Powertrain Walterscheid SW42 User manual

697028 / ADLS1002 - 3
Date 09.14 | Update 1.2023
Read and observe this operating
ma
nual before the initial
commis
sioning.
Keep this manual for future use.
OPERATING MANUAL
SPECIAL TOOL SW42
Torque tester for overload clutches

IDENTIFICATION DATA
2
Identification Data
Enter the identification data of the special tool here. The
identification data are on the type plate.
Type:
Serial number:
Year of manufacture:
Address of the manufacturer
WALTERSCHEID GmbH
Address:
Town:
Tel.:
website:
E-mail:
Hauptstraße 150
D-53797 Lohmar
+ 49 (0) 22 46 12 - 0
www.walterscheid.com
[email protected]
Formalities for the operating manual
Creation date: Date 09.14 | Update 1.2023

Copyright WALTERSCHEID GMBH, 2014
All rights reserved.
Reprints whether in whole or in part are only allowed with the
permission of
WALTERSCHEID GMBH.
Printed in Germany Read and observe this operating
ma
nual before the initial
commis
sioning.
Keep this manual for future use.

PREFACE
3
Preface
Dear Customer,
You have purchased a quality product from the extensive
product range of WALTERSCHEID GMBH. Thank you for
your confidence in us.
On receipt of the special tool, establish whether transport
damage has occurred or parts are missing. Check the
completeness of the supplied special tool including the
ordered special equipment using the delivery note.
Compensation will only be made if complaints are made
immediately.
Read and observe this operating manual, particularly the
safety instructions, before the first start-up. You can use the
benefits of your newly acquired special tool completely after
the careful reading.
Ensure that all operators of the special tool read this
operating manual before the special tool is put into
operation.
Please contact us if you have any questions about handling
the special tool or this operating manual.
Regular maintenance and replacement in good time of worn
or damaged parts increase the service life of your special
tool.
User Assessment
Dear Reader,
Our operating manuals are updated regularly. Your
suggestions for improvement help us to make the operating
manual more and more easy to use. Please send us your
suggestions by fax or E-mail to:
WALTERSCHEID GMBH
Address:
Town:
Tel.:
E
-
mail:
Hauptstraße 150
D-53797 Lohmar
+ 49 (0) 22 46 12 - 0
info@
walterscheid.
com

CONTENTS
4
1 User Information ................................................................................................ 6
1.1 Purpose of the document ...................................................................................................... 6
1.2 Location details in the operating manual .............................................................................. 6
1.3 Illustrations used ................................................................................................................... 6
1.4 Terms used ........................................................................................................................... 7
2 Product Description........................................................................................... 8
2.1 Overview – assemblies ......................................................................................................... 9
2.2 Safety devices and protective equipment ........................................................................... 11
2.3 Intended use........................................................................................................................ 12
2.4 Danger zone and danger points.......................................................................................... 12
2.5 Type plate and CE marking................................................................................................. 13
2.6 Technical data ..................................................................................................................... 13
2.7 Conformity ........................................................................................................................... 14
3 Safety Instructions........................................................................................... 15
3.1 Safety-conscious working ................................................................................................... 15
3.2 Organisational measures .................................................................................................... 16
3.2.1 Obligations of the owner ......................................................................................... 16
3.2.2 Obligations of the operator ..................................................................................... 17
3.2.3 Qualification of the persons .................................................................................... 18
3.3 Product Safety..................................................................................................................... 20
3.3.1 Safe operation of the special tool ........................................................................... 20
3.3.2 Safety devices and protective equipment............................................................... 20
3.3.3 Structural changes .................................................................................................. 20
3.3.4 Spare and wear parts and auxiliary materials ........................................................ 21
3.3.5 Warranty and liability............................................................................................... 21
3.4 Basic safety instructions...................................................................................................... 22
3.4.1 General safety and accident prevention instructions.............................................. 22
3.4.2 Hydraulic system..................................................................................................... 23
3.4.3 Cleaning, maintenance and repairs ........................................................................ 24
3.5 Action-related safety instructions and important information .............................................. 25
3.5.1 Action-related safety instructions............................................................................ 25
3.5.2 Important information .............................................................................................. 26
3.6 Warning signs and instruction signs.................................................................................... 27
3.6.1 Warning signs ......................................................................................................... 27
3.6.2 Instruction signs ...................................................................................................... 30
3.6.3 Placement of the warning signs and instruction signs............................................ 31
3.7 Hazards in the case of non-observance of the safety instructions and warning signs ....... 32
4 Preparing Special Tool for Use....................................................................... 33
4.1 Transport ............................................................................................................................. 33
4.2 Unpacking ........................................................................................................................... 34
4.3 Scope of delivery / equipment............................................................................................. 35
5 First Start-up .................................................................................................... 36
5.1 Connecting hydraulic hose lines of the gearbox to the connections of the hydraulic drive 37
5.2 Connecting power supply.................................................................................................... 38
5.3 Installing "SW42 Analysis2_0" program.............................................................................. 39
5.3.1 System requirements .............................................................................................. 39
5.3.2 Installing the program as follows ............................................................................ 39
5.3.3 Setting up computer to receive incoming Bluetooth connections ........................... 40

5
6 Setting up Special Tool....................................................................................42
6.1 Inserting / removing profile pins in / from measuring hub....................................................42
6.2 Selecting torque support / torque flange mounting..............................................................44
6.3 Operating special tool using two-hand control.....................................................................46
7 Attaching Overload Clutch on Profile Pin and Securing...............................47
7.1 Overload clutch with yoke....................................................................................................47
7.2 Overload clutch without yoke...............................................................................................49
8 Testing Functionality of Overload Clutches...................................................50
8.1 Testing friction clutches .......................................................................................................51
8.2 Testing radial pin and cam-type cut-out clutches ................................................................52
8.3 Measuring torque on a friction clutch, radial pin clutch or cam-type cut-out clutch .............52
8.3.1 Switching on measuring hub ...................................................................................52
8.3.2 Starting the "SW42 Analysis2_0" program..............................................................53
8.3.3 Selecting language and inputting company details .................................................53
8.3.4 Selecting COM connection for receiving incoming Bluetooth connections .............54
8.3.5 Entering and/or selecting customer, implement and clutch details .........................55
8.3.6 Conducting a zero point adjustment of the measuring hub.....................................56
8.3.7 Attaching overload clutch on profile pin and securing.............................................56
8.3.8 Starting special tool SW42 for the measurement and performing measurement ...56
8.3.9 Measured data – recording and analysis ................................................................58
8.3.10 Stopping special tool SW42.....................................................................................59
8.3.11 Saving measurement report as PDF file .................................................................60
9 Errors While Testing the Functionality of an Overload Clutch.....................61
9.1 Bluetooth connection is not established ..............................................................................61
9.2 Bluetooth connection is lost during the measurement.........................................................62
9.3 Nominal value for the required torque is not reached..........................................................62
9.4 The "SW42 Analysis2_0" program ends suddenly ..............................................................63
10 Cleaning, Maintenance and Repairs ...............................................................64
10.1 Removing and installing measuring hub..............................................................................64
10.1.1 Removing measuring hub........................................................................................64
10.1.2 Installing measuring hub..........................................................................................66
10.2 Charging battery of the measuring hub ...............................................................................68
10.3 Replacing battery of the measuring hub ..............................................................................69
10.4 Checking oil level .................................................................................................................70
11 EC Declaration of Conformity..........................................................................71
12 Spare Parts List ................................................................................................72
12.1 Frame...................................................................................................................................72
12.2 Counter bearing ...................................................................................................................73
12.3 Hydraulics ............................................................................................................................74
12.4 Hydraulic unit SW42 ............................................................................................................75
12.5 Controller..............................................................................................................................76
12.6 Parts list ...............................................................................................................................77