrench strokes forward the reaction arm will press
against the reaction point. As the pump pressure builds (and thus torque applied to the nut), the nut will break
free. Once the nut has been released, remove the nut by hand if loose enough, or alternatively use an impact
wrench, it is not recommended to use the torque wrench.
NOTE : Should maximum pump pressure be reached, and the nut has still not broken free, use a higher capacity torque
tool (providing that the nut/bolt material will accept the higher torques without damage). Do not, under any circumstances,
strike the torque wrench or nut / bolt in an attempt to ‘shock’ the nut free.
5. Retract the torque wrench, stop the pump unit, and remove from the nut.
Notes on Loosening Bolts
Loosening of bolts using torque tools can be unpredictable and often unsuccessful, especially if the nuts and bolts
are severely corroded. However, some measures can be carried out to increase the success rate of nut breakout.
• In general, loosening mildly rusted bolts requires up to twice the make up torque to release the nut. Heavily cor-
roded bolts may take up to three times the make up torque. Ensure that the bolt and nut material is strong
enough to accept these higher torques.
• Remove surface rust and scale using a wire brush. Apply releasing oil to the nut, bolt and bearing face, and
allow time for the release oil to soak in and penetrate.
• Only use the torque wrench to break the nut free. Using the torque tool to wind the nut from the bolt can induce
high torsion and reaction forces, therefore it is better to use and impact wrench to completely remove the nut.
• Never strike the torque wrench or nut / bolt in an attempt to ‘shock’ the nut free. This will cause damage to the
torque wrench, and could result in operator injury. Evidence of torque wrench abuse will invalidate the
Manufacturer’s Warranty.

Operating Instructions Form No. 1000289
The following procedure is for use with TWLC torque wrenches and outlines the basic steps in order to carry out
the torque tightening of a flanged joint. It is important that personal protective clothing (gloves, footwear, safety hel-
met, eye protection) is worn at all times not only by the Operator, but also by any personnel within the work area.
The torquing procedure is compiled around using a single torque wrench, the object of the procedure being to
accurately achieve a pre-determined residual bolt stress.
SAFETY: Prior to commencement of bolt torquing ensure that:
• All necessary safety precautions have been carried out
• Personnel involved in torquing are competent and fully trained in the use of hydraulic torque tools and tightening
techniques.
• The procedure and data to be used is authorised by a responsible Engineer.
• The joints / pipework to be worked on are not ‘live’. Joints must be at zero pressure and free from hazardous
substances.
• Torque value selected must be based upon the lubricant applied.
STAGE 1 Number each bolt consecutively, 1, 2, 3 etc
STAGE 2 Using torque wrenches (if necessary), square up the flanged joint.
STAGE 3 Working in a diametrical sequence (tightening opposite bolts) apply the minimum torque available. i.e.
set pump to lowest possible output (1000psi). Note the sequence used.
STAGE 4 Repeating the above noted tightening sequence, apply approximately 25% of the torque value specified
in the torque data.
STAGE 5 Using the same noted tightening sequence, apply approximately 50% of the torque value specified in the
torque data.
STAGE 6 Using the same noted tightening sequence, apply the full torque value specified in the torque data.
STAGE 7 Working in a clockwise (or anti-clockwise) direction, make a final pass around the flange, tightening each
bolt to the full torque value specified in the torque data.
STAGE 8 Following completion of Stage 7, using a hammer, “ring” each nut to ensure that each bolt has been cor-
rectly loaded and that no slack bolts remain.
Sheet No. 9 of 28
ev Date: 28 Feb 2008

Operating Instructions Form No. 1000289
Maintenance and Servicing
Post-Use Maintenance
In order to keep the TWLC torque wrench in good working condition, it is recommended that simple post-use main-
tenance be carried following each period of use.
TWLC Torque wrench
1. Wipe away any debris that may have accumulated, particularly around the swivel manifold and hydraulic couplings.
2. Remove the drive head from the body. Check the following areas (see diagram) :
- Hydraulic Couplings for signs of damage – replace if evident.
- Shuttle pins. Ensure they are present and spring freely.
- Head / Body Pin retainer. Ensure it is undamaged and operates correctly.
- Swivel Manifold. Ensure the spiral retaining ring is present and fitted correctly.
Re-lubricate the areas of the body as shown below using ‘ SP Easyrun 100 MoS2 Anti-Scuffing Paste’. It is
recommended that the drive head is re-assembled onto the body for storage to prevent ingress of dirt into the
drive mechanism.
Note that the torque tool drive components must be lubricated using the specified product only. Using alternative lubricants
will affect the torque tool output and possibly lead to premature component failures.
3. It is preferable to lightly spray the torque wrench with water repellent spray (WD40), prior to placing back into
storage.
Hoses and Ancillaries
1. Clean and inspect each hydraulic hose and quick connect coupling. Check the entire length of the hose for cuts,
abrasions and damage. Any evidence of hose damage and the entire hose must be replaced.
2. Coat each quick connect coupling with a water repellent spray (WD40).
HEAD / BODY PIN RETAINER APPLY LUBRICANT TO PISTON
DRIVE PAD AND UNDERSIDE
OF BODY IN AREAS SHOWN
HYDRAULIC COUPLINGS SWIVEL MANIFOLD RETAINING RING
SHUTTLE PINS